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Eureka 1400-1900 Series Vacuum Cleaner User Manual

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2. 33 PTO Drive Pulley Alignment initio 33 Pump Drive Pulley Alignment 33 Rear Caster Pivot Bearings Pre Load CISA CHIL T 34 Hopper Door Adjustment sss 34 Brake Spring Adjustment 34 tob ivo oa Pea ta 35 Clean Engine and Exhaust System PEA iste dtu eds ga Sahat ANE Ee 35 Remove Engine Shrouds and Clean Cooling igi qu E RE 35 Clean Debris From 35 Waste Disposal ese HIS E ERG 35 Tro bleshootng 36 Schemat s ru ved noe eiim eic ite 38 Safety Safety Safety Alert Symbol This Safety Alert Symbol Figure 2 1s used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Figure 2 1 Safety alert symbol The safety alert symbol appeats above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION DANGER White lettering Red background Indicates an imminently hazardous situation which if not avoided Will result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided Could result in death or serious injury CAUTION Black lettering
3. A WARNING iem BATTERY CONTAINS SULFURIC ACID AVOID CONTACT OR USE BOOSTER CABLES OR ADJUST POST CONNECT Y AND ALWAY FACE ION FROM BATTERY CIGARETTES FLAMES OR SPARKS ACCIDENT FLUSH WITH WATER AND CALL A PHYSICIAN COULD CAUSE BATTERY TO EXPLODE DO NOT CHARGE IMMEDIATELY KEEP OUT OF REACH OF CHILDREN 1 513747 WARNING New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any ait bubbles Familiarize yourself with the following safety signs and instruction labels They critical to the safe operation of your Exmark commercial mower f WARNING PINCH POINT Can cause serious injury Keep hands clear of door hinge bars and door frame with the door open 103 8444 103 8444 5 65 2690 AWARNING 2 98 4361 SPEED d CONTROL e t dm IGNITION 103 8451 103 8451 F DANGER COVER IS MISSING DO NOT OPERATE 385354 THIS UNIT WHEN COVER IS NOT IN PLACE 98 5954 PINCH POINT Only use handles to lift and lower hopper Can cause serious injury e Keep hands out from under hopper on 103 8495 ROTATING DRIVELINE Can cause serious injury or death ET PA Keep a
4. 6006950 HIGH PRESSURE CHARGE PUMP CASE DRAIN 40 Exmark Commercial Turf Equipment 2 Year Limited Warranty Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part on these products and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship for a period of two years This warranty applies to Exmark commercial turf equipment sold in the U S or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery Year Prorated Engine 2 years The Engine warranty is covered by the engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following Pickup and delivery charges to and from any authorized Exmark Service Dealer Any damage or deterioration due to normal use wear and tear or exposure Cost of regular maintenance service or parts such as filters
5. All implied warranties of merchantability that the product is fit for ordinary use and fitness for use that the product is fit for a particular purpose are limited to the duration of the express warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state G4500 425 NEW EXMARK PREMIUM HYDRO OIL BENEFITS Designed amp manufactured with superior anti wear protection Superior thermal stability Consistent hydro performance Superior shear resistance under heavy loads Field tested amp proven performance Twice the shear stability of SPECIALLY FORMULATED amp competing oils MANUFACTURED FOR SUPERIOR P CR CORMANCE IN ALL EXMARK Enhanced control performance DRAULIC DRIVE SYSTEMS Specially formulated for any 1 US Quart 946 ML 32 FL oz Exmark hydraulic system NOW AVAILABLE FOR PURCHASE Part No 109 9828 42 This is a 5 slope No Slope Example Compare slope with a tree building fence post pole etc Align this edge with a
6. Do Not overfill the hydraulic reservoir Carefully fill only to the recommended level Replace the brake band if it becomes contaminated with oil 1 Stop engine and wait for all moving patts to stop Engage patking brake 2 Tilt hopper up Clean area around hydraulic reservoir cap and remove cap Oil level should be to the top of the baffle inside the tank If not add oil Use only Exmark Premium Hydro oil Replace hydraulic reservoir cap and tighten until snug Do Not overtighten Do Not overfill Note The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level Do Not ovetfill Check Tire Pressures Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Check tire pressure in drive tires Inflate drive tires to 15 psi 103 kPa 4 The rear caster tire is semi pneumatic and does not need to be inflated Note Do Not add any type of tire liner or foam fill material to the tires Exce
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8. Move speed control lever to neutral position Engage park brake Stop engine Check the function of the operator presence controls OPC safety system daily Do NOT defeat the OPC system Stop engine and remove key before adjusting servicing or cleaning machine and attachments Hearing protection is recommended Molded into Front of Hopper Specifications Specifications Model Numbers Serial Nos 790 000 and Higher NAV20KC NAV27KC Systems Engine Engine Specifications See your Engine Owner s Manual RPM Full Speed 3600 50 RPM No Load Idle 1500 RPM Fuel System Capacity 7 5 gal 28 L Type of Fuel Regular unleaded gasoline 87 octane higher Fuel Filter In line 30 Micron Kohler P N 2405010 Fuel Shut Off Valve 1 4 turn increments in line valve by fuel filtet Electrical System Charging System Flywheel Alternator Charging Capacity 15 amps Battery Type BCI Group U1 Battery Voltage 12 Volt Polarity Negative Ground Fuses Two 20 amp and one 30 amp blade type Safety Interlock System PTO must be disengaged brake engaged and speed control lever in neutral position to start engine It is not necessary for the operator to be in the seat to start the engine Operator must be in seat when PTO is engaged brake is disengaged or speed control lever is moved out of neutral or engine will stop Engine will stop in the following conditions If t
9. Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Note Brake must be engaged speed control lever rearward neutral position and PTO disengaged to start engine It is not necessary for the operator to be in the seat to start the engine Hour Meter Located on the right hand console The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run If the ignition switch is left on without engine running hour meter will not run Note This switch is not a low oil sensor and will not alert the operator if the engine oil is low Fuel Shut Off Valve Located in fuel line by fuel tank and fuel filter accessible by raising the hopper fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days during transport to and from the jobsite and when parked inside a building Rotate the valve 1 4 turn clockwise to shut off the fuel rotate the valve 1 4 turn counterclockwise to turn on the fuel 16 Operation Drive Wheel Release Valves Located on the top left front corner of hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running Tilt seat up to gain access to pumps With a 7 16 wrench turn both valves one turn counterclockwise
10. To prevent engine cut outs on rough terrain the seat kill switch has a 1 2 second delay 1 Check starting circuit Starter should crank with parking brake engaged PTO disengaged and speed control lever in the neutral position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and speed control lever in the neutral position starter must not crank Try to start with operator in seat parking brake engaged PTO engaged and speed control lever in the neutral position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the speed control lever forward out of neutral starter must not crank Check the kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must initiate shutdown after approximately 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise offof seat but do not get off of machine engine must initiate shutdown after 1 2 second has elapsed Note If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER Important It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing Check for Loose
11. within the warranty period This warranty extends only to turf equipment operated under normal conditions You must read the operator s manual You must also properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein Neither Exmark nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage Such damages include but are not limited to Expenses related to gasoline oil or lubricants Travel time overtime after hours time or other extraordinary repair charges or charges relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark Service Dealer Rental of like or similar replacement equipment during the period of any warranty repair or replacement work Any telephone or telegram charges or travel charges Loss or damage to person or property other than that covered by the terms of this warranty Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower
12. 3 Spring Arm Pivot 4 Toggle Pivot Lubricate Brake Rod Bushings Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Unhook seat latch and tilt seat up Lubricate bronze bushings on each end of brake rod shaft with a spray type lubricant or a light oil bushings are located to the inside of the flange bearings Lubricate Steering Linkage Rod Ends Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Unhook seat latch and tilt seat up Lubricate each end of both steering linkage rods with a spray lubricant or a light oil Lubricate Hopper Actuator Service Interval Every 160 hours Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise hopper and locate actuator on right hand side of mainframe 3 Lubricate switch actuator rod with a spray lubricant a light oil Check Spark Plugs Service Interval Every 160 hours Remove spark plugs check condition and reset gaps or replace with new plugs See Engine Owner s Manual Change Fuel Filter Service Interval As required fuel filter is installed between the fuel tank and the engine Replace when necessaty Replacement Filters Kohler Kohler P N 2405010 26 Maintenance Change Hydraulic System Filter Service Interval After the first 250 hours Every 500
13. Caster Wheel Hubs section for special lubrication instructions on the rear caster wheel 5 Remove castet whe l caster forks hubs 3 Remove seal guards from the wheel hub 4 Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has been applied to lock the spacer nuts to the axle Remove the axle with the other spacer nut still assembled to it from Hr the wheel assembly L 5 Pry out seals and inspect bearings for wear or damage and replace if necessary 6 Pack the bearings with a NGLI grade 1 multi purpose grease 7 Insert one bearing one new seal into the wheel Note Seals Exmark PN 103 0063 must be replaced 4 8 Ifthe axle assembly has had both spacer nuts Deck shown for reference only See attachment removed or broken loose apply a thread locking manual for schedule adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward Do 3 Lubricate caster pivots once a year Remove hex Not thread spacer nut all of the way onto the end plug and cap Thread grease zerk in hole and of the axle Leave approximately 1 8 inch 3 mm pump with grease until it oozes out around top from the outer surface of the spacer nut to the beating Remove grease zerk and thread plug back end of the axle inside the nut in Place cap back on 5 Insert the assembled nut and a
14. fuel lubricants tune up parts and adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S or Canada customers may also call 402 223 6375 41 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer
15. into tank Dielectric Grease Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact Adjustments Note Disengage PTO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit PTO Drive Belt Tension Self tensioning No adjustment necessary Pump Drive Belt Tension Self tensioning No adjustment necessary PTO Belt Replacement 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 With engine off engage PTO lever then remove the hairpin and clevis pin at the bottom of the PTO brake band 3 Rotate the brake band upwards out of the way of the belts keeping clear of the belt drive 4 Disengage PTO lever 5 Loosen belt guides A and B See Figure 8 6 Remove current belts 7 Route new belts onto sheaves as shown in the decal located on the back of the left drive shield see Figure 8 1 2 3 4 5 6 7 Figure 8 1 Idler 5 Engine 2 Belt Guide B 6 Belt Guide A 3 PTO Belt 7 Blower 4 Jackshaft 8 Engage the PTO lever 9 Rotate brake band back down into original position Maintenance 10 Re install clevis pin and hairpin to secure brake band 11 Engage the PTO lever 12 Loosen the jam nuts and adjust linkage until the top of the idler arm is aligned with the bottom of
16. or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance Whenever you need service genuine Exmark parts ot additional information contact an Authorized Service Dealer or Exmark Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers the space provided 1 6006831 Figure 1 Model and serial number location Model No Serial No Contents ERR Lan 3 Mov dp 5 Safety Alert eii 5 Safe Operating 5 Safety and Instructional Decals 10 13 e ade orat p d tnt 13 A 13 Dimensio oec tc 14 Torque Requirements ed tds ates 15 Product cade L5 16 16 PEPE SLADE etna 17 Operating Instr retloris s scu ocn etra 17 MAUS POPU 19 MAINE CE 21 Recommended Maintenance Schedule
17. pid 1 Stop engine wait for all moving parts to stop and Figure 13 remove key Engage parking brake 2 in speed control lever can be adjusted 1 Brake engaged 4 Brake Bolt by adjusting the tightness of the lever pivot bolt position which is located under the seat near the speed 2 Loosen nut here 5 Brake Swivel control levee see 15 3 1 2 inch 1 8 inch 1 3 44 gu 0 33 3 Setthe tension high enough that the speed control lever position is maintained during operation and 30 Maintenance loose enough to be moved comfortably by the operator a 6006841 Figure 15 1 Speed Control Lever 2 Friction Plate 3 Spring disc washers 4 Hexlocknut Speed Control Linkage Adjustment WARNING Engine must be running and drive wheels must be turning so motion control adjustment can be performed Contact with moving parts or hot surfaces may cause personal injury Keep fingers hands and clothing clear of rotating components and hot surfaces 31 CAUTION Raising the mower deck for service or maintenance relying solely on mechanical hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack st
18. system 36 Disengage the PTO Set the parking brake Ensure the speed control lever is in the neutral position Charge the battery Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Replace the blown fuse Contact an Authorized Service Dealer Fill the fuel tank Open the fuel shutoff valve Add oil to the crankcase Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the ON position for a cold engine or the OFF position for a warm engine Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Contact an Authorized Service Dealer Clean adjust or replace spark plug Check the spark plug wire connection Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Clean or replace the fuel cap Replace the fuel filter Contact an Authorized Service Dealer Troubleshooting Engine overheats Mowet pulls left or right with levers fully forwatd Machine does not drive Abnotmal vibration Engine lo
19. tension spring Loosen the 4 jackshaft mounting bolts S990 c gs Measuring from the blower pulley as a baseline move the engine and jackshaft until the rear surface of all 3 pulleys are aligned within 1 32 33 inch to 1 16 inch 0 8 1 6 mm Use a straight edge to align all three surfaces see Figure 20 Figure 20 Align three pump drive pulley surfaces shown with this pattern within 1 32 inch to 1 16 inch 0 8 1 6 mm 2 Align three PTO drive pulley surfaces shown with this pattern within 1 32 inch to 1 16 inch 0 8 1 6 mm 10 11 12 13 Tighten the four engine mounting bolts and four jackshaft mounting bolts Check alignment after tightening Re install pump belt tension spring Swing fuel tank in and re install tank mounting nuts Complete the Pump Drive Pulley Alignment section Pump Drive Pulley Alignment Pump drive pulley alignment is necessary for any of the following conditions The engine mounting bolts have been loosened or the engine has been moved or replaced The pump pulleys have been loosened moved replaced The PTO pulley alignment has been performed see PTO Drive Pulley Alignment section Stop engine wait for all moving parts to stop and remove key Engage parking brake Loosen set screws on both pump pulleys Using a straight edge align each pump pulley with the engine pulley by sliding along the pump shaft see Figure 20 Re tighten pulley set s
20. vertical surface it 1 1 i y J 1 ii D RE FEST Vig Vit 1 i w t mp TUN Ay m drm it ME mhi TETTE nara 1 G000503 43 SEE EXMARK S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM ROPS DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM ROLL OVER PROTECTION SYSTEM ROPS WEATHER CAB GRASS CATCHER TURF STRIPER MICRO MULCH SYSTEM STANDON Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Date Purchased Engine Model No and Spec No Model No Engine Serial No E No Serial No 2009 Exmark Mfg Co Inc Part No 4500 367 Rev A Industrial Park Box 808 402 223 6300 Cf Beatrice NE 68310 Fax 402 223 5489 All Rights Reserved Printed in the USA www exmark com
21. Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Visually inspect machine for any loose hardware ot any other possible problem Tighten hardware ot correct the problem before operating Service Air Cleaner Service Interval Every 50 hours Service the air cleaner May need more often under severe conditions See the Engine Owner s Manual for additional information 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Tilt hopper up to gain access to the air cleanet Loosen retaining clips and remove air cleaner compartment cover Remove paper element Check the condition of the paper element Replace if dirty bent or damaged Check the condition of the inner element Replace whenever it appears dirty typically every other time the paper element is replaced Clean the base around the inner element before removing so dirt does not get into the engine Do Not wash or use pressurized air to clean paper element or inner element Reinstall elements Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips Change Engine Oil Service Interval After the first 5 hours Every 100 hours May need more often under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Drain oil whil
22. NAVIGATOR E eo E 2 5 Ca o For Serial Nos 790 000 amp Higher Part No 4500 367 Rev AWARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancet birth defects or other reproductive harm Important When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES 002 Ce syst me d allumage par tincelle de v hicule est conforme la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers accept no responsibility fo
23. Yellow background Indicates a potentially hazardous situation which 1 not avoided May result in minor or moderate injury This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safe Operating Practices Training Read the Operator s Manual and other training material If the operatot s or mechanic s can not read English it is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and safety signs e All operators and mechanics should be trained The owner is responsible for training the users e Never let children or untrained people operate ot service the equipment Local regulations may restrict the age of the operator e The owner uset can prevent and is responsible for accidents or injuries occurring to himself or herself other people or property Preparation Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark e Wear appropriate clothing including safety glasses substantial footwear long trousers and hearing protection Do Not operate when barefoot or when wearing open sandals Long hair loose clothing or jewelry may get tangled in moving parts CAUTION This ma
24. ad is excessive Oil level in the crankcase is low Cooling fins and air passages for the engine are plugged Tracking needs adjustment Tire pressure in drive tires not correct Reverse indicator and speed control linkage need adjustment Bypass valve is not closed tight Drive or pump belt is worn loose or broken Drive or pump belt is off a pulley Broken or missing idler spring Hydraulic fluid level is low or too hot Engine mounting bolts are loose Loose engine pulley idler pulley or blade pulley Engine pulley is damaged Belt is damaged 37 Reduce the ground speed Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Adjust the tracking Adjust tire pressure in the drive tires Adjust the reverse indicator and the speed control linkage Tighten the bypass valve Change the belt Change the belt Replace the spring Add hydraulic fluid to reservoir or let it cool down Tighten the engine mounting bolts Tighten the appropriate pulley Contact an Authorized Service Dealer Install new belt Schematics Schematics Electrical Diagram
25. afe Zone Use the mower here on slopes less than 15 trees ot other objects that may obscure vision P degrees 2 Danger Zone Use a walk behind mower and or hand trimmer on slopes greater than 15 degrees near Slope Operation drop offs and water Use Extreme caution when mowing and or turning a ENNIS on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation Remove or mark obstacles such as rocks tree on slopes limbs etc from the mowing area Tall grass can hide obstacles e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Safety Avoid sudden starts when mowing downhill Mower may tip forwards Be aware that operating on wet grass across steep slopes ot downhill may cause the mowet to lose traction Loss of traction to the drive wheels may result in sliding and a loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights or counter weights to improve stability Use extreme cate with attachments These can change the stability of the machine and cause loss of conttol Maintenance and Storage Disengage drives lower implement set parking brake stop engine and remove key or disconnect spark plug wire Wait for all moveme
26. aily May be required more often in dry or dirty conditions A CAUTION Excessive debris around the engine cooling ait intake and inside of the pump drive belt compartment and damaged or missing rubber baffles can cause the engine and hydraulic system to overheat which can create a fire hazard Clean all debris from inside of pump drive belt compartment daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all debris from rotating engine air intake screen and from around engine shrouding and exhaust system area 3 Clean all debris from around engine drive belts and exhaust system area Remove Engine Shrouds and Clean Cooling Fins Service Interval Every 80 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Remove cooling shroud clean out covers from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause improper cooling Make sure cooling shroud clean out covers are reinstalled Operating the engine without cooling shroud clean out covers will cause engine damage due to overheating For 27HP Kohler units Swing out the fuel tank and remove debris from around the oil cooler positioned at right front corner of engine Important Do Not use water to clean engine Use low pressure compressed air See Engine Owner s Manual Clean Debris From Machine Serv
27. ands or equivalent support Adjust steering levers 1 Stop engine and wait for all moving parts to stop 2 Pullthe speed control lever completely back to the neutral position The two steering levers should be straight up and down vertical necessary adjust steering levers by changing the length of the link between the speed control lever and the control arm on the end of the steering control shaft see Figure 16 2 G006842 Figure 16 1 Loosen jam nuts here to 2 Steering levers should adjust linkage be vertical Set neutral 1 Remove the electrical connection from the seat safety switch located directly in front of the seat switch assembly 2 neutral adjustment must be made with the drive wheels turning Raise the frame and place on jack stands so that drive wheels can rotate freely Temporarily install a jumper wire Maintenance actoss the terminals in the connector of the wiring harness Start the engine 4 Run the unit at least 5 minutes with the speed control lever at full forward speed to bring hydraulic system oil up to operating temperature Return speed control lever to neutral full rear position 5 obtain the neutral position adjust the left and right pump control rod linkages that connect the steering control to the pump control arms until the wheels stop or creep slightly in reverse 6 Adjust the left pump linkage by rotating the track
28. be slowed down ot travel backward in a straight line Steering is controlled by varying the position of the steering levers relative to each other Speed Control Lever Located on right hand console The speed control lever sets maximum forward speed Moving speed control lever rearward to the neutral position places the drive system in neutral Choke Control Located on right hand console The choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke the ON position and moving the choke lever to the rear will put the choke in the OFF position DO NOT run a warm engine with choke in ON position Throttle Control Located on right hand console The throttle is used to control engine speed Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed Brake Lever Located on left side of unit between the seat and console The brake lever engages a parking brake on the drive wheels Pull the lever up and rearward to engage the brake Push the lever forward and down to disengage the brake The unit must be tied down and brake engaged when transporting Ignition Switch Located on the right hand console The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the position
29. chine produces sound levels in excess of 85 dBA at the operator s ear and can cause heating loss through extended periods of exposure Weat hearing protection when operating this machine e Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders Safety DANGER In certain conditions during fueling static electricity can be released causing a spark which ignite gasoline vapors fire or explosion from gasoline can burn you and others and cause property damage A DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire ot explosion from gasoline can burn you others and cause property damage Fill the fuel tank outdoors in an open area when the engine is cold Wipe up any gasoline that spills Never refill the fuel tank or drain the machine indoors inside an enclosed trailer Do Not fill the fuel tank completely full Add gasoline to the fuel tank until the level is 1 4 to 1 2 inch 6 13 mm below the bottom of the filler neck This empty space in the tank allows gasoline to expand Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by spark Store gasoline in an approved container and keep it out of the reach of children Add
30. cm 42 6 inches 108 2 cm Overall Length Without Deck 42 inch Deck 48 inch Deck 67 3 inches 91 8 inches 94 5 inches 170 9 cm 233 2 cm 240 0 cm Overall Height Without Deck 42 inch Deck 48 inch Deck 51 2 inches 51 2 inches 51 2 inches 130 0 cm 130 0 cm 130 0 cm Tread Width Center to Center of Tires Widthwise o 42inch Deck 48 inch Deck Drive Wheels 32 7 inches 32 7 inches 83 1 cm 83 1 cm Wheel Base Center of Drive Wheel to Center of Rear Caster Wheel 42 inch Deck 48 inch Deck 44 2 inches 112 3 cm 44 2 inches 112 3 cm 14 Product Overview Curb Weight Product Overview Torque Requirements Blade Mounting Bolt 85 110 ft lb 115 149 N m Engine Mounting Bolts 30 35 ft lb 41 47 N m Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Motor Mounting 72 77 ft lb 98 104 N m Bolts Wheel Hub Locknut 210 250 ft lb 285 339 N m Figure 4 1 Speed Control Lever 4 Steering Levers 2 Controls 5 PTO Engagement Lever 3 Fuel Cap 6 Parking Brake Lever 15 Operation Operation Note Determine the left and right sides of the machine from the normal operating position Controls Steering Levers Located in the center in front of the seat Pulling back on the steering levers progressively slows then reverses the direction of travel of the respective drive wheels gt moving both steering levers an equal amount back the machine can
31. crews and recheck alignment Maintenance Rear Caster Pivot Bearings Pre Load Adjustment Remove dust cap from caster and tighten nyloc nut until washers are flat Back off 1 4 of a turn to properly set the pre load on the bearings If disassembled make sure the spring disc washers are reinstalled as shown in Figure 21 Figure 21 1 Spring disc washers Hopper Door Adjustment Door Closing Loosen six door hinge nuts see Figure 22 Open door and place a 3 8 inch rubber strip or 3 8 inch diameter hose between the hopper and hopper door see Figure 22 Close door and push tight against hopper Tighten hinge hardware Open hopper door and remove rubber strip Figure 22 2 Place a piece of 3 8 inch 9 5 mm rubber on this surface 1 Loosen door hinge nuts three per side PTO Brake Spring Adjustment PTO brake spring adjustment is only necessary if the blower has been removed or replaced or if the PTO drive idler arm has been disassembled 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Locate the brake spring and thread the two jam nuts out to the end of the brake spring rod see Figure 23 3 Tighten jam nuts together at end of brake spring rod Figure 23 1 Tighten jam nuts here 2 PTO Brake spring assembly Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval Before each use or d
32. ds Lubricate hopper actuator Check the spark plugs Change the hydraulic filter Every 250 hours yearly if using Mobil 1 15W50 Every 500 hours Check the wheel hub locknuts torque specification Check the wheel lug nut torque specification 21 Maintenance Maintenance Service Maintenance Procedure Interval 0 Monthly o Check the battery charge 000000000000 the battery Check the battery charge 000000000000 Veatly Lubricate grease fittings Lubricate the caster wheel hubs Periodic Maintenance Check Engine Oil Level Service Interval Before each use or daily 1 Stop engine and wait for all moving patts to stop Make sure unit is on a level surface 2 Check with engine cold 3 Raise hoppet Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick and push it all the way down into the tube Remove the dipstick and read the oil level 5 If the oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Use oil as specified in Engine Owner s Manual Do Not overfill Important Do Not operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check Battery Charge Service Interval Monthly CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead comp
33. e To move forward in a straight line move the speed control lever forward Operation To turn left or right pull one of the steering levers back toward neutral in the direction desired The machine will move faster the farther the speed control lever is moved away from neutral To stop pull the speed control lever back to the neutral position Driving in Reverse 1 To move rearward in a straight line applying equal pressure pull both steering levers rearward To turn left or right release pressure on the steering lever toward the direction desired To stop release the steering levers to the neutral position Emptying Hopper 1 A full hopper is indicated by a buzzer located behind the operator in the hopper Empty hopper when buzzer sounds to prevent clogging of the blower or deck Disengage PTO move speed control to neutral set park brake and dismount unit to dump hopper 3 Make sure unit is on a dry level surface Lift the rear door up and allow it to rest on top of hopper Dump hopper by firmly grasping one of the hopper handles on either side of the unit and lifting the hopper Clearing Hopper Screen Screen may be removed by firmly lifting screen handles see Figure 5 Pull screen towards the back to remove Gently tap debris from the screen as needed Excessive build up on the screen can cause the blower to plug Note In conditions where the screen clogs quickly the front removab
34. e engine is warm from operation Tilt hopper up to gain access to the engine area The oil drain valve is located on right hand side of engine at the back of the unit Remove two nuts near right hand drive tire and swing out the fuel tank Install oil drain hose supplied in the literature pack onto oil drain valve Place pan under machine to catch oil Open valve to allow oil to drain and then close valve Replace the oil filter every other oil change Clean around oil filter and unscrew filter to remove 23 Maintenance Before reinstalling new filter apply a thin coating of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 2 to 3 4 turn 6 Clean around oil fill cap and remove cap Fill to specified capacity and replace cap 7 Remove drain hose close fuel tank and lower hopper 8 Use oil recommended in engine owner s manual Do Not overfill Start the engine and check for leaks 9 Wipe up any spilled oil from engine deck mounting surfaces Check Hydraulic Oil Level Service Interval Every 40 hours WARNING Oil spilled or vented from an overfilled hydraulic reservoir onto the PTO brake band will cause a longer stopping time for the deck and blower rotating components The deck and blower rotating components can cause serious injuty e Wait for all moving parts to come to a complete stop before servicing
35. el tanks For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 or higher Regular grade leaded gasoline may also be used however combustion chamber and cylinder head will require more frequent service See Engine Owner s Manual Do Not add oil to gasoline Do Not overfill fuel tank Never fill the fuel tank so that the fuel level rises above a level that is 1 2 inch 13 mm below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage Make sure you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all the necessary inspection and maintenance steps Operating Instructions Open the Fuel Shut Off Valve The fuel shut off valve is located on the right side of unit in fuel line next to the fuel filter Raise the hopper to access Rotate the valve 1 4 counterclockwise to turn on fuel Starting the Engine 1 Move the speed control lever to the neutral position 2 Pull up and back on the parking brake lever to engage the parking brake 3 Push the PTO engagement lever down to the STOP position Note It is not necessary for the operator to be in the seat to start the engine 4 Place the throttle midway between the SLOW and FAST positions 5 Ona cold engine push the choke lever forward into the position On a warm engine leave the choke i
36. er wheel bearings 13 Grease belt idlers rator s manual for additional details 116 1175 116 1175 mm BRAKE 5l M J Molded in LH Console 12 DANGER Greater than 15 Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning To avoid loss of control and possibility of rollover Do NOT operate near drop offs or near water Do NOT operate on slopes greater than 15 Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes e A rollbar is available and its use is recommended for areas where there are Slopes drop offs or water To avoid serious injury or death Avoid blades unless engine and blades are stopped A WARNING To avoid serious injury or death Read and understand the operator s manual before using this machine Do NOT operate unless trained to safely use this machine Pick up objects that could be thrown by the blades Do NOT mow when people and pets are in the area Do NOT carry passengers Do NOT operate under the influence of alcohol or drugs Do NOT operate without shields guards and safety devices in place and working Look behind and to the side before changing directions Before leaving operator s position Disengage PTO
37. fications Hydraulic Filter Replaceable cartridge type Summer use above 32 F 0 C P N 109 0071 25 microns 10 psi bypass Winter use below 32 F 0 C P N 1 523541 40 microns 18 psi bypass Speeds 0 7 0 mph 11 3 km hr forward 0 5 5 mph 8 6 km hr reverse Drive wheel release valves allow machine to be moved when engine is not running Tires amp Wheels Drive Front Rear Caster Caster Pneumatic Semi Semi Air Filled Pneumatic Pneumatic Tread Multi Trac Smooth Smooth C S Size 18 x 8 x 3 00 4 13 x 8 00 6 10 50 10 Pressure 15 psi 103 kPa Cutting Deck Sold separately Model Numbers CD42CD CD48CD Cutting Width 42inch Deck 42 inch 106 7 cm 48 inch Deck 48 inch 121 9 cm Discharge Center Blade Size 2 ea w 42 inch Deck 22 00 inches 55 9 cm w 48 inch Deck 25 00 inches 63 5 cm Deck Drive Clutching belt on horizontal engine shaft Dual section hexagon belt with spring tensioned idler to jackshaft and blower Heavy duty cast iron spiral bevel gearbox is final drive to blades Deck Full floating deck is attached to out front support frame Deck design allows for bagging or mulching Deck Depth 42inch Deck 4 5 8 inches 11 7 cm 48 inch Deck 4 5 8 inches 11 7 cm Dimensions Overall Width Without Deck 42 inch Deck 48 inch Deck 43 2 inches 109 7 cm 49 2 inches 125 0
38. fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot If fuel is spilled Do Not attempt to start the engine Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Do Not operate without entire exhaust system in place and in proper working condition Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never sip
39. he speed control lever is moved from neutral position while brake is engaged Ifthe PTO is engaged while the hopper is tilted up Operator Controls Steering and Motion Control Speed Control levet located on RH console sets maximum forward speed Steering levers centered in front of the seat control the speed and direction of travel of the respective drive wheels Moving speed control lever rearward to the neutral position places the drive system in neutral Note The unit may be moved in reverse while the speed control is in the neutral position by pulling back the steering levers PTO Engagement Lever Engages drive to mower deck and blowet e Parking Brake Lever Pull back to engage parking brake Seat Type Standard seat with high back foam padded internal suspension Mounting Seat is hinged to tilt up for access to hydraulic pumps and other components The seat is held in the tilted position with a link Armrests None Seat Safety Switch Internal to the bottom seat cushion non serviceable Time delay module incotporated into the Safety Interlock System eliminates rough ground cut outs Hydrostatic Ground Drive System Hydrostatic Pumps Two Hydro Gear variable displacement piston pumps Wheel Motors Hydro Gear planetary reduction motots Hydraulic Oil Type Use Exmark Premium Hydro oil Hydraulic Oil Capacity 4 0 qt 3 8 L 13 Speci
40. hon by mouth Safety Check that the operator s presence controls safety switches and shields are attached and functioning properly Do Not operate unless they are functioning propetly Operation WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land A WARNING Engine exhaust contains carbon monoxide which is an odorless deadly poison that can kill you Do Not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect WARNING Operating a Navigator tractor without an approved Exmark front mount attachment increases the possibility of operator entanglement in drive wheels or forward tip over Entanglement or tip over could cause serious injury death When operating a Navigator tractor without an approved Exmark front mount attachment observe the following Keep feet and clothing away from tires Limit operation to minimum required to install a different front mount attachment Minimize speed and use extreme caution Only operate on a flat level s
41. hours Yearly whichever comes first thereafter Every 250 hours Yearly if using Mobil 1 15W50 Note Use only Exmark Part No 109 0071 for Summer use above 32 F 09 or P N 1 523541 for Winter use below 32 F 0 C Refer to the Hydrostatic Ground Drive System section in Specifications for filter specifications 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system 3 Unsctew filter to remove and allow oil to drain from reservoir Important Before reinstalling new filter fill it with Exmark Premium Hydro oil and apply a thin coat of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn 4 Fill reservoir as stated in Check Hydraulic Oil Level section Exmark Premium Hydro Oil is recommended Refer to the chart for an acceptable alternative Hydro Oil Change Interval Exmark Premium Hydro 500 Hours Oil Preferred Mobil 1 15W50 250 Hours 5 Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely 6 Start engine and move throttle control ahead to full throttle position Move the speed control levers to the full speed and run for several minutes Shut down machine and recheck o
42. ice Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Clean off any oil debris ot grass build up on the machine especially around the fuel tank around engine and exhaust area Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations Battery Disposal A DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns e Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is being replaced or if the unit containing the battery is no longer operating and is being scrapped take the battery to a local certified recycling center If no local recycling is available return the battery to any certified battery reseller 35 Troubleshooting Troubleshooting Important It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use When a problem occurs do not overlook
43. il level Note Do Not change hydraulic system oil except for what can be drained when changing filter unless it is felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Maintenance Check Wheel Hub Locknuts Service Interval After the first 100 hours Every 500 hours thereafter Torque to 210 250 ft Ib 285 339 N m Check Wheel Lug Nuts Service Interval After the first 100 hours Every 500 hours thereafter Torque to 90 95 ft lb 122 129 N m cross pattern Fuel Tank Mounting Hardware Specifications Service Interval As required When installing the nuts on the fuel tank studs fully tighten the nyloc nut and back off 1 2 turn This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels Thread Locking Adhesives Thread locking adhesives such as Loctite 242 Fel Pro Pro Lock Nut are used on the following fasteners e Pump drive sheave set screws Square head setscrews on Hydro pump control arms Sheave retaining bolt in the end of engine crankshaft blower shaft and jackshaft e Caster wheel spacer nuts Fuel tank bulkhead fitting nuts Adhesives such as Loctite RC 609 RC 680 or Fel Pro Pro Lock Retaining I or Retaining are used on the following Fuel tank studs where studs are inserted
44. ing adjustment knob 7 Adjust the right pump linkage by using a wrench to turn the double nuts on the assembly see Figure 17 6006843 Figure 17 2 Rotate double nuts on right side 1 Rotate tracking knob on left side 8 Move the steering levers to the reverse position While applying slight pressure to the levers allow the steering levers to return to neutral The wheels must stop turning or slightly creep in reverse 9 Stop engine and wait for all moving parts to stop Remove jumper wire from wire harness connector and plug connector into seat switch 10 Lower from jackstands 32 Set forward stop bolt 1 1 Remove seat deck with seat attached to obtain a clear view of the steering control shaft to complete this adjustment Push the speed control lever forward to full forward speed position If either steering control lever surface does not contact the stop bar at the full forward speed position adjust the stop bolt until contact occurs see Figure 18 Once contact occurs turn the stop bolt one more full turn to prevent bottoming of the hydraulic pump internal stops Figure 18 Contact must be maintained between these components at full forward speed condition Speed control Lever 2 forward stop bolt Steering Control Lever Response Adjustment Stop engine wait for all moving parts to stop and
45. ition Check all bolts frequently to maintain proper tightness Frequently check for worn deteriorating components that could create a hazard All replacement parts must be the same as equivalent to the parts supplied as original equipment WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system Safety Safety and Instructional Decals Keep all safety signs legible Remove all grease e dirt and debris from safety signs and instructional labels Replace all worn damaged or missing safety signs When replacement components are installed be sure that current safety signs are affixed to the replaced components If an attachment or accessory has been installed make sure current safety signs are visible
46. kes on both sides can be simultaneously adjusted by lengthening or shortening the linkage Adjust all safety switches so plunger extends 3 16 shown in Figure 14 inch to 1 4 inch 4 8 mm 6 4 mm from switch body when plunger is compressed see Figure 12 1 Mosa Qe 6006849 Figure 12 1 3 16 inch to 1 4 inch 4 8 mm 6 4 mm bi 1 G006949 Brake Adjustment Figure 14 Check to make sure each brake is adjusted properly Brake i Sides 1 Pull th kel k to th ull the brakeileve us engaged 1 Brake Lever engaged 3 Rotate yoke position position 2 gap must exist between the bottom of the brake 2 Remove 4 Loosen nut here bolt head and the top surface of the brake swivel 2 shown in Figure 13 If a gap does not exist 4 If individual adjustment is necessary loosen the adjust the linkage to a maximum gap of 1 2 inch jam nut on the brake bolt that is against the clevis 1 8 inch 1 3 0 33 h 1 8 inch 1 3 cm 0 33 cm as shown connected to the brake arm on the wheel motor Turn the brake bolt to achieve proper adjustment 5 Tighten the jam nut against the clevis Repeat for other side of unit Engage and disengage the brakes to check for proper engagement and disengagement Readjust if necessaty When the brakes are disengaged there should be free play in the brake linkage with no dragging in the brakes Adjust Speed Control Lever Tension
47. le screen panel can be turned and reinstalled under the primary screen to allow free air flow from the hopper Figure 5 1 Front removable screen can be rotated and stored for wet condtions Front removable screen 3 Primary screen 4 Handles Transporting Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure a trailer with a safety chain CAUTION This unit does not have proper turn signals lights reflective markings or a slow moving vehicle emblem Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and or fines Do Not dtive a unit on a public street or roadway 19 Operation WARNING Loading a unit on a trailer or truck increases the possibility of tip over Tip over could cause serious injury death Use extreme caution when operating a unit on a ramp Use only a single full width ramp Do Not use individual ramps for each side of the unit If individual ramps must be used use enough ramps to create an unbroken ramp s
48. lever upward until locked over center Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle to the MIDWAY position 2 Push PTO lever down to the STOP position stopping the PTO and blower Stopping the Engine 1 Bring the unit to a full stop 2 Disengage the PTO 3 Move speed control lever to the neutral position 4 Engage the parking brake 5 Place the throttle midway between the SLOW and FAST positions Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine Remove the key to prevent children or other unauthorized persons from starting engine Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machine A CAUTION Machine can spin very rapidly by positioning one lever too much ahead of the other Operator may lose control of the machine which may cause damage to the machine or injury e Use caution when making turns Slow the machine down before making sharp turns Important To begin movement forward or backward the operator must be in the seat the brake lever must be disengaged pushed down before the speed control lever can be moved forward or the engine will stop Driving Forward 1 Start the engine 2 3 Release the parking brak
49. ll driveline shields in place Securely attach both ends of the driveline 103 8425 103 8425 START PTO RELAY RELAY RELAY 103 8611 103 8611 Safety WHEN ENGAGED IDLER ARM POSITION MUST BE IN 27 AREA OR ADJUSTMENT IS REQUIRED READ OPERATOR S MANUAL FOR ADJUSTMENT PROCEDURE ES 103 9034 103 9034 PTO DRIVE BELT ROUTING BELT 103 6737 mraAajouvro 109 4638 DANGER ROTATING BLADES Can cause serious injury or death Disengage PTO stop engine engage parking brake remove key WAIT FOR ALL MOVING PARTS TO STOP before 103 9724 reaching into discharge chute opening Do not operate mower with BELT 103 4244 103 9274 109 7318 hopper raised 109 7318 DRIVE WHEEL RELEASE ONLY USE EXMARK HYDRO OIL FILL TO TOP OF BAFFLE One turn counterclockwise to release Do not over tighten 109 4273 di CAUTION ilico nl SURFACE 116 0404 116 0404 SERVICE AID 10 Every 8 hours 1 Check engine oil 2 Grease front caster wheel bearings Every 40 hours 3 Check hydraulic oil Only use recommended hydro oil 4 Check tire pressure 15 psi 5 Grease deck drive PTO 6 Check air cleaner Every 100 hours 7 Grease deck lock mechanism 8 Grease deck pivots 9 Check gearbox oil Use only Mobil 1 75W 90 gear oil Yearly 10 Grease front caster pivots 11 Grease rear caster pivot 12 Grease rear cast
50. n become entangled in rotating parts Contact with the rotating parts can cause traumatic amputation or severe lacerations Do Not mow slopes when grass is wet Do Not mow near drop offs or near water Do Not mow slopes greater than 15 degrees Do Not operate the machine without guards shields and safety devices in place and working properly Reduce speed and use extreme caution on slopes Avoid sudden turns rapid speed Keep hands feet hair jewelry clothing away from rotating parts changes NEVER carry passengers DO NOT operate See inside the back cover to determine the the mower when people especially children or approximate slope angle of the area to be mowed pets are in the area e Usea walk behind mower and or a hand trimmer alert slow down and use caution when making neat drop offs ditches steep banks or water turns Look behind and to the side before Figure 5 changing directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to cw be mowed Beawate of the mower discharge path and direct discharge away from others 3 SO SN Do Not operate the mower under the influence SS of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck 6006832 Figure 3 Use care when approaching blind corners shrubs oa 1 S
51. n the OFF position 6 Turn ignition switch to the START position Release the switch as soon as the engine starts 17 Operation Important Do Not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor If the choke is in the position gradually return choke to the OFF position as the engine warms up Engaging the PTO DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck when the blades are engaged DANGER An uncovered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blower blades could occur Thrown objects or blade contact can cause serious injuty death Never operate the mower with the hopper or hopper door raised removed or altered unless there is a mulch kit in place and working properly The PTO lever engages the PTO and blower Be sure that the hopper is down the hopper door is securely closed and all persons are clear of the mower deck and discharge area before engaging PTO Important Operator must be in seat before the PTO can be engaged 1 Set the throttle to the MIDWAY position 2 Pull the PTO
52. njure you other bystanders Allow the engine to cool completely before service or making repairs around the engine Remove the key from the ignition switch area engage parking brake and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s Recommended Maintenance Schedule s Maintenance Service Maintenance Procedure Interval After the first 5 hours Change the engine oil After the ftst 100 hours heck the wheel hub locknuts torque specification heck the wheel lug nut torque specification After the first 250 hours ge the hydraulic filter k the engine oil level k the safety interlock system Before each use or daily k for loose hardware emove accumulated debris from engine see Cleaning section ean the grass and debris build up from the machine heck the hydraulic oil level Every 40 hours heck the tire pressures heck the condition of the belts Service the air cleaner May need more often under severe conditions See the Engine Every 50 hours gt UM 3 Owner s Manual for additional information Every 80 hours Remove engine shrouds and clean cooling fins see Cleaning section Every 100 hours Change the engine oil May need more often under severe conditions Lubricate the brake handle pivot Lubricate the brake rod bushings Every 160 hours Lubricate the steering linkage rod en
53. notch on tension arm as shown in Figure 9 DA RA 6006837 Figure 9 Tension Arm Loosen jam nuts 3 When PTO is engaged align top of idler arm with bottom of notch on tension arm as shown 4 Idler Arm 13 Tighten jam nuts and disengage PTO lever Re engage PTO lever and check alignment 14 Check and adjust belt guides as stated in Belt Guide Adjustment section Pump Drive Belt Replacement 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove PTO Belts See PTO Belt Replacement section for removal instructions 3 Pull spring idler or remove spring to relieve pump drive belt tension Remove old belt 4 Route new belt onto sheaves as shown in the decal located on the back of the left drive shield see Figure 10 G006838 Figure 10 Pump Drive Belt 4 Pump 2 Pump 5 Idler Idler 6 Engine 5 Reinstall PTO Belts as stated in the PTO Belt Replacement section Belt Guide Adjustment 1 Stop engine wait fot all moving patts to stop and remove key Engage parking brake Engage PTO lever Adjust belt guides as shown in Figure 11 4 a Figure 11 1 8 inch 3 mm 4 Rotate wireform guide to center belts in guide 7 16 inch 11 mm 5 1 4 inch 6 mm 1 8 inch 3 mm 6 5 16 inch 8 mm Clearance Maintenance Adj ust Safety Switch 3 bra
54. nt to stop before adjusting cleaning or repairing Keep engine engine area and pump drive belt compartment free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Let engine cool before storing and do not store near flame any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spark plug wire before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s ot wear gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep hands and feet away from moving parts If possible do not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools Keep all guards shields and all safety devices in place and in safe working cond
55. ol mon BE BB B 3 B ot HIUMS Na E 83440 504 1 NI HOSN3S N3HM 1 MOINS 40 HOLIMS TIl E 1 02 LON o SNISSOUD 53414 c 10831057374 lt lt 30 80 01049 01910938 lt Limon TIN 3NIN3 lt UHM o 3 4 10 lt amea Q3193NNO9 S38M mx O amo os 931915 NYO 3d HLS YOVIBIONYHO E 3900 Mae dM dq o ch oW 1 pes we 38 o 038 t MOTA esa HOLIMS 1 90 o i asna d divo T 13 N a 5 1 9 19913 6 1 div 02 ru is 1 be oly Atx 1 330 p _ 13104 3X VIA LINDHID NOILISOd 3505 39Nv80 X WNIWHSL E E E E HOLIM 55 g i 8 pet 22338 E 3 RR 1 8 1 pur 84 337209 T S 1 1 HOLINS 775 NE 508 aNnouwd HOLIMS S 155 5 pe 3080 NNOG H34dOH anaon Av taa 35 an WS NI AV3Hd3A0 3014340 ANIONS Orid ANOSSIIOV 39 Schematics Hydraulic Diagram BYPASS VALVE BYPASS VALVE HIGH PRESSURE REVERSE HIGH PRESSURE FORWARD HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE
56. ounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater Important Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart for recommended charger settings Percent Charge Maximum Charging Charger Settings 12 6 or 100 16 volts 7 No greater amps Charging Required 12 48 12 6 75 100 16 volts 7 230 Minutes amps 12 2 12 4 50 75 16 volts 7 1 Hour amps 12 0 12 2 25 509 o 14 4 volts 4 2 Hours amps 11 7 12 0 0 25 14 4 volts 4 5 Hours amps 11 7 orless 0 14 4 volts 2 6 Hours ot amps More Maintenance Check Safety Interlock System Service Interval Before each use or daily Note
57. r variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 2009 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PS 0 OVERNIGHT FREE If your Exmark dealer does not have the Exmatk part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed Some restrictions apply See your participating Exmark Dealer for details Contact us at www Exmark com Printed in the USA Rights Reserved Introduction CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation This manual contains operating maintenance adjustment and safety instructions for your Exmark mowet BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact yout authorized Exmark equipment dealer or distributor Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field
58. remove key Engage parking brake Move the speed control lever to the full forward position Lift the seat and locate the pump control springs To increase responsiveness increase spring tension by hooking the rear spring anchor directly to the anchor bolt To decrease responsiveness hook the rear spring anchor to the anchor tab Note Be sure both springs maintain the same adjustment Maintenance 6006845 Figure 19 1 To increase steering responsiveness hook pump control sprints directly on anchor bolt To decrease steering responsiveness hook pump control springs on anchor tabs as shown Tracking Adjustment See Motion Control Linkage Adjustment section PTO Drive Pulley Alignment PTO drive pulley alignment is necessary for any of the following conditions The blower has been removed or replaced The engine mounting bolts have been loosened ot the engine has been moved or replaced The jackshaft mounting bolts have been loosened ot the jackshaft has been moved or replaced 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Move the speed control lever to the neutral position 3 Disengage the PTO lever 4 Remove fuel tank mounting nuts and swing out fuel tank 5 Verify that the blower is installed and secured tightly Loosen the 4 engine mounting bolts Unhook the pump belt
59. s 21 Periodic Maintenance eode degere 22 Check Engine Oil Level a ueteres teu 22 Check Battery iocur do Pado eos 22 Check Safety Interlock System 23 Check for Loose Hardware 23 Service Air Cleaner FATE Es 23 Change Engine Qil oec 23 Check Hydraulic Oil Level iiber cliens 24 Check Hire 24 Check Condition Of Belts 24 Lubricate Grease uet pho 24 Lubricate Rear Caster Wheel Hubs 25 Lubricate Brake Handle Pivot toes 26 Lubricate Brake Rod Bushings 26 Lubricate Steering Linkage Rod Ends 26 Lubricate Hopper 26 Gheck Spark sce see tomi aure vere 26 Change Hydraulic System Filtet 2 Check Wheel Hub Locknuts 28 Cheek Wheel Lug Nuts each 28 Thread Locking Adhesives 28 D electte 28 Xd USt Befis a ek ea 28 PTO Drive Belt Tension auc eterni 28 Pump Drive Belt Tensi n etes 28 PTO Belt Replicement PR 28 Pump Drive Belt Replacement 29 Belt Guide Adjustimeetit 29 Adjust Safety Switch opm petebat 30 Brake issue vinnie 30 Adjust Speed Control Lever Tension 30 Speed Control Linkage Adjustment 31 Steering Control Lever Response Pl S ni co Ra ora 32 Tracking Adjustment
60. ssive loads created by foam filled tires may cause failures to the hydro drive system frame and other components Foam filling tires will void the warranty Check Condition Of Belts Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Tilt hopper up and check pump and PTO drive belts for wear cracking or contamination 3 Belts are spring tensioned and no adjustment is necessary unless belts are replaced See PTO Belt Replacement and Pump Drive Belt Replacement sections for belt replacement Lubricate Grease Fittings Note See chart for service intervals 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the Lubrication Chart for fitting locations and lubrication schedule 24 Maintenance Lubrication Chart 1 Stop engine wait for all moving parts to stop and Fitting Initial Number of Service Locations Pumps Places Interval 1 Caster 0 3 Yearly Pivot remove key Engage parking brake 2 PTO 1 1 Yearly Idler 3 Pump 1 1 Yearly Idler 4 Rear 1 Yearly Caster Hub G006115 Figure 6 See step 3 for special lubrication instructions on 1 Seal guard 2 Spacer nut with wrench the front and rear caster pivots and the Lubricate flats Rear
61. the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do Not attempt to service or replace major items or any items that call for special timing or adjustments procedures such as valves governor etc Have this work done by your Engine Service Dealer Note When disconnecting electrical connectors Do Not pull on the wires to separate the connectors Starter does not crank Engine will not start starts hard or fails to keep running Engine loses power PTO is engaged Parking brake is not set Speed control lever is not in neutral position Battery does not have a full charge Electrical connections are corroded loose ot faulty Fuse is blown Relay or switch is defective Fuel tank is empty Fuel shutoff valve is closed Oil level in the crankcase is low The throttle and choke ate not in the correct position Dirt in fuel filter Dirt watet or stale fuel is in the fuel system Air cleaner is dirty Electrical connections are corroded loose ot faulty Relay or switch is defective Faulty spark plug Spark plug wire is not connected Engine load is excessive Ait cleaner is dirty Oil level in the crankcase is low Cooling fins and air passages for the engine are plugged Vent hole in the fuel cap is plugged Dirt in fuel filter Dirt watet or stale fuel is in the fuel
62. to release drive system Turn clockwise to reset system Do Not overtighten Do Not tow machine Tracking Adjustment Knob Located under the seat on the left pump control link Rotating this knob allows fine tuning adjustments so that the machine tracks straight with the drive levers in the full forward position Run unit at 3 4 speed for at least 5 minutes to bring hydraulic oil up to operating temperature Stop machine and wait for all moving parts to stop Engage park brake Tilt seat forward to gain access to the tracking knob Rotate the knob towards the right to steer right and rotate towards the left to steer left Adjust in 1 8 turn increments until the machine tracks straight Check that the machine does not creep when in neutral with the park brakes disengaged Important Do Not rotate the knob too far as this may cause the machine to creep in neutral Refer to the Motion Control Linkage Adjustment section in Maintenance PTO Engagement Lever Located immediately left of the left console Lever must be moved up to the ROTATE position to engage the PTO and blower drives Lever is moved down to the STOP position to stop the drives Engine Oil Temperature Light and Buzzer Located on the right console The engine oil temperature light monitors the temperature of the engine oil An illuminated engine oil temperature light and intermittent buzzing sound signals the engine is overheating Pre Start Fill fu
63. urface Do not operate up or down a trailer ramp Avoid sudden acceleration or deceleration Operate only in daylight or good artificial light keeping away from holes and hidden hazards Be sure all drives are in neutral and parking brake 15 engaged before starting engine Nevet raise deck with blades running Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting or overspeed the engine Stop engine wait for all moving parts to stop remove key and engage parking brake Before checking cleaning or working on the mower After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Safety Stop engine wait for all moving parts to stop and engage patking brake DANGER Before refueling Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning Before dumping the grass catcher A WARNING Hands feet hair clothing or accessories ca
64. urface wider than the unit Do Not exceed a 15 angle between ramp and ground or between ramp and trailer truck Avoid sudden acceleration while driving unit on a ramp Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp is required If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip If loading on near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible Important Do Not attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving on a ramp 20 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position WARNING A WARNING While maintenance or adjustments are being The engine can become very hot Touching made someone could start the engine a hot engine can cause severe burns Accidental starting of the engine could seriously i
65. xle into the wheel on the side of the wheel with the new seal and Lubricate Rear Caster Wheel bearing Hubs 10 With the open end of the wheel facing up fill the area inside the wheel around the axle full of Service Interval Yearly NGLI grade 1 multi purpose grease 25 Maintenance 11 Insert the second beating and new seal into the wheel 12 Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outwatd Torque the nut to 75 80 in lb 8 9 N m loosen then re torque to 20 25 in lb 2 3 N m Make sure axle does not extend beyond either nut 13 14 Reinstall the seal guards over the wheel hub insert wheel into caster fork Reinstall caster bolt and tighten nut fully Important To prevent seal and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Reapply thread locking adhesive Lubricate Brake Handle Pivot Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Lubricate bronze bushings on brake handle pivot with a spray type lubricant or light oil see Figure 7 G006835 Figure 7 Left Side of Unit Shown 1 Brake Handle Pivot 2 PTO Handle Pivot

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