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

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Place Model No. and Serial No.
Label Here (Included in the Literature
Pack) or Fill in Below
Model No.
Serial No.
NAVIGATOR
®
Date Purchased
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
For Serial Nos.
720,000 & Higher
Part No. 4500-212 Rev. A

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Summary of Contents for Exmark NAVIGATOR

  • Page 1 For Serial Nos. 720,000 & Higher NAVIGATOR ® Place Model No. and Serial No. Date Purchased Label Here (Included in the Literature Pack) or Fill in Below Engine Model No. and Spec. No. Model No. Engine Serial No. (E/No) Serial No. Part No.
  • 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 4: 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 5: Table Of Contents

    Contents Speed Control Linkage Adjustment....31 Steering Control Lever Response Adjustment ..........33 Introduction ............4 Tracking Adjustment ........33 Safety ..............6 PTO Drive Pulley Alignment ......33 Safety Alert Symbol ......... 6 Pump Drive Pulley Alignment......34 Safe Operating Practices ........6 Rear Caster Pivot Bearings Pre-Load Safety and Instructional Decals .....

  • Page 6: Safety

    • Evaluate the terrain to determine what accessories ALERT! YOUR SAFETY IS INVOLVED! and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by Exmark. • Wear appropriate clothing including safety glasses, Figure 2 substantial footwear, long trousers, and hearing 1.
  • Page 7 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 8 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 9: 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 10: Maintenance And Storage

    Safety • Avoid sudden starts when mowing downhill. • Keep hands and feet away from moving parts. Mower may tip forwards. If possible, do not make adjustments with the engine running. • Be aware that loss of traction may occur going uphill.

  • 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 103–8611 103–9724 103–9032 109–4273 103–9034...
  • Page 13 Safety 109–4638 109–7318 Molded into Front of Hopper Molded in LH Console...

  • Page 14: Specifications

    Specifications Specifications Model Numbers Serial Nos: 720,000 and Higher NAV20KC; NAV27KC Systems Operator Controls • Steering and Motion Control: Engine – Speed Control lever, located on RH console, • Engine Specifications: See your Engine Owner’s sets maximum forward speed. Manual –...

  • Page 15: Dimensions

    Specifications • Hydraulic Filter: Replaceable cartridge type. – Heavy-duty cast iron, spiral bevel gearbox is final drive to blades. – Summer use above 32°F (0°C): • Deck: P/N 109-0071: 25 microns, 10 psi bypass Full floating deck is attached to out-front support –...

  • Page 16: Torque Requirements

    Product Overview Curb Weight: Product Overview 42 inch Deck 48 inch Deck W/72 inch Deck 850 lb (386 kg) 1145 lb (519 kg) 1170 lb (531 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)

  • 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. Regular grade leaded gasoline may Drive wheel release valves are used to release the also be used;...

  • Page 19: Stopping The Engine

    Operation Disengaging the PTO Important: Do Not crank the engine continuously for more than ten seconds at a 1. Set the throttle to the “MIDWAY” position. time. If the engine does not start, allow a 60 2. Push PTO lever down to the “STOP” position second cool-down period between starting 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. • Lubricate the caster wheel hubs. Yearly • Change the hydraulic filter. Periodic Maintenance storage when the open circuit voltage drops to 12.4 volts. Check Engine Oil Level Note: To prevent damage due to freezing, battery should be fully charged before putting away for...

  • Page 24: Check Safety Interlock System

    Note: If machine does not pass any of these tests, severe conditions.) do not operate. Contact your authorized EXMARK 1. Stop engine, wait for all moving parts to stop, and SERVICE DEALER. remove key. Engage parking brake.

  • Page 25: Check Hydraulic Oil Level

    Maintenance Before reinstalling new filter, apply a thin coating it is at 75°F (24°C). Fill to the appropriate level of oil on the surface of the rubber seal. Turn depending upon the temperature of the oil. For filter clockwise until rubber seal contacts the filter example: If the oil is about 150°F (65°C), fill to adapter then tighten filter an additional 1/2 to halfway between the “HOT”...

  • Page 26: 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 27: 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 28: Change Hydraulic System Filter

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

  • Page 29: 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 30: 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 12). Figure 10 Figure 12 1. Pump Drive Belt 4. Pump 1. 3/16 inch to 1/4 inch (4.8 mm-6.4 mm) 2.

  • Page 31: 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 14. Figure 15 Figure 14 Brake Adjustment for Both Sides 1. Speed Control Lever 3.
  • Page 32 Maintenance rotate freely. Temporarily install a jumper wire CAUTION across the terminals in the connector of the wiring harness. Raising the mower deck for service or maintenance relying solely on mechanical 3. Start the engine. or hydraulic jacks could be dangerous. The 4.

  • Page 33: 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 18).

  • Page 34: 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 20). 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 35: Pto Brake Spring Adjustment

    Maintenance Cleaning Remove Accumulated Debris from Engine Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) Engine parts should be kept clean to reduce the risk of overheating and ignition of accumulated debris. Figure 22 CAUTION 1.

  • Page 36: Waste Disposal

    Maintenance Important: Do Not use water to clean engine. Use low pressure compressed air. See Engine Owner’s Manual. Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at a certified recycling center or according to your state and local regulations.

  • Page 37: 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 38 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 39: 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 40 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 41: 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 42 No Claim of breach of warranty shall be cause for cancellation included with the product. or rescission of the contract of sale of any Exmark mower. All warranty work must be performed by an authorized Some states do not allow exclusions of incidental or...
  • Page 44 © 2005–2007 Exmark Mfg. Co., Inc. Part No. 4500-212 Rev. A Industrial Park Box 808 (402) 223-6300 Beatrice, NE 68310 Fax (402) 223–5489 All Rights Reserved Printed in the USA.

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