Exmark NAVIGATOR 4500-367 manual

NA VIGA TOR ® For Serial Nos. 790,000 & Higher Part No. 4500-367 Rev . A[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals known to the State of Califor nia to cause cancer, bir th defects, or other reproductiv e har m. Important: When the mower is used or operated on any Califor nia forest, br ush or grass co vered land, a w orking spark arr ester must be attached to t[...]

Introduction CONGRATULATIONS on the purchase of y our Exmark Mow er . T his product has been carefully designed and manufactured to giv e you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for y our Exmark mow er . BEFORE OPERATING Y OUR MO WER[...]

Contents Introduction .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 3 Safety .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . 5 Safety Alert Symbol . . . . . . . .. . . . . . . . . . . . . . . . .[...]

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both in this man ual and on the machine to identify important safety messages which m ust be follow ed to av oid accidents This symbol means: ATTENTION! BECOME ALERT! Y OUR SAFETY IS INV OL VED! Figure 2 1. Safety alert symbol The safety alert symbol appears abo ve inform[...]

Safety DANGER In certain conditions gasoline is extremely ammable and v apors are explosi ve. A re or explosion from gasoline can bur n y ou, others, and cause proper ty damage. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any gasoline that spills. • Never rell the fuel tank or drain the machine indoo[...]

Safety • Check that the operator’ s presence controls , safety switc hes , and shields are attached and functioning properly . Do Not operate unless they are functioning properly . Operation W ARNING Operating engine par ts, especially the mufer, become extremely hot. Severe bur ns can occur on contact and debris, such as leav es, grass, br [...]

Safety • Stop engine, wait for all mo ving par ts to stop , and engag e parking brak e: – Before refueling . – Before dumping the grass catc her . W ARNING Hands, feet, hair , clothing , or accessories can become entang led in rotating par ts. Contact with the rotating par ts can cause traumatic amputation or sev ere lacerations. • Do Not o[...]

Safety • A void sudden starts when mowing downhill. Mow er may tip forwards . • Be aw are that operating on w et g rass , across steep slopes or downhill ma y cause the mo wer to lose traction. Loss of traction to the dri ve wheels may result in sliding and a loss of braking and steering . • Alwa ys av oid sudden starting or stopping on a slo[...]

Safety Safety and Instructional Decals • Keep all safety signs legible . Remo ve all grease, dirt and debris from safety signs and instr uctional labels . • R eplace all w or n, damaged, or missing safety signs . • When replacement components are installed, be sure that cur rent safety signs are afx ed to the replaced components . • If a[...]

Safety 103-9034 103-9724 109-4273 109-4638 109-7318 1 16-0404 1 1[...]

Safety 1 16-1 175 Molded in LH Console Molded into Front of Hopper 12[...]

Specications Specications Model Numbers Serial Nos: 790,000 and Higher NA V20K C; NA V27K C Systems Engine • Engine Specications: See y our Engine Owner’ s Manual • RPM: Full Speed: 3600 ±50 RPM (No Load) Idle: 1500 RPM Fuel System • Capacity: 7.5 gal. (28 L) • T ype of Fuel: R egular unleaded gasoline, 87 octane or higher . •[...]

Specications • Hydraulic Filter : R eplaceable cartridge type . – Summer use abov e 32°F (0°C): P/N 109-0071: 25 microns , 10 psi b ypass – Winter use belo w 32°F (0°C): P/N 1-523541: 40 microns , 18 psi b ypass • Speeds: – 0-7.0 mph (11.3 km/hr) forw ard. – 0-5.5 mph (8.6 km/hr) rev erse. • Driv e wheel release valv es allow m[...]

Product Overview Curb W eight: 42 inch Deck 48 inch Deck 850 lb (386 kg) 1145 lb (519 kg) T orque Requirements Bolt Location T orque 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 (98-104 N-m) Wheel Hub Lockn ut 210-250 ft-l[...]

Operation Operation Note: Deter mine the left and right sides of the machine from the normal operating position. Controls Steering Levers Located in the center in front of the seat. Pulling back on the steering lev ers , progressively slows , then rev erses the direction of trav el of the respectiv e dri ve wheels . By moving both steering lev ers [...]

Operation Drive Wheel Release V alves Located on the top left front corner of h ydrostatic pumps . Driv e wheel release v alves are used to release the hy drostatic driv e system to allow the mac hine to be pushed without the engine r unning . Tilt seat up to gain access to pumps . With a 7/16 wrench, turn both v alves one turn counterclockwise to [...]

Operation Important: Do Not crank the engine continuously for more than ten seconds at a time. If the engine does not star t, allow a 60 second cool-down period betw een star ting attempts. F ailure to follow these guidelines can bur n out the starter motor . 7. If the chok e is in the “ON” position, gradually return c hoke to the “OFF” pos[...]

Operation T o turn left or right, pull one of the steering lev ers back tow ard neutral in the direction desired. The mac hine will mo ve faster the farther the speed control lev er is mov ed aw ay from neutral. 4. T o stop , pull the speed control lever back to the neutral position. Driving in Rev erse 1. T o mo ve rearward in a straight line appl[...]

Operation W ARNING Loading a unit on a trailer or tr uck increases the possibility of tip-ov er . Tip-ov er could cause serious injur y or death. • Use extreme caution when operating a unit on a ramp . • Use only a single, full width ramp; Do Not use indi vidual ramps for each side of the unit. • If individual ramps must be used, use enough r[...]

Maintenance Maintenance Note: Deter mine the left and right sides of the machine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental star ting of the engine could seriously injure y ou or other bystanders. Remo ve the k ey from the ignition s witch, engage parkin[...]

Maintenance Maintenance Ser vice Inter val Maintenance Procedure Monthly • Check the battery c harge. Y early • Lubricate grease ttings . • Lubricate the caster wheel hubs . Periodic Maintenance Check Engine Oil Level Service Interval: Before each use or daily 1. Stop engine and wait for all moving parts to stop . Make sure unit is on a le[...]

Maintenance Check Safety Interlock System Service Interval: Before each use or daily Note: T o prev ent engine cut-outs on rough terrain the seat kill switch has a 1/2 second delay . 1. Check starting circuit. Starter should crank with, parking brak e engaged , PTO disengaged and speed control lev er in the neutral position. The operator does not n[...]

Maintenance Before reinstalling new lter , apply a thin coating of oil on the surface of the rubber seal. T urn lter clockwise until r ubber seal contacts the lter adapter then tighten lter an additional 1/2 to 3/4 tur n. 6. Clean around oil ll cap and remo ve cap . Fill to specied capacity and replace cap . 7. R emov e drain hose[...]

Maintenance Lubrication Chart Fitting Locations Initial Pumps Number of Places Ser vice Inter val 1. Caster Piv ot *0 3 *Y early 2. PTO Idler 1 1 Y early 3. Pump Idler 1 1 Y early 4. Rear Caster Hub *0 1 *Y early * See step 3 for special lubrication instructions on the front and rear caster piv ots and the Lubricate Rear Caster Wheel Hubs section f[...]

Maintenance 11. Insert the second bearing and new seal into the wheel. 12. Apply a thread loc king adhesi ve to the 2nd spacer nut and thread onto the axle with the wrench ats facing outward. 13. T orque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-tor que to 20-25 in-lb (2-3 N-m). Make sure axle does not extend bey ond either nut. 14. R ei[...]

Maintenance Change Hydraulic System Filter Service Interval: After the rst 250 hours Every 500 hours/Y early (whichever comes rst) thereafter (Every 250 hours/Y early if using Mobil 1 15W50) Note: Use only Exmark P art No . 109-0071 for Summer use abov e 32°F (0°C) or P/N 1-523541 for Winter use belo w 32°F (0°C). (R efer to the Hydrostat[...]

Maintenance Check Wheel Hub Locknuts Service Interval: After the rst 100 hours Every 500 hours thereafter T or que to 210–250 ft-lb (285–339 N-m). Check Wheel Lug Nuts Service Interval: After the rst 100 hours Every 500 hours thereafter T or que to 90–95 ft-lb (122–129 N-m) cross pattern. Fuel T ank — Mounting Hardware Specicatio[...]

Maintenance 10. R e-install clevis pin and hairpin to secure brak e band. 11. Engag e the PTO lev er . 12. Loosen the jam nuts and adjust linkage until the top of the idler ar m is aligned with the bottom of notch on tension ar m as sho wn in Figure 9. Figure 9 1. T ension Arm 2. Loosen jam nuts 3. When PT O is engaged, align top of idler arm with [...]

Maintenance Adjust Safety Switch Adjust all safety switc hes so plunger extends 3/16 inch to 1/4 inch (4.8 mm-6.4 mm) from switc h body when plunger is compressed (see Figure 12). Figure 12 1. 3/16 inch to 1/4 inch (4.8 mm-6.4 mm) Brake Adjustment Check to make sure eac h brak e is adjusted properly . 1. Pull the brake lev er up and back to the eng[...]

Maintenance loose enough to be mov ed comfortably by the operator . Figure 15 1. Speed Control Lever 3. Spring disc washers 2. Friction Plate 4. Hex locknut Speed Control Linkage Adjustment W ARNING Engine must be running and driv e wheels must be tur ning so motion control adjustment can be perfor med. Contact with moving par ts or hot surfaces ma[...]

Maintenance across the ter minals in the connector of the wiring harness. 3. Start the engine . 4. R un the unit at least 5 min utes with the speed control lev er at full forward speed to bring hy draulic system oil up to operating temperature. R eturn speed control lever to neutral (full rear) position. 5. T o obtain the neutral position, adjust t[...]

Maintenance Figure 19 1. T o increase steering responsiveness hook pump control sprints directly on anchor bolt. T o decrease steering responsiveness hook pump control springs on anchor tabs as shown. T racking Adjustment See Motion Control Linkage Adjustment section PT O Drive Pulley Alignment PTO dri ve pulley alignment is necessar y for any of t[...]

Maintenance Rear Caster Pivot Bearings Pre-Load Adjustment R emov e dust cap from caster and tighten nyloc nut until w ashers are at. Bac k off 1/4 of a turn to properly set the pre-load on the bearings . If disassembled, make sure the spring disc w ashers are reinstalled as sho wn in Figure 21. Figure 21 1. Spring disc washers Hopper Door Adjus[...]

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 Excessi ve debris around the engine cooling air intak e and inside of the pump driv e belt compar tment and damaged or missing r ubber bafes can cause the engine and hy draulic syst[...]

T roubleshooting T roubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mow er use. When a problem occurs , do not ov erlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The follo wing table lists some of the common causes [...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e. 1. R educe the ground speed. 2. Oil lev el in the crankcase is low . 2. Add oil to the crankcase . Engine ov erheats . 3. Cooling ns and air passages for the engine are plug ged. 3. R emove the obstructions from the cooling ns and air passages . 1. T ra[...]

Schematics Schematics Electrical Diagram ENGINE ENGINE OVERHEA T BUZZER ENGINE O VERHEA T LED ACCESSOR Y PLUG CLOSED WITH HOPPER DOWN SWITCH IS CLOSED WITH OPERA TOR IN SEA T TEMP SWITCH SEA T DELA Y MODULE CONTROL SEA T SWITCH BA TTER Y GROUND SEA T DELA Y MODULE INPUT HOPPER SWITCH BLACK ORANGE ORANGE PINK PINK ORANGE ORANGE PINK ORANGE PINK T AN[...]

Schematics Electrical Logic Schematic BLACK BLACK ACCESSOR Y PLUG ORANGE BLACK RED L T . BLUE BLACK VIOLET WIPER MOT OR HOPPER FILL SWITCH S P + BUZZER M BLACK L T . BLUE BLACK L T . BLUE BRO WN SEA T SWITCH BA TTER Y (+) 12V RED BRO WN ORANGE PINK PINK ORANGE ORANGE ORANGE DK. BLUE S P + TEMP SWITCH BUZZER ORANGE ORANGE PINK PINK ENGINE OVERHEA T [...]

Schematics Hydraulic Diagram G006950 CASE DRAIN CHARGE PUMP HIGH PRESSURE BYP ASS V AL VE BYP ASS V AL VE HIGH PRESSURE FOR W ARD HIGH PRESSURE FOR W ARD HIGH PRESSURE REVERSE HIGH PRESSURE REVERSE 40[...]

Conditions and Products Co vered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty Company , pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair , replace or adjust any part on these products and found by us (in the ex ercise of our reasonable discretion) to be defective in factory [...]

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MID-MOUNT RIDING A CCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF A CCESSORIES AND OPTIONS W ALK-BEHIND A CCESSORIES AND OPTIONS GRASS CA TCHER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM FULL SUSPENSION SEA T DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V PO WER PORT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED[...]