Exmark NAV27KC, NAV20KC User Manual

For Serial Nos.
510,000 & Higher
Part No. 103-8573 Rev. B
WARNING
operator injury or even death. HOW TO AVOID THE HAZARD Keep all shields, guards, and safety devices (especially the grass
discharge system) in place and in proper working condit ion. Stop engine and wait for all moving parts to stop. Remove spark
plug wire(s) or remove key before adjust ing, servicing, or
performing maint enance. If mower deck becomes clogged, stop engine and wait for all
moving parts to stop. Remove spark plug wire(s) or r em ove k ey
before cleaning blockage.
Keep hands, feet, and clothing away from power driven parts . Keep off mower unless seat platf o r m is pr ovided. Keep others off mower.
WARNING
vapors has caused cancer in laboratory animals. WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness. HOW TO AVOID THE HAZARD
Avoid prolonged breathing of vapors. Keep face away from nozzle and gas tank/container opening. Keep away from eyes and skin. Never siphon by mouth.
IMPORTANT
When the mower is used or oper ated on any California forest, brush or grass covered land, a working spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442 Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.
This spark ignition system complies with Canadian ICES-002 Ce système d’allumage par ètincelle de vèhicule est conform e à la norme NMB-002 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 M anual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.
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EXMARK PARTS PLUS® PROGRAM
EFFECTIVE DATE: September 1, 1995 Program
If your Exmark dealer does not have the Exmark part in stock, Exmark will 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 "down" unit at
2. Distributor ships part(s) to dealer or customer, as
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by
5. The customer pays for the part
6. Who pays for the part A. Under any circumstance the customer does not pay. B. If the part does not arrive overnight due to:
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus
®
shipment of six (6) line items or less.
requested by dealer, same day, overnight UPS Distributor bills dealer for part and freight charges where applicable.
®
order, he contacts Exmark by 3:00 p.m.,
central time, with an Exmark Parts Plus
®
order of six (6) line items or less.
distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.
and freight if it is shipped under the Exmark Parts Plus® and if it arrives in
accordance to the program.
and freight if it fails to arrive overnight in accordance to the program?
1. The dealer not submitting the Exmark Parts Plus
®
order to his Exmark distributor by 1:00 p.m., the dealer
pays for the part and freight.
®
order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
Exmark pays for the part and freight.
pays for the part.
The following restrictions apply
-- The Exmark Parts Plus® Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus
®
Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
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CONGRATULATIONS on the purchase of your Exmark mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free oper at ion.
OPERATOR'S MANUAL
This manual contains assembly, operating, maintenance, adjustment, and safety instructions for your Exmark mower.
BEFORE OPERATING YOUR MOWER,
CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
By following the operating, maint enance, and safety instructions, you will prolong the life of your mower, mainta in it s m aximum efficiency, and promote safe oper ation.
If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor.
All Exmark equipment dealers and distribut or s are kept informed of the latest methods of servicing and are equipped t o pr ovide prom pt and efficient service in the field or at their service stations. T hey carr y ample stock of service parts or can secure them promptly for you fr om the factory.
All Exmark parts are thoroug hly test ed and inspect ed before leaving the factory, however, attention is required on your part if you are t o obt ain the fullest measure of satisfaction and performance.
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TABLE OF CONTENTS
1. SAFETY PAGE
1.1 Safety Alert Symbol....................................................................................... 1
1.2 Training.........................................................................................................1
1.3 Preparation.................................................................................................1-3
1.4 Operation ...................................................................................................4-6
1.5 Maintenance & Storage..............................................................................6-7
1.6 Safety Signs............................................................................................. 8-10
2. SPECIFICATIONS
2.1 Model Number............................................................................................. 10
2.2 Engine......................................................................................................... 10
2.3 Fuel System ................................................................................................ 10
2.4 Electrical System....................................................................................10-11
2.5 Operator Controls........................................................................................ 11
2.6 Seat............................................................................................................. 11
2.7 Hydrostatic Ground Drive System ...............................................................11
2.8 Tires............................................................................................................12
2.9 Mower Deck ................................................................................................ 12
2.10 Dimensions.................................................................................................. 12
2.11 Torque Requirements..................................................................................12
3. ASSEMBLY INSTRUCTIONS
3.1 Uncrate Mower............................................................................................12
3.2 Service Battery.......................................................................................12-13
3.3 Install Drive Wheels..................................................................................... 13
3.4 Check Tire Pressure....................................................................................13
3.5 Service Engine............................................................................................ 13
3.6 Service Hydraulic Oil................................................................................... 14
4. OPERATION INSTRUCTIONS
4.1 Controls.................................................................................................. 14-16
4.2 Pre-Start...................................................................................................... 16
4.3 Operating Instructions ............................................................................ 16-18
4.4 Transporting........................................................................................... 18-19
5. MAINTENANCE & ADJUSTMENTS
5.1 Periodic Maintenance.............................................................................20-27
5.2 Adjustments ...........................................................................................27-35
6. WASTE DISPOSAL
6.1 Motor Oil Disposal.......................................................................................35
6.2 Mercury Switch Disposal ............................................................................. 36
6.3 Battery Disposal.......................................................................................... 36
7. TROUBLESHOOTING ..................................................................................37-38
8. ELECTRICAL DIAGRAM ................................................................................... 39
9. HYDRAULIC DIAGRAM ....................................................................................40
10. WARRANTY ..................................................................................................... 41
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1. SAFETY
1.1 SAFETY ALERT SYMBOL
This SAFETY ALERT SYMBOL is used both in this manual and on the machine to
identify important safety messages which must be followed to avoid accidents. This symbol means:
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
The safety alert symbol appears above information which alerts you to unsafe actions or
situations and will be followed by the word DANGER, WARNING, or CAUTION.
DANGER: White lettering / Red background. I ndicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injur y.
WARNING: Black lettering / O r ange background. Indicates a pot ent ially hazardous
situation which, if not avoided, COULD result in deat h or serious injury.
CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous
situation which, if not avoided, MAY result in minor or moderate injury.
1.2 TRAINING
1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit.
1.2.2 Read the instructions carefully. Familiarize yourself with the controls and the proper use of the equipment. If the operator(s) or mechanic(s) can not read English, it is the owner’s responsibility to explain this mater ial t o them.
1.2.3 Do not allow operation of this machine by untrained personnel. Never allow children, teenagers, or people unfamiliar with these instructions to use the mower. Local regulations may restrict the age of the operator.
1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.
1.3 PREPARATION
1.3.1 Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by Exmark.
1.3.2 The use of per sonal pr ot ective equipment, such as (but not limited to) pr otection for the eyes, ears, feet , and head is r ecom m ended.
CAUTION
dBA at the operator’s ear when in operation.
WHAT CAN HAPPEN Exposure to sound levels of 85 dBA or above for
extended periods of time can cause hearing loss.
HOW TO AVOID THE HAZARD Wear hearing protection when operating this machine.
1.3.3 While mowing, always wear substantial footwear and long trousers. Do not operate equipment when barefoot or when wearing open sandals.
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1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operat or or bystanders.
WARNING
POTENTIAL HAZARD Engine exhaust contains carbon monoxide, which is
an odorless deadly poison.
WHAT CAN HAPPEN Carbon monoxide can kill you.
HOW TO AVOID THE HAZARD Do not run engine indoors or in a small confined area
where dangerous carbon monoxide fumes can collect.
DANGER
POTENTIAL HAZARD In certain conditions gasoline is extremely flamm able
and highly explosive.
WHAT CAN HAPPEN A fire or explosion from gasoline can bur n you, ot hers,
and cause property damage.
HOW TO AVOID THE HAZARD DO NOT smoke while refueling , and stay away from
an open flame or where gasoline fumes m ay be ignited by spark.
Refuel only outdoors. Store gasoline in an approved container and keep it
out of the reach of children.
Add fuel before start ing the engine. Never remove the
cap of the fuel tank or add fuel when engine is running or when the engine is hot.
Never fill the fuel tank so t hat the gasoline level rises
above a level that is 1/2” below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage.
If fuel is spilled, DO NOT attempt to start the engine.
Move away from the area of the spill and avoid creating any source of ignition unt il fuel vapors have dissipated.
Do not operate without entire exhaust system in place
and in proper working condition.
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DANGER
POTENTIAL HAZARD In certain conditions gasoline is extremely flamm able
and highly explosive.
WHAT CAN HAPPEN A static charge can ignite g asoline vapors. A fire or
explosion from gasoline can burn you, others, and cause property damage.
HOW TO AVOID THE HAZARD Purchase and store gasoline only in an approved
container.
Always place gasoline containers on the ground away
from your vehicle before f illing.
Do not fill gasoline containers inside a vehicle or on a
truck or trailer bed because interior car pets or plastic truck bed liners may insulate the container and slow the loss of any static charge.
When practical, r emove gas-powered equipment from
the truck or trailer and r efuel the equipment with its wheels on the ground.
If this is not possible, then refuel such equipment on a
truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.
If a gasoline dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.
WARNING
POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and
may be ignited by electrical sparks or hot engine/exhaust components.
WHAT CAN HAPPEN Explosion and fire may occur, resulting in proper t y
damage, personal injury, and/or death.
HOW TO AVOID THE HAZARD Provide adequate ventilation of any enclosed trailer to
prevent build up of gasoline vapors, especially at floor level.
Refuel only outdoors, never inside an enclosed trailer. Be sure all fuel tanks and gasoline st or age containers
have proper caps installed to prevent spillage and minimize vapor escaping into the trailer.
Do not place any equipment that is leaking gasoline in
an enclosed trailer.
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1.4 OPERATION
Although hazard control and accident prevention are partially dependent upon the
design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence, and proper training of t he personnel i nvolved in the operation, transport, maintenance, and st orage of t he equipment. It is essential that all Operator Safety Mechanisms be connect ed and i n operat i ng condition prior to use for mowing.
WARNING
extremely hot.
WHAT CAN HAPPEN
Severe burns can occur on contact. Debris, such as leaves, grass, brush, etc. can cat ch fire.
HOW TO AVOID THE HAZARD Allow engine parts, especially the muff ler , to cool before
touching.
Remove accumulated debris from muffler and engine area. Install and maintain in working order a spar k arrester before
using equipment on forest - covered, grass-covered, or brush-covered unimproved land.
WARNING
entangled in rotating part s.
WHAT CAN HAPPEN Contact with rotating parts can cause traum at ic am putation
or severe lacerations.
HOW TO AVOID THE HAZARD Do not operate the machine without guards, shields, and
safety devices in place and working.
Keep hands, feet, hair, je welry, or clothing away from
rotating parts.
1.4.1 Give complete, undivided attention to the job at hand.
1.4.2 Mow only in daylight or good artif icial light, keeping away from holes and hidden hazards. NEVER carry passengers.
DO NOT operate the mower when children or others are in the area.
1.4.3 When feasible, avoid operating the equipment in wet grass.
1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tr action and/or tip-over could occur. The operator is r esponsible for safe operation on slopes.
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DANGER
loss of control.
WHAT CAN HAPPEN Wheels dropping over edges, ditches, steep banks, or
water can cause rollovers, which may result in serious injury, death or drowning.
HOW TO AVOID THE HAZARD
Do not mow slopes when grass is wet. Do not mow near drop-offs or near water. Do not mow slopes greater than 15 degrees. Reduce speed and use extreme caution on slopes. Avoid sudden turns or rapid speed changes.
See inside the back cover to determine the approximate slope angle of the
area to be mowed.
Use a walk behind mower and/or a hand trimmer near drop- offs, ditches, steep
banks or water. This area can be dangerous, see Figure 1.
Figure 1
SAFE ZONE FOR MOWING
Progressively greater care is needed as the slope increases.
Always avoid sudden starting or stopping on a slope. If tir es lose t r action,
disengage the blades and proceed slowly off the slope.
Avoid sudden stops when mowing downhill. Mower may tip forwards.
Be aware that loss of traction may occur going uphill. Weight transfer to the
rear wheel may cause drive wheels to slip and cause loss of braking and steering.
Watch for ditches, holes, rocks, dips, and r ises t hat change the operating
angle, as rough terrain could overtur n the machine.
Remove or mark obstacles such as rocks, t r ee lim bs, etc. from the mowing
area. Tall grass can hide obstacles.
Use extreme care with attachments. These can change t he stability of the
machine and cause loss of control.
Follow the manufacturer’s recommendations for wheel weights or
counterweights to improve stability.
1.4.5 Use EXTREME caut ion when backing up. LOOK BEHIND YOU!
1.4.6 Stop the blades when crossing surfaces other than gr ass and when transporting the mower to and from the area to be m owed.
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1.4.7 Never operate the mower with damaged guards, shields, or covers. Always have safety shields, guards, switches, and other devices in place and in proper working condition.
1.4.8 DO NOT change the engine g overnor set tings or overspeed the engine. Operating an engine at excessive speed may increase the hazard of personal injury.
1.4.9 Disengage PTO befor e starting engine.
1.4.10 Start
the engine carefully with feet well away from the blades.
1.4.11 Keep hands, feet, and clothing away from r o t at ing parts while the mower is being operated.
1.4.12 Stop engine, wait for all moving parts to stop, and remove key:
Before checking, cleaning or work ing on the mower.
After striking a foreign object (inspect the m ower for damage and make
repairs before restart ing and operating the mower).
Before clearing blockages.
Whenever you leave the mower.
Stop the engine and wait for all moving part s t o st op:
Before refueling.
Before dumping the gr ass cat c her .
1.4.13 Before stopping the engine, place the throt t le cont r ol midway between the “slow” and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then stop the engine.
1.4.14 The fuel system is provided with a shut-off valve. Shut off the fuel:
When the machine will not be used for a few days.
During transport to and from the job.
When parked inside a building.
1.4.15 This mower was designed for one operator only. Keep all others away fr om mower during operation.
1.4.16 Do Not mow with the grass catcher door or the grass cat cher r aised, removed or altered.
1.4.17 Do Not operate mower under the influence of alcohol or dr ugs.
1.4.18 Use extra care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
1.4.19 If jump starting is required:
a) connect the positive (+) power cable from the positive post on the booster
battery to the positive terminal post on the star ter solenoid switch (this post has the positive battery cable attached to it).
b) connect the negative or ground cable (-) from the negative post on the
booster battery to the engine block as far away from the battery as possible.
c) disconnect battery cables in the reverse order after starting.
1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maintenance, follow the engine manufacturer’s recommendations precisely as stated in the engine manual.
1.5.2 Disconnect the battery cable from the negative battery post when the unit will be allowed to sit for more than 30 days without use.
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1.5.3 Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and ser vice life. To preserve optimum battery performance and lif e, recharge batteries in storage when the open circuit voltage drops to 12.4 volts.
Note: To prevent damage due to freezing, bat t er y should be fully charged
before putting away for winter storag e.
1.5.4 Keep engine, engine area, and pump drive belt compartment free from accumulation of grass, leaves, excessive grease or oil, and ot her debris which can accumulate in these areas. These materials can become com bustible and may result in a fire.
1.5.5 Store fuel in a container specifically designed for this purpose in a cool, dry place.
1.5.6 Keep the m ower and fuel container in locked storage to pr event childr en from playing or tampering with them.
1.5.7 Gasoline powered eq uipm ent or fuel containers should not be stored in a basement or any enclosed area where open pilot lights or heat appliances are present.
1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly.
1.5.9 Check all bolts frequently to maint ain proper tightness.
1.5.10 Keep all guards, shields, and all safety devices in place and in safe working condition.
1.5.11 Frequently check for worn or deteriorating com ponent s t hat could create a hazard.
1.5.12 All replacement parts must be the same as or equivalent to the par t s supplied as original equipment.
WARNING
POTENTIAL HAZARD Hydraulic fluid escaping under pressure can penetrat e
skin and cause injury.
WHAT CAN HAPPEN 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 ma y result .
HOW TO AVOID THE HAZARD Make sure all hydraulic fluid hoses and lines are in
good condition an all hydraulic connections and fittings are tight before applying pressure to hydraulic system.
Keep body and hands away from pinhole leaks or
nozzles that eject high pressure hydraulic fluid.
Use cardboard or paper, not your hands, to f ind
hydraulic leaks.
Safely relieve all pressure in the hydraulic system, by
placing the motion control levers in neutral and shutting off t he engine, before perfor m ing any work on the hydraulic system.
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1.6 SAFETY SIGNS
1.6.1 Keep all saf et y sig ns legible. Remove all grease, dirt and debris from safety signs and instructional labels.
1.6.2 Saf et y sig ns m ust be replaced if they are missing or illegible.
1.6.3 When new components are installed, be sure that cur r ent safety signs are affixed to the replaced components.
1.6.4 New safety signs m ay be obtained from Exmark Mfg. Co. I nc.
1.6.5 Saf et y 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.
1.6.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They are critical to the safe operation of your Exmark commercial mo wer.
LOCATION: Molded in LH Console
PART NO. 79-0360 LOCATION: On Front of Blower
Discharge Chute
PART NO. 1-643401 LOCATION: On Frame, Next to Mercury Switch
or On Mercury Switch
PART NO. 98-4361 LOCATION: - On Top of Pump Mounting Plate
- On PTO Shield
PART NO. 98-5954 LOCATION: - On Gear Box Cover, Under Rubber Cover
- On Top of Deck, Under Gear Box Cover
- On LH Frame, Under PTO Shield
- On RH Lower Frame, behind fuel tank
PART NO. 103-8451 LOCATION: On RH Console
PART NO. 1-523552 LOCATION: On Top of Oil Reservoir
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PART NO. 103-8611 LOCATION: On Pump Plate,
Above Relays
WARNING
HOT
SURFACE
PART NO. 65-2690 LOCATION: - On Frame LH side in Front
- On Frame RH side behind
PART NO. 103-8444 LOCATION: On Hopper Door Hinge, Each Side
PART NO. 103-8495 LOCATION: On Top of Mainframe, Under Hopper
PART NO. 1-513747 LOCATION: On Battery Cover
65-2690
of Exhaust Cutout Exhaust Cutout
PART NO. 103-8812 LOCATION: On RH Console
LOCATION: Molded into front of hopper
PART NO. 103-8416 LOCATION: On Top of Seat Console, Under Seat
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PART NO. 103-9724 LOCATION: On PTO Guard
PART NO. 103-8425 LOCATION: - On front console,
- On driveshaft
Under Seat
PART NO. 103-9032 LOCATION: On Back of Seat
PART NO. 103-9034 LOCATION: On Rear of LH Drive
Wheel Fender
2. SPECIFICATIONS
2.1 MODEL NUMBER: NAV20KC, NAV27KC
2.2 ENGINE:
2.2.1 Engine Specifications: 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 gal (28 L)
2.3.2 Type of Fuel: Regular unleaded g asoline, 87 oct ane or higher
2.3.3 Fuel Filter: Kohler units: In-line 15 Micron Kohler P/ N 2405002.
2.3.4 Fuel Shut-Off Valve: 1/4 turn “in-line” valve by fuel filter.
2.4 ELECTRICAL SYSTEM
2.4.1 Charging System: Flywheel Alternator
2.4.2 Charging Capacity: 15 amps
2.4.3 Battery Type: BCI Group U1
2.4.4 Battery Voltage: 12 Volt
2.4.5 Polarity: Negative Ground
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