Page 2 - IMPORTANT
- i - WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system...
Page 4 - CONGRATULATIONS; on the purchase of your Exmark mower. This product has; BEFORE OPERATING YOUR MOWER,
-iii- 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 operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment, and safety ins...
Page 5 - TABLE OF CONTENTS
- iv - TABLE OF CONTENTS 1. SAFETY PAGE 1.1 Safety Alert Symbol ....................................................................................... 1 1.2 Training ......................................................................................................... 1 1.3 Preparation ............
Page 6 - SAFETY ALERT SYMBOL; YOUR SAFETY IS INVOLVED!; PREPARATION; CAUTION
- 1 - 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 ...
Page 7 - DO NOT
- 2 - 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 operator or bystanders. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, ...
Page 9 - NEVER
- 4 - 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 the personnel involved in the operation, transport, maintenan...
Page 10 - DANGER; Figure 1; SAFE ZONE FOR MOWING; EXTREME
- 5 - DANGER POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can cause sliding and 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 slo...
Page 11 - midway; Do Not; MAINTENANCE AND STORAGE
- 6 - 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 governor settings or overspeed the engine. Operating an engine at excessive speed may ...
Page 12 - WARNING
- 7 - 1.5.3 Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries in storage when the open circuit voltage drops to 12.4 volts. Note: To prevent dama...
Page 13 - Safety signs must be replaced if they are missing or illegible.
- 8 - 1.6 SAFETY SIGNS 1.6.1 Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels. 1.6.2 Safety signs must be replaced if they are missing or illegible. 1.6.3 When new components are installed, be sure that current safety signs are affixed to t...
Page 14 - HOT; SURFACE
- 9 - HOT SURFACE 65-2690 WARNING LOCATION: Molded into front of hopper PART NO. 103-8812 LOCATION: On RH Console PART NO. 65-2690 LOCATION: - On Frame LH side in Front of Exhaust Cutout - On Frame RH side behind Exhaust Cutout PART NO. 1-513747 LOCATION: On Battery Cover PART NO. 103-8495 LOCATION:...
Page 15 - unleaded; Kohler; ELECTRICAL SYSTEM
- 10 - 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 gasoline, 87 octane or high...
Page 17 - TORQUE REQUIREMENTS; ASSEMBLY INSTRUCTIONS; The machine is shipped with a filled lead acid battery.
- 12 - 2.8 TIRES Drive Front Caster Rear Caster Pneumatic (Air-Filled) Semi-Pneumatic Semi-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 Pressure 15 psi (103 kPa) 2.9 MOWER DECK (Sold Separately) 2.9.1 Models CD42CD CD48CD Discharg...
Page 18 - cable and the red wire
- 13 - 3.2.1 Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater. IMPORTANT: Make sure the negative battery ca...
Page 19 - SERVICE HYDRAULIC OIL; OPERATION INSTRUCTIONS; equal
- 14 - 3.6 SERVICE HYDRAULIC OIL The machine is shipped with hydraulic oil in the reservoir. Run the machine for approximately 15 minutes to allow any extra air to purge out of the hydraulic system. Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 1...
Page 21 - OPERATING INSTRUCTIONS; crank the engine continuously for more then ten (10)
- 16 - With a 7/16 wrench, turn both valves one turn counter-clockwise to release drive system. Turn clockwise to reset system. DO NOT overtighten. DO NOT tow machine. 4.2 PRE-START 4.2.1 Fill fuel tank. For best results use only clean, fresh regular grade unleaded gasoline with an octane rating of ...
Page 23 - Clearing Hopper Screen:; FIGURE 3; TRANSPORTING
- 18 - FIGURE 2 DISABLING HOPPER AUTO DOOR OPEN 4.3.7 Clearing Hopper Screen: a) Screen may be removed by firmly lifting screen handles. See Figure 3. b) Pull screen towards the back to remove. Gently tap debris from the screen as needed. c) Excessive build-up on the screen can cause the blower to p...
Page 25 - PERIODIC MAINTENANCE; Service Interval: Daily; operate the engine with the oil level below the; Service Interval: Monthly
- 20 - 5. MAINTENANCE & ADJUSTMENTS WARNING POTENTIAL HAZARD ♦ While maintenance or adjustments are being made, someone could start the engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD ♦ Remove the key from the ig...
Page 26 - For 27HP Kohler units
- 21 - a) Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater. IMPORTANT: Make sure the negative battery cable...
Page 27 - paper element
- 22 - b) Check the kill circuits. Run engine at one-third throttle, disengage parking brake and raise off of seat (but do not get off of machine) engine must stop after approx. 1/2 second has elapsed (seat has time delay kill switch to prevent cut-outs on rough terrain). Run engine at one-third thr...
Page 28 - Use only Mobil 1; LUBRICATION CHART
- 23 - 5.1.8 Check hydraulic oil level: Service Interval: 40 hr. a) Stop engine and wait for all moving parts to stop. b) Tilt hopper up. c) Clean area around hydraulic reservoir cap and remove cap. Oil level should be to the top of the baffle inside the tank. If not, add oil. Use only Mobil 1 15W-5...
Page 29 - Service Interval: Once Yearly; NOTE
- 24 - c) Lubricate caster pivots once a year. Remove hex plug and cap. Thread grease zerk in hole and pump with grease until it oozes out around top bearing. Remove grease zerk and thread plug back in. Place cap back on. 5.1.12 Lubricate rear caster wheel hub: Service Interval: Once Yearly a) Stop ...
Page 30 - b) Raise hopper and locate actuator on right hand side of mainframe.; FIGURE 6; Lubricate brake rod bushings:
- 25 - 5.1.14 Lubricate hopper actuator: Service Interval: 160 hrs. a) Stop engine, wait for all moving parts to stop, and remove key. b) Raise hopper and locate actuator on right hand side of mainframe. c) Lubricate switch actuator rod with spray type lubricant or light oil. 5.1.15 Lubricate the pi...
Page 32 - Service Interval: 500 hrs; ADJUSTMENTS; Spring Tensioned - No adjustment necessary.; FIGURE 8
- 27 - 5.1.22 Wheel Hub – slotted nut torque specification Service Interval: 500 hrs When tightening the slotted nut on the wheel motor tapered shaft: a) Torque the slotted nut to 125 ft-lbs (169 N-m). NOTE: Do not use antisieze on wheel hub. 5.1.23 Fuel Tank – mounting hardware specification When i...
Page 34 - BRAKE BOLT ADJUSTMENT
- 29 - 5.2.5 Adjust Seat Switch a) If necessary, adjust the seat actuator rod length to where the machine will shut off when the operator raises off the seat (with brake disengaged or PTO engaged ) but will continue to run with operator in seat (a slight shift in weight should not shut machine off)....
Page 36 - Adjust steering levers:; SPEED CONTROL LEVER ADJUSTMENT; Temporarily
- 31 - CAUTION POTENTIAL HAZARD ♦ Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury...
Page 37 - TRACKING ADJUSTMENT; Set forward stop bolt:; FORWARD STOP BOLT ADJUSTMENT
- 32 - FIGURE 16 TRACKING ADJUSTMENT h) Move the steering levers to the reverse position. While applying slight pressure to the levers, allow the steering levers to return to neutral. The wheels must stop turning (or slightly creep in reverse). i) Stop engine and wait for all moving parts to stop. R...
Page 40 - HOPPER DOOR ADJUSTMENT; PTO Brake Spring Adjustment:; PTO BRAKE SPRING ADJUSTMENT; MOTOR OIL DISPOSAL
- 35 - Door Opening: a) Locate the hopper door cables. Loosen the jam nut next to the yoke at the end of the hopper door cable/shaft assembly on each side and rotate the shaft until the rear door has a clearance of 1/8”-3/8”. See Figure 22. b) Verify the cables are pulled equally tight on each side....
Page 41 - MERCURY SWITCH DISPOSAL; BATTERY DISPOSAL
- 36 - 6.2 MERCURY SWITCH DISPOSAL CAUTION POTENTIAL HAZARD ♦ The mercury contained in the tilt switch is poisonous. WHAT CAN HAPPEN ♦ Exposure to mercury can cause severe illness. HOW TO AVOID THE HAZARD ♦ Never attempt to open or repair the tilt switch ♦ Avoid contact with the mercury. The tilt sw...
Page 43 - ENGINE TROUBLESHOOTING TABLE
- 38 - ENGINE TROUBLESHOOTING TABLE PROBLEM NO FUEL IMPROPER FUEL DIRT IN FUEL LINE DIRTY AIR FILTER FAULTY SPARK PLUG ENGINE OVERLOADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN INSUFFICIENT BATTERY CHARGE Will not start X X X X X X X Hard starting X X X X X X X Stops suddenly X X X ...
Page 44 - ELECTRICAL DIAGRAM
Page 45 - DIAGRAM
Page 48 - RIDING ACCESSORIES; PART; Check us out on the Web:
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