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

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NAVIGATOR
®
For Serial Nos.
850,000 & Higher
Part No. 4500-628 Rev. B

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Summary of Contents for Exmark NAVIGATOR

  • Page 1 NAVIGATOR ® For Serial Nos. 850,000 & Higher Part No. 4500-628 Rev. B...
  • 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 Speed Control Linkage Adjustment....33 Steering Control Lever Response Adjustment ..........34 Introduction ............3 Tracking Adjustment ........35 Safety ..............5 PTO Drive Pulley Alignment ......35 Safety Alert Symbol ......... 5 Pump Drive Pulley Alignment......35 Safe Operating Practices ........5 Rear Caster Pivot Bearings Pre-Load Safety and Instructional Decals .....

  • Page 5: Safety

    Only use accessories and DANGER: White lettering / Red background. attachments approved by Exmark. Indicates an imminently hazardous situation which, if • Wear appropriate clothing including safety glasses, not avoided, Will result in death or serious injury.
  • Page 6 Safety DANGER DANGER In certain conditions gasoline is extremely In certain conditions during fueling, static flammable and vapors are explosive. electricity can be released causing a spark which can ignite gasoline vapors. A fire or A fire or explosion from gasoline can burn explosion from gasoline can burn you and you, others, and cause property damage.
  • Page 7 WARNING When operating a Navigator tractor Operating engine parts, especially the without an approved Exmark front mount muffler, become extremely hot. Severe burns attachment, observe the following: can occur on contact and debris, such as • Keep feet and clothing away from tires.

  • Page 8: Slope Operation

    Safety • Stop engine, wait for all moving parts to stop, and DANGER engage parking brake: Operating on wet grass or steep slopes can – Before refueling. cause sliding and loss of control. Wheels – Before dumping the grass catcher. dropping over edges, ditches, steep banks, or water can cause rollovers, which may result WARNING...

  • Page 9: Maintenance And Storage

    The model number explode causing serious injury. for the ROPS attachment is FRPSNAV. Contact an • Keep sparks, flames, or cigarettes away Authorized Exmark Service Dealer for more details. from battery. • Ventilate when charging or using battery Maintenance and Storage in an enclosed space.
  • Page 10 Failure the hydraulic system. to use original Exmark parts could cause serious injury or death. Replace all parts including, but not limited to, tires, belts, and blades with original...

  • 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 103-9724 109-7318 109-4273 116-0404...
  • Page 13 Safety 116-1175 117–2718 Molded in LH Console Molded into Front of Hopper...

  • Page 14: Specifications

    Specifications Specifications Model Numbers Serial Nos: 850,000 and Higher NAV20KC; NAV27KC Systems ◊ If the PTO is engaged while the hopper is tilted up. Engine Operator Controls • Engine Specifications: See your Engine Owner’s Manual • Steering and Motion Control: •...

  • Page 15: Dimensions

    Specifications • Hydraulic Oil Type: Use Exmark Premium Hydro – Clutching belt on horizontal engine shaft. oil. Dual “A” section hexagon belt with spring tensioned idler to jackshaft and blower. • Hydraulic Oil Capacity: 4.0 qt. (3.8 L) – Heavy-duty cast iron, spiral bevel gearbox is •...

  • Page 16: Torque Requirements

    Product Overview Curb Weight: Product Overview 42 inch Deck 48 inch Deck 850 lb (386 kg) 1145 lb (519 kg) Torque Requirements Bolt Location Torque Blade Mounting Bolt 85-110 ft-lb (115-149 N-m) Engine Mounting Bolts 30-35 ft-lb (41-47 N-m) Wheel Lug Nuts 90-95 ft-lb (122-129 N-m) Wheel Motor Mounting 72-77 ft-lb (98-104 N-m)

  • Page 17: Operation

    Operation Brake Lever Operation Located on left side of unit, between the seat and Note: Determine the left and right sides of the console. machine from the normal operating position. The brake lever engages a parking brake on the drive wheels.

  • Page 18: Pre-Start

    Operation Drive Wheel Release Valves Pre-Start Located on the top left front corner of hydrostatic Fill fuel tanks. For best results use only clean, fresh pumps. regular grade unleaded gasoline with an octane rating of 87 or higher. Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be Important: Never use methanol, gasoline pushed without the engine running.

  • Page 19: Stopping The Engine

    Operation Disengaging the PTO 6. Turn ignition switch to the “START” position. Release the switch as soon as the engine starts. 1. Set the throttle to the “MIDWAY” position. Important: Do Not crank the engine 2. Push PTO lever down to the “STOP” position continuously for more than ten seconds at a stopping the PTO and blower.

  • Page 20: 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 21 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 22: 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 made, someone could start the engine. a hot engine can cause severe burns. Accidental starting of the engine could Allow the engine to cool completely before seriously injure you or other bystanders.

  • Page 23: Periodic Maintenance

    Maintenance Maintenance Service Maintenance Procedure Interval • Check the battery charge. Monthly • Lubricate grease fittings. Yearly • Lubricate the caster wheel hubs. Periodic Maintenance Note: To prevent damage due to freezing, battery should be fully charged before putting away for winter storage.

  • Page 24: Check Safety Interlock System

    Maintenance Note: Be sure the vent caps are tight and level. CAUTION Place a damp cloth, if available, over any vent caps on both batteries. Be sure the vehicles do Corrosion or loose connections can cause not touch and that both electrical systems are unwanted electrical voltage spikes at anytime off and at the same rated system voltage.

  • Page 25: Check For Loose Hardware

    Change Engine Oil 1/2 second has elapsed. Service Interval: After the first 5 hours Note: If machine does not pass any of these tests, do not operate. Contact your authorized EXMARK Every 100 hours (May SERVICE DEALER. need more often under severe conditions.)

  • Page 26: Check Hydraulic Oil Level

    Note: See chart for service intervals. baffle inside the tank. If not, add oil. Use only Exmark Premium Hydro oil. Replace hydraulic 1. Stop engine, wait for all moving parts to stop, and reservoir cap and tighten until snug. Do Not remove key.

  • Page 27: 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 Deck shown for reference only.

  • Page 28: Lubricate Brake Handle Pivot

    Maintenance Lubricate Brake Rod 11. Insert the second bearing and new seal into the wheel. Bushings 12. Apply a thread locking adhesive to the 2nd spacer Service Interval: Every 160 hours nut and thread onto the axle with the wrench flats facing outward.

  • Page 29: Change Hydraulic System Filter

    (Every 250 hours/Yearly if using Mobil 1 15W50) Service Interval: After the first 100 hours Note: Use only Exmark Part No. 109-0071 for Every 500 hours thereafter Summer use above 32°F (0°C) or P/N 1-523541 for Winter use below 32°F (0°C). (Refer to the Torque to 210–250 ft-lb (285–339 N-m).

  • Page 30: Dielectric Grease

    Maintenance Adjustments Fuel tank studs, where studs are inserted into tank. Note: Disengage PTO, shut off engine, wait for Dielectric Grease all moving parts to stop, engage parking brake, and remove key before servicing, cleaning, or making any Dielectric grease is used on all blade type electrical adjustments to the unit.

  • Page 31: Pump Drive Belt Replacement

    Maintenance 10. Re-install clevis pin and hairpin to secure brake band. 11. Engage the PTO lever. 12. Loosen the jam nuts and adjust linkage until the top of the idler arm is aligned with the bottom of notch on tension arm as shown in Figure 10. Figure 11 1.

  • Page 32: Adjust Safety Switch

    Maintenance Adjust Safety Switch 3. The brakes on both sides can be simultaneously adjusted by lengthening or shortening the linkage Adjust all safety switches so plunger extends 3/16 shown in Figure 15. inch to 1/4 inch (4.8 mm-6.4 mm) from switch body when plunger is compressed (see Figure 13).

  • Page 33: Speed Control Linkage Adjustment

    Maintenance loose enough to be moved comfortably by the CAUTION operator. Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury.

  • Page 34: Steering Control Lever Response Adjustment

    Maintenance across the terminals in the connector of the Set forward stop bolt: wiring harness. 1. Remove seat deck (with seat attached) to obtain 3. Start the engine. a clear view of the steering control shaft to complete this adjustment. 4.

  • Page 35: Tracking Adjustment

    Maintenance inch to 1/16 inch (0.8-1.6 mm). Use a straight edge to align all three surfaces (see Figure 21). Figure 20 Figure 21 1. To increase steering responsiveness hook pump control sprints directly on anchor bolt. 1. Align three pump drive 2.

  • Page 36: Rear Caster Pivot Bearings Pre-Load Adjustment

    Maintenance Rear Caster Pivot Bearings Pre-Load Adjustment Remove dust cap from caster and tighten nyloc nut until washers are flat. Back off 1/4 of a turn to properly set the pre-load on the bearings. If disassembled, make sure the spring disc washers are reinstalled as shown in Figure 22.

  • Page 37: Cleaning

    Maintenance Cleaning Important: Do Not use water to clean engine. Use low pressure compressed air. See Engine Owner’s Manual. Clean Engine and Exhaust System Area Clean Debris From Machine Service Interval: Before each use or daily Service Interval: Before each use or daily (May be required more 1.

  • Page 38: 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 39 Troubleshooting Problem Possible Cause Corrective Action Engine overheats. 1. Engine load is excessive. 1. Reduce the ground speed. 2. Oil level in the crankcase is low. 2. Add oil to the crankcase. 3. Cooling fins and air passages for the 3.

  • Page 40: Schematics

    Schematics Schematics Electrical Diagram GREEN GREEN WHITE DK.GREEN GREEN BLACK BLACK BLACK BLACK BLACK BLACK STRIPE ORANGE/BLACK GREEN YELLOW BLUE BLUE BROWN GREEN GRAY BLUE BROWN GREEN GREEN BLUE BLUE BLACK BLUE BLACK PINK BLACK GRAY BLACK ORANGE ORANGE ORANGE BROWN ORANGE BLUE...
  • Page 41 Schematics Electrical Logic Schematic GREEN GREEN GREEN GREEN WHITE BLACK BLACK GREEN BLACK BLACK BLACK GREEN BLACK GREEN GREEN STRIPE ORANGE/BLACK YELLOW BLUE BLUE GREEN BLUE GRAY GREEN GREEN BLACK BLUE BLUE BLUE BROWN BLACK BLACK GRAY BLUE BLACK ORANGE PINK PINK ORANGE...

  • Page 42: Hydraulic Diagram

    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 43 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 44 Notes:...

  • Page 45: Service Record

    Service Record Date: Description of Work Done: Service Done By:...
  • Page 47 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 48 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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