Exmark NAV20KC User Manual

For Serial Nos.

670,000 & Higher

Part No. 109-3923 Rev. A

WARNING

POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating pr actices can result in serious

operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass

discharge system) in place and in proper working condit ion. ♦ Stop engine, wait for all moving part s t o st op, and engage

parking brake. Remove spark plug wire(s) or remove key before

adjusting, servicing, or performing maintenance. ♦ If mower deck becomes clogged, stop engine, wait for all moving

parts to stop, and engage par king brake. Remove spark plug

wire(s) or remove key before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts . ♦ Keep off mower unless seat platf o r m is pr ovided. ♦ Keep others off mower.

WARNING

POTENTIAL HAZARD ♦ Gasoline is harmful or f at a l if swallowed. Long-term exposure to

vapors has caused cancer in laboratory animals. WHAT CAN HAPPEN ♦ Failure to use caution may cause serious injury or illness. HOW TO AVOID THE HAZARD

♦ Avoid prolonged breathing of vapors. ♦ Keep face away from nozzle and gas tank/container opening. ♦ Keep away from eyes and skin. ♦ Never siphon by mouth.

IMPORTANT

When the mower is used or oper ated on any California forest, brush or grass covered land, a working spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442 Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.

This spark ignition system complies with Canadian ICES-002 Ce système d’allumage par ètincelle de vèhicule est conform e à 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 M anual with your unit. Should this engine O wner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995 Program

If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

2. Distributor ships part(s) to dealer or customer, as

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by

5. The customer pays for the part

6. Who pays for the part A. Under any circumstance the customer does not pay. B. If the part does not arrive overnight due to:

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus

3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,

4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark

the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus

shipment of six (6) line items or less.

requested by dealer, same day, overnight UPS Distributor bills dealer for part and freight charges where applicable.

order, he contacts Exmark by 3:00 p.m.,

central time, with an Exmark Parts Plus

order of six (6) line items or less.

distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.

and freight if it is shipped under the Exmark Parts Plus® and if it arrives in

accordance to the program.

and freight if it fails to arrive overnight in accordance to the program?

1. The dealer not submitting the Exmark Parts Plus

order to his Exmark distributor by 1:00 p.m., the dealer

pays for the part and freight.

order

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

Exmark pays for the part and freight.

pays for the part.

The following restrictions apply

-- The Exmark Parts Plus® Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus

Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

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 oper at ion.

OPERATOR'S MANUAL

This manual contains assembly, operating, maintenance, adjustment, and safety instructions for your Exmark mower.

BEFORE OPERATING YOUR MOWER,

CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.

By following the operating, m aint enance, and safety instructions, you will prolong the life of your mower, mainta in it s m aximum efficiency, and promote safe oper ation.

If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor.

All Exmark equipment dealers and distribut or s are kept informed of the latest methods of servicing and are equipped t o pr ovide prom pt and efficient service in the field or at their service stations. T hey carr y ample stock of service parts or can secure them promptly for you fr om the factory.

All Exmark parts are thoroug hly test ed and inspect ed before leaving the factory, however, attention is required on your part if you are t o obt ain the fullest measure of satisfaction and performance.

iii

TABLE OF CONTENTS

1. SAFETY PAGE

1.1 Safety Alert Symbol....................................................................................... 1

1.2 Training.........................................................................................................1

1.3 Preparation.................................................................................................1-5

1.4 Operation...................................................................................................5-9

1.5 Maintenance & Storage............................................................................ 9-10

1.6 Safety Signs........................................................................................... 10-12

2. SPECIFICATIONS

2.1 Model Number............................................................................................. 13

2.2 Engine......................................................................................................... 13

2.3 Fuel System ................................................................................................ 13

2.4 Electri cal System......................................................................................... 13

2.5 Operator Controls........................................................................................ 13

2.6 Seat............................................................................................................. 13

2.7 Hydrostatic Ground Drive System ............................................................... 14

2.8 Tires............................................................................................................ 14

2.9 Mow er Deck ................................................................................................ 14

2.10 Dimensions..................................................................................................14

2.11 Torque Requirements..................................................................................14

3. OPERATION INSTRUCTIONS

3.1 Control s.................................................................................................. 14-16

3.2 Pre-Start...................................................................................................... 16

3.3 Operating Instructions............................................................................17-18

3.4 Transporting........................................................................................... 19-20

4. MAINTENANCE & ADJUSTMENTS

4.1 Periodic Maintenance.............................................................................20-27

4.2 Adjustments ...........................................................................................28-35

5. WASTE DISPOSAL

5.1 Motor Oil Disposal....................................................................................... 35

5.2 Battery Disposal.......................................................................................... 35

6. TROUBLESHOOTING .................................................................................. 35-37

7. ELECTRICAL DIAGRAM ...................................................................................38

8. ELECTRICAL LOGIC SCHEMATIC................................................................... 39

9. HYDRAULIC DIAGRAM .................................................................................... 40

10. WARRANTY ..................................................................................................... 41

11.

EVAPORATIVE EMISSION CONTROL WARRANTY...................................42

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is 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!

The safety alert symbol appears above information which alerts you to unsafe actions or

situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White let t e r ing / Red background. Indicates an im m inent ly hazardous situat ion

which, if not avoided, WILL result in death or serious injur y.

WARNING: Black lettering / Orange background. Indicates a potentially hazardous

situation which, if not avoided, COULD result in deat h or serious injury.

CAUTION: Black lettering / Yellow backg round. Indicates a potentially hazardous

situation which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

1.2.1 Regard t he Exmar k mower as a piece of power equipment and teach this regard to all who operate this unit.

1.2.2 Read the instructions carefully. Familiarize yourself with the controls and the proper use of the equipment. If the operator(s) or m echanic(s) can not read English, it is the owner’s responsibility to explain this mater ial t o them.

1.2.3 Do not allow operation of this machine by untrained personnel. Never allow children, teenagers, or people unfamiliar with these instructions to use the mower. Local regulations may restrict the age of the operator.

1.2.4 Avoid mowing while people, especially children, or pets, are near by. Keep in m ind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

1.3 PREPARATION

1.3.1 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.

1.3.2 The use of personal protective equipment, such as (but not lim ited to) protection for the eyes, ears, feet , and head is r ecom mended.

CAUTION

POTENTIAL HAZARD ♦ This machine produces sound levels in

excess of 85 dBA at the operator’s ear

when in operation. WHAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or

above for extended periods of time can

cause hearing loss. HOW TO AVOID THE HAZARD

♦ Wear hearing protection when operating

this machine.

1.3.3 While mowing, always wear substantial footwear and long trousers. Do not operate equipment when barefoot or when wearing open sandals.

1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operat or or bystander s.

WARNING

POTENTIAL HAZARD ♦ Engine exhaust contains carbon

monoxide, which is an odorless deadly

poison. WHAT CAN HAPPEN ♦ Carbon monoxide can kill you. HOW TO AVOID THE HAZARD

♦ Do not run engine indoors or in a small

confined area where dangerous carbon

monoxide fumes can collect.

DANGER

POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely

flammable and highly explosive. WHAT CAN HAPPEN ♦ A fire or explosion from gasoline can burn

you, others, and cause property damage. HOW TO AVOID THE HAZARD

♦ DO NOT smoke while refueling , and stay

away from an open flame or where gasoline fumes may be ignited by spark .

♦ Refuel only outdoors. ♦ Store gasoline in an approved container

and keep it out of the reach of children.

♦ Add fuel before start ing the engine.

Never remove the cap of the fuel t ank or

add fuel when engine is running or when the engine is hot.

♦ Never fill the fuel tank so that the gasoline

level rises above a level that is 1/2” below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage.

♦ 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.

DANGER

POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely

flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite g asoline

vapors. A fire or explosion from g asoline

can burn you, others, and cause property

damage. HOW TO AVOID THE HAZARD

♦ Purchase and store gasoline only in an

approved container.

♦ 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, r em ove g as- powered

equipment from t he t r uck 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 t r ailer 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 com p let e.

WARNING

POTENTIAL HAZARD ♦ Gasoline vapor can collect inside

enclosed trailers and may be ignited by

electrical sparks or hot engine/ exhaust

components. WHAT CAN HAPPEN ♦ Explosion and fire may occur, resulting in

property damage, personal injury, and/or

death. HOW TO AVOID THE HAZARD

♦ Provide adequate ventilation of any

enclosed trailer to prevent build up of gasoline vapors, especially at floor level.

♦ Refuel only outdoors, never inside an

enclosed trailer.

♦ Be sure all fuel tanks and gasoline

storage containers have proper caps installed to prevent spillage and minimize vapor escaping into the trailer.

♦ Do not place any equipment that is

leaking gasoline in an enclosed trailer.

1.4 OPERATION

Although hazard control and accident prevention are partially dependent upon the

design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence, and proper training of t he personnel i nvolved in the operation, transport, maintenance, and st orage of t he equipment. It is essential that all Operator Safety Mechanisms be connect ed and i n operat i ng condition prior to use for mowing.

WARNING

POTENTIAL HAZARD ♦ Operating engine parts, especially the

muffler, become extremely hot. WHAT CAN HAPPEN

♦ Severe burns can occur on contact. ♦ Debris, such as leaves, grass, brush, etc.

can catch fire. HOW TO AVOID THE HAZARD

♦ Allow engine parts, especially the muff ler ,

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 br ush-

covered unimproved land.

WARNING

POTENTIAL HAZARD ♦ Hands, feet, hair, clothing, or accessories

can become entangled in rotating part s . WHAT CAN HAPPEN ♦ Contact with rotating parts can cause

traumatic amputation or severe

lacerations. HOW TO AVOID THE HAZARD

♦ Do not operate the machine without

guards, shields, and safety devices in place and working.

♦ Keep hands, feet, hair, jewelry, or clothing

away from rotating parts.

1.4.1 Give complete, undivided attention to the job at hand.

1.4.2 Mow only in daylight or good artificial light, keeping away from holes and hidden hazards. NEVER carry passengers.

DO NOT operate the mower when children or others are in the area.

1.4.3 When f easible, avoid operating the equipment in wet grass.

WARNING

POTENTIAL HAZARD ♦ Operating a Navigator tract or without an

approved Exmark front mount at t achm ent increases the possibility of operator entanglement in drive wheels or forward

tip over. WHAT CAN HAPPEN ♦ Entanglement or tip-over could cause

serious injury or death. HOW TO AVOID THE HAZARD

♦ When operating a Navigator tractor

without an approved Exmark front mount attachment, observe the following:

9 Keep feet and clothing away from tires.

9 Limit operation to minimum required to

install a different front mount attachment.

9 Minimize speed and use extreme

caution.

9 Only operate on a flat level surface.

9 Do not operate up or down a trailer

ramp.

9 Avoid sudden acceleration or

deceleration.

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tr action and/or tip-over could occur. The operator is r esponsible for safe operation on slopes.

DANGER

POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can

cause sliding and loss of control. WHAT CAN HAPPEN ♦ Wheels dropping over edges, ditches,

steep banks, or water can cause

rollovers, which may result in serious

injury, death or drowning. HOW TO AVOID THE HAZARD

♦ 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.

♦ Reduce speed and use extreme caution

on slopes.

♦ Avoid sudden turns or rapid speed

changes.

• See inside the back cover to determine the approximate slope angle of t he area to be mowed.

• Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep banks or water. This area can be dangerous, see Figure 1.

FIGURE 1

• Progr essively great er care is needed as the slope increases.

• Always avoid sudden starting or stopping on a slope. I f tires lose traction,

disengage the blades and proceed slowly off the slope.

• Avoid sudden stops when mowing downhill. Mower may tip forwards.

• Be aware that loss of traction may occur going uphill. Weight tr ansfer to the

rear wheel may cause drive wheels to slip and cause loss of braking and steering.

• Watch for ditches, holes, rocks, dips, and rises that chang e t he oper ating angle, as rough terrain could overtur n the machine.

• Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing area. Tall grass can hide obstacles.

• Use extreme care with attachm ent s. These can change the stability of the machine and cause loss of control.

• Follow the manufact urer’s recommendations for wheel weights or counterweights to improve stability.

1.4.5 Use EXTREME caution when backing up. LOOK BEHI ND YOU!

1.4.6 Stop the blades when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed.

1.4.7 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.

1.4.8 DO NOT change the engine governor settings or overspeed the engine. Operating an engine at excessive speed may increase the hazard of personal injury.

1.4.9 Disengage PTO befor e starting engine.

1.4.10 Start

the engine carefully with feet well away from the blades.

1.4.11 Keep hands, feet, and clothing away from r otat ing par ts while the mower is being operated.

1.4.12 Stop engine, wait for all moving parts t o stop, and remove key. Eng age parking brake:

• Before checking, cleaning or work ing on the mower.

• After striking a foreign object (inspect the m ower for damage and make

repairs before restart ing and operating the mower).

• Before clearing blockages.

• Whenever you leave the mower.

Stop the engine and wait for all moving part s t o stop:

• Before refueling.

• Before dumping the gr ass cat c her .

1.4.13 Before stopping the engine, place the throt t le cont r ol midway between the “slow” and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then stop the engine.

1.4.14 The f uel system is pr ovided with a shut-off valve. Shut off the fuel:

• When the machine will not be used for a few days.

• During transport to and from the job.

• When parked inside a building.

1.4.15 This mower was designed fo r one oper at or only. Keep all others away from mower during operation.

1.4.16 DO NO T m ow with the grass cat cher door or the grass catcher raised, removed or altered.

1.4.17 DO NO T oper ate mower under the influence of alcohol or drug s.

1.4.18 Use extra care when approaching blind corners, shr ubs, trees, or other objects that may obscure vision.

1.4.19 If jump starting is required: a) connect the positive (+) power cable from the positive post on the booster

battery to the positive terminal post on the star ter solenoid switch (this post has the positive battery cable attached to it).

b) connect the negative or ground cable (-) from t he negative post on the

booster battery to the engine block as far away from the battery as possible.

c) disconnect battery cables in the reverse order after starting.

1.5 MAINTENANCE AND STORAGE

1.5.1 For engine m aint enance, follow the engine manufacturer’s recommendations

precisely as stated in the engine manual.

1.5.2 Disconnect the battery cable from the negative batter y post when the unit will be

allowed to sit for more than 30 days without use.

1.5.3 Allowing batteries to st and for an extended period of time without recharg ing

them will result in reduced performance and ser vice life. To preserve optimum battery performance and lif e, 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 storag e.

1.5.4 Keep engine, engine area, and pump drive belt compartment free from

accumulation of grass, leaves, excessive grease or oil, and ot her debris which can accumulate in these areas. These materials can become com bustible and may result in a fire.

1.5.5 Store fuel in a container specifically designed for this purpose in a cool, dry place.

1.5.6 Keep the mower and f uel cont ainer in locked storage to prevent children f r om

playing or tampering with them.

1.5.7 Gasoline powered equipment or fuel containers should not be stored in a basement or

any enclosed area where open pilot lights or heat appliances are present.

1.5.8 Maximum mowing results and safet y can only be achieved if the m ower is properly

maintained and operated correctly.

1.5.9 Check all bolts frequently to maintain proper tightness.

1.5.10 Keep all guards, shields, and all safety devices in place and in safe working condit ion.

1.5.11 Frequently check for worn or deteriorating components that could create a hazard.

1.5.12 All replacement parts must be the same as or eq uivalent t o t he parts supplied as

original equipment.

WARNING

POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure

can penetrate skin and cause injury. WHAT CAN HAPPEN ♦ Fluid accidentally injected into the skin

must be surgically removed within a few

hours by a doctor familiar with this for m of

injury or gangrene may result. HOW TO AVOID THE HAZARD

♦ Make sure all hydraulic fluid hoses and

lines are in good condition an 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 perf o r m ing any work on

the hydraulic system.

1.6 SAFETY SIGNS

1.6.1 Keep all safety signs legible. Remove all gr ease, dirt and debris from safe t y signs and instructional labels.

1.6.2 Safety signs must be replaced if they are missing or illegible.

1.6.3 When new components are installed, be sur e that current safety signs are affixed to the replaced components.

1.6.4 New safety signs may be obtained from Exmark Mfg. Co. Inc.

1.6.5 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 air bubbles.

1.6.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They are critical to the safe operat ion of your Exmark commercial mower.

LOCATION: Molded in LH Console

PART NO. 98-4361 LOCATION: - On Top of Pump Mounting Plate

- On PTO Shield

PART NO. 79-0360 LOCATION: On Front of Blower

Discharge Chute

PART NO. 103-8451 LOCATION: On RH Console

PART NO. 103-8425 LOCATION: - On front console,

- On driveshaft

Under Seat

PART NO. 103-9034 LOCATION: On Rear of LH Drive

Wheel Fender

WARNING

PART NO. 65-2690 LOCATION: - On Frame LH side in Front

- On Frame RH side behind

HOT

SURFACE

65-2690

of Exhaust Cutout Exhaust Cutout

PART NO. 98-5954 LOCATION: - On Gear Box Cover, Under Rubber Cover

- On Top of Deck, Under Gear Box Cover

- On LH Frame, Under PTO Shield

- On RH Lower Frame, behind fuel tank

PART NO. 103-8812 LOCATION: On RH Console

PART NO. 103-8444 LOCATION: On Hopper Door Hinge, Each Side

PART NO. 103-8495 LOCATION: On Top of Mainframe, Under Hopper

PART NO. 1-513747 LOCATION: On Battery Cover

PART NO. 103-8611 LOCATION: On Pump

Plate, Above Relays

PART NO. 103-9724 LOCATION: On PTO Guard

PART NO. 1-523552 LOCATION: On Top of Oil

Reservoir

LOCATION: Molded into Front

of Hopper

PART NO. 103-9032 LOCATION: On Back of Seat

PART NO.: 109-4273 LOCATION: Top of Console

Under Seat

2. SPECIFICATIONS

2.1 MODEL NUMBER: NAV20KC, NAV27KC

2.2 ENGINE:

2.2.1 Engine Specif ications: See your Engine Owner’s Manual

2.2.2 RPM: Full Speed: 3600 ± 50 RPM (No Load) Idle: 1500 RPM

2.3 FUEL SYSTEM

2.3.1 Capacity: 7.5 g al (28 L)

2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or hig her

2.3.3 Fuel Filter: Kohler units: In-line 15 Micron Kohler P/N 2405010.

2.3.4 Fuel Shut-O ff Valve: 1/4 turn “in-line” valve by fuel filter.

2.4 ELECTRICAL SYSTEM

2.4.1 Charging System: Flywheel Alternator

2.4.2 Charging Capacity: 15 amps

2.4.3 Battery T ype: BCI Group U1

2.4.4 Batter y Voltage: 12 Volt

2.4.5 Polarity: Nega t ive Gr ound

2.4.6 Safet y Int er lock System:

PTO must be disengaged, brake engaged, and speed control lever i n neut ral

position to start engine. (It is not necessary for the operat or 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 the speed control lever is moved from neutral posi t i on while brake is engaged.

• If the PTO is engaged while the hopper is tilted up.

2.5 OPERATOR CONTROLS

2.5.1 St eering and Motion Control:

Speed Control lever, located on RH console, sets maximum forward speed. Steering levers, centered in front of the seat, control t he speed and dir ection 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 t he neutral

position by pulling back on the steering levers.

2.5.2 PTO Engagement Lever

2.5.3 Par king Brake Lever

: Pull back to engage parking brake.

2.6 SEAT

2.6.1 Type: Standard seat with high back, foam padded (internal suspension) .

2.6.2 Mounting: Seat is hing ed to tilt up for access to hydraulic pumps and other com ponents. The seat is held in the tilted position with a link.

2.6.3 Seat Saf ety Switch: Internal to the bottom seat cushion, non ser viceable. Time delay module incorporated into the Safet y Int erlock System eliminates rough gr ound cut outs.

2.6.4 Armrest: None

: Engages drive to PTO (mower deck) and blower.

2.7 HYDROSTATIC GROUND DRIVE SYSTEM

2.7.1 Hydrostatic Pumps: Two Hydro Gear variable displacement piston pumps.

2.7.2 Wheel Motors: Hydro Gear planetary reduction mot ors.

2.7.3 Hydraulic Oil Type: Use Mobil 1 15W-50 Synthetic Motor Oil.

2.7.4 Hydraulic Oil Capacity: 4.0 qt. (3.8 L.)

2.7.5 Hydraulic Filter: Replaceable car tridge type.

P/N 109-0071: 25 microns, 10 psi bypass (Summer use above 32° F (0°C))

P/N 1-523541: 40 microns, 18 psi bypass (Winter use below 32° F (0°C))

2.7.6 Speeds: 0-7.0 m ph ( 11.3 Km/hr) forward

0-5.5.mph (8.6 km/hr) reverse

2.7.7 Drive wheel release valves allow machine to be moved when engine is not running.

2.8 TIRES

Pneumatic (Air-Filled) Semi-Pneumatic Semi-Pneumatic Quantity 2 2 1 Tread Multi Trac C/S Smooth Smooth Size 18 x 10.50-10 8 x 3.00-4 13 x 8.00-6 Ply Rating 4 Pressure 15 psi (103 kPa)

Drive Front Caster Rear Caster

2.9 MOWER DECK ( Sold Separ ately)

2.9.1

2.9.2 Deck Drive: Clutching belt on horizontal engine shaft. Dual “ A” section hexagon

2.10 DIMENSIONS

Overall Width 42.6” (108.2 cm) 43.2” (109.7 cm) 49.2” (125.0 cm) Overall Height 51.2” (130.0 cm) 51.2” (130.0 cm) 51.2” (130.0 cm) Overall Length 67.3” (170.9 cm) 91.8” (233.2 cm) 94.5” (240.0 cm) Curb Weight 850 lbs (386 kg) 1145 lbs (519 kg) 1170 lbs (531 kg)

Tread Width (Center to Center of Drive Wheels) Wheel Base (Center of Drive Wheel to Center of Rear Caster Wheel)

Models CD42CD CD48CD

Discharge Center Discharge Center Discharge Cutting Width 42 in. (106.7 cm) 48 in. (121.9 cm)

belt with spring tensioned idler to jackshaft and blower. Heavy-duty cast iron, spiral bevel gearbox is final drive to blades.

Without deck With 42” Deck With 48” Deck

32.7” (83.1 cm)

44.2” (112.3 cm)

2.11 TORQUE REQUIREMENTS Bolt Location

Torque

Blade Mounting Bolt.....................................................85-110 ft-lbs. (115-149 N-m)

Engine Mounting Bolts ......................................................30-35 ft-lbs. (41-47 N-m)

Wheel Lug Nuts.............................................................90-95 ft-lbs. (122-129 N-m)

Wheel Motor Mounting Bolts............................................72-77 ft -lbs. (98-104 N-m)

3. OPERATION INSTRUCTIONS

3.1 CONTROLS

3.1.1 Familiarize yourself with all controls before operating the mower.

3.1.2 Steering and Motion Control Speed Control lever, located on RH console, sets maximum forward speed.

Moving speed control lever rearward to the neutral position places the drive system in neutral.

Pulling back on the steering levers, cent er ed in front of the seat, pr ogressively slows, then reverses the direction of travel of t he respective drive wheels.

By moving both steering levers an equal amount back, the machine can be slowed down or travel backward in a straight line.

Steering is controlled by varying the position of the steering levers relative to each other.

To turn left while moving forward, move the left steering lever back toward neutral to slow the left drive wheel.

To turn right wile moving forward, move the right steering lever back toward neutral to slow the right drive wheel.

To turn to the left while backing, move the left lever f o r ward toward neutral. To turn to the right while backing , m ove the right lever forward toward neutral.

NOTE: The unit may be moved in reverse while the speed control is in t he neutral position by pulling back on the steering levers.

CAUTION

POTENTIAL HAZARD ♦ Machine can spin very rapidly by

positioning one lever too much ahead of

the other. WHAT CAN HAPPEN ♦ Operator may lose control of the

machine, which may cause damage to

the machine or injury. HOW TO AVOID THE HAZARD

♦ Use caution when making turns.

♦ Slow the machine down before making

sharp turns.

3.1.3 Tracking Adjustment Knob: Located under the seat on the left pump control link. Rotating this k nob allows f ine t uning adjustments so that the machine tracks straight.

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 m achine t racks 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 section 4.2. 8 f or cont rol l inkage adjustment.

3.1.4 PTO Engagement Lever 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.

3.1.5 Choke Control Choke is used to aid in starting a cold engine. Moving the choke lever forward

will put the choke in the “ON” position and moving the choke lever t o t he rear will put the choke in the “OFF” position. DO NO T r un a warm engine with choke in the “ON” position.

: Located on right hand console.

: Located immediately left of the left console.

3.1.6 Throttle Control 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.

3.1.7 Brake Lever 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 transpor ting.

3.1.8 Ignition Switch 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 “ON” position. Rotat e clockwise to the next position to engage the star t er (key must be held against spring pr essur e in t his position).

Brake must be engaged, speed control lever in neutral and PTO l ever “OFF” to start engine. (It is not necessar y for the operator to be in the seat to

start the engine.)

3.1.9 Hour Meter a pressure switch installed in the engine block and it recor ds t he num ber 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.

3.1.10 Engine Oil Temperat ur e Light and Buzzer: 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.

3.1.11 Fuel Shut-Off Valve raising the hopper). The fuel shut-off valve is used to shut off the fuel when the machine will not be used for a few days, during transpor t t o and from the job site, and when parked inside a building.

3.1.12 Drive W heel Release Valves 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, t ur n both valves one turn counter-clockwise to release drive system. Turn clockwise to reset system. DO NOT overtighten. DO NOT tow machine.

: Located on right hand console.

: Located on left side of unit , between the seat and console. The

: Located on the right hand console.

: Located on the right hand console. The hour m et er is connected to

: Located in fuel line by fuel tank and fuel filter (accessible by

: Located on the top left front corner of hydrostatic

Located on the right console. The

3.2 PRE-START

3.2.1 Fill fuel tank. For best results use only clean, fresh regular g rade unleaded gasoline with an octane rating of 87 or higher. Regular grade leaded g asoline 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 t ank. Never fill the fuel t ank so that the fuel level rises

above a level that is 1/2” below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage.

3.2.2 Make sure you understand the contr ols, their locations, their functions, and t heir safety requirements.

3.2.3 Refer t o Maintenance, Sect ion 4, and perform all the necessary inspection and maintenance steps.

3.3 OPERATING INSTRUCTIONS

3.3.1 Open fuel shut-of f valve: The fuel shut-of f valve is located on the right side of unit in fuel line next to the fuel

filter. Raise the hopper to access.

3.3.2 Starting Engine

Brake must be engaged, speed control lever in neutral position and PTO lever “OFF” to start engine. (It is not necessar y for the operator to be in the

seat to start the engine.) On a cold engine, place the throttle midway between the “SLOW” and “FAST”

positions and push choke lever forward into the “ON” position. Turn ignition switch to the “start” position. Release the switch as soon as the engine starts.

IMPORTANT:

DO NOT crank the engine continuously for more then ten (10) seconds at a time. If the engine does not start, allow a 60 second cooldown period between starting attempts. Failure to f ol l ow these guidelines can burn out the starter motor.

After starting a cold engine, gradually return choke to the “OFF” position as the engine warms up.

On a warm engine, place the throttle midway between the “SLOW” and “FAST” positions and leave the choke in the “OFF” position.

3.3.3 Engaging PTO

DANGER

POTENTIAL HAZARD ♦ The rotating blades under the mower

deck are dangerous. WHAT CAN HAPPEN ♦ Blade contact can cause serious injury or

kill you. HOW TO AVOID THE HAZARD

♦ DO NOT put hands or feet under the

mower or mower deck when the blades

are engaged.

DANGER

POTENTIAL HAZARD ♦ An uncovered discharge opening will

allow objects to be thrown in an

operator’s or bystander’s direction. Also,

contact with the blade could occur. WHAT CAN HAPPEN ♦ Thrown objects or blade contact can

cause serious injury or death. HOW TO AVOID THE HAZARD

♦ Always operate the mower with the grass

catcher down and with the grass catcher

door securely closed.

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 and hopper must be dow n bef ore

the PTO can be engaged.

Set throttle to "midway" position. Pull PTO lever upward until locked over center. Accelerate to full throttle to begin mowing.

3.3.4 Stopping PTO

: Set throttle to the “midway” position. Push PTO lever down to

the “STOP” position stopping t he PTO and blower.

3.3.5 Stopping Engine

: Bring unit to a full stop. Disengage the PTO, move speed

control lever to the neutral position and set t he parki ng brake. Before stopping the eng ine, place t he throttle control midway between the “slow”

and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then stop the engine.

Rotate ignition switch to “OFF” posit ion. Rem o ve the key to prevent children or other unauthorized persons from star t ing engine.

Close fuel shut-off valve when machine will not be used for a few days, when transporting, and when the unit is park ed inside a building.

3.3.6 Emptying Hopper

a) A full hopper is indicated by a buzzer located behind the operator in the

hopper. Empty hopper when buzzer sounds to prevent clogging of t he blower or deck

b) Disengage PTO, move speed control to neutral, set par k brake and

dismount unit to dump hopper. c) Make sure unit is on a dry level surface. d) Lift the rear door up and allow it to rest on top of hopper. e) Dump hopper by firmly grasping one of the hopper handles on either side of

the unit and lifting the hopper .

3.3.7 Clearing Hopper Screen

: a) Screen may be removed by firmly lifting screen handles. See Figure 2. b) Pull screen towards the back to remove. Gently tap debris from the scr een

as needed.

c) Excessive build-up on the screen can cause the blower to plug.

NOTE: In conditions where the screen clogs quickly, the front removable screen panel can be turned and reinstalled under the primar y screen to allow free air flow from the hopper.

FIGURE 2

3.4 TRANSPORTING

IMPORTANT: Do not transport Navigator tractor without an approved Exmark f r ont

mount attachment.

3.4.1 Transpor t ing a Unit brake and block wheels. Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Be sure t hat the trailer or truck has all necessary lighting and marking as required by law. Secure the trailer with a safet y chain.

POTENTIAL HAZARD ♦ This unit does not have proper turn

signals, lights, reflective markings, or a slow moving vehicle emblem. These items are required to drive on a public street or roadway.

WHAT CAN HAPPEN ♦ Driving on a street or roadway without

such equipment is dangerous and can lead to accidents causing personal injury.

♦ Driving on a street or roadway without

such equipment may also be a violation of State laws and the operator may be subject to traff ic tickets and/or fines.

HOW TO AVOID THE HAZARD

♦ Do not drive a unit on a public street or

roadway.

: Use a heavy-duty trailer or truck to tr anspor t the machine. Lock

CAUTION

WARNING

POTENTIAL HAZARD ♦ Loading a unit on a trailer or truck

increases the possibility of tip-over. WHAT CAN HAPPEN ♦ Tip-over of the unit could cause serious

injury or death. HOW TO AVOID THE HAZARD

♦ 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 surface wider than the unit.

♦ DO NOT exceed a 15° angle between

ramp and ground or between ramp and trailer or truck.

♦ Avoid sudden acceleration while driving

unit on a ramp.

3.4.2 Loading a Unit

: Use extreme caution when loading units on trailers or t rucks. One full width ramp is required. I f 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 tr uck do not exceed 15°. A steeper angle may cause mower deck components to get caught as t he unit moves from ramp to trailer or truck. St eeper angles may also cause the unit to tip. If loading on or near a slope, position the trailer or tr uck so it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp ang le. The trailer or truck should be as level as possible.

DO NOT attempt to tur n t he unit while on the ramp, you may lose control and drive off the side.

Avoid sudden acceleration when driving on a ramp.

4. MAINTENANCE & ADJUSTMENTS

WARNING

POTENTIAL HAZARD ♦ While maintenance or adjustments are

being made, someone could start the

engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could

seriously injure you or other bystanders. HOW TO AVOID THE HAZARD

♦ Remove the key from the ignition switch

and pull the wire(s) off the spar k plug(s)

before you do any maintenance. Also

push the wire(s) aside so it does not

accidentally contact the spark plug(s) .

WARNING

POTENTIAL HAZARD ♦ The engine can become very hot. WHAT CAN HAPPEN ♦ Touching a hot engine can cause severe

burns. HOW TO AVOID THE HAZARD

♦ Allow the engine to cool completely before

service or making repairs around the

engine area.

4.1 PERIODIC MAINTENANCE

4.1.1 Check engine oil level:

Service Interval: Daily

a) Stop engine and wait for all moving parts to stop. Make sure unit is on a

level surface.

b) Check with engine cold. c) Raise hopper. d) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert t he

dipstick and push it all the way down into the tube. Remove the dipstick and read the oil level.

e) If the oil level is low, wipe off the area around the oil fill cap, r e m ove 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.

4.1.2 Check battery charge

Service Interval: Monthly

Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and ser vice life. To preserve optimum battery performance and lif e, 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 storag e.

a) Check the voltage of the battery with a digital voltmeter . Locate the voltage

reading of the batter y in the t able below and charge the battery for the recommended time interval to bring t he 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 char ging the battery has an output of 16 volts and 7 amps or less to avoid damaging the batter y (see char t below for recommended charger settings).

Voltage

Reading

12.6 or greater 100% 16 volts/7 amps No Charging Required

12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes

12.2 – 12.4 50 – 75% 16 volts/7 amps 1 Hour

12.0 – 12.2 25 – 50% 14.4 volts/ 4 am ps 2 Hours

11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours

11.7 or less 0% 14.4 volts/2 amps 6 Hours or More

Percent

Charge

Maximum

Charger Settings

Charging Interval

4.1.3 Clean engine cooling system:

Service Interval: Daily or more often in dry condi t i ons

CAUTION

POTENTIAL HAZARD ♦ Excessive debris can cause the engine

and hydraulic system to overheat. WHAT CAN HAPPEN ♦ Excessive debris around the engine

cooling air intake and drive belts can

create a fire hazard. HOW TO AVOID THE HAZARD

♦ Clean all debris from around engine and

drive belts daily.

a) Stop engine, wait for all moving part s to stop, and remove key. Engage

parking brake.

b) Clean all debris from rotating engine air intake scr een and from around

engine shrouding. c) Clean all debris from around eng ine and dr ive belts. d) For 27HP Kohler units: Swing out the fuel tank and rem ove debris from

around the oil cooler positioned at right front corner of eng ine.

4.1.4 Check safety interlock system

Service Interval: Daily

a) Check starting circuit. Starter should cr ank with, parking brake engaged,

PTO disengaged and speed control lever in the neut ral position. The operator does not need to be in the seat to star t the engine.

Try to start with operator in seat, parking brak e disengaged, PTO

disengaged and speed control lever in the neutral position - starter must not crank.

Try to start with operator in seat, parking brak e engaged, PTO engaged and speed control lever in the neutral position - star ter must not crank.

Try to start with operator in seat, parking brak e engaged, PTO

disengaged, and the speed control lever forward (out of neutral), starter must not crank.

b) 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 stop after approx. 1/2 second has elapsed (seat has t im e delay kill switch to prevent cut-outs on rough terrain) .

Run engine at one-third throttle, engage PTO and raise off of seat (but do not get off of machine) engine must stop af t er 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.

4.1.5 Check for loose hardware

Service Interval: Daily

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake.

b) Visually inspect machine for any loose hardware or any other possible

problem. Tighten hardware or correct the problem before operating .

4.1.6 Service air cleaner

Service Interval: 50 hrs.

More often under severe conditions. See Engine manual for additional information.

a) Stop engine, wait for all moving parts to stop, and remove. b) Tilt hopper up to gain access to the air cleaner. c) Loosen retaining clips and rem ove air cleaner com par tment cover. d) Remove paper element. Check the condition of the paper element.

Replace if dirty, bent or damag ed.

e) 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 r em oving, so dir t does not get into the engine.

f) DO NO T wash or use pressur ized air to clean paper element or inner element. g) Reinstall elements. Position the cover so that the rubber dust ejector is

pointing downward and secure with retaining clips.

4.1.7 Change engine oil

Service Interval: 100 hrs.

NOTE: Change oil and filter after first five (5) hrs. of operation.

a) Stop engine, wait for all m oving par ts to stop, and remove key. Engag e

parking brake. b) Tilt hopper up to gain access to the engine area. c) Drain oil while engine is warm from operation. d) The oil drain valve is located on left hand side of engine at the back of t he

unit.

Place pan under machine to catch oil and open valve. Allow oil to drain,

then close valve. e) Replace the oil filter every ot her oil change. Clean around oil filter and

unscrew filter to remove. Bef ore reinstalling new filter, apply a thin coating of

oil on the surface of the r ubber seal. Turn filter clock wise until rubber seal

contacts the filter adapt er t hen tighten filter an additional 2/3 to 3/4 turn. f) Clean around oil fill cap and remove cap. Fill to specified capacity and replace

cap. Use oil recommended in engine owner’s manual. DO NO T overfill. g) Lower hopper. h) Start the engine and check for leaks.

4.1.8 Check hydraulic oil level

Service Interval: 40 hr.

a) Stop engine and wait for all m oving par ts to stop. b) Tilt hopper up. c) Clean area around hydraulic reservoir cap and remove cap. Oil level should

be to the top of the baf fle inside the tank. If not, add oil. Use only Mobil 1

15W-50 synthetic motor oil. Replace hydraulic reservoir cap and tighten

until snug. Do not overtighten.

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 appropriat e 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 temperatur e

(about 75° F (24°C)), fill only to the “COLD” level.

4.1.9 Check tire pressures

Service Interval: 40 hrs.

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Check tire pressure in drive tires. Inflate drive tires to 15 psi (103 k Pa). c) 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.

Excessive 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.

4.1.10 Check condition of belts:

Service Interval: 40 hrs.

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Tilt hopper up and check pum p and PTO drive belts. c) Belts are spring tensioned and no adjustment is necessary unless belts ar e

replaced. See section 4.2.2 and 4.2.3 f or belt replacement.

4.1.11 Lubricate gr ease fittings

Service Interval: Refer to chart.

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Lubricate fittings with one to two pumps of NGLI grade #2 multi- pur pose

gun grease.

Refer to the following chart for fitting locations and lubrication schedule.

LUBRICATION CHART

FITTING

LOCATIONS

1. Caster Pivot *0 3 *yearly

2. PTO Idler 1 1 yearly

3. Pump Idler 1 1 yearly

4. Rear Caster Hub *0 1 or 2 *yearly

INITIAL

PUMPS

NO. of

PLACES

SERVICE

INTERVAL

* See Section 4.1.11 c) for special lubrication

instructions on the front and rear caster pivots and Section 4.1.12 for special lubrication inst r uctions on the rear caster wheel hub.

c) Lubricate caster pivots once a year. Remove hex plug and cap. Thread

grease zerk in hole and pump with grease until it oozes out around top bearing.

Remove grease zerk and thread plug back in. Place cap back on.

4.1.12 Lubricate rear cast er wheel hub:

Service Interval: Once Yearly

a) Stop engine, wait for all moving parts to

stop, and remove key. Engage park ing

brake. b) Remove caster wheel from caster forks. c) Remove seal guards from t he wheel hub. d) 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) fr om t he wheel

assembly. e) Pry out seals, and inspect bearings for wear

or damage and replace if necessary. f) Pack the bearings with a NGLI grade #1 multi-purpose grease. g) Insert (1) bearing, (1) new seal into the wheel.

NOTE: Seals (Exmark PN 103-0063) must be replaced.

FIGURE 3

h) If the axle assembly has had both spacer nuts removed (or broken loose),

apply a thread locking adhesive to (1) spacer nut and thr ead onto the axle

with the wrench flats facing outward. Do not thr ead spacer nut all of the way

onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer

surface of the spacer nut to the end of the axle inside the nut. i) Insert the assembled nut and axle into the wheel on the side of the wheel

with the new seal and bearing. j) With the open end of the wheel facing up, fill the area inside the wheel

around the axle full of NGLI grade #1 multi-purpose grease. k) Insert the second bearing and new seal into the wheel. l) Apply a thread locking adhesive to the 2

with the wrench flats facing outward. m) T or que the nut to 75-80 in-lbs. (8-9 N-m ) , loosen, then re-torque to

20-25 in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut . n) Re-install the seal guards over the wheel hub and insert wheel into caster

fork. Re-install cast er bolt and tighten nut fully.

IMPORTANT: To prevent seal and bearing damage, check the bearing

adjustment often. Spin t he 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. Re-apply

threadlocking adhesive.

4.1.13 Lubricate hopper actuator:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and r em o ve k ey. Engage

parking brake. b) Raise hopper and locate actuator on right hand side of mainframe. c) Lubricate switch actuator rod with spray type lubricant or light oil.

4.1.14 Lubricate the pivot bushing s ( locat ions shown in Figur e 3)

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and r em o ve k ey. Engage

parking brake. b) Lubricate bronze bushings on brake handle pivot with a spray type lubricant

or light oil.

spacer nut and thread onto the axle

LEFT SIDE OF UNIT SHOWN

FIGURE 4

4.1.15 Lubricate brake rod bushings

Service Interval: 160 hrs.

a) Stop engine, wait for all m oving par ts to stop, and remove key. Engage

parking brake.

b) Unhook seat latch and tilt seat up.

c) Lubricate bronze bushings on each end of brake rod shaft with a spray type

lubricant or a light oil (bushings ar e locat ed to the inside of the flange bear ings).

4.1.16 Lubricate steer ing linkage rod ends

Service Interval : 160 hrs.

a) Stop engine, wait for all moving parts to stop, and rem ove k ey. Engage parking

brake.

b) Tilt seat up. c) Lubricate each end of both steering linkage rods with a spray lubricant or a light

oil.

4.1.17 Remove engine shrouds and clean cooling fins

Service Interval: 80 hrs.

a) Stop engine, wait for all moving parts to stop, and r em o ve k ey. Engage

parking brake. b) Remove cooling shroud clean-out covers from engine and clean cooling f ins.

Also clean dust, dirt, and oil from exter nal sur faces of engine, which can cause

improper cooling. c) Make sure cooling shroud clean-out covers are r einst alled. Operating the

engine without cooling shroud clean-out covers will cause engine damage due

to overheating.

4.1.18 Check spark plugs

Service Interval: 160 hrs.

a) Remove spark plugs, check condition and reset gaps, or replace with new

plugs. See Engine Owners Manual.

4.1.19 Change fuel filter

Service Interval: As Required

a) A fuel filter is installed between the fuel tank and t he engine. Replace when

necessary.

Replacement Filters

Kohler P/N 2405010

4.1.20 Change hydraulic system filter:

Service Interval: After First 250 hrs. Then yearly thereafter

NOTE: Use only Exmark Part No.109-0071 for summer use above 32°

or Part No. 1-523541 for winter use below 32°

F (0°C).

a) Stop engine, wait for all moving parts t o stop, and remove key. Engage

parking brake.

b) Carefully clean area around filter. It is important that no dirt or

contamination enter hydraulic system.

c) Unscrew filter t o remove and allow oil to drain from reservoir.

IMPORTANT: Before reinstalling new filter, fill it with Mobil 1 15W-50 and apply a thin coat of oil on the surface of the rubber seal.

Turn filter clock wise until rubber seal contacts the filter adapter , then tighten the filter an addit ional 2/ 3 to 3/4 turn.

d) Fill reservoir as stated in Section 4.1.8.

F (0°C)

CAUTION

POTENTIAL HAZARD ♦ Raising the mower deck for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

could cause injury. HOW TO AVOID THE HAZARD

♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

jack stands or equivalent support.

e) Raise the drive wheels off of the ground and suppor t with jack stands (or

equivalent support) just high enough to allow drive wheels to turn freely.

f) Start engine and move throt tle control ahead to full throttle position. Move

the speed control lever to the full speed and run for several minutes. Shut down machine and recheck oil level.

Do not change hydraulic system oil (except for what can be drained when changing filter), unless it is felt the oil has been contaminat ed or been extremely hot.

Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system.

4.1.21 Wheel Hub

Service Interval: 500 hrs

a) Torque the lock nut to 125 ft-lbs (169 N-m).

4.1.22 Fuel Tank When installing the nuts on the fuel tank studs, fully tighten the nyloc nut and

back off 1/2 t ur n. This allows for normal fuel tank expansion and contraction with changes in temperature and f uel levels.

4.1.23 Thread lock ing adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type” are used on the following fasteners:

a) Pump drive sheave set screws. b) Squar e head set scr ews on Hydro pump contr ol ar m s. c) Sheave retaining bolt in the end of eng ine cr ankshaft, blower shaft and

d) Caster wheel spacer nuts e) Fuel tank bulkhead fitting nuts.

4.1.24 Dielectric grease is used on blade type electrical connections to prevent corrosion and loss of contact. Do not apply grease to sealed connect ors inside hopper.

– lock nut torque specif icat ion

When tig ht ening the lock nut on the wheel motor tapered shaft:

NOTE: Do not use antisieze on wheel hub.

– mounting hardware specification

jackshaft.

4.2 ADJUSTMENTS

IMPORTANT: 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.

4.2.1 Pump Drive Belt Tension

Spring Tensioned - No adjustment necessary.

4.2.2 PTO Belt Replacement a) Stop eng ine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) With engine “off”, engage PT O lever, then remove the hairpin and clevis

pin at the bottom of the PTO brake band.

c) Rotate the brake band upwards out of t he way of the belts keeping clear of

the belt drive. d) Disengage PTO lever. e) Loosen belt g uides A and B (See Figure 5). f) Remove current belts. g) Route new belts onto sheaves as shown in the decal located on the back of

the left drive shield. See Figure 5.

h) Engage the PTO lever. i) Rotate brake band back down into original position. j) Re-install clevis pin and hairpin to secure br ake band. k) Engage the PTO lever. l) Loosen the jam nut s and adjust linkage until the top of the idler arm is

aligned with the bottom of notch on tension arm as shown in Figure 6.

FIGURE 5

FIGURE 6

m) Tighten jam nuts and disengage PTO lever. Re-engage PTO lever and

check alignment. n) Check and adjust belt guides per 4.2.4.

4.2.3 Pump Drive Belt Replacement. a) Stop eng ine, wait for all moving parts to stop, and remove key. Engage

parking brake. b) Remove PTO Belt s. See section 4.2.2 for removal instruct ions. c) Pull spring idler or remove spring t o r e lieve pump dr ive belt t ension.

Remove old belt. d) Route new belt onto sheaves as shown in the decal located on the back of

the left drive shield. See Figure 7. e) Reinstall PT O Belts as stated in section 4.2.2.

FIGURE 7

4.2.4 Belt Guide Adjustment a) Stop eng ine, wait for all moving parts to stop, and remove key. Engage

parking brake. b) Engage PTO lever. c) Adjust belt guides as shown in Figure 8.

FIGURE 8

4.2.5 Adjust Safety Switch a) Adjust all safety switches so plunger extends 3/16”-1/4” (4.8 mm-6.4 mm)

from switch body when plunger is compressed (See Figure 9).

FIGURE 9

4.2.6 Brake Adjustment

Check to make sure each brak e is adjusted properly.

a) Pull the brake lever up and back to the engaged position.

b) A gap must exist between the bottom of the brake bolt head and the top surface

of the brake swivel as shown in Figure 10. If a gap does not exist, adjust the linkage to a maximum gap of 0. 5” ± 0.13” (1.3 cm ± 0.33 cm) as shown.

c) The brakes on both sides can be simultaneously adjusted by leng t hening or

shortening the linkage shown in Figur e 10.

FIGURE 10

d) If individual adjustment is necessary, loosen the jam nut on the brake bolt that

is against the clevis connected to the brake arm on the wheel motor. Turn the

brake bolt to achieve proper adjustment . e) Tighten the jam nut against the clevis. f) Repeat for other side of unit . g) Engage and diseng age the brakes to check f or pr oper engagement and

disengagement. Readjust if necessary. When t he br akes are disengaged,

there should be free play in the brake linkage with no dragging in the brakes.

4.2.7 Adjust Speed Control Lever Tension a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake.

b) Tension in speed control lever can be adjusted by adjusting the tightness of

the lever pivot bolt, which is located under the seat near the speed control lever. See Figure 11.

c) Set the tension high enough that the speed control lever position is

maintained during operation and loose enough t o be m oved comfortably by the operator.

FIGURE 11

4.2.8 Motion control linkage adjustment

WARNING

POTENTIAL HAZARD ♦ Engine must be running and drive wheels

must be turning so motion control

adjustment can be performed. WHAT CAN HAPPEN ♦ Contact with moving parts or hot surfaces

may cause personal injury. HOW TO AVOID THE HAZARD

♦ Keep fingers, hands, and clothing clear of

rotating components and hot surf aces.

CAUTION

POTENTIAL HAZARD ♦ Raising the mower deck for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

could cause injury. HOW TO AVOID THE HAZARD

♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

jack stands or equivalent support.

Adjust steer ing lever s:

a) Stop engine and wait for all m oving par ts to stop. b) Pull the speed control lever completely back to the neutral position. The

two steering levers should be straight up and down (vertical). If 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 shaf t . See Figure 12.

FIGURE 12

Set neutral:

a) Remove the electrical connection from the seat safety switch, located direct ly

in front of the seat switch assembly.

b) The neutral adjustment must be made with the drive wheels turning. Raise the

frame and place on jack stands so t hat dr ive wheels can rotate freely.

Temporarily install a jumper wire across the terminals in the connector of the

wiring harness. c) Start the engine. d) Run the unit at least 5 minutes with the drive levers at full forward speed to

bring hydraulic system oil up to operating tem per ature.

e) To obtain the neutral position, adjust the left and right pump control rod

linkages that connect the steering control to the pump control ar m s unt il t he

wheels stop, or creep slightly in reverse. f) Adjust the left pum p linkage by rotating the tracking adjustment knob. g) Adjust the right pump linkage by using a wrench to turn the double nut s on

the assembly. See Figure 13.

h) Move the steering levers to the reverse position. W hile applying slight

pressure to the levers, allow the steering levers to return to neutral. The

wheels must stop turning (or slight ly creep in reverse) . i) Stop engine and wait for all moving parts to stop. Remove jumper wire from

wire harness connector and plug connector into seat switch. j) Lower from jackstands.

Set forward stop bolt:

a) Remove seat deck (with seat attached) to obtain a clear view of the steering

control shaft to complete this adjustment. b) Push the speed control lever forward to full forward speed position. c) If either st eer ing control lever surface does not contact t he st op bar at the full

forward speed position, adjust the stop bolt until contact occurs. See Figure 14.

Once contact occurs, turn the stop bolt one more full turn to prevent bott om ing

of the hydraulic pump internal stops.

FIGURE 13

FIGURE 14

4.2.9 Steering Control Lever Response Adjustment: a) Stop engine, wait for all m oving par t s t o st op and r emove key. Engage

parking brake. b) Move the speed control lever to the full forward position. c) Lift the seat and locate the pump contr ol spr ings. 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.

FIGURE 15

4.2.10 Tracking Adjustment:

4.2.11 PTO Dr ive Pulley Alignm ent

See Section 4.1.3 for adjustm ent.

PTO drive pulley alignment is necessary for any of the following conditions:

• The blower has been removed or replaced.

• The eng ine m ounting bolts have been loosened or the engine has been

moved or replaced.

• The jackshaft mounting bolts have been loosened or t he jackshaft has been moved or replaced.

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Move the speed control lever to the neutral position. c) Disengage the PTO lever. d) Remove fuel tank mount ing nuts and swing out fuel tank. e) Verify that the blower is installed and secured t ig htly. f) Loosen the 4 engine mounting bolts. g) Unhook the pump belt tension spr ing. h) Loosen the 4 jackshaf t m ounting bolts i) Measuring f r om the blower pulley as a baseline, move the engine and

jackshaft until t he r ear surface of all 3 pulleys are aligned within 1/32”-1/ 16”

(0.8 - 1.6 mm). Use a st r aight edge to align all 3 surf aces. See Figure 16.

FIGURE 16

j) Tight en the 4 engine mounting bolts and 4 jack shaft mounting bolts.

Check alignment aft er tightening. k) Re-install pump belt tension spring. l) Swing fuel tank in and re-install tank mounting nuts. m) Complete Pump Drive Pulley Alignment Section 4.2.12.

4.2.12 Pump Drive Pulley Alignment

Pump drive pulley alignment is necessary for any of the following conditions:

• The engine mount ing bolts have been loosened or the engine has been moved or replaced.

• The pump pulleys have been loosened, moved, or replaced.

• The PTO pulley alig nm ent (Section 4.2.11) has been performed.

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake. b) Loosen set screws on both pump pulleys. c) Using a straight edge, align each pump pulley with the engine pulley by

sliding along the pump shaft . See Figure 16. d) Re-tighten pulley set screws and recheck alignment.

4.2.13 Rear caster pivot bearings pre-load adjustment

a) Remove dust cap from caster and tighten nyloc nut

until washers are flat. Back the nyloc off 1/4 of a turn to properly set the pre-load on the bearings .

Note: If disassembled, make sure the

spring washers are reinstalled as shown in Figure 17.

4.2.14 Hopper Door Adjust m ent

Door Closing:

RE 17

a) Loosen 6 door hing e nut s. See Figure 18. b) Open door and place a 3/ 8” r ubber strip or 3/8” diameter hose between the

hopper and hopper door. See Figure 18.

c) Close door and push tight against hopper. d) Tig ht en hinge hardware. Open hopper door and remove rubber strip.

FIGURE 18

4.2.15 PTO Brake Spring Adjustment

PTO brake spring adjustment is only necessary if the blower has been removed

or replaced or if the PTO dr ive idler ar m has been disassem bled.

a) Stop eng ine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Locate the br ake spring and thread the two jam nuts out t o t he end of the

brake spring rod. See Figur e 19.

c) Tighten jam nuts tog ether at end of brake spring r od.

FIGURE 19

5. WASTE DISPOSAL

5.1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at

a certified recycling center or accor ding to your state and local regulations.

5.2 BATTERY DISPOSAL

DANGER

POTENTIAL HAZARD ♦ Battery electrolyte contains sulfuric acid,

which is poisonous and can cause severe

burns. WHAT CAN HAPPEN ♦ Swallowing electrolyte can be fatal or if it

touches skin can cause severe burns. HOW TO AVOID THE HAZARD

♦ 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 batt ery is no longer operating and is being scrapped, take the battery to a local certified recycling center. I f no local recycling is available return the battery to any certified battery reseller.

6. TROUBLE SHOOTING

6.1 MOWER PULLS LEFT OR RIGHT (W/LEVERS FULLY FORWARD).

a) Ref er t o Tracking Adjustment Sect ion 3. 1.3. b) Check air pr essure in drive tires; 15 psi

Semi-pneumatic casters do not require inflation.

6.2 MOWER CUTS UNEVENLY.

a) Check air pr essure in drive tires; 15 psi.

Semi-pneumatic casters do not requir e inflation. A more uniform cutting height may be obtained with higher tire pressure on

rough terrain. A lower tire pressure provides more flotation.

b) Check deck support pins are secure and correct spacers are posit ion under

hairpins.

c) Check deck leveling (See Adjustment s in Deck Manual).

Note: The front of the mower deck will be approximately 1/4” lower than the back of the mower deck. T his is t he “rake” of the deck.

d) Check t he distance from the bottom edg e of the deck skirt t o t he t ip of each

blade. Measurement should be consistent between all blade tips.

6.3 ENGINE WILL NOT START.

a) Make sure the battery has a full charge. See section 4.1.2 for charging

instructions.

b) Be sure the t h r ot tle 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 eng ine. c) Make sure there is fuel in the fuel tank and that the fuel valve is open. d) Make sure the par king brake is set and speed control levers in the neut r al

position. e) Check t hat the PTO is disengaged, park brake is engaged and speed

control is in “Neutral”. f) Check that the spark plug wires are properly connected. g) Check for loose or faulty wiring connections. h) Check for corrosion at all wiring connections. Even minor corrosion may

cause a faulty connection. Clean connector terminals thor oughly with

electrical contact cleaner, apply dielectric grease and r econnect. i) Check safety switch adjustment (See Section 4.2.5).

NOTE: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.

NOTE: After carefully checking the above steps, attempt to start the engine. If it does not start, cont act your authorized Exmark service dealer.

IMPORTANT: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use.

When a problem occur s , do not overlook the simple causes. For example: starting problems could be caused by an empty fuel tank.

The following table lists some of t he common causes of trouble. Do not att em pt to service or replace major items or any item s t hat call for special timing of adjustments procedures (such as valves, governor, etc. ) . Have this work done by your Engine Service Dealer.

PROBLEM

Will not start

Hard starting

Stops suddenly

Lacks power

Operates erratically

Knocks or pings

Skips or misfires

Backfires

Overheats

High fuel

consumption

ENGINE TROUBLESHOOTING TABLE

FUEL

IMPROPER

FUEL

DIRT IN

FUEL LINE

DIRTY AIR

FILTER

X X X X X

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

X X X X X X X X

X X X X X X X X X X X X X X X X X X X

X X X X

X X X

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

SCREEN

AIR

INSUFFICIENT

BATTERY

CHARGE

X X

7. ELECTRICAL DIAGRAM

8. ELECTRICAL LOGIC SCHEMATIC

9. HYDRAULIC DIAGRAM

10. 2-Year Limited Warranty

Exmark Turf Equipment

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 manufactured by Exmark 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 turf equipment purchased on or after October 1, 2004 sold in the US 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.

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 and Metro 26 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

*Please refer to the engine manufacturer’s warranty statement that is included in the literature packet. We are not authorized to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

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, 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.

All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts.

1. 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. Customers may also call 402-223-6375.

2. Bring the product and your proof of purchase (sales receipt) to the Exmark Service Dealer.

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

Warranty Period

Items and Conditions Not Covered

Instructions for Obtaining Warranty Service

(For units purchased on or after October 1, 2004)

service@exmark.com

Owner’s Responsibilities

The Exmark turf equipment, including any defective part, must be returned to an authorized Exmark service dealer within the warranty period. This warranty extends only to turf equipment operated under normal conditions. You must 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.

As a condition to this warranty, customer shall have read the operator's manual and shall have completed and submitted to Exmark Warranty Company, within the prescribed time, the Exmark warranty registration.

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein. Neither Exmark nor Exmark Warranty

Company shall have any liability for any other cost, loss or damage, including but not limited to, any incidental or consequential loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other

extraordinary repair charges or charge 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.

There are no understandings, agreements, representations, or warranties, express or implied, including but not limited to any regarding the merchantability (that product is fit for ordinary use) or fitness for use (that product is fit for a particular purpose), not specified herein, respecting the equipment which is the subject of this 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.

11. Evaporative Emission Control Warranty Statement

California Evaporative Emission Control Warranty Statement

Your Warranty Rights and Obligations

The California Air Resources B oard and Exmark Manufacturing Company are pleased to explain the evaporative emission control system’s warranty on your 2006 m odel year equi pment. In California, new equipment that uses sm al l off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog st andards. Exmark Manufacturing Com pany must warrant the evaporative emission control system on your equipm ent for two years provided there has been no abuse, neglect or i mproper maintenance of your equipm ent. Your evaporative emission control system m ay i nclude parts such as: fuel lines, fuel line fitt i ngs, and clamps.

Manufacturer’s Warranty Coverage:

This evaporative emissi on control system is warranted f or two years. If any evaporative emiss i on-rel ated part on your equipment is defective, the part will be repaired or replaced by Exmark Manufact uring Company.

Owner’s Warranty Responsibilities:

 As the equipment owner, you are res ponsible for performance of t he requi red maintenance listed in your Operat or’ s Manual.

Exmark Manufacturing Company rec ommends that you retain al l receipts covering maintenance on your equipment, but Exma rk Manufacturing Company cannot deny warranty sol ely for the lack of receipt s.

 As the equipment owner, you should however be aware that Exmark Manufacturing Company may deny you warranty coverage if

your emission warranty parts have fai led due to abuse, neglect, or improper maintenance or unapproved modifications.

 You are responsible for pres enting your equipment to an Authorized Servi ce Dealer as soon as the problem exist s. The warranty

repairs should be complet ed i n a reasonable amount of tim e, not to exceed 30 days. If you have a question regarding your warranty coverage, you should contact E xm ark Manufacturing Company at 1-402-223-6375.

Defects Warranty Requirements:

1. The warranty period begins on the date the engine or equi pment is delivered to an ultimate purchaser.

2. General Evaporative Emi ssions Warrant y Coverage. The emission warranty parts must be warranted to the ultimate purchaser

and any subsequent owner that the evaporative emi ssion control system when installed was: A. Designed, built, and equi pped so as to conform with all appli cable regulations; and B. Free from defect s in materials and workmans hi p that causes the failure of a warranted part for a period of two years.

3. The warranty on evaporative emissions-related part s will be interpreted as follows: A. Any warranted part that is not scheduled for replacement as required maintenance in the written i nstructions must be

warranted for the warranty period of two years. If any suc h part fails during the period of warranty coverage, i t must be repaired or replaced by Exmark Manufacturing Company. Any such part repaired or replac ed under the warranty must be warranted for a time not less than the remaining warranty period.

B. Any warranted part that is s cheduled only for regular inspection in the written instructions must be warranted for the

warranty period of two years. A statement in such written instructions to the eff ect of “repair or replace as necessary” will not reduce the period of warranty coverage. Any suc h part repaired or replaced under warranty must be warranted for a ti me not less than the remaini ng warranty period.

C. Any warranted part that is scheduled for replacement as required maintenance i n the written instructions must be warranted

for the period of time prior to the first scheduled replacement point for that part . If the part fails prior t o the first scheduled replacement, the part must be repaired or replaced by Exmark Manufacturing Company. Any such part repaired or replaced under warranty must be warranted for a time not less than the remainder of the period prior to the first scheduled replacement point for t he part .

D. Repair or replacement of any warranted part under the warranty provisions of this article must be performed at no charge to

the owner at an Authorized Service Dealer.

E. Notwithstanding the provisions of subsection (D) above, warranty s ervi ces or repairs must be provided at an Authorized

Service Dealer.

F. The owner must not be charged for diagnostic l abor that leads to the determination that a warranted part is in fact def ective,

provided that such diagnosti c work is performed at an Authorized S ervi ce Dealer.

G. Throughout the evaporative emiss i on control system's two year warranty period, Exmark Manufacturing Company must

maintain a supply of warranted parts sufficient to m eet the expected demand for such parts .

H. Manufact urer approved repl acement parts mus t be used in the performance of any warranty maintenance or repairs and

must be provided without charge to the owner. Such us e will not reduc e the warranty obligations of Exmark Manufacturing Company.

I. The use of any add-on or m odif i ed parts will be grounds for disallowing a warranty claim made in accordance with t his

article. Exmark Manufacturing Company will not be liable under this Article to warrant failures of warranted parts caused by the use of an add-on or modified part .

J. Exmark Manufacturing Company shall provide any documents that describe the warranty procedures or pol i cies within five

working days of request by the Air Resources Board.

Emission Warranty Parts List:

The following list includes the parts covered under this warranty:

• Fuel Lines

• Fuel Line Fittings

• Clamps

Introduction

NOTES

SERVICE RECORD

Date Description of Work Done Service Done By

GHTS

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

STANDON

Check us out on the Web:

www.exmark.com

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

ALL RI

RESERVED PRINTED IN U.S.A.

FG. CO. INC.

Exmark NAV20KC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual