Exmark FR23KC, FR27KC, FR20KC User Manual
For Serial Nos.
600,000 & Higher
Part No. 109-4288 Rev. A
WARNING
POTENTIAL HAZARD
♦ This product is a piece of power equipment.
WHAT CAN HAPPEN
♦ Failure to follow safe operating pr actices 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 condit ion.
♦ Stop engine, wait for all moving part s t o stop and engage parking
brake. Remove spark plug wire(s) or r emove key before
adjusting, servicing, or performing maintenance.
♦ If mower deck becomes clogged, stop engine, wait for all moving
parts to stop and engage parking brake. Remove spark plug
wire(s) or remove key before cleaning blockage.
♦ Keep hands, feet, and clothing away from power driven parts .
♦ Keep off mower unless seat platf o r m is pr ovided.
♦ Keep others off mower.
WARNING
POTENTIAL HAZARD
♦ Gasoline is harmful or f at a l if swallowed. Long-term exposure to
vapors has caused cancer in laboratory animals.
WHAT CAN 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 oper ated on any California forest, brush or grass covered land, a working
spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442
Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.
This spark ignition system complies with Canadian ICES-002
Ce système d’allumage par ètincelle de vèhicule est conform e à la norme NMB-002 du Canada
The enclosed Engine Owner’s Manual is supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and the California Emission Control Regulation of
emission systems, maintenance and warranty.
Keep this engine Owner’s M anual with your unit. Should this engine O wner’s Manual become
damaged or illegible, replace immediately. Replacements may be ordered through the engine
manufacturer.
i
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
2. Distributor ships part(s) to dealer or customer, as
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by
5. The customer pays for the part
6. Who pays for the part
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
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.
requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.
®
order, he contacts Exmark by 3:00 p.m.,
central time, with an Exmark Parts Plus
®
order of six (6) line items or less.
distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.
and freight if it is shipped under the Exmark Parts Plus® and if it arrives in
accordance to the program.
and freight if it fails to arrive overnight in accordance to the program?
1. The dealer not submitting the Exmark Parts Plus
®
order to his Exmark distributor by 1:00 p.m., the dealer
pays for the part and freight.
®
order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
Exmark pays for the part and freight.
pays for the part.
The following restrictions apply
-- The Exmark Parts Plus® Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available
only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental
United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air
charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no
responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by
3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus
®
Program are:
Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and
5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United
Parcel Service size and weight restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day
or Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be
ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
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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 oper at ion.
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.
By following the operating, maint enance, and safety instructions, you will prolong
the life of your mower, mainta in it s m aximum efficiency, and promote safe oper ation.
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 distribut or s are kept informed of the latest
methods of servicing and are equipped t o pr ovide prom pt and efficient service in the
field or at their service stations. T hey carr y ample stock of service parts or can
secure them promptly for you fr om the factory.
All Exmark parts are thoroug hly test ed and inspect ed before leaving the factory,
however, attention is required on your part if you are t o obt ain the fullest measure of
satisfaction and performance.
-iii-
TABLE OF CONTENTS
1. SAFETY PAGE
1.1 Safety Alert Symbol....................................................................................... 1
1.2 Training.........................................................................................................1
1.3 Preparation.................................................................................................1-5
1.4 Operation...................................................................................................5-9
1.5 Maintenance & Storage............................................................................ 9-10
1.6 Safety Signs........................................................................................... 10-12
2. SPECIFICATIONS
2.1 Model Number............................................................................................. 12
2.2 Engine......................................................................................................... 12
2.3 Fuel System................................................................................................ 12
2.4 Electrical System....................................................................................12-13
2.5 Operator Controls........................................................................................ 13
2.6 Seat............................................................................................................. 13
2.7 Hydrostatic Ground Drive System ............................................................... 13
2.8 Tires............................................................................................................14
2.9 Mower Deck ................................................................................................ 14
2.10 Dimensions..................................................................................................14
2.11 Torque Requirements..................................................................................15
3. OPERATION INSTRUCTIONS
3.1 Controls.................................................................................................. 15-17
3.2 Pre-Start...................................................................................................... 17
3.3 Operating Instructions ............................................................................17-19
3.4 Transporting...........................................................................................19-20
4. MAINTENANCE & ADJUSTMENTS
4.1 Periodic Maintenance.............................................................................21-30
4.2 Adjustments ...........................................................................................30-34
5. WASTE DISPOSAL
5.1 Motor Oil Disposal....................................................................................... 35
5.2 Battery Disposal.......................................................................................... 35
6. TROUBLESHOOTING....................................................................................35-36
7. ELECTRICAL DIAGRAM .................................................................................... 37
8. HYDRAULIC DIAGRAM...................................................................................... 38
9. WARRANTY.......................................................................................................... 39
10.
EVAPORATIVE EMISSION CONTROL WARRANTY...................................40
iv
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. Indicates an im m inent ly hazardous situat ion
which, if not avoided, WILL result in death or serious injur y.
WARNING: Black lettering / Or ange background. Indicates a potent ially hazardous
situation which, if not avoided, COULD result in deat h or serious injury.
CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous
situation which, if not avoided, MAY result in minor or moderate injury.
1.2 TRAINING
1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to
all who operate this unit.
1.2.2 Read the instructions carefully. Familiar ize yourself with the cont r ols and t he
proper use of the equipment. If the operator(s) or m echanic(s) can not read
English, it is the owner’s responsibility to explain this mater ial t o 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. Keep in mind
that the operator or user is responsible for accidents or hazards occurring to other
people or their property.
1.3 PREPARATION
1.3.1 Evaluate the terrain to determine what accessories and attachment s ar e needed t o
properly and safely perform the job. Only use accessories and attachments
approved by Exmark.
1.3.2 The use of personal protective equipment , such as (but not limited to) protect ion
for the eyes, ears, feet , and head is r ecom mended.
1
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 foot wear and long trousers. Do not operate
equipment when barefoot or when wearing open sandals.
1.3.4 Thoroughly inspect the area where the equipment is t o be used and r emove all
stones, sticks, wires, bones, and other foreign objects which may damage the
equipment or cause personal injury to the operat or or bystander s.
WARNING
POTENTIAL HAZARD
♦ Engine exhaust contains carbon
monoxide, which is an odorless deadly
poison.
WHAT CAN HAPPEN
♦ Carbon monoxide can kill you.
HOW TO AVOID THE HAZARD
♦ Do not run engine indoors or in a small
confined area where dangerous carbon
monoxide fumes can collect.
2
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 start ing the engine.
Never remove the cap of the fuel t ank or
add fuel when engine is running or when
the engine is hot.
♦ Never fill the fuel tank so that the gasoline
level rises above a level that is 1/2” below
the bottom of the filler neck to allow for
gasoline expansion and prevent fuel
spillage.
♦ If fuel is spilled, DO NOT attempt to start
the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.
♦ Do not operate without entire exhaust
system in place and in proper working
condition.
3
DANGER
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
♦ A static charge can ignite g asoline
vapors. A fire or explosion from g asoline
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.
♦ Do not fill gasoline containers inside a
vehicle or on a truck or trailer bed
because interior carpets or plastic truck
bed liners may insulate the container and
slow the loss of any static charge.
♦ When practical, r em ove g as- powered
equipment from t he t r uck or trailer and
refuel the equipment with its wheels on
the ground.
♦ If this is not possible, then refuel such
equipment on a truck or t r ailer 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 com p let e.
4
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.
♦ Be sure all fuel tanks and gasoline
storage containers have proper caps
installed to prevent spillage and minimize
vapor escaping into the trailer.
♦ Do not place any equipment that is
leaking gasoline in an enclosed trailer.
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 t he personnel i nvolved in
the operation, transport, maintenance, and st orage of t he equipment. It is essential
that all Operator Safety Mechanisms be connect ed and i n operat i ng condition prior
to use for mowing.
WARNING
POTENTIAL HAZARD
♦ Operating engine parts, especially the
muffler, become extremely hot.
WHAT CAN HAPPEN
♦ Severe burns can occur on contact.
♦ Debris, such as leaves, grass, brush, etc.
can catch fire.
HOW TO AVOID THE HAZARD
♦ Allow engine parts, especially the muff ler ,
to cool before touching.
♦ Remove accumulated debris from muffler
and engine area.
♦ Install and maintain in working order a
spark arrester before using equipment on
forest-covered, grass-covered, or br ush-
covered unimproved land.
5
WARNING
POTENTIAL HAZARD
♦ Hands, feet, hair, clothing, or accessories
can become entangled in rotating part s .
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, j ewelry, or clot hing
away from rotating parts.
1.4.1 Give complete, undivided attention to the job at hand.
1.4.2 Mow only in daylight or good artificial light, keeping away from holes and hidden
hazards. NEVER carry passengers.
DO NOT operate the mower when children or others are in the area.
1.4.3 When f easible, avoid operating the equipment in wet grass.
WARNING
POTENTIAL HAZARD
♦ Operating a FrontRunner tr act or without
an approved Exmark front mount
attachment increases the possibility of
forward tip over.
WHAT CAN HAPPEN
♦ Tip-over could cause serious injury or
death.
HOW TO AVOID THE HAZARD
♦ When operating a FrontRunner tractor
without an approved Exmark front mount
attachment, observe the following:
9 Limit operation to minimum required to
install a different front mount
attachment.
9 Minimize speed and use extreme
caution.
9 Only operate on a flat level surface.
9 Do not operate up or down a trailer
ramp.
9 Avoid sudden acceleration or
deceleration.
6
1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tr action
and/or tip-over could occur. The operator is r esponsible 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.
♦ Do not mow near drop-offs or near water.
♦ Do not mow slopes greater than 15
degrees.
♦ Reduce speed and use extreme caution
on slopes.
♦ Avoid sudden turns or rapid speed
changes.
• See inside the back cover to determine the approximate slope angle of the
area to be mowed.
• Use a walk behind mower and/or a hand trimmer near drop- offs, ditches, steep
banks or water. This area can be dangerous, see Figure 1.
FIGURE 1
• Progressively greater care is needed as the slope 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 r ises t hat change the operating
angle, as rough terrain could overtur n the machine.
7
• Remove or mark obstacles such as rocks, t r ee lim bs, etc. from the mowing
area. Tall grass can hide obstacles.
• Use extreme care with attachments. These can change t he st ability of the
machine and cause loss of control.
• Follow the manufacturer’s recommendations for wheel weights or
counterweights to improve stability.
1.4.5 Use EXTREME caution when backing up. LOOK BEHI ND YOU!
1.4.6 Stop the blades when crossing surfaces other than grass and when transporting
the mower to and from the area to be m owed.
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. Oper at ing
an engine at excessive speed may increase the hazard of personal injury.
1.4.9 Disengage PTO befor e starting engine.
1.4.10 Start
the engine carefully with feet well away from the blades.
1.4.11 Keep hands, feet, and clothing away from rotating par t s while the mower is being
operated.
1.4.12 Stop engine, wait for all moving parts to stop, and remove key. Engage parking
brake.
• Before checking, cleaning or work ing on the mower.
• After striking a foreign object (inspect the m ower for damage and make
repairs before restart ing and operating the mower).
• Before clearing blockages.
• Whenever you leave the mower.
Stop the engine and wait for all moving part s t o st op:
• Before refueling.
• Before dumping the gr ass cat c her .
1.4.13 Before stopping the engine, place the throt t le cont r ol midway between the “slow”
and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then stop
the engine.
1.4.14 The f uel system is pr ovided 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 fo r one oper at or only. Keep all others away from
mower during operation.
1.4.16 DO NO T m ow with the discharge deflector raised, removed or altered unless
there is a grass collection system or mulch k it in place and work ing properly.
1.4.17 DO NOT oper ate mower under the influence of alcohol or drug s.
1.4.18 Use extra care when approaching blind corners, shr ubs, trees, or other objects
that may obscure vision.
1.4.19 If jump starting is required:
a) connect the positive (+) power cable from the positive post on the booster
battery to the positive terminal post on the star ter solenoid switch (this post
has the positive battery cable attached to it).
8
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 m anufacturer’s recommendations
precisely as stated in the engine manual.
1.5.2 Disconnect the battery cable from t he negative battery post when the unit will be
allowed to sit for more than 30 days without use.
1.5.3 Allowing batteries to stand for an extended period of time without recharging
them will result in reduced performance and ser vice life. To preserve optimum
battery performance and lif e, 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 storag e.
1.5.4 Keep engine, engine area, and pump drive belt compar tment free from
accumulation of grass, leaves, excessive grease or oil, and ot her debris which
can accumulate in these areas. These materials can become com bustible and
may result in a fire.
1.5.5 Store fuel in a container specif ically desig ned for this purpose in a cool, dry place.
1.5.6 Keep the mower and fuel container in locked storage to prevent children from
playing or tampering with them.
1.5.7 Gasoline powered equipment or fuel containers should not be stored in a basement or
any enclosed area where open pilot lights or heat appliances are present.
1.5.8 Maximum mowing results and safety 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 condit ion.
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 eq uivalent t o t he parts supplied as
original equipment.
9
WARNING
A
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 for m 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.
♦ The woven guards that protect the
hydraulic hoses may deteriorate and wear
over time. Check the guards frequently
and replace if necessary.
♦ Keep body and hands away from pinhole
leaks or nozzles that eject high pressure
hydraulic fluid.
♦ Use cardboard or paper, not your hands,
to find hydraulic leaks.
♦ Safely relieve all pressure in the hydraulic
system, by placing the motion control
levers in neutral and shutting off the
engine, before perf o r m ing any work on
the hydraulic system.
1.6 SAFETY SIGNS
1.6.1 Keep all safety sig ns legible. Remove all grease, dirt and debris from safety
signs and instructional labels.
1.6.2 Safety sign s m ust 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 the replaced components.
1.6.4 New safety signs may be obtained from Exmark Mfg. Co. I nc.
1.6.5 Safety signs m ay be affixed by peeling off the back ing to expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.
1.6.6 Familiarize yourself with the f ollowing safety signs and instruction labels. They
are critical to the safe operat ion of your Exmark commercial mower.
PART NO. 1-513746
LOCATION: Outside of Rear
Muffler Guard
PART NO. 1-513747
TION: LH Side of Battery Holder
LOC
10
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