Exmark FR20KC manual

For Serial Nos. 600,000 & Higher Part No. 109-4288 Rev. A[...]

i WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment. W HAT CAN HAPPEN ♦ Failure to f ollow safe operating pr act ices can result in serious operator inj ur y or even death. HOW TO AVO ID THE HAZARD ♦ Keep all shields, guar ds, and saf ety devices (especially the grass discharge system) in place and in pr oper working con[...]

ii EXMARK PA RTS PLUS ® PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not have the Exmark part in stock, Exmark w ill 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 "dow n" unit at the time of r[...]

-iii- CONGRAT ULATIONS on the purchase of your Exmark mower. T his product has been caref ully designed and manuf actured to g ive you a max im um amount of dependability and years of tr ouble- f ree operat ion. OPERA TOR'S M ANUA L This manual cont ains oper at ing , maintenance, adj ustment, and saf ety instructi ons for your E xmark mowe r.[...]

iv TA BLE OF CONTENTS 1 . S A F E T Y P A G E 1.1 Safety Alert Sy mbol ....................................................................................... 1 1.2 Trai ning ......................................................................................................... 1 1.3 Preparat ion ..................................................[...]

1 1. SA FETY 1.1 SA FETY A LERT SYMBOL This SAFET Y ALERT SYMBOL is used both in this manual and on t he m achine t o identif y import ant safet y messag es which must be followed to avoid accidents. T his symbol means: A TTENTION! BECOME A LERT! YOUR SA FETY IS INVOLVED! The saf ety alert symbol appears above inform at ion w hich aler ts you to un[...]

2 CA UTION POTENT IAL HAZARD ♦ This machine pr oduces sound levels in excess of 85 dBA at the oper at or’s ear when in operation. W HAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss. HOW TO AVO ID THE HAZARD ♦ W ear hear ing protection when operating this mach ine. 1.3.3 W hile [...]

3 DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flamm able and highly explosive. W HAT CAN HAPPEN ♦ A fire or explosion f rom gasoline can bur n you, others, and cause proper t y damage. HOW TO AVO ID THE HAZARD ♦ DO NOT sm ok e while refueling, and st ay away f rom an open f lame or where gasoline f umes may be ig[...]

4 DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flamm able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g asoline vapors. A fir e or explosion f rom gasoline can burn you, others, and cause pr oper t y damage. HOW TO AVO ID THE HAZARD ♦ Purchase and store g asoline only in an approved contai[...]

5 WA RNING POTENT IAL HAZARD ♦ Gasoline vapor can collect inside enclosed trailers and m ay be ignited by electrical spark s or hot eng ine/ exhaust components. W HAT CAN HAPPEN ♦ Explosion and fire may occur, r e sult ing in property damag e, personal injury, and/or death. HOW TO AVO ID THE HAZARD ♦ Provide adequate ventilation of any enclos[...]

6 WA RNING POTENT IAL HAZARD ♦ Hands, f eet , hair, clothing , or accessor ies can become entang led in r ot at ing parts. W HAT CAN HAPPEN ♦ Contact with rotating par ts can cause traumat ic am put ation or severe lacera tions. HOW TO AVO ID THE HAZARD ♦ Do not operate t he m achine without guards, shields, and saf ety devices in place and w[...]

7 1.4.4 Use EXTREME caution when mowing and/or tur ning on slopes as loss of tr act ion and/or tip-over could occur . T he operator is responsible f or saf e operation on slopes. WA RNING POTENT IAL HAZARD ♦ Mow ing on wet g r ass or st eep slopes can cause sliding and loss of control. W HAT CAN HAPPEN ♦ W heels dropping over edges, ditches, st[...]

8 • Remove or mark obst acles such as r ock s, tree lim bs, et c. fr om t he m owing area. T all g rass can hide obstacles. • Use extreme care with attachment s. These can change t he stability of t he machine and cause loss of cont r ol. • Follow the manufact ur er ’s r ecom m endat ions for wheel weights or counterweights t o im prove sta[...]

9 b) connect the negative or ground cabl e (-) from the neg ative post on the booster batt er y to t he eng ine block as f ar away f rom t he bat t ery as possible. c) disconnect batter y cables in the reverse or der af ter st ar t ing . 1.5 MAINTENA NCE A ND STORAGE 1.5.1 For engine maint enance, follow the eng ine m anuf acturer’s r ecom m enda[...]

10 WA RNING POTENT IAL HAZARD ♦ Hydraulic fluid escaping under pr essur e can penetrate sk in and cause injury. W HAT CAN HAPPEN ♦ Fluid accidentally injected into t he skin must be surg ically removed wi t hin a few hours by a doctor f amiliar with this for m of injury or g ang rene may result. HOW TO AVO ID THE HAZARD ♦ Make sure all hydrau[...]

11 PART NO. 1- 523552 LOCATI ON: Top Sur face of Hy dr aulic Tank PART NO. 1- 643339 LOCATIO N: Inside Hood Support, RH Side PART NO. 103- 5881 LOCATI ON: Inside Surfac e of Hood Support – Each Side PART NO. 103- 7218 LOCATI ON: On Seat Support Plate PART NO. 107- 2102 LOCATIO N: Inside Surfac e of Upper Roll bar PART NO. 107- 2112 LOCATI ON: Top[...]

12 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: 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) I dle: 1500 RPM 2.3 FUEL SYSTEM 2.3.1 Capacity: 8.5 g al ( 32 L) 2.3.2 Type of Fuel: Regular unleaded g asoline, 87 octane or higher 2.3.3 Fuel Filter: I n-line 15 Micron[...]

13 2.4.6 Safet y Int er lock System: PTO must be di sengaged , brake engaged , and speed control lever in neut ral positio n to start engi ne . (It is not necessar y for the operat or t o be in the seat to start t he eng ine.) Operator m ust be in seat when PTO is eng aged , brake is disengaged , or speed control lever i s moved out of neut ral or [...]

14 2.8 TIRES 20 HP & 23 HP Kohler Units Drive Front Caster Rear Caster (Single T ail Wheel) Pneum atic (Air-F illed) Sem i-Pneumatic Sem i-Pneumatic Quantity 2 2 1 Tread T urf mate Smooth Sm ooth Size 23 x 10.50-10 9 x 3.50-4 13 x 6.5-6 Ply Rating 4 Pressu re 13 psi (90 k Pa) 27 HP Kohler Units Drive Front Caster Rear Casters (Dual Tail Wheel) [...]

15 2.11 TORQUE REQUIREMENTS Bolt Location T o r q u e Cutter Housing Spindle Nut (secured with thr eadlock er) 160-185 f t-lbs. ( 217- 251 N- m) Blade Mounting Bolt ............................................................... 55- 60 f t-lbs. (75-81 N-m) Sheav e Mountin g N ut ...................................................... 90- 110 ft -lbs[...]

16 To make a zero turn to the le ft , pull the left lever back beyond neutral while holding the r ig ht lever slight ly ahead of neutral. To make a zero turn to the right , pull the righ t lever back beyond neutral while holding the lef t lever slight ly ahead of neutral. Pulling the l evers back f rom t he neut ral position will cause the respecti[...]

17 3.1.8 Hour Meter : Located on t he r ig ht fuel t ank console. The hour m et er is connected to a pressure switch installed in t he eng ine block and it r ecor ds t he number of hours that t he eng ine has run. If the ignit ion switch is lef t on without engine running, hour m eter will not run. NOTE: T his switch is not a low oil sensor and wil[...]

18 3.3.3 Star ting Engine : Brake must be engaged, speed control l ever i n neut ral position and PTO switch “O FF” t o st art engi ne. ( I t is not necessary for t he operator to be in t he seat to star t t he engine.) On a cold engine, place the throttle midway between the “SLOW ” and “ FAST ” positions and push choke lever f orward i[...]

19 The PTO push-pull switch engages the cut ting blades. Be sur e t hat all persons are clear of the mower deck and dischar g e area before engaging the PTO. IMPORT A NT : Operator must be in seat bef ore t he PTO can be engaged. Set thro ttle to "midw ay" po sition. Pu ll the sw itch out to th e “ROTATE” pos ition. Accele rate to ful[...]

20 WA RNING POTENT IAL HAZARD ♦ Loading a unit on a t r ailer or truck increases the possibility of tip-over. W HAT CAN HAPPEN ♦ Tip-over of t he unit could cause serious injury or death. HOW TO AVO ID THE HAZARD ♦ Use extreme caution when operating a unit on a ramp. ♦ Use only a single, f ull width ramp; DO NOT use individual ramps f or ea[...]

21 4. MAINTENA NCE & A DJUSTMENTS WA RNING POTENT IAL HAZARD ♦ W hile maint enance or adj ustments are being made, som eone could st ar t the engine. W HAT CAN HAPPEN ♦ Accidental start ing of the eng ine could seriously injure you or other bystanders. HOW TO AVO ID THE HAZARD ♦ Remove the key f rom the ig nit ion switch, engage par king [...]

22 4.1.2 Check batt er y charg e : Service Interval : M ont hl y Allowing batteries to st and f or an extended period of time without recharg ing them will result in reduced per f ormance and ser vice lif e. To preser ve optim um battery perf ormance and lif e, recharg e bat t eries in storage when the open circuit voltag e dr ops t o 12.4 volts. N[...]

23 4.1.4 Check saf ety interlock system . Servic e Interval: Da ily a) Check starting ci rcuit : Starte r should crank wi t h, parking br ak e engaged, PTO disengaged and motion contr ol levers m o ved out in t he neutral lock position. The operator does not need to be in the seat t o start the eng ine. Try to sta rt with operator in seat , parking[...]

24 Run the engine at half throt t le and pu ll up on t he PTO engag ement switch. The PTO must not engage . NOT E: If machine does not pass any of these t est s, do not operate. Contact your authorized EXMARK SERVICE DEA LER. IMPORTA NT: It i s essent i al that operator safet y mechanisms be connected and in proper operating condi t ion prior to us[...]

25 drain, then close t he valve by pushing inward and rotating 1/4 turn clockwise. Remove and retain the hose f or f uture use. e) Replace the oil f ilt er every other oil chang e. Clean around oil filt er and unscrew filter t o r em ove. Bef ore reinst alling new filter , apply a thin coat ing of oil on the surf ace of the r ubber seal. Tur n f il[...]

26 4.1.10 Check tire pr essur es : Service Interval: 40 hrs. a) Stop engine, wait f or all moving part s to stop, and r em ove key. Engag e parking br ak e. b) Check tire pr essure in drive tires. For 20 and 23 HP Kohler Units: T he drive tires should be inflat ed t o 13 psi (90 kpa) . For 27 HP Koher Units: T he drive tires should be inf lat ed t [...]

27 4.1.13 Lubricate rear cast er wheel hub: Service Interval: Once Yearly a) Stop eng ine, wait for all m oving par t s t o stop, and rem ove k ey. Eng ag e parking brake. b) Remove caster wheel fr om cast er f orks. c) Rem ove seal guar ds from t he wheel hub. d) Remove one of t he spacer nuts f r om t he axle assembly in the caster wheel. Note th[...]

28 4.1.15 Lubricate the br ak e rod bushings: Service Interval: 160 hrs. a) Stop eng ine, wait for all m oving par t s to stop, and r em ove key. Engag e parking br ak e. b) Tilt seat for ward and raise hood. c) Lubricat e br onze bushings on each end of the brak e rod shaft with a spray type lubricant or lig ht oil (bushings ar e locat ed to the i[...]

29 4.1.21 Change f uel filter : Servi ce I nt erval : As Required a) A f uel f ilter is inst alled bet ween the fuel tank and t he engine. Replace when necessary. Replacement Filter s Kohler P/N 2405010 4.1.22 Change hydraulic system f ilter : Service Interval: After First 250 hrs. T h e n yearly thereaft er NOTE : Use only Exmark Par t No. 103-214[...]

30 4.1.23 W heel Hub – lock nut torq ue specificat ion Service Interval: 500 hrs W hen tig htening the lock nut on the wheel motor t aper ed shaf t: a) Torque the lock nut to 125 ft -lbs (169 N-m). NOTE: Do not use ant isieze on w heel hub. 4.1.24 Fuel Tank – m ounting hardware specif ication W hen installing the nuts on the f uel tank st uds, [...]

31 d) Locate t he park brak e spring assembly. See Fig ure 7. Ther e should be a gap of 1/8” (3 mm ) bet ween the yoke and thin nyloc nut on the brake bolt . If necessary, rotate t he thin nyloc nut to obtain the 1/ 8” g ap. FIGURE 7 e) I f park br ak e does not f ully diseng ag e when the lever is disengaged check t he brake r od link age asse[...]

32 4.2.5 Motion control linkag e adj ustment WA RNING POTENT IAL HAZARD ♦ Engine must be r unning and drive wheels must be tur ning so motion control adjustment can be per f ormed. W HAT CAN HAPPEN ♦ Contact with moving parts or hot sur f aces may cause personal injury. HOW TO AVO ID THE HAZARD ♦ Keep fing er s, hands, and clothing clear of r[...]

33 FIGURE 10 h) Move the motion control levers t o t he reverse position. Ret ur n t he motion control levers to neut ral. The wheels must st op t urning (or slig htly creep in reve rse). i) Stop engine and wait f or all moving part s t o stop. Remove jum per wire f rom wire harness connector and plug connector into seat switch. j) Lower from jack [...]

34 WA RNING POTENT IAL HAZARD ♦ W eig ht t r ansfer spring s may have stored energy. W HAT CAN HAPPEN ♦ Removing the weight tr ansfer spr ing s without releasing the st or ed ener gy can cause serious injury HOW TO AVO ID THE HAZARD ♦ Fold mower deck and f ront f r am e and lock in service position t o r em ove spring tension and release stor[...]

35 5. WA STE DISPOSAL 5.1 MOTOR OIL DISPOSA L Engine oil and hydraulic oil are both pollut ant s to the environment. Dispose of used oil at a certif ied recycling center or accor ding to your state and local reg ulations. 5.2 BATTERY DISPOSA L DA NGER POTENT IAL HAZARD ♦ Battery electr olyte cont ains sulf uric acid, which is poisonous and can ca[...]

36 6.3 ENGINE W I LL NOT START. a) Make sure the bat t er y has a f ull charge. See sect ion 4. 1.2 for char g ing instructions. b) Be sure the t hrottle contr ol is m idway between the “SLOW ” and “ FAST ” positions, and the chok e is in the “ON” posit ion for a cold eng ine or the “O FF” position f or a warm eng ine. c) Make sur e[...]

37 7. ELECTRICA L DIA GRAM[...]

38 8. HYDRA ULIC DIAGRA M[...]

39 9. 2-Y ear Limited Warra nty Exmark Tu rf Equipment (For units pur chased on or af ter October 1, 2004) Conditions and Products Covered Exmark M fg. Co. Inc. and its affiliate, Exmark W arranty Company, pursuant to an agreement betw een them, jointly warrant on the terms and conditions herein, that w e will repair, replace or adjust any part man[...]

40 10. Evaporat ive Emission Cont rol Warranty Statement California Evapor ative Emiss ion Control W ar ranty Statem ent Your W arr anty Rights and O bligations Introduction The California A i r Res ources Board and E xm ark Manufacturing Com pany are pleased to explain the evaporat ive emis s ion control system ’s warranty on your 2006 m odel ye[...]

41 NOTES[...]

42[...]

® M FG . CO. IN C. SEE EXMA RK’S COMPLETE LINE OF A CCESSORIES RIDING A CCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT KI T MICRO-MULCH SY ST EM ROLL OVER PROTECT ION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONT AINER TURF STRIPER ULTRA VAC COLLECT ION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WA LK BEHIND A CC[...]