Exmark NAVIGATOR NV640KC User manual

Brand: Exmark

Model: NAVIGATOR NV640KC

Category: Lawnmowers

Type: User manual

This manual is also suitable for

NA VIGATOR®

ForSerialNos.

312,000,000&Higher

PartNo.4500-987Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Theengineinthisproductisnot

equippedwithasparkarrestermufer.Itisa

violationofCaliforniaPublicResourceCode

(CPRC)Section4442touseoroperatethis

engineonanyforest-covered,brush-covered,

orgrass-coveredlandasdenedinCPRC4126.

Otherstatesorfederalareasmayhavesimilar

laws.

Toacquireasparkarresterforyourunit,seeyour

EngineServiceDealer.

Thissparkignitionsystemcomplieswiththe

CanadianstandardICES-002.Cesystèmed’allumage

parètincelledevèhiculeestconformeàlanorme

NMB-002duCanada.

TheenclosedEngineOwner’sManualis

suppliedforinformationregardingTheU.S.

EnvironmentalProtectionAgency(EPA)and

theCaliforniaEmissionControlRegulationof

emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit.

ShouldthisengineOwner’sManualbecome

damagedorillegible,replaceimmediately.

Replacementsmaybeorderedthroughthe

enginemanufacturer.

Exmarkreservestherighttomakechangesor

addimprovementstoitsproductsatanytime

withoutincurringanyobligationtomakesuch

changestoproductsmanufacturedpreviously.

Exmark,oritsdistributorsanddealers,accept

noresponsibilityforvariationswhichmaybe

evidentintheactualspecicationsofitsproducts

andthestatementsanddescriptionscontained

inthispublication.

IndustrialParkBox808

Beatrice,NE68310

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour

ExmarkMower.Thisproducthasbeencarefully

designedandmanufacturedtogiveyouamaximum

amountofdependabilityandyearsoftrouble-free

operation.

Thismanualcontainsoperating,maintenance,

adjustment,andsafetyinstructionsforyourExmark

mower.

BEFOREOPERATINGYOURMOWER,

CAREFULLYREADTHISMANUALINITS

ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety

instructions,youwillprolongthelifeofyourmower,

maintainitsmaximumefciency,andpromotesafe

operation.

Ifadditionalinformationisneeded,orshould

yourequiretrainedmechanicservice,contactyour

authorizedExmarkequipmentdealerordistributor.

Exmarkpartsmanualsareavailableonlineat

http://www.exmark.com

AllExmarkequipmentdealersanddistributorsare

keptinformedofthelatestmethodsofservicing

andareequippedtoprovidepromptandefcient

serviceintheeldorattheirservicestations.They

carryamplestockofservicepartsorcansecurethem

promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected

beforeleavingthefactory,however,attentionis

requiredonyourpartifyouaretoobtainthefullest

measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,

oradditionalinformation,contactanAuthorized

ServiceDealerorExmarkCustomerServiceandhave

themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial

numbersontheproduct.Writethenumbersinthe

spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals......................11

Specications........................................................15

ModelNumbers.............................................15

Systems..........................................................15

Dimensions....................................................16

TorqueRequirements.....................................17

ProductOverview.................................................17

Operation..............................................................18

Controls.........................................................18

Pre-Start.........................................................19

OperatingInstructions...................................19

Transporting..................................................21

Maintenance..........................................................23

RecommendedMaintenanceSchedule(s)............23

PeriodicMaintenance........................................24

CheckEngineOilLevel..................................24

CheckSafetyInterlockSystem........................25

CheckforLooseHardware.............................26

ServiceAirCleaner.........................................26

ChangeEngineOil.........................................26

CheckHydraulicOilLevel..............................27

CheckTirePressures......................................27

CheckConditionOfBelts...............................27

LubricateGreaseFittings................................27

LubricateRearCasterWheelHubs..................28

LubricateBrakeHandlePivot.........................29

LubricateBrakeRodBushings........................29

LubricateSteeringLinkageRodEnds..............29

LubricateHopperActuator.............................29

CheckSparkPlugs..........................................29

ChangeHydraulicSystemFilter......................29

CheckWheelHubLocknuts...........................30

CheckWheelLugNuts...................................30

ThreadLockingAdhesives..............................30

DielectricGrease............................................30

Adjustments......................................................31

PTODriveBeltTension.................................31

PumpDriveBeltTension................................31

PTOBeltReplacement...................................31

PumpDriveBeltReplacement.......................31

BeltGuideAdjustment...................................32

AdjustSafetySwitch.......................................32

BrakeAdjustment...........................................32

AdjustSpeedControlLeverTension...............33

SpeedControlLinkageAdjustment.................33

SteeringControlLeverResponse

Adjustment................................................35

TrackingAdjustment......................................35

PTODrivePulleyAlignment..........................35

PumpDrivePulleyAlignment.........................36

RearCasterPivotBearingsPre-Load

Adjustment................................................36

HopperDoorAdjustment..............................36

PTOBrakeSpringAdjustment.......................37

Cleaning............................................................37

CleanEngineandExhaustSystem

Area...........................................................37

RemoveEngineShroudsandClean

CoolingFins...............................................37

CleanDebrisFromMachine...........................38

WasteDisposal...............................................38

Troubleshooting....................................................39

Schematics............................................................41

Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheB71.4

specicationsoftheAmericanNationalStandards

Instituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer

reasonablysafeservice;however,failuretocomply

withthefollowinginstructionsmayresultinpersonal

injury.

ThisSafetyAlertSymbol(

Figure2)isusedbothin

thismanualandonthemachinetoidentifyimportant

safetymessageswhichmustbefollowedtoavoid

accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

SafetyAlertSymbol

Thesafetyalertsymbolappearsaboveinformation

whichalertsyoutounsafeactionsorsituations

andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if

notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground.

Indicatesapotentiallyhazardoussituationwhich,if

notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Yellowbackground.

Indicatesapotentiallyhazardoussituationwhich,if

notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight

information.Importantcallsattentiontospecial

mechanicalinformationandNoteemphasizes

generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining

material.Iftheoperator(s)ormechanic(s)can

notreadEnglishitistheowner’sresponsibilityto

explainthismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.

Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate

orservicetheequipment.Localregulationsmay

restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate

amower,andevenmatureteenagersshouldhave

adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator's

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe

mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible

foraccidentsorinjuriesoccurringtohimselfor

herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories

andattachmentsareneededtoproperlyand

safelyperformthejob.Onlyuseaccessoriesand

attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,

substantialfootwear,longtrousers,andhearing

protection.DoNotoperatewhenbarefootor

whenwearingopensandals.Longhair,loose

clothingorjewelrymaygettangledinmoving

parts.

CAUTION

Thismachineproducessoundlevelsinexcess

of85dBAattheoperator’searandcancause

hearinglossthroughextendedperiodsof

exposure.

Wearhearingprotectionwhenoperatingthis

machine.

Safety

•Inspecttheareawheretheequipmentistobe

usedandremoveallrocks,toys,sticks,wires,

bones,andotherforeignobjectswhichcanbe

thrownbythemachineandmaycausepersonal

injurytotheoperatororbystanders.

DANGER

Incertainconditionsgasolineisextremely

ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn

you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground,

inanopenarea,whentheengineiscold.

Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe

machineindoorsorinsideanenclosed

trailer.

•DoNotllthefueltankcompletelyfull.

Fillthefueltanktothebottomoftheller

neck.Theemptyspaceinthetankallows

gasolinetoexpand.Overllingmayresult

infuelleakageordamagetotheengine

oremissionsystem.

•Neversmokewhenhandlinggasoline,and

stayawayfromanopenameorwhere

gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer

andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never

removethecapofthefueltankoradd

fuelwhenengineisrunningorwhenthe

engineishot.

•Iffuelisspilled,DoNotattempttostart

theengine.Moveawayfromtheareaof

thespillandavoidcreatinganysourceof

ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust

systeminplaceandinproperworking

condition.

DANGER

Incertainconditionsduringfueling,static

electricitycanbereleasedcausingaspark

whichcanignitegasolinevapors.Areor

explosionfromgasolinecanburnyouand

othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe

groundawayfromyourvehiclebefore

lling.

•DoNotllgasolinecontainersinsidea

vehicleoronatruckortrailerbedbecause

interiorcarpetsorplastictruckbedliners

mayinsulatethecontainerandslowthe

lossofanystaticcharge.

•Whenpractical,removegas-powered

equipmentfromthetruckortrailerand

refueltheequipmentwithitswheelson

theground.

•Ifthisisnotpossible,thenrefuelsuch

equipmentonatruckortrailerfroma

portablecontainer,ratherthanfroma

gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe

used,keepthenozzleincontactwiththe

rimofthefueltankorcontaineropening

atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.

Long-termexposuretovaporshascaused

cancerinlaboratoryanimals.Failuretouse

cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas

tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

Safety

•Checkthattheoperator'spresencecontrols,

safetyswitches,andshieldsareattachedand

functioningproperly.DoNotoperateunlessthey

arefunctioningproperly.

Operation

WARNING

Operatingengineparts,especiallythemufer,

becomeextremelyhot.Severeburnscanoccur

oncontactanddebris,suchasleaves,grass,

brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to

coolbeforetouching.

•Removeaccumulateddebrisfrommuferand

enginearea.

•Installandmaintaininworkingordera

sparkarresterbeforeusingequipment

onforest-covered,grass-covered,or

brush-coveredunimprovedland.

WARNING

Engineexhaustcontainscarbonmonoxide,

whichisanodorlessdeadlypoisonthatcankill

you.

DoNotrunengineindoorsorinasmallconned

areawheredangerouscarbonmonoxidefumes

cancollect.

WARNING

OperatingaNavigatortractorwithoutan

approvedExmarkfrontmountattachment

increasesthepossibilityofoperatorentanglement

indrivewheelsorforwardtipover.Entanglement

ortip-overcouldcauseseriousinjuryordeath.

WhenoperatingaNavigatortractorwithout

anapprovedExmarkfrontmountattachment,

observethefollowing:

•Keepfeetandclothingawayfromtires.

•Limitoperationtominimumrequiredto

installadifferentfrontmountattachment.

•Minimizespeedanduseextremecaution.

•Onlyoperateonaatlevelsurface.

•Donotoperateupordownatrailerramp.

•Avoidsuddenaccelerationordeceleration.

•Operateonlyindaylightorgoodarticiallight,

keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake

isengagedbeforestartingengine.

•Neverraisedeckwithbladesrunning.

•Neveroperatethemowerwithdamagedguards,

shields,orcovers.Alwayshavesafetyshields,

guards,switchesandotherdevicesinplaceandin

properworkingcondition.

•Nevermowunlessthereisagrasscollection

systemormulchkitinplaceandworkingproperly.

•DoNotchangetheenginegovernorsettingor

overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait

forallmovingpartstostop,removekeyand

engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor

damageandmakerepairsbeforerestarting

andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

Safety

•Stopengine,waitforallmovingpartstostop,and

engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

Hands,feet,hair,clothing,oraccessoriescan

becomeentangledinrotatingparts.Contact

withtherotatingpartscancausetraumatic

amputationorseverelacerations.

•DoNotoperatethemachinewithout

guards,shields,andsafetydevicesinplace

andworkingproperly.

•Keephands,feet,hair,jewelry,orclothing

awayfromrotatingparts.

•NEVERcarrypassengers.DONOToperate

themowerwhenpeople,especiallychildren,or

petsareinthearea.

•Bealert,slowdownandusecautionwhen

makingturns.Lookbehindandtothesidebefore

changingdirections.

•Stoptheblades,slowdown,andusecaution

whencrossingsurfacesotherthangrassandwhen

transportingthemowertoandfromtheareato

bemowed.

•Beawareofthemowerdischargepathanddirect

dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence

ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe

machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning

onslopesaslossoftractionand/ortip-overcould

occur.Theoperatorisresponsibleforsafeoperation

onslopes.

DANGER

Operatingonwetgrassorsteepslopescancause

slidingandlossofcontrol.Wheelsdroppingover

edges,ditches,steepbanks,orwatercancause

rollovers,whichmayresultinseriousinjury,

deathordrowning.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon

slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Seeinsidethebackcovertodeterminethe

approximateslopeangleoftheareatobemowed.

•Useawalkbehindmowerand/orahandtrimmer

neardrop-offs,ditches,steepbanksorwater.

(

Figure3).

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15

degrees

2.DangerZone-Useawalkbehindmowerand/orhand

trimmeronslopesgreaterthan15degrees,near

drop-offsandwater.

3.Water

•Removeormarkobstaclessuchasrocks,tree

limbs,etc.fromthemowingarea.Tallgrasscan

hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat

changetheoperatingangle,asroughterraincould

overturnthemachine.

•Avoidsuddenstartswhenmowingdownhill.

Mowermaytipforwards.

•Beawarethatoperatingonwetgrass,acrosssteep

slopesordownhillmaycausethemowertolose

Safety

traction.Lossoftractiontothedrivewheelsmay

resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona

slope.Iftireslosetraction,disengagetheblades

andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor

wheelweightsorcounterweightstoimprove

stability.

•Useextremecarewithattachments.Thesecan

changethestabilityofthemachineandcauseloss

ofcontrol.

Note:A2–postfoldableROPS(RolloverProtection

System)isavailablefortheNavigatorasanaccessory.

AROPSisrecommendedifyouwillbemowing

nexttodrop-offs,nearwater,oronsteepbanks

whichcouldresultinarollover.Themodelnumber

fortheROPSattachmentisFRPSNAV .Contactan

AuthorizedExmarkServiceDealerformoredetails.

TheCaliforniaCodeofRegulationsrequiresROPS

andseatbelt(ifequipped)onallcommercialmowers

effectiveMarch1,2011.BecauseallNavigatorswere

designedwithanoptionalROPSaccessory,theyare

subjecttothisregulationandmustberetrottedwith

ROPS.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking

brake,stopengineandremovekeyordisconnect

sparkplugwire.Waitforallmovementtostop

beforeadjusting,cleaningorrepairing.

•Keepengine,enginearea,andpumpdrivebelt

compartmentfreefromaccumulationofgrass,

leaves,excessivegreaseoroil,andotherdebris

whichcanaccumulateintheseareas.These

materialscanbecomecombustibleandmayresult

inare.

•Letenginecoolbeforestoringanddonotstore

nearameoranyenclosedareawhereopenpilot

lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do

Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow

untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen

required.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Disconnectbatteryorremovesparkplugwire

beforemakinganyrepairs.Disconnectthe

negativeterminalrstandthepositivelast.

Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)

orweargloves,andusecautionwhenservicing

them.Onlyreplacedamagedblades.Never

straightenorweldthem.

•Keephandsandfeetawayfrommovingparts.

Ifpossible,donotmakeadjustmentswiththe

enginerunning.

•Chargebatteriesinanopenwellventilatedarea,

awayfromsparkandames.Unplugcharger

beforeconnectingordisconnectingfrombattery.

Wearprotectiveclothinganduseinsulatedtools.

DANGER

Chargingorjumpstartingthebatterymay

produceexplosivegases.Batterygasescan

explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway

frombattery.

•Ventilatewhenchargingorusingbattery

inanenclosedspace.

•Makesureventingpathofbatteryis

alwaysopenoncebatteryislledwith

acid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid,

whichispoisonousandcancausesevere

burns.Swallowingelectrolytecanbefatalor

ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and

rubberglovestoprotectskinandclothing

whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith

waterandcalladoctorimmediately.

Safety

CAUTION

Iftheignitionisinthe“ON”positionthere

ispotentialforsparksandengagementof

components.Sparkscouldcauseanexplosion

ormovingpartscouldaccidentallyengage

causingpersonalinjury.

Besureignitionswitchisinthe“OFF”

positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin

placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper

tightness.

•Frequentlycheckforwornordeteriorating

componentsthatcouldcreateahazard.

WARNING

Removingstandardoriginalequipmentparts

andaccessoriesmayalterthewarranty,traction,

andsafetyofthemachine.Failuretouseoriginal

Exmarkpartscouldcauseseriousinjuryor

death.Makingunauthorizedchangestothe

engine,fuelorventingsystem,mayviolateEPA

andCARBregulations.

Replaceallpartsincluding,butnotlimitedto,

tires,belts,blades,andfuelsystemcomponents

withoriginalExmarkparts.

WARNING

Hydraulicuidescapingunderpressure

canpenetrateskinandcauseinjury.Fluid

accidentallyinjectedintotheskinmustbe

surgicallyremovedwithinafewhoursbyadoctor

familiarwiththisformofinjuryorgangrenemay

result.

•Ifequipped,makesureallhydraulicuid

hosesandlinesareingoodconditionandall

hydraulicconnectionsandttingsaretight

beforeapplyingpressuretohydraulicsystem.

•Keepbodyandhandsawayfrompinhole

leaksornozzlesthatejecthighpressure

hydraulicuid.

•Usecardboardorpaper,notyourhands,to

ndhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic

systembyplacingthemotioncontrollevers

inneutralandshuttingofftheenginebefore

performinganyworkonthehydraulicsystem.

ForKohlerEFI(ElectronicFuelInjection)Units:

WARNING

Fuelsystemcomponentsareunderhigh

pressure.Theuseofimpropercomponentscan

resultinsystemfailure,gasolineleakageand

possibleexplosion.

Useonlyapprovedfuellinesandfuelltersfor

highpressuresystems.

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,

dirtanddebrisfromsafetysignsandinstructional

labels.

•Replaceallworn,damaged,ormissingsafety

signs.

•Whenreplacementcomponentsareinstalled,be

surethatcurrentsafetysignsareafxedtothe

replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,

makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom

yourauthorizedExmarkequipmentdealeror

distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe

backingtoexposetheadhesivesurface.Apply

onlytoaclean,drysurface.Smoothtoremove

anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns

andinstructionlabels.Theyarecriticaltothesafe

operationofyourExmarkcommercialmower.

65-2690

98-4361

98-5954

103-8425

103-8444

103-8451

1.Fast3.Neutral

2.Slow

103-8495

103-8611

Safety

103-9034

103-9724

109-4273

109-4638

AllUnitsExceptEFI

1.Neutral5.Engineoiltemperature

light

2.Reverse

6.Choke-on

3.Fast

7.Choke-off

4.Slow

109-7318

Safety

116-0404

116-1175

116-4581

EFIUnitsOnly

1.Neutral

4.Slow

2.Reverse5.Engineoiltemperature

light

3.Fast

117–2718

MoldedinLHConsole

1.PTO-disengage

3.Parkbrake-release

2.PTO-engage

4.Parkbrake-engage

Safety

MoldedintoFrontofHopper

Specications

ModelNumbers

SerialNos:312,000,000andHigher

NV640KC;NV740KC;NV730EKC

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s

Manual

•EngineOilType:Exmark4–CyclePremium

EngineOil

•RPM:FullSpeed:3600±50RPM(NoLoad)Idle:

1500RPM

FuelSystem

•Capacity:7.5gal.(28L)

•FuelRecommendations:

–Forbestresults,useonlyclean,fresh,unleaded

gasolinewithanoctaneratingof87orhigher

((R+M)/2ratingmethod).

–Oxygenatedfuelwithupto10%ethanolor

15%MTBEbyvolumeisacceptable.

–DoNotuseethanolblendsofgasoline(such

asE15orE85)withmorethan10%ethanol

byvolume.Performanceproblemsand/or

enginedamagemayresultwhichmaynotbe

coveredunderwarranty.

–DoNotusegasolinecontainingmethanol.

–DoNotstorefueleitherinthefueltankor

fuelcontainersoverthewinterunlessafuel

stabilizerisused.

–DoNotaddoiltogasoline.

•FuelFilter:

–AllunitsexceptKohlerEFI:

KohlerP/N2405013

–KohlerEFI:

KohlerP/N2505042

•FuelShut-OffValve:1/4turnincrementsin-line

valvebyfuellter.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

–AllunitsexceptKohlerEFI:15amps

–KohlerEFI:20amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:Two20ampandone30ampbladetype

•SafetyInterlockSystem:

–PTOmustbedisengaged,brakeengaged,and

speedcontrolleverinneutralpositiontostart

engine.(Itisnotnecessaryfortheoperatorto

beintheseattostarttheengine.)

–OperatormustbeinseatwhenPTOis

engaged,brakeisdisengaged,orspeedcontrol

leverismovedoutofneutralorenginewill

stop.

–Enginewillstopinthefollowingconditions:

◊Ifthespeedcontrolleverismovedfrom

neutralpositionwhilebrakeisengaged.

◊IfthePTOisengagedwhilethehopper

istiltedup.

OperatorControls

•SteeringandMotionControl:

–SpeedControllever,locatedonRHconsole,

setsmaximumforwardspeed.

–Steeringlevers,centeredinfrontoftheseat,

controlthespeedanddirectionoftravelof

therespectivedrivewheels.

–Movingspeedcontrolleverrearwardtothe

neutralpositionplacesthedrivesystemin

neutral.

Note:Theunitmaybemovedinreverse

whilethespeedcontrolisintheneutral

positionbypullingbackonthesteeringlevers.

Specications

•PTOEngagementLever:EngagesdrivetoPTO

(mowerdeck)andblower.

•ParkingBrakeLever:Pullbacktoengageparking

brake.

Seat

•Type:Standardseatwithhighback,foampadded

(internalsuspension).

•Mounting:Seatishingedtotiltupforaccessto

hydraulicpumpsandothercomponents.Theseat

isheldinthetiltedpositionwithalink.

•Armrests:None.

•SeatSafetySwitch:Internaltothebottomseat

cushion,nonserviceable.Timedelaymodule

incorporatedintotheSafetyInterlockSystem

eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearvariable

displacementpistonpumps.

•WheelMotors:HydroGearplanetaryreduction

motors.

•HydraulicOilType:UseExmarkPremiumHydro

oil.

•HydraulicOilCapacity:4.0qt.(3.8L)

•HydraulicFilter:Replaceablecartridgetype.

–Summeruseabove32°F(0°C):

P/N109-0071:25microns,10psibypass

–Winterusebelow32°F(0°C):

P/N1-523541:40microns,18psibypass

•Speeds:

–0-7.0mph(11.3km/hr)forward.

–0-5.5mph(8.6km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe

movedwhenengineisnotrunning.

Tires&Wheels

Drive

Front

Caster

RearCaster

Pneumatic

(Air-Filled)

Semi-

Pneumatic

Semi-

Pneumatic

Quantity

221

Tread

“Multi-Trac

C/S”

SmoothSmooth

Drive

Front

Caster

RearCaster

Size

18x

10.50-10

8x3.00-413x8.00-6

PlyRating

Pressure

15psi(103

kPa)

CuttingDeck

(Soldseparately)

•ModelNumbers:

–CD42CD

–CD48CD

•CuttingWidth:

–42inchDeck:42inch(106.7cm)

–48inchDeck:48inch(121.9cm)

•Discharge:Center

•BladeSize:(2ea.)

–w/42inchDeck:22.00inches(55.9cm)

–w/48inchDeck:25.00inches(63.5cm)

•DeckDrive:

–Clutchingbeltonhorizontalengineshaft.

Dual“A”sectionhexagonbeltwithspring

tensionedidlertojackshaftandblower.

–Heavy-dutycastiron,spiralbevelgearboxis

naldrivetoblades.

•Deck:

Fulloatingdeckisattachedtoout-frontsupport

frame.Deckdesignallowsforbaggingor

mulching.

•DeckDepth:

–42inchDeck:45/8inches(11.7cm)

–48inchDeck:45/8inches(11.7cm)

Dimensions

OverallWidth:

WithoutDeck42inchDeck48inchDeck

42.6inches(108.2

cm)

43.2inches(109.7

cm)

49.2inches(125.0

cm)

ProductOverview

OverallLength:

WithoutDeck42inchDeck48inchDeck

67.3inches(170.9

cm)

91.8inches(233.2

cm)

94.5inches(240.0

cm)

OverallHeight:

WithoutDeck42inchDeck48inchDeck

51.2inches

(130.0cm)

51.2inches

(130.0cm)

51.2inches

(130.0cm)

TreadWidth:(CentertoCenterof

Tires,Widthwise)

42inchDeck48inchDeck

DriveWheels32.7inches

(83.1cm)

32.7inches

(83.1cm)

WheelBase:(CenterofDriveWheel

toCenterofRearCasterWheel)

42inchDeck48inchDeck

44.2inches(112.3cm)44.2inches(112.3cm)

CurbWeight:

42inchDeck48inchDeck

850lb(386kg)1145lb(519kg)

TorqueRequirements

BoltLocation

Torque

BladeMountingBolt85-110ft-lb(115-149N-m)

EngineMountingBolts

30-35ft-lb(41-47N-m)

WheelLugNuts

90-95ft-lb(122-129N-m)

WheelMotorMounting

Bolts

72-77ft-lb(98-104N-m)

WheelHubLocknut210-250ft-lb

(285-339N-m)

ProductOverview

Figure4

1.SpeedControlLever4.SteeringLevers

2.Controls5.PTOEngagementLever

3.FuelCap

6.ParkingBrakeLever

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

SteeringLevers

Locatedinthecenterinfrontoftheseat.

Pullingbackonthesteeringlevers,progressively

slows,thenreversesthedirectionoftravelofthe

respectivedrivewheels.

Bymovingbothsteeringleversanequalamountback,

themachinecanbesloweddownortravelbackward

inastraightline.

Steeringiscontrolledbyvaryingthepositionofthe

steeringleversrelativetoeachother.

SpeedControlLever

Locatedonrighthandconsole.

Thespeedcontrolleversetsmaximumforwardspeed.

Movingspeedcontrolleverrearwardtotheneutral

positionplacesthedrivesysteminneutral.

ChokeControl(AllUnitsExcept

KohlerEFI)

Locatedonthecontrolconsolefrontrighthandside.

Chokeisusedtoaidinstartingacoldengine.The

chokecontrolispulledouttobeinthe“ON”position

andpushedintobeinthe“OFF”position.DoNot

runawarmenginewithchokeinthe“ON”position.

ThrottleControl

Locatedonrighthandconsole.

Thethrottleisusedtocontrolenginespeed.Moving

throttleleverforwardwillincreaseenginespeedand

movingthrottlelevertotherearwilldecreaseengine

speed.

BrakeLever

Locatedonleftsideofunit,betweentheseatand

console.

Thebrakeleverengagesaparkingbrakeonthedrive

wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe

brake.

Theunitmustbetieddownandbrakeengagedwhen

transporting.

IgnitionSwitch

Locatedontherighthandconsole.

Theignitionswitchisusedtostartandstopthe

engine.Theswitchhasthreepositions“OFF”,“ON”

and“START”.Insertkeyintoswitchandrotate

clockwisetothe“ON”position.Rotateclockwiseto

thenextpositiontoengagethestarter(keymustbe

heldagainstspringpressureinthisposition).

Note:Brakemustbeengaged,speedcontrollever

rearward(neutralposition)andPTOdisengagedto

startengine.(Itisnotnecessaryfortheoperatorto

beintheseattostarttheengine.)

HourMeter

Locatedontherighthandconsole.

Thehourmeterisconnectedtoapressureswitch

installedintheengineblockanditrecordsthe

numberofhoursthattheenginehasrun.Ifthe

ignitionswitchisleftonwithoutenginerunning,

hourmeterwillnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot

alerttheoperatoriftheengineoilislow.

FuelShut-OffValve

Locatedinfuellinebyfueltankandfuellter

(accessiblebyraisingthehopper).

Thefuelshut-offvalveisusedtoshutoffthefuel

whenthemachinewillnotbeusedforafewdays,

duringtransporttoandfromthejobsite,andwhen

parkedinsideabuilding.

Rotatethevalve1/4turnclockwisetoshutoffthe

fuel.rotatethevalve1/4turncounterclockwiseto

turnonthefuel.

DriveWheelReleaseValves

Locatedonthetopleftfrontcornerofhydrostatic

pumps.

Drivewheelreleasevalvesareusedtoreleasethe

hydrostaticdrivesystemtoallowthemachinetobe

Operation

pushedwithouttheenginerunning.Tiltseatupto

gainaccesstopumps.

Witha7/16wrench,turnbothvalvesoneturn

counterclockwisetoreleasedrivesystem.Turn

clockwisetoresetsystem.DoNotovertighten.Do

Nottowmachine.

TrackingAdjustmentKnob

Locatedundertheseatontheleftpumpcontrollink.

Rotatingthisknoballowsnetuningadjustmentsso

thatthemachinetracksstraightwiththedrivelevers

inthefullforwardposition.

Rununitat3/4speedforatleast5minutesto

bringhydraulicoiluptooperatingtemperature.

Stopmachineandwaitforallmovingpartstostop.

Engageparkbrake.Tiltseatforwardtogainaccess

tothetrackingknob.Rotatetheknobtowardsthe

righttosteerrightandrotatetowardsthelefttosteer

left.Adjustin1/8turnincrementsuntilthemachine

tracksstraight.Checkthatthemachinedoesnotcreep

wheninneutralwiththeparkbrakesdisengaged.

Important:DoNotrotatetheknobtoofar,as

thismaycausethemachinetocreepinneutral.

RefertotheMotionControlLinkageAdjustment

sectioninMaintenance.

PTOEngagementLever

Locatedimmediatelyleftoftheleftconsole.

Levermustbemoveduptothe“ROTATE”position

toengagethePTOandblowerdrives.Leverismoved

downtothe“STOP”positiontostopthedrives.

EngineOilTemperatureLightand

Buzzer

Locatedontherightconsole.

Theengineoiltemperaturelightmonitorsthe

temperatureoftheengineoil.Anilluminatedengine

oiltemperaturelightandintermittentbuzzingsound

signalstheengineisoverheating.

ElectronicControlUnitMalfunction

Indicator

KohlerEFIUnitsOnly:

Theelectroniccontrolunit(ECU)continuously

monitorsoperationoftheEFIsystem.Ifaproblem

orfaultwithinthesystemisdetected,themalfunction

indicatorlight(MIL)isilluminated.TheMIListhe

lightlocatedintherightconsolepaneltotherightof

thethrottlecontrol.Followthetroubleshootingsteps

outlinedintheKohlerengineoperator’smanualifthe

MILisilluminated.

Pre-Start

Fillfueltanks.SeeFuelRecommendationsin

theSpecicationssectionforadditionalgasoline

information.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe

tankallowsgasolinetoexpand.Overllingmayresult

infuelleakageordamagetotheengineoremission

system.

Makesureyouunderstandthecontrols,their

locations,theirfunctions,andtheirsafety

requirements.

RefertotheMaintenancesectionandperformallthe

necessaryinspectionandmaintenancesteps.

OperatingInstructions

OpentheFuelShut-OffValve

Thefuelshut-offvalveislocatedontherightsideof

unitinfuellinenexttothefuellter.Raisethehopper

toaccess.Rotatethevalve1/4counterclockwiseto

turnonfuel.

StartingtheEngine

1.Movethespeedcontrollevertotheneutral

position.

2.Pullupandbackontheparkingbrakeleverto

engagetheparkingbrake.

3.PushthePTOengagementleverdowntothe

“STOP”position.

Note:Itisnotnecessaryfortheoperatortobe

intheseattostarttheengine.

4.Placethethrottlemidwaybetweenthe“SLOW”

and“FAST”positions.

5.Onacoldengine,pushthechokeleverforward

intothe“ON”position(exceptKohlerEFI).

Operation

Onawarmengine,leavethechokeinthe“OFF”

position.

6.Turnignitionswitchtothe“START”position.

Releasetheswitchassoonastheenginestarts.

Important:DoNotcranktheengine

continuouslyformorethantensecondsata

time.Iftheenginedoesnotstart,allowa60

secondcool-downperiodbetweenstarting

attempts.Failuretofollowtheseguidelines

canburnoutthestartermotor.

7.Ifthechokeisinthe“ON”position,gradually

returnchoketothe“OFF”positionastheengine

warmsup.

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeckare

dangerous.Bladecontactcancauseserious

injuryorkillyou.

DoNotputhandsorfeetunderthemoweror

mowerdeckwhenthebladesareengaged.

DANGER

Anuncovereddischargeopeningwillallow

objectstobethrowninanoperator’sor

bystander’sdirection.Also,contactwiththe

blowerbladescouldoccur.Thrownobjectsor

bladecontactcancauseseriousinjuryordeath.

Neveroperatethemowerwiththehopperor

hopperdoorraised,removed,oralteredunless

thereisamulchkitinplaceandworking

properly.

ThePTOleverengagesthePTOandblower.Besure

thatthehopperisdown,thehopperdoorissecurely

closed,andallpersonsareclearofthemowerdeck

anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe

PTOcanbeengaged.

1.Setthethrottletothe“MIDWAY”position.

2.PullthePTOleverupwarduntillockedover

center.

3.Placethethrottleinthe“FAST”positiontobegin

mowing.

DisengagingthePTO

1.Setthethrottletothe“MIDWAY”position.

2.PushPTOleverdowntothe“STOP”position

stoppingthePTOandblower.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movespeedcontrollevertotheneutralposition.

4.Engagetheparkingbrake.

5.Placethethrottlemidwaybetweenthe“SLOW”

and“FAST”positions.

6.Allowtheenginetorunforaminimumof15

seconds,thenturntheignitionswitchtothe

“OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother

unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalvewhenthemachine

willnotbeinuseforafewdays,when

transporting,orwhentheunitisparkedinside

abuilding.

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioningone

levertoomuchaheadoftheother.Operatormay

losecontrolofthemachine,whichmaycause

damagetothemachineorinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp

turns.

Important:Tobeginmovement(forwardor

backward)theoperatormustbeintheseat,the

brakelevermustbedisengaged(pusheddown)

beforethespeedcontrollevercanbemoved

forwardortheenginewillstop.

DrivingForward

1.Starttheengine.

2.Releasetheparkingbrake.

3.Tomoveforwardinastraightlinemovethespeed

controlleverforward.

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Exmark NAVIGATOR NV640KC User manual

Brand: Exmark

Model: NAVIGATOR NV640KC

Category: Lawnmowers

Type: User manual

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