Exmark NAVIGATOR Manual

NAVIGATOR®

SetupInstructions

ForSerialNos.316,000,000&Higher

WARNING

CALIFORNIA

Proposition65Warning

ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato

causecancer,birthdefects,orreproductiveharm.

TheengineexhaustfromthisproductcontainschemicalsknowntotheStateofCalifornia

tocausecancer,birthdefects,orotherreproductiveharm.

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer

extranet.

DealerPack

Part#DescriptionQty.Use

103-2106Key,ExmarkLogo1

1-603511Key,Standard1

Fillouttheonlinewarrantyregistration

formandplacekeysintoliterature

pack.

LiteraturePack

Manual,Operator's

Manual,EngineOperator's

UncratingtheUnit

1.Lowertheendsofthecrate.

2.Removetheretainingstraps.

LoweringtheDeck

CAUTION

Themowerdeckisshippedinthe“up”position,

butnotlatched.Removingshippingreinforcements

withoutsupportingthefrontofthedeckwillcause

thedecktodropwhichmayresultininjuryor

propertydamage.

Alwayssecurelysupportthefrontofthedeckwhile

settinguptheunit.

1.Tilttheseatforward.

2.Ifusinganoverheadhoist,placethehooksintothe

rearmostupperholeoftheROPSmountingplate

locatedoneachsideoftheframe(seeFigure1).

Raisethefrontoftheunitandsupportitwithjack

standsorequivalentsupport.Makesurethehoistis

holdingthemajorityoftheweightofthemachine.

Ifdrivingtheunitoffthecrate,liftthedeckjust

enoughtoremovethedecksupportandtoinsert

othersupportsintocrateopening.

Important:Theliftspringsmaybedamagedif

thedeckisliftedrst.

P .O.Box808

Beatrice,NE68310

PartNo.4502-725Rev.A

PrintedintheUSA.

AllRightsReserved*4502-725*A

CAUTION

Raisingthemowerdeckforserviceor

maintenancerelyingsolelyonmechanical

orhydraulicjackscouldbedangerous.The

mechanicalorhydraulicjacksmaynotbe

enoughsupportormaymalfunctionallowing

theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic

jacksforsupport.Useadequatejackstandsor

equivalentsupport.

Figure1

1.Upperrearmosthole

3.Removeanddiscardthedecksupportfromunder

thereardeckrollers.

4.Carefullyremovethejackstands.

5.Beforethedeckisloweredintotheoperating

position(steps6through9),thecrateopeningunder

thedeckmustbefullycovered.Placeaplywood

sheet,orsimilarsupport,overtheopeningtoprovide

supportforthedeckwhentheunitisdrivenoffof

thecrate;otherwisedamagemayoccurbetweenthe

blowerdischargetubeandthedeck.

6.Onbothsidesoftheseat,removeanddiscard

thetwosidestruts,mountingbrackets,andtheir

hardware.

7.Removeanddiscardthestrutlocatedbetweenthe

frontdecksupportpins.

8.Makesuredecklockingpinsarepulledoutinthe

unlockpositionandcarefullylowerthedeck(see

Figure2).

Figure2

1.Decklifthandle

2.Rotatethedecklockingpintowardtherearandpulloutward

tounlock

3.Pushthedecklockingpininandrotatetowardthefront

tolock

9.Pushthedecklockingpinsinwardandrotateforward

tosecurelylockthedeckintheloweredposition

WARNING

Operatingmowerwithoutlockingpinssecurely

latchedcanresultinthemowerdeckfolding

upunexpectedly.Themowerdeckfoldingup

unexpectedlycancauseseriousinjury.

Alwaysoperatemowerwithlockingpins

securelylatched.

InstallingtheRearCasterWheel

1.Removetherearcasterwheelassemblyfrominside

thehopper.

2.Raisetherearoftheunitapproximately10–12inches

andsupportitwithjackstandsorequivalentsupport.

3.Removeanddiscardthemetalsupporttrayandits

hardware,locatedbehindthedrivetires,fromthe

machine.

4.Installtherearcasterwheelintothecasterfork.

5.Carefullyremovethejackstandsandlowerthe

machine.

CheckingTirePressure

1.Checkthetirepressureinthedrivetires.Proper

inationfordrivetiresis15psi(103kPa).

2.Adjustifnecessary.

3.Thefrontandrearcastertiresaresemi-pneumatic

anddonotneedtobeinated.

ServicingtheBattery

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

Important:Themachineisshippedwithalled

leadacidbattery.

DANGER

Chargingorjumpstartingthebatterymayproduce

explosivegases.Batterygasescanexplodecausing

seriousinjury.

•Keepsparks,ames,orcigarettesawayfrom

battery.

•Ventilatewhenchargingorusingbatteryinan

enclosedspace.

•Makesureventingpathofbatteryisalwaysopen

oncebatteryislledwithacid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid,whichis

poisonousandcancausesevereburns.Swallowing

electrolytecanbefatalorifittouchesskincan

causesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber

glovestoprotectskinandclothingwhen

handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwaterand

calladoctorimmediately.

1.Checkthevoltageofthebatterywithadigital

voltmeter.Locatethevoltagereadingofthebattery

inthetablebelowandchargethebatteryforthe

recommendedtimeintervaltobringthechargeup

toafullchargeof12.6voltsorgreater.

Important:Makesurethenegativebattery

cableisdisconnectedandthebatterycharger

usedforchargingthebatteryshouldhave

anoutputof16voltsand7ampsorlessto

avoiddamagingthebattery(seechartfor

recommendedchargersettings).Thisis

especiallyimportantonKohlerEFI(Electronic

FuelInjection)units.Failuretodosomay

damagetheECU(ElectronicControlUnit).

Voltage

Reading

Percent

Charge

Maximum

Charger

Settings

Charging

Interval

12.6or

greater

100%16volts/7

amps

NoCharging

Required

12.4–12.675–100%16volts/7

amps

30Minutes

12.2–12.450–75%16volts/7

amps

1Hour

12.0–12.225–50%14.4volts/4

amps

2Hours

11.7–12.00–25%14.4volts/4

amps

3Hours

11.7orless0%14.4volts/2

amps

6Hoursor

CAUTION

Iftheignitionisinthe“ON”positionthere

ispotentialforsparksandengagementof

components.Sparkscouldcauseanexplosionor

movingpartscouldaccidentallyengagecausing

personalinjury.

Besureignitionswitchisinthe“OFF”position

beforechargingthebattery.

2.Connectthenegativebatterycable.

Note:Ifthepositivecableisalsodisconnected,

connectthepositive(red)cabletothepositive

batteryterminalrst,thenthenegative(black)cable

tothenegativebatteryterminal.Slipinsulatorboot

overthepositiveterminal.

Note:Iftimedoesnotpermitchargingthebattery,

orifchargingequipmentisnotavailable,connect

thenegativebatterycableandrunthevehicle

continuouslyfor20to30minutestosufciently

chargethebattery.

ServicingtheHydraulicOil

Themachineisshippedwithhydraulicoilinthe

reservoir.

1.Runthemachineforapproximately15minutesto

allowanyextraairtopurgeoutofthehydraulic

system.

2.Waituntiltheunitcoolsbeforecheckingthe

hydraulicoil.

3.Tilthopperup.

4.Removethehydraulicreservoircap.

5.Wipethedipstickcleanandre-insertthecapback

intothehydro.Lightlytightenthecap.

6.Checkhydraulicreservoirandifnecessaryllthe

reservoirtotheappropriatelevelwithExmark

PremiumHydroOil.

7.Removethecapagainandchecktheleveloftheoil

onthedipstick.SeeFigure3foroillevels.

Figure3

1.Full2.Add

Note:Theoillevelonthedipstickwillbeincorrect

iftheoilischeckedwhentheunitishot.

8.Ifthedipstickoillevelisatthe“add”mark,add

ExmarkPremiumHydroOil.DoNotoverll.

9.Replacehydraulicreservoircapandtightenuntil

snug.DoNotovertighten.

ServicingtheEngine

Theengineisshippedwithoil;checkoillevelandif

necessarylltotheappropriatelevel.Exmark4-Cycle

PremiumEngineOilisrecommended;refertothe

EngineOwner'smanualforanappropriateAPIrating

andviscosity.

FillingOuttheProduct

Registration

Fillouttheonlinewarrantyregistrationformandplace

keysintoliteraturepack.

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