Exmark Navigator NAV20KC Operator'S Manual Download

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ENGINE TROUBLESHOOTING TABLE

PROBLEM

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

Hard starting

X X X

Stops suddenly

X X X X

Lacks power

X X X X X

Operates erratically

X X X X

Knocks or pings

X X

Skips or misfires

X X

Backfires

X X X

Overheats

X X X

High fuel

consumption

X X X

Summary of Contents for Navigator NAV20KC

Page 1: ...Part No 103 8573 Rev B For Serial Nos 510 000 Higher ...

Page 2: ... 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 operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not th...

Page 3: ...bmitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 3 Exmark being unable to ship the part and the Exmark parts order is received by 3 00 p m central time Exmark pays for the part and freight 4 If the part does not arrive overnight due to the shipper UPS the shipper pays for the freight and Exmark pays for the part The following res...

Page 4: ...ower maintain its maximum efficiency and promote safe operation 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 distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service s...

Page 5: ...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...

Page 6: ...perator s or mechanic s can not read English it is the owner s responsibility to explain this material to 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 Ke...

Page 7: ...can burn you others 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 may 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 starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when t...

Page 8: ...e 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 ...

Page 9: ...and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without guard...

Page 10: ...e increases Always avoid sudden starting or stopping on a slope If tires lose traction 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...

Page 11: ...e 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 from mower during operation 1 4 16 Do Not mow with the grass catcher door or the grass catcher raised removed or altered 1 4 1...

Page 12: ...ty can only be achieved if the mower is properly maintained and operated correctly 1 5 9 Check all bolts frequently to maintain 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 components that could create a hazard 1 5 12 All replacement parts must be the same as or equivalent to the part...

Page 13: ...n dry surface Smooth to remove any air bubbles 1 6 6 Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower PART NO 79 0360 LOCATION On Front of Blower Discharge Chute LOCATION Molded in LH Console PART NO 98 5954 LOCATION On Gear Box Cover Under Rubber Cover On Top of Deck Under Gear Box Cover On LH Frame...

Page 14: ...H 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 On Top of Mainframe Under Hopper PART NO 103 8611 LOCATION On Pump Plate Above Relays PART NO 103 8444 LOCATION On Hopper Door Hinge Each Side PART NO 103 8416 LOCATION On Top of Seat Console Under Seat ...

Page 15: ...ler 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 PART NO 103 9724 LOCATION On PTO Guard PART NO 103 8425 LOCATION On front console Under Seat On driv...

Page 16: ...speed control is in the neutral position by pulling back on the steering levers 2 5 2 PTO Engagement Lever Engages drive to PTO mower deck and blower 2 5 3 Parking Brake Lever Pull back to engage parking brake 2 6 SEAT 2 6 1 Type Standard seat with high back foam padded internal suspension 2 6 2 Mounting Seat is hinged to tilt up for access to hydraulic pumps and other components The seat is held ...

Page 17: ...kg 1170 lbs 531 kg Tread Width Center to Center of Drive Wheels 32 7 83 1 cm Wheel Base Center of Drive Wheel to Center of Rear Caster Wheel 44 2 112 3 cm 2 11 TORQUE REQUIREMENTS Bolt Location Torque Blade Mounting Bolt 85 110 ft lbs 115 149 N M Engine Mounting Bolts 30 35 ft lbs 41 47 N M Wheel Lug Nuts 90 95 ft lbs 122 129 N M Wheel Motor Mounting Bolts 72 77 ft lbs 98 104 N M 3 ASSEMBLY INSTRU...

Page 18: ...age causing personal injury HOW TO AVOID THE HAZARD Be sure ignition switch is in the OFF position before charging the battery 3 2 4 Connect the negative battery cables NOTE If the positive cable is also disconnected connect the positive red cable and the red wire to the positive terminal on the battery first then connect the negative black cable and black wire to the negative terminal on the batt...

Page 19: ...l Pulling back on the steering levers centered in front of the seat progressively slows then reverses the direction of travel of the respective drive wheels By moving both steering levers an equal amount back the machine can be slowed down or travel backward in a straight line Steering is controlled by varying the position of the steering levers relative to each other To turn left while moving for...

Page 20: ...ngage the brake The unit must be tied down and brake engaged when transporting 4 1 8 Ignition Switch Located on the right hand console The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the ON position Rotate clockwise to the next position to engage the starter key must be held against spring press...

Page 21: ... in fuel line next to the fuel filter Raise the hopper to access 4 3 2 Starting Engine Brake must be engaged speed control lever in neutral position and PTO lever OFF to start engine It is not necessary for the operator to be in the seat to start the engine On a cold engine place the throttle midway between the SLOW and FAST positions and push choke lever forward into the ON position Turn ignition...

Page 22: ...3 5 Stopping Engine Bring unit to a full stop Disengage the PTO move speed control lever to the neutral position and set the parking brake Before stopping the engine place the throttle control midway between the slow and fast positions Allow the engine to run a minimum of 15 seconds then stop the engine Rotate ignition switch to OFF position Remove the key to prevent children or other unauthorized...

Page 23: ...creen clogs quickly the front removable screen panel can be turned and reinstalled under the primary screen to allow free air flow from the hopper FIGURE 3 HOPPER SCREEN REMOVAL 4 4 TRANSPORTING 4 4 1 Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sur...

Page 24: ...amps must be used use enough ramps to create an unbroken ramp surface wider than the unit DO NOT exceed a 15 angle between ramp and ground or between ramp and trailer or truck Avoid sudden acceleration while driving unit on a ramp 4 4 2 Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp is required If it is not possible to use one full width ramp use en...

Page 25: ...ing parts to stop Make sure unit is on a level surface b Check with engine cold c Raise hopper d Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick and push it all the way down into the tube Remove the dipstick and read the oil level e If the oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Use oil as spe...

Page 26: ...T CAN HAPPEN Excessive debris around the engine cooling air intake and drive belts can create a fire hazard HOW TO AVOID THE HAZARD Clean all debris from around engine and drive belts daily a Stop engine wait for all moving parts to stop and remove key b Clean all debris from rotating engine air intake screen and from around engine shrouding c Clean all debris from around engine and drive belts d ...

Page 27: ...ion of the paper element Replace if dirty bent or damaged e Check the condition of the inner element Replace whenever it appears dirty typically every other time the paper element is replaced Clean the base around the inner element before removing so dirt does not get into the engine f DO NOT wash or use pressurized air to clean paper element or inner element g Reinstall elements Position the cove...

Page 28: ...r tire is semi pneumatic and does not need to be inflated NOTE Do not add any type of tire liner or foam fill material to the tires Excessive loads created by foam filled tires may cause failures to the hydro drive system frame and other components Foam filling tires will void the warranty 5 1 10 Check condition of belts Service Interval 40 hrs a Stop engine wait for all moving parts to stop and r...

Page 29: ...f the axle Leave approximately 1 8 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut i Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing j With the open end of the wheel facing up fill the area inside the wheel around the axle full of NGLI grade 1 multi purpose grease k Insert the second bearing and new seal in...

Page 30: ... up c Lubricate bronze bushings on each end of brake rod shaft with a spray type lubricant or a light oil bushings are located to the inside of the flange bearings 5 1 17 Lubricate steering linkage rod ends Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Tilt seat up c Lubricate each end of both steering linkage rods with a spray lubricant or a light oil 5...

Page 31: ...ubber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn d Fill reservoir as stated in Section 5 1 8 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 ...

Page 32: ...ad fitting nuts 5 1 25 Dielectric grease is used on blade type electrical connections to prevent corrosion and loss of contact Do not apply grease to sealed connectors inside hopper 5 2 ADJUSTMENTS IMPORTANT Disengage PTO shut off engine wait for all moving parts to stop and remove key before servicing cleaning or making any adjustments to the unit 5 2 1 Pump Drive Belt Tension Spring Tensioned No...

Page 33: ...nt a Stop engine wait for all moving parts to stop and remove key b Remove PTO Belt See section 5 2 4 for removal instructions c Route new belt onto sheaves as shown in the decal located on the back of the left drive shield See Figure 10 d Reinstall PTO Belt as stated in section 5 2 4 FIGURE 10 PTO BELT REPLACEMENT 5 2 4 Belt Guide Adjustment a Stop engine wait for all moving parts to stop and rem...

Page 34: ... A gap must exist between the bottom of the brake bolt head and the top surface of the brake swivel as shown in Figure 12 If a gap does not exist adjust the linkage to a maximum gap of 0 5 0 13 1 3 cm 0 33 cm as shown c The brakes on both sides can be simultaneously adjusted by lengthening or shortening the linkage shown in Figure 12 FIGURE 12 BRAKE BOLT ADJUSTMENT d If individual adjustment is ne...

Page 35: ...nsion high enough that the speed control lever position is maintained during operation and loose enough to be moved comfortably by the operator FIGURE 14 THROTTLE TENSION 5 2 9 Motion control linkage adjustment WARNING POTENTIAL HAZARD Engine must be running and drive wheels must be turning so motion control adjustment can be performed WHAT CAN HAPPEN Contact with moving parts or hot surfaces may ...

Page 36: ...he steering control shaft See Figure 15 FIGURE 15 SPEED CONTROL LEVER ADJUSTMENT Set neutral a Remove the electrical connection from the seat safety switch located directly in front of the seat switch assembly b The neutral adjustment must be made with the drive wheels turning Raise the frame and place on jack stands so that drive wheels can rotate freely Temporarily install a jumper wire across t...

Page 37: ...tached to obtain a clear view of the steering control shaft to complete this adjustment b Push the speed control lever forward to full forward speed position c If either steering control lever surface does not contact the stop bar at the full forward speed position adjust the stop bolt until contact occurs See Figure 17 Once contact occurs turn the stop bolt one more full turn to prevent bottoming...

Page 38: ...bolts have been loosened or the engine has been moved or replaced The jackshaft mounting bolts have been loosened or the jackshaft has been moved or replaced a Stop engine wait for all moving parts to stop and remove key b Move the speed control lever to the neutral position c Disengage the PTO lever d Verify that the blower is installed and secured tightly e Loosen the 4 engine mounting bolts f U...

Page 39: ... the both pump pulleys c Using a straight edge align each pump pulley with the engine pulley by sliding along the pump shaft See Figure 19 d Re tighten pulley set screws and recheck alignment 5 2 14 Rear caster pivot bearings pre load adjustment a Remove dust cap from caster and tighten nyloc nut until washers are flat Back the nyloc off 1 4 of a turn to properly set the pre load on the bearings N...

Page 40: ...PTO brake spring adjustment is only necessary if the blower has been removed or replaced or if the PTO drive idler arm has been disassembled a Stop engine wait for all moving parts to stop and remove key b Locate the brake spring and thread the two jam nuts out to the end of the brake spring rod See Figure 23 c Tighten jam nuts together at end of brake spring rod FIGURE 22 PTO BRAKE SPRING ADJUSTM...

Page 41: ...remaining states it is advisable to follow similar procedures The laws state that these sealed devices contain mercury and should not be placed in the garbage until the mercury is removed and reused recycled or otherwise managed to insure that it does not become part of solid waste or waters Management and disposal practices must be within relevant federal state or local laws Return the switch to ...

Page 42: ...ine c Make sure there is fuel in the fuel tank and that the fuel valve is open d Be sure the seat switch is properly adjusted See Section 5 2 7 e Make sure the parking brake is set and speed control levers in the neutral position f Check that the PTO is disengaged g Check that the spark plug wires are properly connected h Check for loose or faulty wiring connections i Check for corrosion at all wi...

Page 43: ...UEL 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 X X X X Lacks power X X X X X X X X Operates erratically X X X X X X X Knocks or pings X X X Skips or misfires X X X X X Backfires X X X X X Overheats X X X X X High fuel consumption X X X X ...

Page 44: ... 39 8 ELECTRICAL DIAGRAM ...

Page 45: ... 40 9 HYDRAULIC DIAGRAM ...

Page 46: ...with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extend...

Page 47: ...42 ...

Page 48: ... VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER EZ RIDER WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 2005 PART NO 103 8573 Rev B EXMARK MFG CO INC 402 223 6300 INDUSTRIAL PARK BOX 808 FAX 402 223 5489 BEATRICE...

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