Exmark NAVIGATOR NV640KC Operator's Manual
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Exmark NAVIGATOR NV640KC Operator's Manual

Exmark NAVIGATOR NV640KC Operator's Manual

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NAVIGATOR
®
For Serial Nos.
312,000,000 & Higher
Part No. 4500-987 Rev. A

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Summary of Contents for Exmark NAVIGATOR NV640KC

  • Page 1 NAVIGATOR ® For Serial Nos. 312,000,000 & Higher Part No. 4500-987 Rev. A...
  • Page 2 Replacements may be ordered through the engine manufacturer. Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously.

  • Page 3: Introduction

    All Exmark parts are thoroughly tested and inspected before leaving the factory, however, attention is required on your part if you are to obtain the fullest measure of satisfaction and performance.

  • Page 4: Table Of Contents

    Contents Steering Control Lever Response Adjustment ..........35 Tracking Adjustment ........35 Introduction ............3 PTO Drive Pulley Alignment ......35 Safety ..............5 Pump Drive Pulley Alignment......36 Safety Alert Symbol ......... 5 Rear Caster Pivot Bearings Pre-Load Safe Operating Practices ........5 Adjustment ..........36 Safety and Instructional Decals ......11 Hopper Door Adjustment ......36...

  • Page 5: Safety

    English it is the owner’s responsibility to Institute in effect at the time of production. explain this material to them. Exmark designed and tested this lawn mower to offer • Become familiar with the safe operation of the reasonably safe service; however, failure to comply equipment, operator controls, and safety signs.
  • Page 6 Safety • Inspect the area where the equipment is to be DANGER used and remove all rocks, toys, sticks, wires, In certain conditions during fueling, static bones, and other foreign objects which can be electricity can be released causing a spark thrown by the machine and may cause personal which can ignite gasoline vapors.
  • Page 7 Entanglement or tip-over could cause serious injury or death. When operating a Navigator tractor without an approved Exmark front mount attachment, observe the following: • Keep feet and clothing away from tires. • Limit operation to minimum required to install a different front mount attachment.
  • Page 8 Safety • Stop engine, wait for all moving parts to stop, and DANGER engage parking brake: Operating on wet grass or steep slopes can cause – Before refueling. sliding and loss of control. Wheels dropping over edges, ditches, steep banks, or water can cause –...
  • Page 9 The model number DANGER for the ROPS attachment is FRPSNAV. Contact an Authorized Exmark Service Dealer for more details. Charging or jump starting the battery may The California Code of Regulations requires ROPS produce explosive gases. Battery gases can and seatbelt (if equipped) on all commercial mowers explode causing serious injury.
  • Page 10 Failure to use original Exmark parts could cause serious injury or For Kohler EFI (Electronic Fuel Injection) Units: death. Making unauthorized changes to the...

  • Page 11: Safety And Instructional Decals

    Exmark equipment dealer or labels. distributor or from Exmark Mfg. Co. Inc. • Replace all worn, damaged, or missing safety • Safety signs may be affixed by peeling off the signs.
  • Page 12 Safety 103-9034 109-4638 All Units Except EFI 1. Neutral 5. Engine oil temperature light 2. Reverse 6. Choke-on 3. Fast 7. Choke-off 4. Slow 103-9724 109-7318 109-4273...
  • Page 13 Safety 116-0404 116-4581 EFI Units Only 1. Neutral 4. Slow 2. Reverse 5. Engine oil temperature light 3. Fast 116-1175 117–2718 Molded in LH Console 1. PTO-disengage 3. Park brake-release 2. PTO-engage 4. Park brake-engage...
  • Page 14 Safety Molded into Front of Hopper...

  • Page 15: Specifications

    • Engine Specifications: See your Engine Owner’s – All units except Kohler EFI: 15 amps Manual – Kohler EFI: 20 amps • Engine Oil Type: Exmark 4–Cycle Premium • Battery Type: BCI Group U1 Engine Oil • Battery Voltage: 12 Volt •...

  • Page 16: Dimensions

    • Blade Size: (2 ea.) • Wheel Motors: Hydro Gear planetary reduction motors. – w/42 inch Deck: 22.00 inches (55.9 cm) • Hydraulic Oil Type: Use Exmark Premium Hydro – w/48 inch Deck: 25.00 inches (63.5 cm) oil. • Deck Drive: •...

  • Page 17: Torque Requirements

    Product Overview Overall Length: Product Overview Without Deck 42 inch Deck 48 inch Deck 67.3 inches (170.9 91.8 inches (233.2 94.5 inches (240.0 Overall Height: Without Deck 42 inch Deck 48 inch Deck 51.2 inches 51.2 inches 51.2 inches (130.0 cm) (130.0 cm) (130.0 cm) Tread Width: (Center to Center of...

  • Page 18: Operation

    Operation Operation Pull the lever up and rearward to engage the brake. Push the lever forward and down to disengage the Note: Determine the left and right sides of the brake. machine from the normal operating position. The unit must be tied down and brake engaged when transporting.

  • Page 19: Pre-Start

    Operation pushed without the engine running. Tilt seat up to or fault within the system is detected, the malfunction gain access to pumps. indicator light (MIL) is illuminated. The MIL is the light located in the right console panel to the right of With a 7/16 wrench, turn both valves one turn the throttle control.
  • Page 20 Operation Disengaging the PTO On a warm engine, leave the choke in the “OFF” position. 1. Set the throttle to the “MIDWAY” position. 6. Turn ignition switch to the “START” position. 2. Push PTO lever down to the “STOP” position Release the switch as soon as the engine starts.

  • Page 21: Transporting

    Operation To turn left or right, pull one of the steering levers back toward neutral in the direction desired. The machine will move faster the farther the speed control lever is moved away from neutral. 4. To stop, pull the speed control lever back to the neutral position.
  • Page 22 Operation WARNING Loading a unit on a trailer or truck increases the possibility of tip-over. Tip-over could cause serious injury or death. • Use extreme caution when operating a unit on a ramp. • Use only a single, full width ramp; Do Not use individual ramps for each side of the unit.

  • Page 23: Maintenance

    Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING WARNING While maintenance or adjustments are being The engine can become very hot. Touching a hot made, someone could start the engine. engine can cause severe burns.

  • Page 24: Periodic Maintenance

    ECU (Electronic Control 5. If the oil level is low, wipe off the area around the Unit). oil fill cap, remove cap and fill to the “FULL” mark on the dipstick. Exmark 4-Cycle Premium Voltage Percent Maximum Charging Engine Oil is recommended;...

  • Page 25: Check Safety Interlock System

    Maintenance off and at the same rated system voltage. These CAUTION instructions are for negative ground systems only. Corrosion or loose connections can cause 3. Connect the positive (+) cable to the positive (+) unwanted electrical voltage spikes at anytime terminal of the discharged battery that is wired to during the jump starting procedure.

  • Page 26: Check For Loose Hardware

    2. Visually inspect machine for any loose hardware Before reinstalling new filter, apply a thin coating or any other possible problem. Tighten hardware of Exmark 4–Cycle Premium Engine Oil on the or correct the problem before operating. surface of the rubber seal. Turn filter clockwise...

  • Page 27: Check Hydraulic Oil Level

    1. Stop engine, wait for all moving parts to stop, and baffle inside the tank. If not, add oil. Use only remove key. Engage parking brake. Exmark Premium Hydro oil. Replace hydraulic reservoir cap and tighten until snug. Do Not 2. Lubricate fittings with one to two pumps of overtighten.

  • Page 28: Lubricate Rear Caster Wheel Hubs

    6. Pack the bearings with a NGLI grade #1 multi-purpose grease. 7. Insert one bearing, one new seal into the wheel. Note: Seals (Exmark PN 103-0063) must be replaced. 8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one spacer nut and thread onto the Deck shown for reference only.

  • Page 29: Lubricate Brake Handle Pivot

    (Every 250 hours/Yearly if Lubricate Steering Linkage using Mobil 1 15W50) Rod Ends Note: Use only Exmark Part No. 109-0071 for Summer use above 32°F (0°C) or P/N 1-523541 Service Interval: Every 160 hours for Winter use below 32°F (0°C). (Refer to the 1.

  • Page 30: Check Wheel Hub Locknuts

    Service Interval: As required Important: Before reinstalling new filter, fill it with Exmark Premium Hydro oil and apply When installing the nuts on the fuel tank studs, fully a thin coat of oil on the surface of the rubber tighten the nyloc nut and back off 1/2 turn.

  • Page 31: Adjustments

    Maintenance Adjustments 10. Re-install clevis pin and hairpin to secure brake band. Note: Disengage PTO, shut off engine, wait for 11. Engage the PTO lever. all moving parts to stop, engage parking brake, and 12. Loosen the jam nuts and adjust linkage until the remove key before servicing, cleaning, or making any top of the idler arm is aligned with the bottom of adjustments to the unit.

  • Page 32: Belt Guide Adjustment

    Maintenance Adjust Safety Switch Adjust all safety switches so plunger extends 3/16 inch to 1/4 inch (4.8 mm-6.4 mm) from switch body when plunger is compressed (see Figure 13). Figure 13 Figure 11 1. 3/16 inch to 1/4 inch (4.8 mm-6.4 mm) 1.

  • Page 33: Adjust Speed Control Lever Tension

    Maintenance 3. The brakes on both sides can be simultaneously loose enough to be moved comfortably by the adjusted by lengthening or shortening the linkage operator. shown in Figure 15. Figure 16 Figure 15 Brake Adjustment for Both Sides 1. Speed Control Lever 3.
  • Page 34 Maintenance 1. Stop engine and wait for all moving parts to 6. Adjust the left pump linkage by rotating the stop. tracking adjustment knob. 2. Pull the speed control lever completely back to 7. Adjust the right pump linkage by using the neutral position.

  • Page 35: Steering Control Lever Response Adjustment

    Maintenance Set forward stop bolt: 1. Remove seat deck (with seat attached) to obtain a clear view of the steering control shaft to complete this adjustment. 2. Push the speed control lever forward to full forward speed position. 3. If either steering control lever surface does not contact the stop bar at the full forward speed position, adjust the stop bolt until contact occurs (see Figure 19).

  • Page 36: Pump Drive Pulley Alignment

    Maintenance Rear Caster Pivot Bearings inch to 1/16 inch (0.8-1.6 mm). Use a straight edge to align all three surfaces (see Figure 21). Pre-Load Adjustment Remove dust cap from caster and tighten nyloc nut until washers are flat. Back off 1/4 of a turn to properly set the pre-load on the bearings.

  • Page 37: Pto Brake Spring Adjustment

    Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) CAUTION Excessive debris around the engine cooling Figure 23 air intake and inside of the pump drive belt compartment and damaged or missing rubber 1.

  • Page 38: Clean Debris From Machine

    Maintenance Clean Debris From Machine Service Interval: Before each use or daily 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Clean off any oil, debris, or grass build-up on the machine, especially around the fuel tank, around engine and exhaust area.

  • Page 39: Troubleshooting

    Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of trouble.
  • Page 40 Troubleshooting Problem Possible Cause Corrective Action Engine loses power. 1. Engine load is excessive. 1. Reduce the ground speed. 2. Air cleaner is dirty. 2. Clean or replace the air cleaner element. 3. Oil level in the crankcase is low. 3.

  • Page 41: Schematics

    Schematics Schematics Electrical Diagram — All Units Except Kohler EFI...
  • Page 42 Schematics Electrical Diagram — Kohler EFI...
  • Page 43 Schematics Electrical Logic Schematic — All Units Except Kohler EFI G016287...
  • Page 44 Schematics Electrical Logic Schematic — All Units Except Kohler EFI...
  • Page 45 Schematics Hydraulic Diagram BYPASS VALVE BYPASS VALVE HIGH PRESSURE REVERSE HIGH PRESSURE FORWARD HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE G006950 HIGH PRESSURE CHARGE PUMP CASE DRAIN...
  • Page 46 No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower. All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement All implied warranties of merchantability (that the parts.
  • Page 47 Notes:...
  • Page 48 Notes:...
  • Page 49 Service Record Date: Description of Work Done: Service Done By:...
  • Page 51 G011841 Figure 25 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope indicator to determine the degree of slope of hills before operating. Do Not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope.
  • Page 52 SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID-MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM (ROPS) DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT...

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