Page 2 - WARNING; CALIFORNIA
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects, orother reproductive harm. Important: When the mower is used or operated on any California forest, brush or grass coveredland, a working sp...
Page 3 - Introduction; CONGRATULATIONS; on the purchase of your
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefullydesigned and manufactured to give you a maximumamount of dependability and years of trouble-freeoperation. This manual contains operating, maintenance,adjustment, and safety instructions for your Exmark...
Page 4 - Contents; Clean Engine and Exhaust System
Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...
Page 5 - Safety; Safety Alert Symbol; Safe Operating Practices; Training; CAUTION
Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both inthis manual and on the machine to identify importantsafety messages which must be followed to avoidaccidents This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Figure 2 1. Safety alert symbol The s...
Page 6 - DANGER; Avoid prolonged breathing of vapors.
Safety DANGER In certain conditions gasoline is extremelyflammable and vapors are explosive. A fire or explosion from gasoline can burnyou, others, and cause property damage. • Fill the fuel tank outdoors in an openarea, when the engine is cold. Wipe upany gasoline that spills. • Never refill the fu...
Page 7 - Operation; Keep feet and clothing away from tires.; Never raise deck with blades running.
Safety • Check that the operator’s presence controls,safety switches, and shields are attached andfunctioning properly. Do Not operate unless theyare functioning properly. Operation WARNING Operating engine parts, especially themuffler, become extremely hot. Severe burnscan occur on contact and debr...
Page 8 - – Before dumping the grass catcher.; NEVER; operate; Slope Operation; Use; Extreme; caution when mowing and/or turning; Do Not mow slopes when grass is wet.
Safety • Stop engine, wait for all moving parts to stop, andengage parking brake: – Before refueling. – Before dumping the grass catcher. WARNING Hands, feet, hair, clothing, or accessories canbecome entangled in rotating parts. Contactwith the rotating parts can cause traumaticamputation or severe ...
Page 9 - Maintenance and Storage
Safety • Avoid sudden starts when mowing downhill.Mower may tip forwards. • Be aware that operating on wet grass, across steepslopes or downhill may cause the mower to losetraction. Loss of traction to the drive wheels mayresult in sliding and a loss of braking and steering. • Always avoid sudden st...
Page 10 - Safety and Instructional Decals
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease,dirt and debris from safety signs and instructionallabels. • Replace all worn, damaged, or missing safetysigns. • When replacement components are installed, besure that current safety signs are affixed to there...
Page 13 - Specifications; Model Numbers
Specifications Specifications Model Numbers Serial Nos: 790,000 and Higher NAV20KC; NAV27KC Systems Engine • Engine Specifications: See your Engine Owner’sManual • RPM: Full Speed: 3600 ±50 RPM (No Load)Idle: 1500 RPM Fuel System • Capacity: 7.5 gal. (28 L) • Type of Fuel: Regular unleaded gasoline,...
Page 14 - Hydraulic Filter: Replaceable cartridge type.; Cutting Deck; – Clutching belt on horizontal engine shaft.; Dimensions
Specifications • Hydraulic Filter: Replaceable cartridge type. – Summer use above 32°F (0°C): P/N 109-0071: 25 microns, 10 psi bypass – Winter use below 32°F (0°C): P/N 1-523541: 40 microns, 18 psi bypass • Speeds: – 0-7.0 mph (11.3 km/hr) forward. – 0-5.5 mph (8.6 km/hr) reverse. • Drive wheel rele...
Page 15 - Torque Requirements; Product Overview
Product Overview Curb Weight: 42 inch Deck 48 inch Deck 850 lb (386 kg) 1145 lb (519 kg) Torque Requirements Bolt Location Torque Blade Mounting Bolt 85-110 ft-lb (115-149 N-m) Engine Mounting Bolts 30-35 ft-lb (41-47 N-m) Wheel Lug Nuts 90-95 ft-lb (122-129 N-m) Wheel Motor MountingBolts 72-77 ft-l...
Page 16 - Controls
Operation Operation Note: Determine 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 levers, progressivelyslows, then reverses the direction of travel of therespective drive w...
Page 17 - Drive Wheel Release Valves; Do Not overtighten. Do; Tracking Adjustment Knob; Do Not rotate the knob too far, as; PTO Engagement Lever; Do Not; Operating Instructions; Open the Fuel Shut-Off Valve
Operation Drive Wheel Release Valves Located on the top left front corner of hydrostaticpumps. Drive wheel release valves are used to release thehydrostatic drive system to allow the machine to bepushed without the engine running. Tilt seat up togain access to pumps. With a 7/16 wrench, turn both va...
Page 18 - Do Not crank the engine; Engaging the PTO; Operator must be in seat before the; Disengaging the PTO; Use caution when making turns.
Operation Important: Do Not crank the engine continuously for more than ten seconds at atime. If the engine does not start, allow a 60second cool-down period between startingattempts. Failure to follow these guidelinescan burn out the starter motor. 7. If the choke is in the “ON” position, gradually...
Page 19 - Driving in Reverse; Emptying Hopper; Transporting; Transporting a Unit
Operation To turn left or right, pull one of the steering leversback toward neutral in the direction desired. The machine will move faster the farther thespeed control lever is moved away from neutral. 4. To stop, pull the speed control lever back to the neutral position. Driving in Reverse 1. To mo...
Page 20 - Loading a Unit; Do Not attempt to turn the unit; Avoid sudden acceleration when driving on a ramp.
Operation WARNING Loading a unit on a trailer or truck increasesthe possibility of tip-over. Tip-over couldcause serious injury or death. • Use extreme caution when operating aunit on a ramp. • Use only a single, full width ramp; DoNot use individual ramps for each sideof the unit. • If individual r...
Page 21 - Maintenance
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING While maintenance or adjustments are beingmade, someone could start the engine.Accidental starting of the engine couldseriously injure you or other bystanders. Remove the key f...
Page 22 - Periodic Maintenance; Check Engine Oil Level; Service Interval: Before each use or daily; Stop engine and wait for all moving parts to stop.; Check Battery Charge; Service Interval: Monthly; To prevent damage due to freezing, battery
Maintenance Maintenance Service Interval Maintenance Procedure Monthly • Check the battery charge. Yearly • Lubricate grease fittings.• 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...
Page 23 - Check for Loose Hardware; Service Air Cleaner; Service Interval: Every 50 hours—Service; Change Engine Oil; Service Interval: After the first 5 hours
Maintenance Check Safety InterlockSystem Service Interval: Before each use or daily Note: To prevent 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 brake engaged , PTO disengaged and speed control lever in t...
Page 24 - Check Hydraulic Oil Level; Service Interval: Every 40 hours; Check Condition Of Belts; Service Interval: Every 40 hours; Lubricate Grease Fittings
Maintenance Before reinstalling new filter, apply a thin coatingof oil on the surface of the rubber seal. Turnfilter clockwise until rubber seal contacts the filteradapter then tighten filter an additional 1/2 to3/4 turn. 6. Clean around oil fill cap and remove cap. Fill to specified capacity and re...
Page 25 - Lubricate; Service Interval: Yearly
Maintenance Lubrication Chart Fitting Locations Initial Pumps Number of Places Service Interval 1. CasterPivot *0 3 *Yearly 2. PTOIdler 1 1 Yearly 3. PumpIdler 1 1 Yearly 4. RearCaster Hub *0 1 *Yearly * See step 3 for special lubrication instructions onthe front and rear caster pivots and the Lubri...
Page 26 - To prevent seal and bearing damage,; Lubricate Brake Handle Pivot; Lubricate Hopper Actuator
Maintenance 11. Insert the second bearing and new seal into the wheel. 12. Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flatsfacing outward. 13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-torque to 20-25 in-lb (2-3 N-m). Makesure axle d...
Page 27 - Service Interval: After the first 250 hours
Maintenance Change Hydraulic SystemFilter Service Interval: After the first 250 hours Every 500 hours/Yearly(whichever comesfirst) thereafter(Every 250 hours/Yearly ifusing Mobil 1 15W50) Note: Use only Exmark Part No. 109-0071 for Summer use above 32°F (0°C) or P/N 1-523541for Winter use below 32°F...
Page 28 - Service Interval: After the first 100 hours; Adjustments
Maintenance Check Wheel Hub Locknuts Service Interval: After the first 100 hours Every 500 hours thereafter Torque to 210–250 ft-lb (285–339 N-m). Check Wheel Lug Nuts Service Interval: After the first 100 hours Every 500 hours thereafter Torque to 90–95 ft-lb (122–129 N-m) cross pattern. Fuel Tank ...
Page 29 - Belt; Belt Guide Adjustment
Maintenance 10. Re-install clevis pin and hairpin to secure brake band. 11. Engage the PTO lever. 12. Loosen the jam nuts and adjust linkage until the top of the idler arm is aligned with the bottom ofnotch on tension arm as shown in Figure 9. Figure 9 1. Tension Arm 2. Loosen jam nuts 3. When PTO i...
Page 30 - Adjust Safety Switch
Maintenance Adjust Safety Switch Adjust all safety switches so plunger extends 3/16inch to 1/4 inch (4.8 mm-6.4 mm) from switch bodywhen 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 each brake is adjusted properly. 1. P...
Page 31 - Pull the speed control lever completely back to
Maintenance loose enough to be moved comfortably by theoperator. Figure 15 1. Speed Control Lever 3. Spring disc washers 2. Friction Plate 4. Hex locknut Speed Control LinkageAdjustment WARNING Engine must be running and drivewheels must be turning so motion controladjustment can be performed. Conta...
Page 33 - Tracking Adjustment; Motion Control Linkage Adjustment; Pump Drive Pulley Alignment; PTO Drive Pulley Alignment
Maintenance Figure 19 1. To increase steering responsiveness hookpump control sprints directly on anchor bolt.To decrease steering responsiveness hook pumpcontrol springs on anchor tabs as shown. Tracking Adjustment See Motion Control Linkage Adjustment section PTO Drive Pulley Alignment PTO drive p...
Page 34 - Hopper Door Adjustment; Close door and push tight against hopper.
Maintenance Rear Caster Pivot BearingsPre-Load Adjustment Remove dust cap from caster and tighten nylocnut until washers are flat. Back off 1/4 of a turnto properly set the pre-load on the bearings. Ifdisassembled, make sure the spring disc washers arereinstalled as shown in Figure 21. Figure 21 1. ...
Page 35 - Cleaning; Clean all debris from rotating engine air intake; Service Interval: Every 80 hours; Remove cooling shroud clean-out covers from; Do Not use water to clean engine.; Clean Debris From Machine; Waste Disposal; Motor Oil Disposal; Do Not swallow electrolyte.
Maintenance Cleaning Clean Engine and ExhaustSystem Area Service Interval: Before each use or daily (May be required moreoften in dry or dirtyconditions.) CAUTION Excessive debris around the engine coolingair intake and inside of the pump drivebelt compartment and damaged or missingrubber baffles ca...
Page 36 - Troubleshooting; condition prior to mower use.
Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, do not overlook the simple causes. For example: starting problems could be causedby an empty fuel tank. The followi...
Page 38 - Schematics; Electrical Diagram
Schematics Schematics Electrical Diagram ENGINE ENGINE OVERHE AT B UZZER ENGINE OVERHE AT LED ACCESSO RY PLUG CLOSED WITH HOPPER D O WN SWITCH IS CLOSED WITH OPER A TOR IN SE A T TEMP SWITCH SE AT DEL AY MODULE CONT ROL SE AT SWITCH BA TTE RY G ROUND SE AT DEL AY MODULE INPUT HOPPER SWITCH BLACK ORA...
Page 39 - Electrical Logic Schematic
Schematics Electrical Logic Schematic BLACK BL ACK ACCESSO RY PLUG ORANGE BLACK RED LT . BLUE BL ACK VIOLET WIPER M O TOR HOPPER FILL SWITCH S P + BUZZER M BL ACK LT . BLUE BL ACK LT . BLUE BR OWN SE AT SWITCH BA TTE RY (+) 12V RED BRO WN ORANGE PINK PINK ORANGE ORANGE ORANGE DK . BLUE S P + TEMP SW...
Page 40 - Hydraulic Diagram
Schematics Hydraulic Diagram G006950 CASE DRAIN CHARGE PUMP HIGH PRESSURE BYPASS VALVE BYPASS VALVE HIGH PRESSURE FORWARD HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE HIGH PRESSURE REVERSE 40
Page 41 - Exmark Commercial Turf Equipment
Conditions and Products Covered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty 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 exercise of our reason...
Page 44 - M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S; SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS; WALK-BEHIND ACCESSORIES AND OPTIONS
M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS WALK-BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO-MULCH SYSTEM TURF STRIPER STANDON CUSTOM RIDE SEAT SUSPENSION SYSTEM FULL SUSPENSION SEAT DECK LIFT ASSIST KIT HITCH KI...
