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) in...
Page 3 - ii; EXMARK PARTS PLUS
ii 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 f...
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 operating, maintenance, adjustment, and safety instructions ...
Page 5 - iv; TABLE OF CONTENTS; Ground
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
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 info...
Page 8 - DANGER; DO NOT
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 whe...
Page 11 - NEVER; WARNING
6 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 safet...
Page 12 - EXTREME; FIGURE 1
7 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 d...
Page 13 - midway
8 • 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 counterweig...
Page 14 - MAINTENANCE AND STORAGE
9 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 manu...
Page 17 - ENGINE; Engine Specifications: See your Engine Owner’s Manual; Kohler; ELECTRICAL SYSTEM; Flywheel Alternator
12 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 Capacity: 8.5 gal (32 L) 2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or hig...
Page 18 - For 27 HP Kohler Units
13 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...
Page 19 - Models; DIMENSIONS; For 27 HP Kohler Units:
14 2.8 TIRES 20 HP & 23 HP Kohler Units Drive Front Caster Rear Caster (Single Tail Wheel) Pneumatic (Air-Filled) Semi-Pneumatic Semi-Pneumatic Quantity 2 2 1 Tread Turfmate Smooth Smooth Size 23 x 10.50-10 9 x 3.50-4 13 x 6.5-6 Ply Rating 4 Pressure 13 psi (90 kPa) 27 HP Kohler Units Drive Fron...
Page 20 - TORQUE REQUIREMENTS; OPERATION INSTRUCTIONS; FIGURE 2
15 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 .......................................
Page 21 - CAUTION; “ROTATE”
16 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 n...
Page 22 - OPERATING INSTRUCTIONS
17 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...
Page 23 - crank the engine continuously for more then ten (10)
18 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 ch...
Page 24 - TRANSPORTING
19 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” p...
Page 26 - PERIODIC MAINTENANCE; Service Interval: Daily; operate the engine with the oil level below the
21 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 igniti...
Page 28 - FIGURE 3
23 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 star...
Page 29 - paper element
24 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 prop...
Page 30 - Use only Mobil 1; Service Interval: If there is evidence of a leak or the hydraulic; FIGURE 4; Do
25 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 surf...
Page 31 - LUBRICATION CHART; Fitting Locations
26 4.1.10 Check tire pressures: Service Interval: 40 hrs. a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. b) 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 d...
Page 32 - Service Interval: Once Yearly; NOTE
27 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 assembl...
Page 33 - Service
28 4.1.15 Lubricate the brake rod bushings: Service Interval: 160 hrs. 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 oi...
Page 35 - Service Interval: 500 hrs; ADJUSTMENTS; Spring Tensioned - No adjustment necessary.; FIGURE 6
30 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...
Page 36 - Adjust Throttle Lever Tension.; FIGURE 9
31 d) 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 e) If park brake does not fully disengage when the lever is disengaged check...
Page 37 - Temporarily
32 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, ...
Page 40 - For 20 and 23 HP Kohler Units:
35 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 ...
Page 41 - ENGINE TROUBLESHOOTING TABLE
36 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...
Page 42 - ELECTRICAL DIAGRAM
Page 43 - HYDRAULIC DIAGRAM
Page 46 - NOTES
Page 48 - RIDING ACCESSORIES; INDUSTRIAL PARK BOX 808; Check us out on the Web:
® MFG. CO. INC. 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...
