Exmark Navigator User manual

Brand: Exmark

Model: Navigator

Category: Lawnmowers

Type: User manual

NA VIGATOR®

ForSerialNos.

316,000,000&Higher

PartNo.4502-722Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemical

orchemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Theengineinthisproductisnot

equippedwithasparkarrestermufer.Itisa

violationofCaliforniaPublicResourceCode

(CPRC)Section4442touseoroperatethis

engineonanyforest-covered,brush-covered,

orgrass-coveredlandasdenedinCPRC4126.

Otherstatesorfederalareasmayhavesimilar

laws.

Toacquireasparkarresterforyourunit,seeyour

EngineServiceDealer.

Thissparkignitionsystemcomplieswiththe

CanadianstandardICES-002.Cesystèmed’allumage

parètincelledevèhiculeestconformeàlanorme

NMB-002duCanada.

TheenclosedEngineOwner’sManualis

suppliedforinformationregardingTheU.S.

EnvironmentalProtectionAgency(EPA)and

theCaliforniaEmissionControlRegulationof

emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit.

ShouldthisengineOwner’sManualbecome

damagedorillegible,replaceimmediately.

Replacementsmaybeorderedthroughthe

enginemanufacturer.

Labeledpowerratingsaresuppliedbytheengine

manufacturerinaccordancewithSAEtesting

andgross/netpowerratingstandards(J1940,

J1995,J1349).

Exmarkreservestherighttomakechangesor

addimprovementstoitsproductsatanytime

withoutincurringanyobligationtomakesuch

changestoproductsmanufacturedpreviously.

Exmark,oritsdistributorsanddealers,accept

noresponsibilityforvariationswhichmaybe

evidentintheactualspecicationsofitsproducts

andthestatementsanddescriptionscontained

inthispublication.

IndustrialParkBox808

Beatrice,NE68310

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,

maintainitsmaximumefciency,andpromotesafe

operation.

Important:Tomaximizesafety,performance,

andproperoperationofthismachine,itis

essentialthatalloperatorscarefullyreadand

fullyunderstandthecontentsoftheOperator’s

manualprovidedwiththeproduct.Safe

operationofExmarkequipmentisessential.

Failuretocomplywiththeoperatinginstructions

orreceivepropertrainingmayresultininjury.

Gotohttp://www.Exmark.comforadditional

safeoperationinformation,suchassafetytips,

trainingmaterials,andOperator’smanuals.

Ifadditionalinformationisneeded,orshould

yourequiretrainedmechanicservice,contactyour

authorizedExmarkequipmentdealerordistributor.

AllExmarkequipmentdealersanddistributorsare

keptinformedofthelatestmethodsofservicing

andareequippedtoprovidepromptandefcient

serviceintheeldorattheirservicestations.They

carryamplestockofservicepartsorcansecurethem

promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected

beforeleavingthefactory,however,attentionis

requiredonyourpartifyouaretoobtainthefullest

measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,

oradditionalinformation,contactanAuthorized

ServiceDealerorExmarkCustomerServiceandhave

themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial

numbersontheproduct.Writethenumbersinthe

spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals......................11

Specications........................................................17

Systems..........................................................17

Dimensions....................................................18

TorqueRequirements.....................................19

ProductOverview.................................................19

Operation..............................................................20

Controls.........................................................20

Pre-Start.........................................................22

OperatingInstructions...................................22

Transporting..................................................28

Maintenance..........................................................30

RecommendedMaintenanceSchedule(s)............30

PeriodicMaintenance........................................31

CheckEngineOilLevel..................................31

CheckMowerBlades......................................33

CheckSafetyInterlockSystem........................34

CheckforLooseHardware.............................34

ServiceAirCleaner.........................................34

ChangeEngineOil.........................................34

CheckHydraulicOilLevel..............................35

CheckTirePressures......................................35

CheckConditionOfBelts...............................35

ChangeGearboxOil.......................................36

CheckGearboxOil.........................................36

LubricateGreaseFittings................................36

LubricateRearCasterWheelHubs..................37

LubricateBrakeHandlePivot.........................38

LubricateBrakeRodBushings........................38

LubricateSteeringLinkageRodEnds..............38

LubricateHopperSwitchActuator..................38

CheckSparkPlugs..........................................38

ChangeHydraulicSystemFilterand

Fluid..........................................................38

CheckWheelHubLocknuts...........................39

CheckWheelLugNuts...................................39

ThreadLockingAdhesives..............................39

DielectricGrease............................................39

Adjustments......................................................40

DeckLeveling................................................40

PTODriveBeltTension.................................40

PumpDriveBeltTension................................40

PTOBeltReplacement...................................40

PumpDriveBeltReplacement.......................41

BeltGuideAdjustment...................................41

AdjustSafetySwitch.......................................42

ParkingBrakeAdjustment..............................42

ReverseStopRodAdjustment.........................43

AdjustSpeedControlLeverTension...............44

SpeedControlLinkageAdjustment.................44

TrackingAdjustment......................................45

PTODrivePulleyAlignment..........................45

PumpDrivePulleyAlignment.........................46

CasterPivotBearingsPre-Load

Adjustment................................................46

HopperDoorAdjustment..............................46

PTOBrakeSpringAdjustment.......................47

DeckLockingPinStopAdjustment................47

Cleaning............................................................48

CleanEngineandExhaustSystem

Area...........................................................48

RemoveEngineShroudsandClean

CoolingFins...............................................48

CleanDebrisFromMachine...........................48

CleanDebrisFromCuttingDeck....................48

CleanGrassBuild-UpUnderDeck.................48

WasteDisposal...............................................48

Troubleshooting....................................................50

Schematics............................................................52

Safety

SafetyAlertSymbol

ThislawnmowercompliestotheB71.4-2012

specicationoftheAmericanNationalStandards

InstitutewiththeadditionoftheoptionalROPS

accessory.

Exmarkdesignedandtestedthislawnmowertooffer

reasonablysafeservice;however,failuretocomply

withthefollowinginstructionsmayresultinpersonal

injury.

ThisSafetyAlertSymbol(Figure2)isusedbothin

thismanualandonthemachinetoidentifyimportant

safetymessageswhichmustbefollowedtoavoid

accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

SafetyAlertSymbol

Thesafetyalertsymbolappearsaboveinformation

whichalertsyoutounsafeactionsorsituations

andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Indicatesanimminentlyhazardous

situationwhich,ifnotavoided,Willresultindeathor

seriousinjury.

WARNING:Indicatesapotentiallyhazardous

situationwhich,ifnotavoided,Couldresultindeath

orseriousinjury.

CAUTION:Indicatesapotentiallyhazardous

situationwhich,ifnotavoided,Mayresultinminor

ormoderateinjury.

Thismanualusestwootherwordstohighlight

information.Importantcallsattentiontospecial

mechanicalinformationandNoteemphasizes

generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining

material.Iftheoperator(s)ormechanic(s)cannot

readthismanual,itistheowner’sresponsibilityto

explainthismaterialtothem;otherlanguagesmay

beavailableonourwebsite.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.

Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate

orservicetheequipment.Localregulationsmay

restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate

amower,andevenmatureteenagersshouldhave

adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator's

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe

mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible

foraccidentsorinjuriesoccurringtohimselfor

herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories

andattachmentsareneededtoproperlyand

safelyperformthejob.Onlyuseaccessoriesand

attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,

substantialfootwear,andhearingprotection.Do

Notoperatewhenbarefootorwhenwearingopen

sandals.Longhair,looseclothingorjewelrymay

gettangledinmovingparts.

CAUTION

Thismachineproducessoundlevelsinexcess

of85dBAattheoperator’searandcancause

hearinglossthroughextendedperiodsof

exposure.

Wearhearingprotectionwhenoperatingthis

machine.

Safety

•Inspecttheareawheretheequipmentistobe

usedandremoveallrocks,toys,sticks,wires,

bones,andotherforeignobjectswhichcanbe

thrownbythemachineandmaycausepersonal

injurytotheoperatororbystanders.

DANGER

Incertainconditionsgasolineisextremely

ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn

you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground,

inanopenarea,whentheengineiscold.

Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe

machineindoorsorinsideanenclosed

trailer.

•DoNotllthefueltankcompletelyfull.

Fillthefueltanktothebottomoftheller

neck.Theemptyspaceinthetankallows

gasolinetoexpand.Overllingmayresult

infuelleakageordamagetotheengine

oremissionsystem.

•Neversmokewhenhandlinggasoline,and

stayawayfromanopenameorwhere

gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer

andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never

removethecapofthefueltankoradd

fuelwhenengineisrunningorwhenthe

engineishot.

•Iffuelisspilled,DoNotattempttostart

theengine.Moveawayfromtheareaof

thespillandavoidcreatinganysourceof

ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust

systeminplaceandinproperworking

condition.

DANGER

Incertainconditionsduringfueling,static

electricitycanbereleasedcausingaspark

whichcanignitegasolinevapors.Areor

explosionfromgasolinecanburnyouand

othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe

groundawayfromyourvehiclebefore

lling.

•DoNotllgasolinecontainersinsidea

vehicleoronatruckortrailerbedbecause

interiorcarpetsorplastictruckbedliners

mayinsulatethecontainerandslowthe

lossofanystaticcharge.

•Whenpractical,removegas-powered

equipmentfromthetruckortrailerand

refueltheequipmentwithitswheelson

theground.

•Ifthisisnotpossible,thenrefuelsuch

equipmentonatruckortrailerfroma

portablecontainer,ratherthanfroma

gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe

used,keepthenozzleincontactwiththe

rimofthefueltankorcontaineropening

atalltimesuntilfuelingiscomplete.Do

Notuseanozzlelockopendevice.

WARNING

Gasolineisharmfulorfatalifswallowed.

Long-termexposuretovaporshascaused

cancerinlaboratoryanimals.Failuretouse

cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas

tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperatorpresencecontrols,

safetyswitches,andshieldsareattachedand

functioningproperly.DoNotoperateunlessthey

arefunctioningproperly.

Safety

Operation

WARNING

Operatingengineparts,especiallythemufer,

becomeextremelyhot.Severeburnscanoccur

oncontactanddebris,suchasleaves,grass,

brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to

coolbeforetouching.

•Removeaccumulateddebrisfrommuferand

enginearea.

WARNING

Engineexhaustcontainscarbonmonoxide,

whichisanodorlessdeadlypoisonthatcankill

you.

DoNotrunengineindoorsorinasmallconned

areawheredangerouscarbonmonoxidefumes

cancollect.

WARNING

OperatingaNavigatortractorwithoutan

approvedExmarkfrontmountattachment

increasesthepossibilityofoperatorentanglement

indrivewheelsorforwardtipover.Entanglement

ortip-overcouldcauseseriousinjuryordeath.

WhenoperatingaNavigatortractorwithout

anapprovedExmarkfrontmountattachment,

observethefollowing:

•Keepfeetandclothingawayfromtires.

•Limitoperationtominimumrequiredto

installadifferentfrontmountattachment.

•Minimizespeedanduseextremecaution.

•Onlyoperateonaatlevelsurface.

•DoNotoperateupordownatrailerramp.

•Avoidsuddenaccelerationordeceleration.

•Operateonlyindaylightorgoodarticiallight,

keepingawayfromholesandhiddenhazards.

•Lightningcancausesevereinjuryordeath.If

lightningisseenorthunderisheardinthearea,

DoNotoperatethemachine;seekshelter.

•Besurealldrivesareinneutralandparkingbrake

isengagedbeforestartingengine.

•Neverraisedeckwithbladesrunning.

•Neveroperatethemowerwithdamagedguards,

shields,orcovers.Alwayshavesafetyshields,

guards,switchesandotherdevicesinplaceandin

properworkingcondition.

•Nevermowunlessthereisagrasscollection

systemormulchkitinplaceandworkingproperly.

•DoNotchangetheenginegovernorsettingor

overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait

forallmovingpartstostop,removekeyand

engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor

damageandmakerepairsbeforerestarting

andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and

engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

Hands,feet,hair,clothing,oraccessoriescan

becomeentangledinrotatingparts.Contact

withtherotatingpartscancausetraumatic

amputationorseverelacerations.

•DoNotoperatethemachinewithout

guards,shields,andsafetydevicesinplace

andworkingproperly.

•Keephands,feet,hair,jewelry,orclothing

awayfromrotatingparts.

•NEVERcarrypassengers.DONOToperate

themowerwhenpeople,especiallychildren,or

petsareinthearea.

•Bealert,slowdownandusecautionwhen

makingturns.Lookbehindandtothesidebefore

changingdirections.

•Stoptheblades,slowdown,andusecaution

whencrossingsurfacesotherthangrassandwhen

transportingthemowertoandfromtheareato

bemowed.

•Beawareofthemowerdischargepathanddirect

dischargeawayfromothers.

Safety

•DoNotoperatethemowerundertheinuence

ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe

machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning

onslopesaslossoftractionand/ortip-overcould

occur.Theoperatorisresponsibleforsafeoperation

onslopes.

DANGER

Operatingonwetgrassorsteepslopescancause

slidingandlossofcontrol.Wheelsdroppingover

edges,ditches,steepbanks,orwatercancause

rollovers,whichmayresultinseriousinjury,

deathordrowning.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon

slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Seeinsidethebackcovertodeterminethe

approximateslopeangleoftheareatobemowed.

•Useawalkbehindmowerand/orahandtrimmer

neardrop-offs,ditches,steepbanksorwater.

(Figure3).

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15

degrees

2.DangerZone-Useawalkbehindmowerand/orhand

trimmeronslopesgreaterthan15degrees,near

drop-offsandwater.

3.Water

•Removeormarkobstaclessuchasrocks,tree

limbs,etc.fromthemowingarea.Tallgrasscan

hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat

changetheoperatingangle,asroughterraincould

overturnthemachine.

•Avoidsuddenstartswhenmowingdownhill.

Mowermaytipforwards.

•Beawarethatoperatingonwetgrass,acrosssteep

slopesordownhillmaycausethemowertolose

traction.Lossoftractiontothedrivewheelsmay

resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona

slope.Iftireslosetraction,disengagetheblades

andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor

wheelweightsorcounterweightstoimprove

stability.

•Useextremecarewithattachments.Thesecan

changethestabilityofthemachineandcauseloss

ofcontrol.

Note:A2–postfoldableROPS(RolloverProtection

System)isavailablefortheNavigatorasanaccessory.

AROPSisrecommendedifyouwillbemowingnext

todrop-offs,nearwater,oronsteepbankswhich

couldresultinarollover.ContactanAuthorized

ExmarkServiceDealerformoredetails.

Safety

TheCaliforniaCodeofRegulationsrequiresROPS

andseatbelt(ifequipped)onallcommercialmowers

effectiveMarch1,2011.BecauseallNavigatorswere

designedwithanoptionalROPSaccessory,theyare

subjecttothisregulationandmustberetrottedwith

ROPS.

MaintenanceandStorage

•Disengagedrives,setparkingbrake,stopengine

andremovekeyordisconnectsparkplugwire.

Waitforallmovementtostopbeforeadjusting,

cleaningorrepairing.

•Keepengineandengineareafreefrom

accumulationofgrass,leaves,excessivegrease

oroil,andotherdebriswhichcanaccumulate

intheseareas.Thesematerialscanbecome

combustibleandmayresultinare.

•LetenginecoolbeforestoringandDoNotstore

nearameoranyenclosedareawhereopenpilot

lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do

Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow

untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen

required.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Disconnectbatteryorremovesparkplugwire

beforemakinganyrepairs.Disconnectthe

negativeterminalrstandthepositivelast.

Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)

orweargloves,andusecautionwhenservicing

them.Onlyreplacedamagedblades.Never

straightenorweldthem.

•Keephandsandfeetawayfrommovingparts.

Ifpossible,DoNotmakeadjustmentswiththe

enginerunning.

•Chargebatteriesinanopenwellventilatedarea,

awayfromsparkandames.Unplugcharger

beforeconnectingordisconnectingfrombattery.

Wearprotectiveclothinganduseinsulatedtools.

DANGER

Chargingorjumpstartingthebatterymay

produceexplosivegases.Batterygasescan

explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway

frombattery.

•Ventilatewhenchargingorusingbattery

inanenclosedspace.

•Makesureventingpathofbatteryis

alwaysopenoncebatteryislledwith

acid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid,

whichispoisonousandcancausesevere

burns.Swallowingelectrolytecanbefatalor

ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and

rubberglovestoprotectskinandclothing

whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith

waterandcalladoctorimmediately.

CAUTION

Iftheignitionisinthe“ON”positionthere

ispotentialforsparksandengagementof

components.Sparkscouldcauseanexplosion

ormovingpartscouldaccidentallyengage

causingpersonalinjury.

Besureignitionswitchisinthe“OFF”

positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin

placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper

tightness.

•Frequentlycheckforwornordeteriorating

componentsthatcouldcreateahazard.

Safety

WARNING

Removalormodicationoforiginalequipment,

partsand/oraccessoriesmayalterthewarranty,

controllability,andsafetyofthemachine.

Unauthorizedmodicationstotheoriginal

equipmentorfailuretouseoriginalExmark

partscouldleadtoseriousinjuryordeath.

Unauthorizedchangestothemachine,engine,

fuelorventingsystem,mayviolateapplicable

safetystandardssuchas:ANSI,OSHAand

NFPAand/orgovernmentregulationssuchas

EPAandCARB.

WARNING

Hydraulicuidescapingunderpressure

canpenetrateskinandcauseinjury.Fluid

accidentallyinjectedintotheskinmustbe

surgicallyremovedwithinafewhoursbyadoctor

familiarwiththisformofinjuryorgangrenemay

result.

•Ifequipped,makesureallhydraulicuid

hosesandlinesareingoodconditionandall

hydraulicconnectionsandttingsaretight

beforeapplyingpressuretohydraulicsystem.

•Keepbodyandhandsawayfrompinhole

leaksornozzlesthatejecthighpressure

hydraulicuid.

•Usecardboardorpaper,notyourhands,to

ndhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic

systembyplacingthemotioncontrollevers

inneutralandshuttingofftheenginebefore

performinganyworkonthehydraulicsystem.

ForKohlerEFI(ElectronicFuelInjection)Units:

WARNING

Fuelsystemcomponentsareunderhigh

pressure.Theuseofimpropercomponentscan

resultinsystemfailure,gasolineleakageand

possibleexplosion.

Useonlyapprovedfuellinesandfuelltersfor

highpressuresystems.

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,

dirtanddebrisfromsafetysignsandinstructional

labels.

•Replaceallworn,damaged,ormissingsafety

signs.

•Whenreplacementcomponentsareinstalled,be

surethatcurrentsafetysignsareafxedtothe

replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,

makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom

yourauthorizedExmarkequipmentdealeror

distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe

backingtoexposetheadhesivesurface.Apply

onlytoaclean,drysurface.Smoothtoremove

anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns

andinstructionlabels.Theyarecriticaltothesafe

operationofyourExmarkcommercialmower.

93-6696

1.Storedenergyhazard-Removethespringfromthe

tractorsectiononly.SeeOperator’smanualfor

disassemblyprocedure.

93-7818

1.Warning-readtheOperator’smanualforinstructionson

torquingthebladebolt/nutto115–149N-m(85–110

ft-lb).

98-1977

1.Entanglementhazard,belt—stayawayfrommoving

parts.

106-5517

1.Warning—donottouchthehotsurface.

112-8760

1.Thrownobjecthazard—keepbystandersasafedistance

fromthemachine.

2.Cutting/dismembermentofhandorfoot—stayaway

frommovingparts.

112-9028

1.Warning—stayawayfrommovingparts;keepallguards

inplace.

Safety

115-4212

1.Hydraulicoillevel3.Warning—donottouch

thehotsurface.

2.ReadtheOperator's

Manual.

116-8934

1.Warning-Disengage

bladeclutch,shutoff

engine,andremove

keybeforemaking

adjustments,servicing,

orcleaningdeck.

2.Heightofcut.

116-8935

1.Warningfoldingdeckhazard-Lockthepivotjointby

pushinginwardandrotatingtowardsthefrontofthe

deck.

116-8936

1.Danger-DoNotoperatewithdeckintilt-upposition.

116-8941

116-8943

1.Rotatingbladeshazard-DisengagePTO,movespeed

controlleverinneutral,engageparkingbrake,stop

engine,andremovekeybeforeleavingtheoperator’s

position.Readtheinstructionsbeforeservicingor

performingmaintenance.

2.Danger-Donotoperatewithmowerhopperinraised

position

Safety

116-8946

1.Rotatecounterclockwise

torelease

3.Unlocktopushmachine

2.Rotateclockwisetolock4.Readtheinstructions

beforeservicingor

performingmaintenance.

116-9049

1.Rotatingdrivelinehazard-Keepalldrivelinesshieldsin

place.Securelyattachbothendsofthedriveline.

116-9357

EFIUnits

1.Neutral

4.Slow

2.Reverse5.Hopperdown

3.Fast6.Hopperup

116-9375

AllUnitsExceptEFI

1.Neutral3.Fast

2.Reverse

4.Slow

116-9470

AllUnitsExceptEFI

1.Choke-on2.Choke-off

117–2718

Safety

120-0625

1.Pinchpoint,hand-keephandsaway.

126-4207

1.RefertotheOperator’smanualforadjustment

procedure.WhenPTOisengaged,idlerarmposition

mustbeinhatchedareaoradjustmentisrequired.

126-7425

EFIUnits

1.Fast4.Neutral

2.Machinespeed5.Engineoiltemperature

light

3.Slow6.Checkengine

126-7442

AllUnitsExceptEFI

1.Fast4.Neutral

2.Machinespeed5.Engineoiltemperature

light

3.Slow

MoldedinLHConsole

1.PTO-disengage

3.Parkbrake-release

2.PTO-engage

4.Parkbrake-engage

Safety

MessageDisplay

1.Hopperupindicator5.Parkingbrake

2.Battery6.Neutral

3.Hourmeter

7.Operatorpresence

switch

4.PTO

116-9044

1.ReadtheOperator’sManualbeforeperformingany

maintenance.

8.Greasedecklockmechanismevery100hours.

2.Checkengineoilevery8hours.9.Greasedeckpivotsevery100hours.

3.Greasefrontcasterwheelbearingsevery8hours.10.Checkgearboxoilevery100hours(useonlyMobil1

75W-90gearoil).

4.Checkhydraulicoillevelevery40hours(onlyuse

recommendedhydrooil).

11.Greasefrontcasterpivotsevery500hours.

5.Checktirepressureevery40hours.12.Greaserearcasterpivotevery500hours.

6.GreasedeckdrivePTOevery40hours.13.Greaserearcasterwheelevery500hours.

7.Checkaircleanerevery40hours.14.Greasebeltidlersevery500hours.

Safety

MoldedintoFrontofHopper

1.Warning-ReadtheOperator’sManual.DoNotoperatethis

machineunlessyouaretrained.Wearhearingprotection.

5.Warning-Stayawayfrommovingparts;keepallguards

inplace.Stopengineandremovekeybeforeadjusting,

servicing,orcleaning.

2.Sliding,tippinghazard-DoNotusethemachinenear

drop-offswithslopesgreaterthan15degrees,usethe

machineasafedistanceformdrop-offsonslopesless

than15degrees;DoNotturnsharplywhiletravelingfast,

driveslowlywhenturning.

6.Warning-DisengagePTO,movespeedcontrolleverto

neutralposition,engageparkingbrake,andstopengine

beforeleavingtheoperator’sposition.

3.Warning-DoNotusedualramps,useonepieceramps

whentransportingmachine;DoNotuserampswith

inclinationgreaterthan15degrees.

7.Thrownobjecthazard-Pickupobjectsthatcouldbethrown

bymower.DoNotoperatewhenpeopleandpetsarein

thearea.Keepdeectorinplace.

4.Arollbarisavailableanditsuseisrecommendedforareas

wherethereareslopes,drop-offs,orwater

8.Crushing/dismembermenthazardofbystanders-DoNot

carrypassengers,lookforwardanddownwhenoperating

themachine,lookbehindanddownwhenreversing.

Specications

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s

Manual

•EngineOilType:Exmark4–CyclePremium

EngineOil

•RPM:FullSpeed:3600±50RPM(NoLoad)Idle:

1500RPM

FuelSystem

•Capacity:7.5gal.(28L)

•FuelRecommendations:

–Forbestresults,useonlyclean,fresh,unleaded

gasolinewithanoctaneratingof87orhigher

((R+M)/2ratingmethod).

–Oxygenatedfuelwithupto10%ethanolor

15%MTBEbyvolumeisacceptable.

–DoNotuseethanolblendsofgasoline(such

asE15orE85)withmorethan10%ethanol

byvolume.Performanceproblemsand/or

enginedamagemayresultwhichmaynotbe

coveredunderwarranty.

–DoNotusegasolinecontainingmethanol.

–DoNotstorefueleitherinthefueltankor

fuelcontainersoverthewinterunlessafuel

stabilizerisused.

–DoNotaddoiltogasoline.

•FuelFilter:

Allunits:KohlerP/N2405013

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

–AllunitsexceptKohlerEFI:15amps

–KohlerEFI:20amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:Two25ampandone15ampbladetype

SafetyInterlockSystem

•LCDindicatorsappearforthePTO,parkbrake,

drivelevers,andoperatorpresenceinthemessage

displayontheRHcontrolpanel.

•PTOmustbedisengaged,brakeengaged,and

speedcontrolleverinneutraltostartengine.(It

isnotnecessaryfortheoperatortobeintheseat

tostarttheengine.)

•OperatormustbeinseatwhenPTOisengaged,

brakeisdisengaged,orspeedcontrolleveris

movedoutofneutralorenginewillstop.

•Enginewillstopifthehopperisraisedwhilethe

PTOisengaged.

OperatorControls

•SteeringandMotionControl:

–SpeedControllever,locatedonRHconsole,

setsmaximumforwardspeed.

–Steeringlevers,centeredinfrontoftheseat,

controlthespeedanddirectionoftravelof

therespectivedrivewheels.

–Movingspeedcontrolleverrearwardtothe

neutralpositionplacesthedrivesystemin

neutral.

Note:Theunitmaybemovedinreverse

whilethespeedcontrolisintheneutral

positionbypullingbackonthesteeringlevers.

•PTOEngagementLever:EngagesdrivetoPTO

(mowerdeck)andblower.

•ParkingBrakeLever:Pullbacktoengageparking

brake.

Seat

•Type:Standardseatwithhighback,foampadded

(internalsuspension).

•Mounting:Seatishingedtotiltupforaccessto

hydraulicpumpsandothercomponents.Theseat

isheldinthetiltedpositionwithalink.

•Armrests:None.

•SeatSafetySwitch:Internaltothebottom

seatcushion,serviceable.Timedelaymodule

incorporatedintotheSafetyInterlockSystem

eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearvariable

displacementpistonpumps.

Specications

•WheelMotors:HydroGearplanetaryreduction

motors.

•HydraulicOilType:UseExmarkPremiumHydro

oil.

•HydraulicOilCapacity:6.0qt.(5.7L)

•HydraulicFilter:Replaceablecartridgetype.

–Summeruseabove32°F(0°C):

P/N109-4180:25microns,10psibypass

–Winterusebelow32°F(0°C):

P/N1-523541:40microns,18psibypass

•Speeds:

–0-7.0mph(11.3km/hr)forward.

–0-4.5mph(7.2km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe

movedwhenengineisnotrunning.

Tires&Wheels

Drive

Front

Caster

Rear

Caster

Pneumatic

(Air-Filled)

Semi-

Pneumatic

Semi-

Pneumatic

Quantity

221

Tread

“Multi-Trac

C/S”

SmoothSmooth

Size

18x

10.50-10

8x3.00-413x8.00-6

PlyRating

Pressure

15psi(103

kPa)

CuttingDeck

•CuttingWidth:

–42inchDeck:42inch(106.7cm)

–48inchDeck:48inch(121.9cm)

•Discharge:Center

•BladeSize:(2ea.)

–w/42inchDeck:22.00inches(55.9cm)

–w/48inchDeck:25.00inches(63.5cm)

•DeckDrive:

–Clutchingbeltonhorizontalengineshaft.

Dual“A ”sectionhexagonbeltwithspring

tensionedidlertojackshaftandblower.

–Heavy-dutycastiron,spiralbevelgearboxis

naldrivetoblades.

–GearboxOilType:MobilSHC(synthetic)

75W-90gearlube.

•Deck:

Fulloatingdeckisattachedtoout-frontsupport

frame.Deckdesignallowsforbaggingor

mulching.

•DeckDepth:

–42inchDeck:45/8inches(11.7cm)

–48inchDeck:45/8inches(11.7cm)

Dimensions

OverallWidth:

WithoutDeck42inchDeck48inchDeck

42.6inches

(108.2cm)

43.2inches

(109.7cm)

49.2inches

(125.0cm)

OverallLength:

WithoutDeck

67.3inches(170.9cm)

DeckDown

42inchDeck48inchDeck

91.8inches(233.2cm)94.5inches(240.0cm)

DeckUp

42inchDeck48inchDeck

82.4inches(209.3cm)81.8inches(207.6cm)

OverallHeight:

WithoutDeck42inchDeck48inchDeck

51.2inches

(130.0cm)

51.2inches

(130.0cm)

51.2inches

(130.0cm)

TreadWidth:(CentertoCenterof

Tires,Widthwise)

42inchDeck48inchDeck

DriveWheels32.7inches

(83.1cm)

32.7inches

(83.1cm)

ProductOverview

WheelBase:(CenterofDriveWheel

toCenterofRearCasterWheel)

42inchDeck48inchDeck

44.2inches(112.3cm)44.2inches(112.3cm)

CurbWeight:

42inchDeck48inchDeck

1140lb(517kg)1170lb(531kg)

TorqueRequirements

BoltLocation

Torque

BladeMountingBolt85-110ft-lb(115-149

N-m)

EngineMountingBolts

30-35ft-lb(41-47N-m)

WheelLugNuts

85-105ft-lb(122-129

N-m)

WheelMotorMounting

Bolts

72-77ft-lb(115-142N-m)

WheelHubLocknut275-350ft-lb

(373-475N-m)

BladeDriverShearBolts80-100in-lb

(922-1130N-cm)

ProductOverview

Figure4

1.SpeedControlLever4.SteeringLevers

2.Controls5.PTOEngagementLever

3.FuelCap

6.ParkingBrakeLever

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

SteeringLevers

Locatedinthecenterinfrontoftheseat.

Pullingbackonthesteeringlevers,progressively

slows,thenreversesthedirectionoftravelofthe

respectivedrivewheels.

Bymovingbothsteeringleversanequalamountback,

themachinecanbesloweddownortravelbackward

inastraightline.

Steeringiscontrolledbyvaryingthepositionofthe

steeringleversrelativetoeachother.

SpeedControlLever

Locatedonrighthandconsole.

Thespeedcontrolleversetsmaximumforwardspeed.

Movingspeedcontrolleverrearwardtotheneutral

positionplacesthedrivesysteminneutral.

ChokeControl(AllUnitsExcept

KohlerEFI)

Locatedonthecontrolconsolefrontrighthandside.

Chokeisusedtoaidinstartingacoldengine.The

chokecontrolispulledouttobeinthe“ON”position

andpushedintobeinthe“OFF”position.DoNot

runawarmenginewithchokeinthe“ON”position.

Figure5

1.Ignitionswitch5.Throttle

2.Hopperswitch6.Engineoiltemperature

lightandbuzzer

3.Messagedisplay

7.Checkenginelight(EFI

UnitsOnly)

4.Choke(AllUnitsExcept

EFI)

ThrottleControl

Locatedonrighthandconsole.

Thethrottleisusedtocontrolenginespeed.Moving

throttleleverforwardwillincreaseenginespeedand

movingthrottlelevertotherearwilldecreaseengine

speed.

BrakeLever

Locatedonleftsideofunit,betweentheseatand

console.

Thebrakeleverengagesaparkingbrakeonthedrive

wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe

brake.

Theunitmustbetieddownandbrakeengagedwhen

transporting.

IgnitionSwitch

Locatedontherighthandconsole.

Theignitionswitchisusedtostartandstopthe

engine.Theswitchhasthreepositions“OFF”,“ON”

and“START”.Insertkeyintoswitchandrotate

clockwisetothe“ON”position.Rotateclockwiseto

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Exmark Navigator User manual

Brand: Exmark

Model: Navigator

Category: Lawnmowers

Type: User manual

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Exmark Navigator User manual

Exmark Navigator User manual

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