For Serial Nos. 600,000 & Higher Part No. 109-4288 Rev.
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) in place and in proper working condition. ♦ Stop engine, wait for all moving parts to stop and engage parking brake. Remove spark plug wire(s) or remove key before adjusting, servicing, or performing maintenance.
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 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. 2.
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 operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
TABLE OF CONTENTS 1. SAFETY 1.1 1.2 1.3 1.4 1.5 1.6 PAGE Safety Alert Symbol ....................................................................................... 1 Training ......................................................................................................... 1 Preparation................................................................................................. 1-5 Operation ...................................................................................................
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.
CAUTION POTENTIAL HAZARD ♦ This machine produces sound levels in excess of 85 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. 1.3.
DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A fire or explosion from gasoline 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.
DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite gasoline 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 filling.
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 property 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.
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 guards, shields, and safety devices in place and working. ♦ Keep hands, feet, hair, jewelry, or clothing away from rotating parts. 1.4.1 1.4.2 1.4.3 Give complete, undivided attention to the job at hand.
1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of traction and/or tip-over could occur. The operator is responsible for safe operation on slopes. WARNING 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 slopes when grass is wet.
• • • 1.4.5 1.4.6 Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing area. Tall grass can hide obstacles. Use extreme care with attachments. These can change the stability of the machine and cause loss of control. Follow the manufacturer’s recommendations for wheel weights or counterweights to improve stability. 1.4.9 Use EXTREME caution when backing up.
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.
WARNING POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure can penetrate 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 may 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.
PART NO. 1-643339 LOCATION: Inside Hood Support, RH Side PART NO. 1-523552 LOCATION: Top Surface of Hydraulic Tank PART NO. 103-7218 LOCATION: On Seat Support Plate PART NO. 103-5881 LOCATION: Inside Surface of Hood Support – Each Side PART NO. 109-2355 LOCATION: Outside of each Bell Crank PART NO. 107-2112 LOCATION: Top of Floor Pan PART NO. 107-2102 LOCATION: Inside Surface of Upper Roll bar PART NO. 109-2356 LOCATION: Top of Console, RH Side PART NO. 109-2358 LOCATION: On Control Panel PART NO.
PART NO. 98-5954 LOCATION: Top Surface of Hood Support PART NO. 103-3270 LOCATION: Top Surface of Hood Support PART NO. 109-3637 LOCATION: Back of Seat PART NO. 109-2699 LOCATION: On Control Panel PART NO. 93-4361 LOCATION: On LH and RH Side, Near Back of Unit 2. SPECIFICATIONS 2.1 MODEL NUMBER: FR20KC; FR23KC; FR27KC 2.2 ENGINE 2.2.1 Engine Specifications: See your Engine Owner’s Manual 2.2.2 RPM: Full Speed: 3750 RPM (No Load) Idle: 1500 RPM 2.3 FUEL SYSTEM 2.3.1 2.3.2 2.3.3 2.3.4 Capacity: 8.
2.4.6 Safety Interlock System: PTO must be disengaged, brake engaged, and speed control lever in neutral position to start engine. (It is not necessary for the operator to be in the seat to start the engine.) Operator must be in seat when PTO is engaged, brake is disengaged, or speed control lever is moved out of neutral or engine will stop. Engine will stop if the motion control levers are moved from neutral position while brake is engaged. 2.5 OPERATOR CONTROLS 2.5.
20 HP & 23 HP Kohler Units 2.8 TIRES Quantity Tread Size Ply Rating Pressure Drive Front Caster Pneumatic (Air-Filled) 2 Turfmate 23 x 10.50-10 4 13 psi (90 kPa) Semi-Pneumatic 2 Smooth 9 x 3.50-4 Rear Caster (Single Tail Wheel) Semi-Pneumatic 1 Smooth 13 x 6.5-6 27 HP Kohler Units Quantity Tread Size Ply Rating Pressure Drive Front Caster Pneumatic (Air-Filled) 2 AT101 24 x 12.00-12 4 9 psi (62 kPa) Semi-Pneumatic 2 Smooth 9 x 3.
2.11 TORQUE REQUIREMENTS Bolt Location Torque Cutter Housing Spindle Nut (secured with threadlocker) 160-185 ft-lbs. (217-251 N-m) Blade Mounting Bolt............................................................... 55-60 ft-lbs. (75-81 N-m) Sheave Mounting Nut ...................................................... 90-110 ft-lbs. (122-149 N-m) Engine Deck/Front Frame Mount Bolts .................................. 30-35 ft-lbs. (41-47 N-m) Anti-Scalp Roller (See Figure 7) Nyloc Nut ............................
To make a zero turn to the left, pull the left lever back beyond neutral while holding the right lever slightly ahead of neutral. To make a zero turn to the right, pull the right lever back beyond neutral while holding the left lever slightly ahead of neutral. Pulling the levers back from the neutral position will cause the respective drive wheels to rotate in a reverse direction (spring tension can be felt when moving into reverse from neutral).
3.1.8 Hour Meter: Located on the right fuel tank console. The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run. If the ignition switch is left on without engine running, hour meter will not run. NOTE: This switch is not a low oil sensor and will not alert the operator if the engine oil is low. 3.1.9 Hydraulic Lift Switch: Located on the right fuel tank console.
3.3.3 Starting Engine: Brake must be engaged, speed control lever in neutral position and PTO switch “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 switch to the “start” position. Release the switch as soon as the engine starts.
The PTO push-pull switch engages the cutting blades. Be sure that all persons are clear of the mower deck and discharge area before engaging the PTO. IMPORTANT: Operator must be in seat before the PTO can be engaged. Set throttle to "midway" position. Pull the switch out to the “ROTATE” position. Accelerate to full throttle to begin mowing. 3.3.5 Stopping PTO: Set throttle to the “midway” position. Push the switch in to the “STOP” position to stop the PTO. 3.3.
WARNING POTENTIAL HAZARD ♦ Loading a unit on a trailer or truck increases the possibility of tip-over. WHAT CAN HAPPEN ♦ Tip-over of the unit could cause serious injury or death. HOW TO AVOID THE HAZARD ♦ Use extreme caution when operating a unit on a ramp. ♦ Use only a single, full width ramp; DO NOT use individual ramps for each side of the unit. ♦ If individual ramps must be used, use enough ramps to create an unbroken ramp surface wider than the unit.
4. 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 ignition switch, engage parking brake, and pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).
4.1.2 Check battery charge: Service Interval: Monthly 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 damage due to freezing, battery should be fully charged before putting away for winter storage. a) Check the voltage of the battery with a digital voltmeter.
4.1.4 Check safety interlock system. Service Interval: Daily a) Check starting circuit: Starter should crank with, parking brake engaged, PTO disengaged and motion control levers moved out in the neutral lock position. The operator does not need to be in the seat to start the engine. Try to start with operator in seat, parking brake disengaged, PTO disengaged and motion control levers in the neutral lock position - starter must not crank.
Run the engine at half throttle and pull up on the PTO engagement switch. The PTO must not engage. NOTE: If machine does not pass any of these tests, do not operate. Contact your authorized EXMARK SERVICE DEALER. IMPORTANT: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing. 4.1.5 Check for loose hardware. Service Interval: Daily 4.1.6 a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.
4.1.8 drain, then close the valve by pushing inward and rotating 1/4 turn clockwise. Remove and retain the hose for future use. e) Replace the oil filter every other oil change. Clean around oil filter and unscrew filter to remove. Before reinstalling new filter, apply a thin coating of oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 2/3 to 3/4 turn. f) Clean around oil fill cap and remove cap.
4.1.10 Check tire pressures: Service Interval: 40 hrs. a) b) c) Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. Check tire pressure in drive tires. For 20 and 23 HP Kohler Units: The drive tires should be inflated to 13 psi (90 kpa). For 27 HP Koher Units: The drive tires should be inflated to 9 psi (62 kpa) The rear caster tire(s) 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.
4.1.13 Lubricate rear caster wheel hub: Service Interval: Once Yearly a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. b) Remove caster wheel from caster forks. c) Remove seal guards from the wheel hub. d) Remove one of the spacer nuts from the axle assembly in the caster wheel. Note that thread locking adhesive has been applied to lock the spacer nuts to the axle. Remove the axle (with the other spacer nut FIGURE 5 still assembled to it) from the wheel assembly.
4.1.15 Lubricate the brake rod bushings: Service Interval: 160 hrs. 4.1.16 a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. b) Tilt seat forward and raise hood. c) Lubricate bronze bushings on each end of the brake rod shaft with a spray type lubricant or light oil (bushings are located to the inside of the flange bearings). Lubricate the motion control bronze bushings: Service Interval: 160 hrs. 4.1.
4.1.21 Change fuel filter: Service Interval: As Required a) A fuel filter is installed between the fuel tank and the engine. Replace when necessary. Replacement Filters 4.1.22 Kohler P/N 2405010 Change hydraulic system filter: Service Interval: After First 250 hrs. Then yearly thereafter NOTE: Use only Exmark Part No.103-2146 a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. b) Carefully clean area around filter.
4.1.23 Wheel Hub – lock nut torque specification Service Interval: 500 hrs When tightening the lock nut on the wheel motor tapered shaft: a) Torque the lock nut to 125 ft-lbs (169 N-m). NOTE: Do not use antisieze on wheel hub. 4.1.24 Fuel Tank – mounting hardware specification When installing the nuts on the fuel tank studs, fully tighten the nyloc nut and back off 1/2 turn. This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels. 4.1.25 4.1.
d) e) Locate the park brake spring assembly. See Figure 7. There should be a gap of 1/8” (3 mm) between the yoke and thin nyloc nut on the brake bolt. If necessary, rotate the thin nyloc nut to obtain the 1/8” gap. FIGURE 7 If park brake does not fully disengage when the lever is disengaged check the brake rod linkage assembly. The assembly should measure 7 3/8” (18.7 cm) from the center of the ball joint to the center of the lower end of the linkage rod. See Figure 8. FIGURE 8 f) 4.2.
4.2.5 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 cause personal injury. HOW TO AVOID THE HAZARD ♦ Keep fingers, hands, and clothing clear of rotating components and hot surfaces. CAUTION POTENTIAL HAZARD ♦ Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous.
FIGURE 10 h) Move the motion control levers to the reverse position. Return the motion control levers to neutral. The wheels must stop turning (or slightly creep in reverse). i) Stop engine and wait for all moving parts to stop. Remove jumper wire from wire harness connector and plug connector into seat switch. j) 4.2.6 Lower from jackstands. Weight transfer spring adjustment: Weight transfer springs are assembled from the factory to apply the maximum amount of weight onto the drive wheels.
WARNING POTENTIAL HAZARD ♦ Weight transfer springs may have stored energy. WHAT CAN HAPPEN ♦ Removing the weight transfer springs without releasing the stored energy can cause serious injury HOW TO AVOID THE HAZARD ♦ Fold mower deck and front frame and lock in service position to remove spring tension and release stored energy before performing any maintenance or adjustments on the weight transfer springs.
5. WASTE DISPOSAL 5.1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at a certified recycling center or according to your state and local regulations. 5.2 BATTERY DISPOSAL DANGER POTENTIAL HAZARD ♦ Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns WHAT CAN HAPPEN ♦ Swallowing electrolyte can be fatal or if it touches skin can cause severe burns.
6.3 ENGINE WILL NOT START. a) Make sure the battery has a full charge. See section 4.1.2 for charging instructions. b) Be sure the throttle control is midway between the “SLOW” and “FAST” positions, and the choke is in the “ON” position for a cold engine or the “OFF” position for a warm engine. c) Make sure there is fuel in the fuel tank and that the fuel valve is open. d) Make sure the parking brake is set and motion control levers in the neutral position.
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9. 2-Year Limited Warranty Exmark Turf Equipment (For units purchased on or after October 1, 2004) 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 manufactured by Exmark and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship for a period of two years.
10. Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and Exmark Manufacturing Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that uses small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT MICRO-MULCH SYSTEM ROLL OVER PROTECTION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONTAINER TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO-MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER STANDON Check us out on the Web: www.exmark.
