Exmark NAVIGATOR NV640KC Operator'S Manual Download Page 45 | Manualshive

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Schematics

Hydraulic Diagram

G006950

CASE DRAIN

CHARGE PUMP

HIGH PRESSURE

BYPASS VALVE

BYPASS VALVE

HIGH PRESSURE
FORWARD

HIGH PRESSURE

FORWARD

HIGH PRESSURE
REVERSE

HIGH PRESSURE
REVERSE

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Summary of Contents for NAVIGATOR NV640KC

Page 1: ...NAVIGATOR For Serial Nos 312 000 000 Higher Part No 4500 987 Rev A ...

Page 2: ...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 Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manuf...

Page 3: ...e available online at http www exmark com All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving...

Page 4: ...gs 29 Lubricate Steering Linkage Rod Ends 29 Lubricate Hopper Actuator 29 Check Spark Plugs 29 Change Hydraulic System Filter 29 Check Wheel Hub Locknuts 30 Check Wheel Lug Nuts 30 Thread Locking Adhesives 30 Dielectric Grease 30 Adjustments 31 PTO Drive Belt Tension 31 Pump Drive Belt Tension 31 PTO Belt Replacement 31 Pump Drive Belt Replacement 31 Belt Guide Adjustment 32 Adjust Safety Switch 3...

Page 5: ...d the Operator s Manual and other training material If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people oper...

Page 6: ... 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 In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always ...

Page 7: ...gator 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 Minimize speed and use extreme caution Only operate on a flat level surface Do not operate up or down a trailer ramp Avoid sudden acceleration or deceleration Operate only in daylight or good a...

Page 8: ...se Extreme caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes DANGER Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning Do Not mow slopes when gra...

Page 9: ... flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect battery or remove spa...

Page 10: ...uel system components with original Exmark parts WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result If equipped make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections ...

Page 11: ... make sure current safety signs are visible New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc 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 Familiarize yourself with the following safety signs and instruction labels They are...

Page 12: ...Safety 103 9034 103 9724 109 4273 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 109 7318 12 ...

Page 13: ...116 0404 116 1175 116 4581 EFI Units Only 1 Neutral 4 Slow 2 Reverse 5 Engine oil temperature light 3 Fast 117 2718 Molded in LH Console 1 PTO disengage 3 Park brake release 2 PTO engage 4 Park brake engage 13 ...

Page 14: ...Safety Molded into Front of Hopper 14 ...

Page 15: ...y fuel filter Electrical System Charging System Flywheel Alternator Charging Capacity All units except Kohler EFI 15 amps Kohler EFI 20 amps Battery Type BCI Group U1 Battery Voltage 12 Volt Polarity Negative Ground Fuses Two 20 amp and one 30 amp blade type Safety Interlock System PTO must be disengaged brake engaged and speed control lever in neutral position to start engine It is not necessary ...

Page 16: ... 7 0 mph 11 3 km hr forward 0 5 5 mph 8 6 km hr reverse Drive wheel release valves allow machine to be moved when engine is not running Tires Wheels Drive Front Caster Rear Caster Pneumatic Air Filled Semi Pneumatic Semi Pneumatic Quantity 2 2 1 Tread Multi Trac C S Smooth Smooth Drive Front Caster Rear Caster Size 18 x 10 50 10 8 x 3 00 4 13 x 8 00 6 Ply Rating 4 Pressure 15 psi 103 kPa Cutting D...

Page 17: ...e Center of Drive Wheel to Center of Rear Caster Wheel 42 inch Deck 48 inch Deck 44 2 inches 112 3 cm 44 2 inches 112 3 cm Curb Weight 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 Bolts 72 77 ft lb 98...

Page 18: ... brake Push the lever forward and down to disengage the brake The unit must be tied down and brake engaged when transporting Ignition Switch Located on the right hand console 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 Rotate clockwise to the next position to engage the start...

Page 19: ...ls the engine is overheating Electronic Control Unit Malfunction Indicator Kohler EFI Units Only The electronic control unit ECU continuously monitors operation of the EFI system If a problem or fault within the system is detected the malfunction indicator light MIL is illuminated The MIL is the light located in the right console panel to the right of the throttle control Follow the troubleshootin...

Page 20: ...fore the PTO can be engaged 1 Set the throttle to the MIDWAY position 2 Pull the PTO lever upward until locked over center 3 Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle to the MIDWAY position 2 Push PTO lever down to the STOP position stopping the PTO and blower Stopping the Engine 1 Bring the unit to a full stop 2 Disengage the PTO 3 Move speed c...

Page 21: ...firmly lifting screen handles see Figure 5 Pull screen towards the back to remove Gently tap debris from the screen as needed 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 primary screen to allow free air flow from the hopper Figure 5 1 Front removable screen c...

Page 22: ...ll width ramp is required If 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 truck do not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angle...

Page 23: ...cation After the first 250 hours Change the hydraulic filter Before each use or daily Check the engine oil level Check the safety interlock system Check for loose hardware Remove accumulated debris from engine see Cleaning section Clean the grass and debris build up from the machine Every 40 hours Check the hydraulic oil level Check the tire pressures Check the condition of the belts Every 50 hour...

Page 24: ...attery should be fully charged before putting away for winter storage Check the voltage of the battery with a digital voltmeter or with the message display If the ignition key is turned to the on position for a few seconds the battery voltage will be displayed in the area where the hours are normally displayed Locate the voltage reading of the battery in the table and charge the battery for the re...

Page 25: ...r the batteries Note Be sure the vent caps are tight and level Place a damp cloth if available over any vent caps on both batteries Be sure the vehicles do not touch and that both electrical systems are off and at the same rated system voltage These instructions are for negative ground systems only 3 Connect the positive cable to the positive terminal of the discharged battery that is wired to the...

Page 26: ...e parking brake 2 Tilt hopper up to gain access to the air cleaner 3 Loosen retaining clips and remove air cleaner compartment cover 4 Remove paper element Check the condition of the paper element Replace if dirty bent or damaged 5 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 elem...

Page 27: ...al Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Check tire pressure in drive tires 3 Inflate drive tires to 15 psi 103 kPa 4 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 hy...

Page 28: ...uts removed or broken loose apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward Do Not thread spacer nut all of the way onto the end of the axle Leave approximately 1 8 inch 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut 9 Insert the assembled nut and axle into the wheel on the side of the wheel with t...

Page 29: ... each end of both steering linkage rods with a spray lubricant or a light oil Lubricate Hopper Actuator Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise hopper and locate actuator on right hand side of mainframe 3 Lubricate switch actuator rod with a spray lubricant or a light oil Check Spark Plugs Service Interval Every 1...

Page 30: ... felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Check Wheel Hub Locknuts Service Interval After the first 100 hours Every 500 hours thereafter Torque to 210 250 ft lb 285 339 N m Check Wheel Lug Nuts Service Interval After the first 100 hours Every 500 hours thereafter Torque to 90 95 ft ...

Page 31: ...elt Guide B 6 Belt Guide A 3 PTO Belt 7 Blower 4 Jackshaft 8 Engage the PTO lever 9 Rotate brake band back down into original position 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 10 1 Tension Arm 2 Loosen jam ...

Page 32: ...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 1 3 16 inch to 1 4 inch 4 8 mm 6 4 mm Brake Adjustment Check to make sure each brake is adjusted properly 1 Pull the brake lever up and back to the engaged position 2 A gap must exist between the bottom of the brake bolt head and the top surface of the brake sw...

Page 33: ...on 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 16 3 Set the tension high enough that the speed control lever position is maintained during operation and loose enough to be moved comfortably by the operator Figure 16 1 Speed Control Lever 3 Spring disc washers 2 Friction Plate 4 Hex...

Page 34: ...s 3 Start the engine 4 Run the unit at least 5 minutes with the speed control lever at full forward speed to bring hydraulic system oil up to operating temperature Return speed control lever to neutral full rear position 5 To obtain the neutral position adjust the left and right pump control rod linkages that connect the steering control to the pump control arms until the wheels stop or creep slig...

Page 35: ...ook the rear spring anchor to the anchor tab Note Be sure both springs maintain the same adjustment Figure 20 1 To increase steering responsiveness hook pump control sprints directly on anchor bolt To decrease steering responsiveness hook pump control springs on anchor tabs as shown Tracking Adjustment See Motion Control Linkage Adjustment section PTO Drive Pulley Alignment PTO drive pulley alignm...

Page 36: ... moved or replaced The PTO pulley alignment has been performed see PTO Drive Pulley Alignment section 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Loosen set screws on both pump pulleys 3 Using a straight edge align each pump pulley with the engine pulley by sliding along the pump shaft see Figure 21 4 Re tighten pulley set screws and recheck alignment Rear...

Page 37: ...stem to overheat which can create a fire hazard Clean all debris from inside of pump drive belt compartment daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all debris from rotating engine air intake screen and from around engine shrouding and exhaust system area 3 Clean all debris from around engine drive belts and exhaust system area Remove Engine...

Page 38: ...id which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately Federal law states that batteries should not be placed in th...

Page 39: ... Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect 6 Fuse is blown 6 Replace the blown fuse Starter does not crank 7 Relay or switch is defective 7 Contact an Authorized Service Dealer 1 Fuel tank is empty 1 Fill the fuel tank 2 Fuel shutoff valve is closed 2 Open the fuel shutoff valve 3 Oil level in the crankcase is low 3 Add oil to the cr...

Page 40: ... obstructions from the cooling fins and air passages 1 Tracking needs adjustment 1 Adjust the tracking 2 Tire pressure in drive tires not correct 2 Adjust tire pressure in the drive tires Mower pulls left or right with levers fully forward 3 Reverse indicator and speed control linkage need adjustment 3 Adjust the reverse indicator and the speed control linkage 1 Bypass valve is not closed tight 1 ...

Page 41: ...Schematics Schematics Electrical Diagram All Units Except Kohler EFI 41 ...

Page 42: ...Schematics Electrical Diagram Kohler EFI 42 ...

Page 43: ... GREEN FUEL SOLENOID REGULATOR ENGINE KILL OIL PRESSURE DK GREEN TAN BLACK BLACK WHITE BLUE BLUE YELLOW GRAY DK GREEN DK GREEN LT BLUE BLACK BLACK TAN BLACK LT BLUE VIOLET RED ORANGE ORANGE VIOLET VIOLET RED RED BLUE DK BLUE WHITE VIOLET RED SEAT DELAY MODULE BATTERY GROUND 20 AMP FUSE 30 AMP FUSE SPEED CONTROL BRAKE START RELAY IGNITION SWITCH HOUR METER PTO SWITCH KILL RELAY 3 START POSITION 1 O...

Page 44: ...Schematics Electrical Logic Schematic All Units Except Kohler EFI 44 ...

Page 45: ...Schematics Hydraulic Diagram G006950 CASE DRAIN CHARGE PUMP HIGH PRESSURE BYPASS VALVE BYPASS VALVE HIGH PRESSURE FORWARD HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE HIGH PRESSURE REVERSE 45 ...

Page 46: ...r Canada customers may also call 402 223 6375 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 service exmark com Owner s Responsibilities If your product requires warranty service it must be returned to an autho...

Page 47: ...Notes 47 ...

Page 48: ...Notes 48 ...

Page 49: ...Service Record Date Description of Work Done Service Done By 49 ...

Page 50: ...50 ...

Page 51: ...se 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 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 51 ...

Page 52: ...DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB Place Model No and Serial No Label Here Included in the Literature Pack or Fill i...

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