Exmark NAV20KC manual

Part No. 103-8573 Rev. B For Serial Nos. 510,000 & Higher[...]

- i - WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment. W HAT CAN HAPPEN ♦ Failure to f ollow safe operating pr act ices can result in serious operator inj ur y or even death. HOW TO AVO ID THE HAZARD ♦ Keep all shields, guar ds, and saf ety devices (especially the grass discharge system) in place and in pr oper working[...]

- ii - EXMARK PA RTS PLUS ® PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not have the Exmark part in stock, Exmark w ill get the parts to the dealer the next business day or the part will be FREE* Guaranteed!! How the Program Works 1. If dealer does not have part in stock for a "dow n" unit at the time o[...]

-iii- CONGRAT ULATIONS on the purchase of your Exmark mower. T his product has been caref ully designed and manuf actured to g ive you a max im um amount of dependability and years of tr ouble- f ree operat ion. OPERA TOR'S M ANUA L This manual cont ains assem bly, oper at ing , maintenance, adj ust ment, and saf ety instructi ons for your E x[...]

- iv - TA BLE OF CONTENTS 1 . S A F E T Y P A G E 1.1 Safety A lert Symb ol ....................................................................................... 1 1.2 Traini ng ......................................................................................................... 1 1.3 Prepar ation .............................................[...]

- 1 - 1. SA FETY 1.1 SA FETY A LERT SYMBOL This SAFET Y ALERT SYMBOL is used both in this manual and on the m achine t o identif y import ant safet y messag es which must be followed to avoid accidents. T his symbol means: A TTENTION! BECOME A LERT! YOUR SA FETY IS INVOLVED! The saf ety alert symbol appears above inform at ion which alerts you to u[...]

- 2 - 1.3.4 Thoroug hly inspect t he ar ea where the equipment is t o be used and r em ove all stones, stick s, wires, bones, and other f oreign obj ect s which may damage t he equipment or cause per sonal inj ury to the operator or bystander s. WA RNING POTENT IAL HAZARD ♦ Engine exhaust contains carbon m onoxide, which is an odorless deadly poi[...]

- 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flamm able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g asoline vapors. A f ire or explosion from g asoline can burn you, others, and cause property damag e. HOW TO AVO ID THE HAZARD ♦ Purchase and store g asoline only in an approved cont[...]

- 4 - 1.4 OPERA TION Although hazard control and acci dent prevent ion are partiall y dependent upon t he design and configurat i on of t he equipment, these f act ors are al so dependent upon the awareness, concern, prudence, and proper t r ai ni ng of the personnel involved i n the operation, t r ansport , mai nt enance, and storage of the equipm[...]

- 5 - DA NGER POTENT IAL HAZARD ♦ Mow ing on wet gr ass or steep slopes can cause sliding and loss of cont r ol. W HAT CAN HAPPEN ♦ W heels dropping over edges, ditches, st eep bank s, or water can cause rollovers, which may result in serious injury, death or dr owning. HOW TO AVO ID THE HAZARD ♦ Do not mow slopes when grass is wet. ♦ Do no[...]

- 6 - 1.4.7 Never operate the mower with damaged g uards, shields, or covers. Always have safety shields, g uar ds, switches, and ot her devices in place and in proper working condit ion. 1.4.8 DO NOT chang e the engine g overnor set t ings or overspeed the engine. Operating an engine at excessive speed may increase the hazard of per sonal injury. [...]

- 7 - 1.5.3 Allowing batteries to st and f or an extended period of time without recharg ing them will result in reduced per f ormance and ser vice lif e. To preser ve optim um battery perf ormance and lif e, recharg e bat t eries in storage when the open circuit voltag e dr ops t o 12.4 volts. Note: T o pr event dam ag e due to f r eezing, battery[...]

- 8 - 1.6 SA FETY SIGNS 1.6.1 Keep all safet y sig ns leg ible. Remove all grease, dir t and debris fr om saf ety signs and instr uct ional labels. 1.6.2 Safet y sig ns m ust be r eplaced if they are missing or illegible. 1.6.3 W hen new components are inst alled, be sur e t hat current saf ety signs are aff ixed to the replaced components. 1.6.4 N[...]

- 9 - HOT SUR FACE 65- 2690 WARNING LOCATI ON: Molded into front of hopper PART NO. 103- 8812 LOCATIO N: On RH Console PART NO. 65- 2690 LOCATIO N: - On Fram e LH side in Front of Exhaus t Cutout - On Fram e RH side behind Exhaust Cutout PART NO. 1- 513747 LOCATIO N: On Battery Cover PART NO. 103- 8495 LOCATIO N: On Top of Mainfram e, Under Hopper [...]

- 10 - 2. SPECIFICA TIONS 2.1 MODEL NUMBER: NAV20KC, NAV27KC 2.2 ENGINE: 2.2.1 Engine Specif icat ions: See your Engine Owner’s Manual 2.2.2 RPM: Full Speed: 3600 RPM (No Load) Idle: 1500 RPM 2.3 FUEL SYSTEM 2.3.1 Capacity: 7.5 g al ( 28 L) 2.3.2 Type of Fuel: Reg ular unleaded gasoline, 87 octane or higher 2.3.3 Fuel Filter: Kohler unit s: In-li[...]

- 11 - 2.4.6 Safet y Int er lock System: PTO must be di sengaged , brake engaged , and speed control lever in neut ral positio n to start engine . (It is not necessary for the oper at or to be in the seat to start t he eng ine.) Operator m ust be in seat when PTO is eng aged , brake i s di sengaged , or speed control lever i s moved out of neut ral[...]

- 12 - 2.8 TIRES Drive Front Cast er Rear Caster Pneum atic (Air-F illed) Sem i-Pneum atic Sem i-Pneumatic Quantity 2 2 1 Tread Multi Trac C/S Smooth Smooth Size 18 x 10.50-10 8 x 3.00-4 13 x 8.00-6 Ply Rating 4 Pressur e 15 psi (103 k Pa) 2.9 MOWER DECK ( Sold Separ at ely) 2.9.1 M odels CD42CD CD48CD Discharge Center Discharge Center Dis charge C[...]

- 13 - 3.2.1 Check the voltag e of the bat tery with a digital voltmeter . Locate the voltag e r eading of t he bat t ery in the table below and charge the batt ery for the r ecom mended time interval to bring the charge up t o a full charg e of 12.6 volts or g reater. IMPORT A NT: M ak e sure the negat ive battery cables are disconnected and the b[...]

- 14 - 3.6 SERVICE HYDRAULIC OIL The machine is shipped with hydraulic oil in the reser voir. Run t he machine for approximately 15 minutes to allow any extra air to purg e out of t he hydraulic system. Check hydraulic reser voir and if necessary fill t he r eser voir to the appropriat e level with Mobil 1 15W -50 synthetic mot or oil. Replace hydr[...]

- 15 - Run unit at 3/4 speed f or at least 5 m inut es t o bring hydraulic oil up to oper at ing temperat ur e. Stop machine and wait f or all moving parts t o st op. Engage par k brake. T ilt seat f orward to gain access to t he t r ack ing knob. Rotate the k nob towards the right t o st eer r ig ht and rotate t owards the lef t to steer lef t. Ad[...]

- 16 - W ith a 7/ 16 wrench, t ur n bot h valv es one turn counter - c lock wise to release drive system. Turn clockwis e to reset system. DO NOT overti ght en. DO NOT tow machine. 4.2 PRE-STA RT 4.2.1 Fill fuel t ank . For best r esult s use only clean, fresh reg ular gr ade unl eaded gasoline with an octane rat ing of 87 or hig her. Regular g rad[...]

- 17 - DA NGER POTENT IAL HAZARD ♦ An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s dir ection. Also, contact with the blade could occur. W HAT CAN HAPPEN ♦ Thrown objects or blade cont act can cause serious injury or death. HOW TO AVO ID THE HAZARD ♦ Alway s operate the m ower with the gr ass[...]

- 18 - FIGURE 2 DISA BLING HOP PER A UT O DOOR OPEN 4.3.7 Clearing Hopper Screen : a) Screen may be removed by firmly lif t ing screen handles. See Figur e 3. b) Pull screen towards the back to rem ove. Gently tap debris f r om t he screen as needed. c) Excessive build-up on the screen can cause the blower to plug. NOTE: In conditions where the scr[...]

- 19 - CA UTION POTENT IAL HAZARD ♦ This unit does not have proper t ur n sig nals, light s, ref lect ive mark ings, or a slow moving vehicle emblem. These item s ar e r eq uired to drive on a public str eet or roadway. W HAT CAN HAPPEN ♦ Driving on a street or roadway w ithout such equipment is dangerous and can lead t o accident s causing per[...]

- 20 - 5. MAINTENA NCE & A DJUSTMENTS WA RNING POTENT IAL HAZARD ♦ W hile maint enance or adj ustments are being made, someone could start t he eng ine. W HAT CAN HAPPEN ♦ Accidental start ing of the eng ine could seriously injure you or other bystanders. HOW TO AVO ID THE HAZARD ♦ Remove the key f rom the ig nit ion switch and pull the w[...]

- 21 - a) Check the voltage of the batter y with a digital voltm e t er . Locate the voltage reading of the batter y in the t able below and charg e t he battery for the recommended t im e int er val to bring the charg e up to a f ull char g e of 12. 6 volts or great er. IMP ORTA NT : Make sure the neg ative battery cables are disconnected and the [...]

- 22 - b) Check t he k ill circuits. Run engine at one-t hir d thrott le, di sengage par k ing brake and rai se of f of seat (but do not g et of f of m achine) eng ine must stop af t er appr ox. 1/2 second has elapsed (seat has tim e delay kill switch to prevent cut-out s on rough terr ain). Run engine at one-thir d t hrottle, engage PTO and rai se[...]

- 23 - 5.1.8 Check hydraulic oil level : Service Interval: 40 hr. a) St op eng ine and wait for all moving par ts to stop. b) T ilt hopper up. c) Clean area around hydraulic reser voir cap and rem ove cap. Oil level should be to the top of the baf fle inside the t ank . If not, add oil. Use only Mobil 1 15W-50 synthe tic motor oil. Replace hydrauli[...]

- 24 - c) Lubr icat e caster pivots once a year. Remove hex plug and cap. T hr ead grease zerk in hole and pump with grease until it oozes out ar ound t op bearing. Remove grease zerk and t hr ead plug back in. Place cap back on. 5.1.12 Lubricate rear cast er wheel hub: Service Interval: Once Yearly a) Stop engine, wait fo r all m o ving par t s to[...]

- 25 - 5.1.14 Lubr icat e hopper actuator: Service Int erval : 160 hrs. a) Stop eng ine, wait for all moving par t s to stop, and r em ove key. b) Raise hopper and locate act uator on right hand side of mainf rame. c) Lubr icat e switch act uat or r od with spray type lubricant or light oil. 5.1.15 Lubricate the pivot bushing s (locations shown in [...]

- 26 - 5.1.19 Check spark plugs : Service Int erval : 160 hrs. a) Remove spark plug s, check condit ion and reset gaps, or r eplace with new plugs. See Eng ine Owners M anual. 5.1.20 Change f uel filter : Servi ce I nt erval : As Required a) A f uel f ilter is inst alled bet ween the fuel tank and t he engine. Replace when necessary. Replacement Fi[...]

- 27 - 5.1.22 W heel Hub – slotted nut tor q ue specification Service Interval: 500 hrs W hen tig htening the slot t ed nut on the wheel motor tapered shaf t: a) Torque the slotted nut to 125 f t-lbs (169 N-m). NO TE: Do not use ant isieze on wheel hub. 5.1.23 Fuel T ank – mount ing hardware specification W hen installing the nuts on the f uel [...]

- 28 - i) Engage th e PTO lev er. j) Loosen the jam nut s and adjust linkag e as shown in Figure 9 until the pointer is alig ned with the t ension ar m as shown. FIGURE 9 PTO BELT REPLAC EMENT k) Tighten jam nuts and disengag e PT O lever. Re-eng ag e PTO lever and check pointer alig nment. 5.2.3 Pump Drive Belt Replacement . a) Stop eng ine, wait [...]

- 29 - 5.2.5 Adjust Seat Switch a) I f necessary, adjust t he seat actuator rod leng th to where the machine will shut of f when the operator raises of f t he seat (with brake disengaged or PTO engaged ) but will continue to r un with operator in seat (a slig ht shif t in weight should not shut m achine of f) . NOT E: To prevent the engine from cut[...]

- 30 - FIGURE 13 THRO TTLE TE NSI ON 5. 2. 8 Adjust Speed Control Lever T ension a) St op eng ine, wait for all m oving par t s to stop, and r em ove k ey. b) T ension in speed cont rol lever can be adjusted by adjusting t he t ightness of the lever pivot bolt, which is located under the seat near the speed control lever. See Figur e 14. c) Set the[...]

- 31 - CA UTION POTENT IAL HAZARD ♦ Raising the m ower deck f or service or maint enance relying solely on mechanical or hydraulic jack s could be dangerous. W HAT CAN HAPPEN ♦ The mechanical or hydraulic j ack s may not be enough support or m ay malf unction allowing the unit t o fall, which could cause injury. HOW TO AVO ID THE HAZARD ♦ DO [...]

- 32 - FIGURE 16 TRA CKING ADJUST M ENT h) Move the steering levers t o the reverse position. W hile applying slig ht pressure to t he levers, allow the steering levers to r et urn to neutr al. T he wheels must stop turning (or slight ly creep in r everse) . i) Stop eng ine and wait for all m oving par t s t o stop. Remove jum per wire fr om wire h[...]

- 33 - c) Lift t he seat and locate the pump cont r ol spr ing s. To increase responsiveness, increase spring t ension by hooking the rear spr ing anchor directly to the anchor bolt . To decrease r esponsiveness, hook the rear spring anchor t o t he anchor t ab. NOTE: Be sure both springs maint ain t he same adjustment . FIGURE 18 STEERING CONTROL [...]

- 34 - j) Tig ht en the 4 engine mount ing bolts and 4 jack shaf t mount ing bolts. Check alig nm ent after tightening . k ) Re-install pump belt t ension spr ing . l) Swing f uel tank in and r e- inst a ll t ank mounting nut s. m) Complete Pump Dr ive Pulley Alignment Section 5.2. 13. 5.2.13 Pump Drive Pulley Alignment Pump drive pulley alignment [...]

- 35 - Door Opening: a) Locate the hopper door cables. Loosen t he jam nut next to t he yoke at the end of t he hopper door cable/ shaft assem bly on each side and rotat e the shaft unt il t he rear door has a clearance of 1/8”-3/ 8”. See Figur e 22. b) Verify the cables ar e pulled eq ually tight on each side. c) Tight en t he j am nuts agains[...]

- 36 - 6.2 MERCURY S WITCH DISPOSAL CA UTION POTENT IAL HAZARD ♦ The mer cur y contained in t he tilt switch is poisonous. W HAT CAN HAPPEN ♦ Exposure to mercury can cause severe illness. HOW TO AVO ID THE HAZARD ♦ Never attempt to open or repair t he tilt switch ♦ Avoid contact with the mercury. The tilt switch (PN 1- 633782) on t his unit[...]

- 37 - 7. TROUBLE SHOOTING 7.1 MOWER PULLS LEFT OR RIGHT ( W /LEVERS FULLY FORWARD) . a) Ref er t o T racking Adj ust ment Section 4.1. 3. b) Check air pr essur e in drive tires; 15 psi Sem i-pneum at ic casters do not req uire inflat ion. 7.2 MOWER CUTS U NEVENLY. a) Check air pressure in drive tires; 15 psi. Semi-pneumatic caster s do not r eq ui[...]

- 38 - ENGINE TROUBLESHOOTING TA BLE PROBLEM NO FUEL IMPROPER FUEL DIRT IN FUEL LI NE DIRTY AIR FILTER FAU LTY SPARK PLUG ENGINE OVERLOADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN INSUFFICIENT BATT ERY CHARGE Wi ll not start X X X X X X X Hard starting X X X X X X X Stops suddenly X X X X X X X Lacks power X X X X X X X X Operates [...]

- 39 - 8. ELECTRICA L DIA GRAM[...]

- 40 - 9. HYDRA ULIC DIA GRAM[...]

- 41 - 10. 2-Yea r Limited Warranty Exmark Tu rf Equipment (For units pur chased on or af ter October 1, 2004) Conditions and Products Covered Exmark M fg. Co. Inc. and its affiliate, Exmark W arranty Company, pursuant to an agreement betw een them, jointly warrant on the terms and conditions herein, that w e will repair, replace or adjust any part[...]

42[...]

® M FG . CO. IN C. SEE EXMA RK’S COMPLETE LINE OF A CCESSORIES RIDING A CCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT K IT MICRO-MULCH SY ST EM ROLL OVER PROTECT ION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONT AINER TURF STRIPER ULTRA VAC COLLECT ION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WA LK BEHIND A CC[...]