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.

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.

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

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.

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.

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.

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.

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.

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.

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.

• 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).

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.

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 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

PART NO. 1-523552 LOCATION: Top Surface of

PART NO. 103-5881 LOCATION: Inside Surface of Hood

Support – Each Side

PART NO. 107-2112 LOCATION: Top of Floor Pan

PART NO. 109-2356 LOCATION: Top of

Console, RH Side

PART NO. 109-2358 LOCATION: On Control

PART NO. 109-2360 LOCATION: Front of Console

PART NO. 109-2377 LOCATION: On Hydraulic Cylinder

Hydraulic Tank

Panel

PART NO. 103-7218 LOCATION: On Seat Support Plate

PART NO. 109-2355 LOCATION: Outside of each

Bell Crank

PART NO. 109-2357 LOCATION: Top of Console,

LH Side

PART NO. 109-2396 LOCATION: Top of Seat Support Plate

PART NO. 1-643339 LOCATION: Inside Hood

Support, RH Side

PART NO. 107-2102 LOCATION: Inside

Surface of Upper Roll bar

PART NO. 103-3270 LOCATION: Top Surface of

Hood Support

PART NO. 109-3637 LOCATION: Back of Seat

PART NO. 93-4361 LOCATION: On LH and RH Side, Near

Back of Unit

PART NO. 98-5954 LOCATION: Top Surface of Hood

Support

PART NO. 109-2699 LOCATION: On Control Panel

2. SPECIFICATIONS

2.1 MODEL NUMBER: FR20KC; FR23KC; FR27KC

2.2 ENGINE

2.2.1 Engine Specifications: See your Engine O wner’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 g asoline, 87 oct ane or higher

2.3.3 Fuel Filter: In-line 15 Micron Kohler P/N 2405010.

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

2.4.6 Safety Interlock System:

PTO must be disengaged, brake engaged, and speed control lever i n neut ral position to start engine. (It is not necessary for the operat or 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 ar e moved fr om neut ral position while

brake is engaged.

2.5 OPERATOR CONTROLS

2.5.1 Steering and Motion Control:

Separate levers, on each side of the console, contr ol speed and dir ection of travel of the respective drive wheels.

Steering is controlled by varying the position of the levers relative to each other. Moving motion control levers outward NOTE: Motion control levers are adjustable to three heights.

2.5.2 PTO Engagement Lever

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: Hinged to tilt up for access to hydraulic pumps, battery and other

components. The seat is held in the tilted position with a linkage. Adjustable for e and aft seat track.

2.6.3 Seat Safety Switch: Internal to the bot tom seat cushion, non serviceable. Time delay

module incorporated into the Safet y Int er lock System eliminates rough ground cut-outs.

2.6.4 Armrests: Standard seat: foam padded flip-up armrests.

Optional suspension seat: molded adjustable f lip-up

(in slots) locks the drive system in neutral.

: Engages drive to PTO (mower deck).

armrests.

2.7 HYDROSTATIC GROUND DRIVE SYSTEM

2.7.1 Hydrostatic Pumps:

27 HP Kohler Units: Two Hydro Gear PR 16 cc variable displacement piston pumps. 20 HP & 23 HP Kohler Units: Two Hydro Gear PJ 12 cc variable displacement piston

pumps.

2.7.2 Wheel Motors: Hydro Gear planetary reduction motors.

2.7.3 Hydraulic Oil Type: Use Mobil 1 15W-50 Synthet ic Motor O il.

2.7.4 Hydraulic Oil Capacity:

For 27 HP Kohler Units: 5.2 qt. (4.9 L.) For 20 HP & 23 HP Kohler Units: 4.0 qt. (3.8 L.)

2.7.5 Hydraulic Filter: Replaceable cartridge type.

P/N 103-2146: 25 microns, No bypass

2.7.6 Speeds:

27 HP Kohler Units: 0-10.5 mph (16.9 km/hr) f or ward 0-6.6mph (10.6 km/hr ) r everse

20 HP & 23 HP Kohler Units: 0-8.7 mph (14.0 km/hr ) forward 0-5.7mph (9.2 km/hr ) r everse

2.7.7 Drive wheel release valves allow machine to be moved when engine is not running.

2.8 TIRES

Drive Front Caster

20 HP & 23 HP Kohler Units

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)

Drive Front Caster

27 HP Kohler Units

Pneumatic (Air-Filled) Semi-Pneumatic Semi-Pneumatic Quantity 2 2 2 Tread AT101 Smooth Smooth Size 24 x 12.00-12 9 x 3.50-4 13 x 6.5-6 Ply Rating 4 Pressure 9 psi (62 kPa)

2.9 MOWER DECK ( Sold Separ ately)

Models

2.9.1

Discharge Side Discharge Side Discharge Cutting Width 52 in. (132 cm) 60 in. (152 cm)

FR524 FR604

2.10 DIMENSIONS

2.10.1 Overall Width:

without deck 49.0 in. (124.5 cm) 49.0 in. (124 cm) deflector up 53.3 in. (135.4 cm) 61.4 in. (156 cm) deflector down 64.0 in. (163 cm) 72.0 in. (183 cm)

2.10.2 Overall Length:

without deck & floor pan folded 80.4 in. (204.2 cm) 82.3 in. (209.0 cm) w/52” Deck 112.4 in. (285.5 cm) 114.3 in. (290.3 cm) w/60” Deck 112.4 in. (285.5 cm) 114.3 in. (290.3 cm)

2.10.3 Overall Height:

2.10.4 Curb Weight :

w/52” Deck 1303 lbs. (591 kg) w/60” Deck 1348 lbs. (611 kg)

2.10.5 Tread Width (Center t o Center of Drive Wheels):

For 27 HP Kohler Units: 41.4 in. (105.2 cm) For 20 HP & 23 HP Kohler Units: 38.9 in. (98.8 cm)

2.10.6 Wheel Base (Center of Drive Wheel to Center of Rear Caster Wheel): For 27 HP Kohler Units: 51.2 in. (130.0 cm) For 20 HP & 23 HP Kohler Units: 54.1 in (137.4 cm)

2.10.7 Minimum Turning Radius: For 27 HP Kohler Units: 55.25” For 20 HP & 23 HP Kohler Units: 56.3”

w/52” Deck w/60” Deck

20 & 23 HP Kohler 27 HP Kohler

Roll Bar - Up Roll Bar - Down

69.2 in. (175.8 cm) 50.7 in. (128.8 cm)

without Deck 911 lbs. (413 kg)

Rear Caster

(Single Tail Wheel)

Rear Casters

(Dual Tail Wheel)

2.11 TORQUE REQUIREMENTS

Bolt Location 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......................................................................30-35 ft-lbs. (41-47 N-m)

Hex Capscrew...............................................................50-55 ft-lbs. (68-75 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)

Wheel Hub Slotted Nut..................................................minimum125 ft-lbs. (169 N-m)

Rollover Protection System (Roll Bar) Mounting Bolts ...........30-35 ft-lbs. (41-47 N-m)

Clutch Retaining Bolt (secured with threadlocker)..................55-60 ft-lbs. (75-81 N-m)

Torque

3. OPERATION INSTRUCTIONS

3.1 CONTROLS

3.1.1 Familiarize yourself with all controls before operat ing the mower.

3.1.2 Motion Control Levers controls the flow of hydraulic oil from the left hydrostatic pump to the left drive wheel motor. The right lever controls the flow of hydraulic oil from the r ight hydrostatic pump to the right drive wheel motor.

: Located on each side of the console. The left lever

IMPORTANT: To begin movement (forward or backward) the operator must be in the seat, the brake lever must be disengaged (pushed down) before the motion control levers can be moved in or the engine will kill.

When levers are centered in the T-slot the drive system is in the neutral posit ion. With levers moved out in t he T-slot the drive system is in the neutral lock position See Figure 2.

By moving both levers an equal amount forward or back from the neutral position the machine can be caused to move forward or backward in a straight line.

Movement of the left lever forward will cause the left drive wheel to rotate in a forward direction. Movement of the right lever f orw ard will cause the right drive wheel to rotate in a forward direction. To stop forward travel, pull the levers back to the neutral position.

To turn left while moving forward, move the left lever back toward neutral to slow the left drive wheel.

To turn right while moving forward, move the right lever back toward neutral t o slow the right drive wheel.

FIGURE 2

To make a zero turn to the left, pull the left lever back beyond neutral while holding the right lever slight ly ahead of neutral.

To make a zero turn to the right, pull the right lever back beyond neutr al while holding the left lever slight ly ahead of neutral.

Pulling the levers back from t he neutral position will cause the respective drive wheels to rotate in a reverse direction (spring tension can be felt when moving into reverse from neutr al) .

To turn to the left while backing, move the left lever f orward toward neutral. To turn to the right while backing , m ove the right lever forward toward neutral.

CAUTION

POTENTIAL HAZARD ♦ Machine can spin very rapidly by

positioning one lever too much ahead of

the other. WHAT CAN HAPPEN ♦ Operator may lose control of the

machine, which may cause damage to

the machine or injury. HOW TO AVOID THE HAZARD

♦ Use caution when making turns.

♦ Slow the machine down before making

sharp turns.

3.1.3 PTO Engagement Switch: Located on the right fuel tank console. Switch must be pulled out to the “ROTATE” position to engage the PTO. The

Switch is pushed in to the “STOP” position to stop the PTO.

3.1.4 Choke Control

: Located on right fuel tank console.

Choke is used to aid in starting a cold engine. Moving the choke lever forward will put the choke in the “ON” position and moving the choke lever t o t he rear will put the choke in the “OFF” position. DO NO T r un a warm engine with choke in the “ON” position.

3.1.5 Throttle Control

: Located on right fuel tank console.

Throttle is used to control engine speed. Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed.

3.1.6 Brake Lever

: Located on left side of unit , between the seat and the dummy tank.

The brake lever engages a parking brake on the drive wheels.

Pull the lever up to engage the brake. Push the lever down to disengage the brake.

The unit must be tied down and brake engaged when transpor ting.

3.1.7 Ignition Switch

: Located on the right fuel t ank 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. Rotat e clockwise to the next position to engage the star t er (key must be held against spring pr essur e in t his position).

Brake must be engaged, speed control lever in neutral and PTO switch

“OFF” to start engine. (It is not necessar y for the operator to be in the seat to

start the engine.)

3.1.8 Hour Meter to a pressure switch installed in the engine block and it r ecor ds 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 switch is used to raise and lower the mower deck.

Push the front portion of t he hydraulic lift switch down to raise the mower deck to the desired height.

Push the rear portion of the hydraulic lif t switch down to lower the mower deck to the desired height.

3.1.10 Fuel Shut-Off Valve off valve is used to shut off the fuel when the machine will not be used for a fe w days, during transport to and f rom the job site, and when parked inside a building.

3.1.11 Fuel Gauge The fuel gauge monit o r s the amount of fuel left in the right fuel t ank only. The left

tank does not hold fuel.

3.1.12 Drive Wheel Release Valves pumps. Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running.

With a wrench, tur n bot h valves one turn counter -clockwise to release drive system. Turn clockwise to reset system. DO NOT overtighten. DO NOT tow machine.

For 27 HP Kohler Units: Use a 5/8 wrench to turn the valves. For 20 HP & 23 HP Kohler Units: Use a 7/16 wrench to turn the valves.

: Located on the right fuel t ank console. The hour meter is connected

: Located on the right fuel tank console. The hydraulic lift

: Located in fuel line by fuel tank and fuel filter. The fuel shut-

: Located at the rear of t he r ight fuel tank.

: Located on the top left front corner of hydrostatic

3.2 PRE-START

3.2.1 Fill fuel tank. For best r esults use only clean, fresh regular gr ade unleaded

gasoline with an octane rating of 87 or higher. Regular grade leaded ga soline m ay also be used; however, combustion chamber and cylinder head will require more frequent service. See Engine Owner's Manual.

DO NOT add oil to gasoline. DO NOT overfill fuel t ank. Never fill the fuel t ank so that the fuel level rises above

a level that is 1/2” below the bottom of t he filler neck to allow for f uel expansion and prevent fuel spillage.

3.2.2 Make sure you understand the controls, their locations, their functions, and their

safety requirements.

3.2.3 Refer to Maintenance, Section 4, and perf orm all the necessary inspection and

maintenance steps.

3.3 OPERATING INSTRUCTIONS

3.3.1 Raise roll bar:

Operate the unit with the roll bar in the raised and locked position and use seat belt. There is no rollover protection when the roll bar is down. If it is necessary to lower the roll bar, do not wear the seat belt. Raise the roll bar as soon as clearance permits.

3.3.2 Open fuel shut-off valve

The fuel shut-of f valve is located on the right side of unit in fuel line next to the fuel filter. Raise the rear hood t o access fuel shut-off valve.

3.3.3 Starting Engine

Brake must be engaged, speed control lever in neutral position and PTO switch “OFF” to start engine. (I t 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.

IMPORTANT: seconds at a time. If the engine does not st art , allow a 60 second cool-down period between starting at t empt s. Fai lure to follow these guidel ines can burn out the starter motor.

After starting a cold engine, gradually return choke to the “OFF” position as the engine warms up.

On a warm engine, place the throttle midway between the “SLOW” and “FAST” positions and leave the choke in the “OFF” position.

3.3.4 Engaging PTO

POTENTIAL HAZARD ♦ The rotating blades under the mower

WHAT CAN HAPPEN ♦ Blade contact can cause serious injury or

HOW TO AVOID THE HAZARD

♦ DO NOT put hands or feet under t he

DO NOT crank the engine continuously for more then ten (10)

DANGER

deck are dangerous.

kill you.

mower or mower deck when the blades are engaged.

DANGER

POTENTIAL HAZARD ♦ An uncovered discharge opening will

allow objects to be thrown in an operator’s or bystander’s direction. Also,

contact with the blade could occur. WHAT CAN HAPPEN ♦ Thrown objects or blade contact can

cause serious injury or death. HOW TO AVOID THE HAZARD

♦ Never operate the mower with the

discharge deflector raised, r emoved, or

altered unless there is a grass collection

system or mulch kit in place and working

properly.

The PTO push-pull switch engages the cut t ing blades. Be sure that all persons are clear of the mower deck and dischar ge area before engaging the PTO.

IMPORTANT

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 “STOP” position to stop the PTO.

3.3.6 Stopping Engine control levers to the neutral position and set t he parki ng brake .

Before stopping the eng ine, place t he throttle control 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.

Rotate ignition switch to “OFF” posit ion. Rem o ve the key to prevent children or other unauthorized persons from star t ing engine.

Close fuel shut-off valve when machine will not be used for a few days, when transporting, and when the unit is park ed inside a building.

3.4 TRANSPORTING

IMPORTANT: Do not transport FrontRunner tractor without an approved Exmark f r ont

mount attachment.

3.4.1 Transporting a Unit Engage the park brake and block the wheels. Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Be sure that the trailer or t r uck has all necessary lighting and marking as required by law. Secure the trailer with a safety chain.

: Operator must be in seat before the PTO can be engaged.

: Set throttle to the “midway” position. Push the switch in to the

: Bring unit to a full stop. Disengage the PTO, move motion

: Use a heavy-duty trailer or truck to tr anspor t the machine.

CAUTION

POTENTIAL HAZARD ♦ This unit does not have proper turn

signals, lights, reflective markings, or a slow moving vehicle emblem. These items are required to drive on a public street or roadway.

WHAT CAN HAPPEN ♦ Driving on a street or roadway without

such equipment is dangerous and can lead to accidents causing personal injury.

♦ Driving on a street or roadway without

such equipment may also be a violation of State laws and the operator may be subject to traff ic tickets and/or fines.

HOW TO AVOID THE HAZARD

♦ Do not drive a unit on a public street or

roadway.

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.

♦ 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.

3.4.2 Loading a Unit: Use extreme caution when loading units on tr ailer s or t rucks. One full width ramp is required. I f it is not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp.

Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or tr uck do not exceed 15°. A steeper angle may cause mower deck components to get caught as t he unit moves from ramp to trailer or truck. St eeper angles may also cause the unit to tip. If loading on or near a slope, position the trailer or tr uck so it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp ang le. The trailer or truck should be as level as possible.

DO NOT attempt to tur n t he unit while on the ramp, you may lose control and drive off the side.

Avoid sudden acceleration when driving on a ramp.

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).

WARNING

POTENTIAL HAZARD ♦ The engine can become very hot. WHAT CAN HAPPEN ♦ Touching a hot engine can cause severe

burns. HOW TO AVOID THE HAZARD

♦ Allow the engine to cool completely before

service or making repairs around the

engine area.

4.1 PERIODIC MAINTENANCE

4.1.1 Check engine oil level:

Service Interval: Daily

a) Stop engine and wait for all moving parts to st op. Make sur e unit is on a

level surface. b) T ilt seat forward and raise hood to gain access to access to engine area. c) Check with engine cold. d) Clean area ar ound dipstick. Remove dipstick and wipe oil off. Reinser t 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 specified in Engine

Owner’s Manual. DO NOT overfill.

IMPORTANT: DO NOT operate the engine with the oil level below the “LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

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 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.

a) Check the voltage of the battery with a digital voltmet er . Locate the voltage

reading of the batter y in the t able below and charge the battery for the recommended time interval to bring t he charge up to a full charge of 12.6 volts or greater.

IMPORTANT: Make sure the negative battery cables are disconnected and the battery charger used for char ging the battery has an output of 16 volts and 7 amps or less to avoid damaging the batter y (see char t below f or recommended charger settings).

Voltage

Reading

Percent

Charge

Maximum

Charger Settings

Charging Interval

12.6 or greater 100% 16 volts/7 amps No Charging Required

12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes

12.2 – 12.4 50 – 75% 16 volts/7 amps 1 Hour

12.0 – 12.2 25 – 50% 14.4 volts/4 amps 2 Hours

11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours

11.7 or less 0% 14.4 volts/2 amps 6 Hours or More

4.1.3 Clean engine cooling system:

Service Interval: Dail y or more of t en in dry conditions

WARNING

POTENTIAL HAZARD ♦ Excessive debris can cause the engine

and hydraulic system to overheat. WHAT 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. Engage

parking brake.

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.

4.1.4 Check safety interlock system.

Service Interval: Daily

a) Check st arting 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 posit ion - starter must not crank.

Try to start with operator in seat, parking brake engaged, PTO engaged and motion control levers in the neutral lock position - starter must not crank.

Try to start with operator in seat, parking brake engaged, PTO

disengaged, and the left motion control lever in, starter must not crank, repeat again with the right lever in, then with both l evers i n -

starter must not crank.

b) Check the kill circuits:

Run engine at one-third throttle, disengage parking brake and rai se of f of seat (but do not get of f of machine) engine must stop after approx. 1/2 second has elapsed (seat has time delay kill switch to prevent cut-outs on rough terrain).

Run engine at one-third throttle, engage PTO and raise off of seat (but do not get off of machine) engine must stop af t er 1/2 second has elapsed.

Run engine at one-third throttle, with brake disengaged, move levers in and rise off seat (but do not get off of m achine) engine must stop after 1/2 second has elapsed.

Again, run engine at one-thir d throttle, brake engaged, and move left motion control lever in - engine must st op.

Repeat again moving the right lever in, t hen m oving bot h l evers in engine must stop whether operator is on seat or not.

c) Check the PTO circuit:

See the FR524 and FR604 Operator’s manual to become familiar with the deck operation. Open the f olding deck latches, disengage the park br ake, move the motion control levers in to neutral, and disengage the PTO. Lower the deck until the PTO switch arm is no longer depressing the PTO “kill” switch. See Figure 3.

FIGURE 3

Run the engine at half throt tle 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

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake.

b) Visually inspect machine for any loose hardware or any other possible

problem. Tighten hardware or correct the problem before operating .

4.1.6 Service air cleaner

Service Interval: 50 hrs.

More often under severe conditions. See Engine manual for additional information.

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake.

b) Tilt seat forward and raise hood to gain access to the air cleaner.

For 27 HP Kohler Units:

c) Loosen retaining clips and rem ove air cleaner com par tment cover. d) Remove paper element. Check the condition of the paper element.

Replace if dirty, bent or damag ed.

e) Check the condit ion 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 r em oving, so dir t does not get into the engine. f) DO NOT wash or use pressurized air to clean paper elem ent or inner element. g) Reinstall elements. Position the cover so that the rubber dust ejector is

pointing downward and secure with retaining clips.

For 20 HP and 23 HP Kohler Units:

h) Remove foam pr e-cleaner element and wash in warm water with detergent.

Rinse until all traces of deterg ent ar e eliminated and squeeze out excess

water (DO NOT wring). Air dry. Saturate with engine oil and squeeze out

excess oil. i) Check paper elem ent . DO NOT wash or use pressurized air to clean paper

element. Replace if dirty, bent or dam aged. j) Reinstall f oam pre-cleaner to paper element, then reinstall paper element

and cover.

4.1.7 Change engine oil

Service Interval: 100 hrs.

NOTE: Change oil and filter after first five (5) hrs. of operation.

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake. b) Tilt seat forward and raise hood to gain access to the engine area. c) Drain oil while engine is warm fr om operation. d) Fit hose in literature pack over oil drain valve. Rotate the valve 1/4

counterclockwise and gently pull outward to open the valve. Allow the oil to

drain, then close the valve by pushing inward and rotating 1/4 turn

clockwise. Remove and retain the hose for f ut u r e use. e) Replace the oil f ilter every other oil change. Clean around oil f ilt er and

unscrew filter to remove. Bef ore reinstalling new filter, apply a thin coating of

oil on the surface of the r ubber seal. Turn filter clock wise until rubber seal

contacts the filter adapt er t hen tighten filter an additional 2/3 to 3/4 turn. f) Clean around oil fill cap and remove cap. Fill to specified capacity and replace

cap. Use oil recommended in engine owner’s manual. DO NO T overfill. g) Lower the hood and seat. h) Start t he engine and check for leaks.

4.1.8 Check hydraulic oil level

Service Interval: 40 hr.

a) Stop engine and wait for all moving parts to stop. b) Tilt seat up. c) Clean area around hydraulic reservoir cap and rem ove cap. O il level should

be to the top of the baf fle inside the tank. If not, add oil. Use only Mobil 1

15W-50 synthetic motor oil. Replace hydraulic reservoir cap and tighten

until snug. Do not overtighten.

NOTE: The baffle is labeled “HOT” and “COLD”. The oil level varies with

the temperature of the oil. The “HOT” level shows the level of oil when it is

at 225°F (107°C). The “COLD” level shows the level of the oil when it is at

75°F (24°C). Fill to the appropriat e level depending upon the temperature

of the oil. For example: If the oil is about 150° F (65°C), fill to halfway

between the “HOT” and “COLD” levels. If the oil is at room temperatur e

(about 75° F (24°C)), fill only to the “COLD” level.

4.1.9 Check auxiliary hydraulic oil level

Service Interval: If there is evidence of a leak or the hydraul i c

cylinder does not perform normally.

a) Retract t he hydraulic cylinder. b) Stop engine and wait for all moving parts to stop. c) Tilt the seat forward. d) Locate the auxiliary hydraulic power unit reservoir. See Figure 4.

FIGURE 4

e) Clean area around the r eser voir plug and remove. Oil level should be up to

the reservoir plug hole. If not , add oil. Use only Mobil 1 15W-50

synthetic motor oil. Replace reservoir plug and tighten until snug. Do

not overtighten.

4.1.10 Check tire pr essur es :

Service Interval: 40 hrs.

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake. b) Check tire pressure in drive tires.

For 20 and 23 HP Kohler Units: The drive tires should be inf lat ed t o 13 psi

(90 kpa).

For 27 HP Koher Units: The drive tires should be inf lat ed t o 9 psi ( 62 kpa)

c) The rear caster tire(s) is semi-pneumatic and does not need to be inf lat ed.

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.

4.1.11 Check condition of belts

Service Interval: 40 hrs.

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake. b) Check pump and PTO drive belts. c) Belts are spring t ensioned and no adj ustment is necessary. See section

4.2.2 and 4.2.3 for belt r eplacem ent.

4.1.12 Lubricate gr ease fittings

Service Interval: Refer to chart.

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake. b) Lubricate fittings with one to two pumps of NGLI gr ade #2 multi-purpose

gun grease.

Refer to the fo llowing chart for fitting locations and lubr ication schedule.

LUBRICATION CHART

Fitting Locations

1. Hitch and Cylinder Pivots 2 4 40 hrs

2. Fold Pivot Pin 2 2 100 hrs

3. Fold Lock Pin 2 2 yearly

4. Rear Caster Pivot *0 1 *yearly

5. Belt Idlers 1 2 yearly

6. Motion Control Pivots 1 2 yearly

7. Transfer Spring Ends 1 4 yearly

8. Dual Tail Wheel Pivot (if applicable)

Initial

Pumps

No. of

Places

2 1 40 hrs

Service Interval

* See Section 4.1.12 c) for special lubrication

instructions on the rear caster pivots and Section

4.1.13 for special lubrication instr uct ions on the rear caster wheel hub.

c) Lubricate caster pivots once a year. Rem ove hex plug and cap. Thread

grease zerk in hole and pump with grease until it oozes out around top

bearing. Remove grease zerk and thr ead plug back in. Place cap back on.

4.1.13 Lubricate rear caster wheel hub:

Service Interval: Once Yearly

a) St op engine, wait for all moving parts t o

stop, and remove key. Engage park ing

brake. b) Remove caster wheel f r om cast er forks. c) Remove seal guards from t he 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

still assembled to it) fr om t he wheel

assembly. e) Pry out seals, and inspect bearings for wear

or damage and replace if necessary. f) Pack the bearings with a NGLI grade #1 multi-pur pose grease. g) In ser t (1) bearing, (1) new seal into the wheel.

NOTE: Seals (Exmark PN 103-0063) must be replaced.

h) If the axle assembly has had both spacer nuts removed (or broken loose) ,

apply a thread locking adhesive to (1) spacer nut and thr ead onto the axle

with the wrench flats facing outward. Do not thr ead spacer nut all of the way

onto the end of 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 t he assem bled 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 into the wheel.

l) Apply a thread locking adhesive to the 2

spacer nut and thread onto the axle

with the wrench flats facing outward. m) Torque the nut to 75-80 in-lbs. (8-9 N- m ) , loosen, then re-torque to 20- 25 in-

lbs. (2-3 N-m). Make sure axle does not extend beyond either nut. n) Re-inst all t he seal guards over the wheel hub and insert wheel into caster

fork. Re-install cast er bolt and tighten nut fully.

FIGURE 5

IMPORTANT: To prevent seal and bearing damage, check the bearing

adjustment often. Spin t he caster tire. The tire should not spin freely (more

than 1 or 2 revolutions) or have any side play. If the wheel spins freely,

adjust torque on spacer nut until there is a slight amount of drag. Re-apply

threadlocking adhesive.

4.1.14 Lubricate the br ake handle pivot

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake. b) Tilt seat forward. c) Lubricate bronze bushing s on br ake handle pivot with a spray type lubricant

or light oil.

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 oil (bushings are located to the inside of the flange

bearings).

4.1.16 Lubricate the m ot ion cont r ol br onze bushing s

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake. b) Tilt seat forward. c) Lubricate bronze bushings on the flange bearings securing t he m ot ion

control arm shafts with a light oil or a spray type lubricant.

4.1.17 Lubricate the motion control shaft

Service Interval: Yearly.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake. b) Tilt seat forward. c) Remove tab at rear of motion control shaft. d) Pull mot ion cont r ol shaft out and lubricate with an NGLI gr ade #2 m u lt i-

purpose gun grease. e) Re-install shaft and tab.

4.1.18 Lubricate steer ing linkage rod ends

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to st op, and remove key. Engage parking

brake. b) Tilt seat forward. c) Lubricate each end of both steering linkage rods with a spray lubricant or light

oil.

4.1.19 Remove engine shrouds and clean cooling fins

Service Interval: 80 hrs.

a) Stop engine, wait for all moving parts t o st op, and remove key. Engage

parking brake.

b) Remove cooling shr oud clean- out covers from engine and clean cooling fins.

Also clean dust, dirt, and oil from exter nal sur faces of engine, which can cause

improper cooling.

c) Make sure cooling shroud clean-out covers are r einst alled. Operating the

engine without cooling shroud clean-out covers will cause engine damage due

to overheating.

4.1.20 Check spark plugs

Service Interval: 160 hrs.

a) Remove spark plugs, check condition and reset gaps, or r eplace with new

plugs. See Engine Owners Manual.

4.1.21 Change fuel filter

Service Interval : As Required

a) A fuel filter is installed between the f uel t ank and the engine. Replace when

necessary.

Replacement Filters

4.1.22 Change hydraulic system filter:

Service Interval: After Fi rst 250 hrs. Then yearly thereafter

NOTE: Use only Exmark Part No.103-2146

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake.

b) Caref ully clean area ar ound filter. It is important that no dirt or

contamination enter hydraulic system.

c) Unscrew filter t o r e m ove and allow oil to drain from reservoir.

IMPORTANT: Before reinstalling new filter, fill it with Mobil 1 15W-50 and apply a thin coat of oil on the surface of the rubber seal.

Turn filter clock wise until rubber seal contacts the filter adapter , then tighten the filter an addit ional 2/ 3 to 3/4 turn.

d) Fill reservoir as stat ed in Sect ion 4.1.8.

Kohler P/N 2405010

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, which

could cause injury. HOW TO AVOID THE HAZARD

♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

jack stands or equivalent support.

e) Raise the drive wheels off of the ground and support with jack stands (or

equivalent support) just high enough to allow drive wheels to turn freely.

f) Start engine and move throttle control ahead t o full throttle position. Move

the motion control levers to the f ull speed and run for several minutes. Shut down machine and recheck oil level.

Do not change hydraulic system oil (except for what can be drained when changing filter), unless it is felt the oil has been contaminat ed or been extremely hot.

Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system.

4.1.23 Wheel Hub – lock nut torque specification

Service Interval: 500 hrs

When tig ht ening 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 When installing the nuts on the fuel tank studs, fully tighten the nyloc nut and

back off 1/2 t ur n. This allows for normal fuel tank expansion and contraction with changes in temperature and f uel levels.

4.1.25 Thread lock ing adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type” are used on the following fasteners:

a) Pump dr ive sheave set screws. b) Line shaft sheave setscrews. c) Square head setscrews on Hydro pump control arms. d) Sheave retaining bolt in the end of engine crank shaft. e) Caster wheel spacer nuts. f) Fuel tank bulkhead fitting nuts. g) Motion control tab retaining bolt.

4.1.26 Dielectric grease and loss of contact.

– mounting hardware specification

is used on blade type electrical connections to prevent corrosion

4.2 ADJUSTMENTS

IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop,

engage parking brake, and remove key before servicing, cleaning, or making any adjustments to the unit.

4.2.1 Pump Drive Belt Tension

Spring Tensioned - No adjustment necessary.

4.2.2 Pump Drive Belt Replacement a) St op engine, wait for all moving parts to stop, and remove key. Engage

parking brake. b) Remo ve pump dr ive belt. c) Route new belt onto sheaves as shown in the decal located on the right

hand side of the left hood support . See Figure 6.

4.2.3 Park Brake Adjustm ent

Check to make sure each brak e is adjusted properly.

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake. b) Tilt seat forward and raise hood. c) Pull the brake lever up into t he engaged position.

FIGURE 6

d) Locate the park brake spring assembly. See Figure 7. T her e 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 par k brake does not fully disengag e when the lever is disengaged check the

brake rod linkage assembly. T he assem b ly 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) If the linkage does not measure 7 3/8” (18.7 cm ) or st ill does not disengage as

desired, remove the bolt that secures the ball joint to the brake lever and

loosen the jam nut next to the ball joint . Rotate the ball joint in half-t urns

counter-clockwise until desired disengagement is obtained.

4.2.4 Adjust Thr ot tle Lever Tension

a) Stop engine, wait for all moving parts to stop, and r emove key. Engage

parking brake.

b) Tension in throttle lever can be adjusted by adjusting the tightness of the

lever pivot bolt, which is located under the console. See Figure 9.

FIGURE 9

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 surf aces.

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, which

could cause injury. HOW TO AVOID THE HAZARD

♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

jack stands or equivalent support.

Set neutral:

a) Remove the elect r ical connection from the seat safet y switch, located dir ectly

in front of the seat switch assembly.

b) T he neut ral adjustment must be made with the drive wheels turning. Raise t he

frame and place on jack stands so t hat dr ive wheels can rotate freely.

Temporarily install a jumper wire across the terminals in the connector of the

wiring harness. c) Start the engine. d) Run the unit at least 5 minutes with the drive levers at full f or ward speed to

bring hydraulic system oil up to operating tem per ature.

e) T o obtain the neutral position, adjust the left and right pump control r od

linkages that connect the steering control to the pump control ar m s unt il t he wheels stop, or creep slightly in reverse.

f) To adjust each linkage, loosen the jam nut next t he ball joint at the upper

end of the linkage rod assem bly. T hen rotate the assembly using a wrench to turn the double nuts on the assembly. See Figur e 10.

g) Re-tighten the jam nut against the ball joint on each side.

4.2.6 Weight transfer spring adjustment

Weight transfer springs are assembled from the factory to apply the maximum

FIGURE 10

h) Move the motion contr ol levers t o t he r everse 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. Rem ove jumper wire from

wire harness connector and plug connector into seat switch.

j) Lower from jackstands.

amount of weight onto the drive wheels. This sett ing provides the greatest amount of traction. Som e condit ions m ay require the rear wheel lift to be reduced. This can be done by reducing the amount to weight transfer, which will increase the amount of weight on the front and rear castors.

a) Rot at e the left motion control arm up and int o the operation position. b) Locate and loosen the knob under the rear of t he left fender. See Figure 11.

FIGURE 11

c) Slide the fender forward and twist upward and outward to remove. d) To adjust the weight t r ansfer springs, fold the m ower deck and front frame

and lock in service position. See Deck Manual for complete inst ructions.

4.2.7 Rear caster pivot bearings pre-load adjustm ent

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 fr ame and

lock in service position to remove spring

tension and release stored energy before

performing any maintenance or

adjustments on the weight transfer

springs. (See Deck Manual for Deck

Raising instructions)

e) Remove the retaining ring and washer at either end of the weight transfer

spring that retains it to t he t ransfer bellcrank pins and/or weight transfer spring anchor pins. See Figure 12.

f) Pull the spr ing off of front or rear pin and re-install in t he out er hole, to

reduce the spring force. Re- inst all t he washer and ret a ining ring.

FIGURE 12

g) Re- inst all t he left fender. h) For addit ional weight t r ansfer adjustment, repeat st eps st eps d) through g)

on the right side of the unit.

a) Remove dust cap from caster and tighten

nyloc nut until washers are flat. Back the nyloc off 1/4 of a tur n t o properly set the preload on the bearings.

Note: If disassembled, make sure the spring washers are reinstalled as shown in Figure 13.

FIGURE 13

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 accor ding 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. HOW TO AVOID THE HAZARD

♦ Wear safety glasses to shield eyes, and

rubber gloves to protect skin and clothing when handling electrolyte.

♦ Do not swallow electrolyte.

Federal law states that bat teries should not be placed in the garbage. Management and

disposal practices must be within relevant federal, state, or local laws.

If a battery is being replaced or if the unit containing the battery is no longer operating and

is being scrapped, take the battery to a local certified recycling center. I f no local recycling is available return the battery to any certified battery reseller.

6. TROUBLE SHOOTING

6.1 MOWER PULLS LEFT OR RIGHT (WITH LEVERS FULLY FORWARD).

a) Refer to Tracking Adj ust m ent Section 4.2.5 b) Check air pressure in drive tires.

For 20 and 23 HP Kohler Units: The drive tires should be inf lated to 13 psi (90 kpa).

For 27 HP Koher Units: The drive tires should be inflated t o 9 psi ( 62 kpa) For All Units: Semi-pneumatic casters do not require inflation.

6.2 MOWER CUTS UNEVENLY.

a) Check air pressure in drive tires.

For 20 and 23 HP Kohler Units: The drive tires should be inf lated to 13 psi (90 kpa).

For 27 HP Koher Units: The drive tires should be inflated t o 9 psi ( 62 kpa) For All Units: Semi-pneumatic casters do not require inflation.

A more uniform cutting height may be obtained with higher tire pressure on rough terrain. A lower tire pressure provides more flotat ion.

b) Check deck leveling (See Adjustments in Deck Manual).

Note: The front of the mower deck will be approximately 1/4” lower than the back of the mower deck. T his is t he “rake” of the deck.

c) Check the distance from t he bottom edge of the deck skirt to the tip of each

blade. Measurement should be consistent between all blade tips.

6.3 ENGINE WILL NOT START.

a) Make sure t he bat t ery 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 “O FF”

position for a warm engine. c) Make sure there is fuel in t he fuel tank and that the fuel valve is open. d) Make sure t he par king brake is set and motion contr ol levers in the neutral

position. e) Check that the PTO is disengaged, park brake is engaged and m otion

control is in “Neutral”. f) Check that the spark plug wires are properly connected. g) Check for loose or faulty wiring connections. h) Check for corrosion at all wiring connections. Even minor corr osion m ay

cause a faulty connection. Clean connector terminals thor oughly with

electrical contact cleaner, apply dielectric grease and r econnect. i) Check safety switch adjustment (See Section 4.2.5).

NOTE: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.

NOTE: After carefully checking the above steps, attempt to start the engine. If it does not start, cont act your authorized Exmark service dealer.

IMPORTANT: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use.

When a problem occur s , do not overlook the simple causes. For example: starting problems could be caused by an empty fuel tank.

The following table lists some of t he common causes of trouble. Do not att em pt to service or replace major items or any item s t hat call for special timing of adjustments procedures (such as valves, governor, etc. ) . Have this work done by your Engine Service Dealer.

PROBLEM

Will not start Hard starting

Stops suddenly

Lacks power

Operates erratically

Knocks or pings

Skips or misfires

Backfires

Overheats

High fuel

consumption

ENGINE TROUBLESHOOTING TABLE

FUEL

IMPROPER

FUEL

DIRT IN

FUEL LINE

DIRTY AIR

FILTER

X X X X X

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

X X X X X X X X

X X X X X X X X X X X X X X X X X X X

X X X X

X X X

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

SCREEN

AIR

INSUFFICIENT

BATTERY

CHARGE

X X

7. ELECTRICAL DIAGRAM

8. HYDRAULIC DIAGRAM

2-Year Limited Warranty

Exmark Turf Equipment

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.

This warranty applies to Exmark turf equipment purchased on or after October 1, 2004 sold in the US or Canada. This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer. The warranty period commences upon the date of the original retail purchase.

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 and Metro 26 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

*Please refer to the engine manufacturer’s warranty statement that is included in the literature packet. We are not authorized to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized Exmark Service Dealer.

• Any damage or deterioration due to normal use, wear and tear, or exposure.

• Cost of regular maintenance service or parts, such as filters, fuel, lubricants, tune-up parts, and adjustments.

• Any product or part which has been altered or misused or required replacement or repair due to normal wear, accidents, or lack of proper maintenance.

• Any repairs necessary due to use of parts, accessories or supplies, including gasoline, oil or lubricants, incompatible with the turf equipment or other than as recommended in the operator's manual or other operational instructions provided by Exmark.

All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts.

1. Contact any Exmark Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our website at www.exmark.com. U.S. Customers may also call 402-223-6375.

2. Bring the product and your proof of purchase (sales receipt) to the Exmark Service Dealer.

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:

Exmark Customer Service Department The Exmark W arranty Company 2101 Ashland Avenue Beatrice, NE 68310

402-223-6375 or

Warranty Period

Items and Conditions Not Covered

Instructions for Obtaining Warranty Service

(For units purchased on or after October 1, 2004)

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 extends only to turf equipment operated under normal conditions. You must properly service and maintain your Exmark product as described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

As a condition to this warranty, customer shall have read the operator's manual and shall have completed and submitted to Exmark Warranty Company, within the prescribed time, the Exmark warranty registration.

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein. Neither Exmark nor Exmark Warranty

Company shall have any liability for any other cost, loss or damage, including but not limited to, any incidental or consequential loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other

extraordinary repair charges or charge relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark service dealer.

• Rental of like or similar replacement equipment during the period of any warranty, repair or replacement work.

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that

covered by the terms of this warranty.

• Any claims for lost revenue, lost profit or additional cost as a result of a claim of breach of warranty.

• Attorney's fees.

No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower.

There are no understandings, agreements, representations, or warranties, express or implied, including but not limited to any regarding the merchantability (that product is fit for ordinary use) or fitness for use (that product is fit for a particular purpose), not specified herein, respecting the equipment which is the subject of this warranty.

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

10.

Evaporative Emission Control Warranty Statement

California Evaporative Emission Control Warranty Statement

Your Warranty Rights and Obligations

Introduction

The California Air Resources B oard and Exmark Manufacturing Company are pleased to explain the evaporative emission control system’s warranty on your 2006 m odel year equi pment. In California, new equipment that uses sm al l off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog st andards. Exmark Manufacturing Com pany must warrant the evaporative emission control system on your equipm ent for two years provided there has been no abuse, neglect or i mproper maintenance of your equipm ent. Your evaporative emission control system m ay i nclude parts such as: fuel lines, fuel line fitt i ngs, and clamps.

Manufacturer’s Warranty Coverage:

This evaporative emissi on control system is warranted f or two years. If any evaporative emiss i on-rel ated part on your equipment is defective, the part will be repaired or replaced by Exmark Manufact uring Company.

Owner’s Warranty Responsibilities:

 As the equipm ent owner, you are res ponsible for performance of t he requi red maintenance listed in your Operat or’ s Manual.

Exmark Manufacturing Company rec ommends that you retain al l receipts covering maintenance on your equipment, but Exma rk Manufacturing Company cannot deny warranty sol ely for the lack of receipt s.

 As the equipm ent owner, you should however be aware that Exmark Manufacturing Company may deny you warranty coverage if

your emission warranty parts have fai led due to abuse, neglect, or improper maintenance or unapproved modifications.

 You are responsible for presenting your equipment to an Authori zed S ervi ce Dealer as soon as the problem exist s. The warranty

repairs should be complet ed i n a reasonable amount of tim e, not to exceed 30 days. If you have a question regarding your warranty coverage, you should contact E xm ark Manufacturing Company at 1-402-223-6375.

Defects Warranty Requirements:

1. The warranty period begins on the date the engine or equipment is delivered t o an ul timate purchaser.

2. General Evaporative E missions Warranty Coverage. The emiss i on warranty parts must be warranted to the ultimate purchaser

and any subsequent owner that the evaporative emi ssion control system when installed was: A. Designed, bui l t, and equipped so as to conform with all applicable regulations; and B. Free from defects in materials and workmanship that causes the failure of a warranted part for a period of two years.

3. The warranty on evaporative emissi ons-related parts will be interpreted as follows: A. Any warranted part that i s not scheduled for replacement as required maintenance in the written instructions must be

warranted for the warranty period of two years. If any suc h part fails during the period of warranty coverage, i t must be repaired or replaced by Exmark Manufacturing Company. Any such part repaired or replac ed under the warranty must be warranted for a time not less than the remaining warranty period.

B. Any warranted part that is scheduled only for regular ins pection in the written instruct i ons must be warranted for the

warranty period of two years. A statement in such written instructions to the eff ect of “repair or replace as necessary” will not reduce the period of warranty coverage. Any suc h part repaired or replaced under warranty must be warranted for a ti me not less than the remaini ng warranty period.

C. Any warranted part that is scheduled for replacement as required m ai ntenance in the written instruct i ons must be warranted

for the period of time prior to the first scheduled replacement point for that part . If the part fails prior t o the first scheduled replacement, the part must be repaired or replaced by Exmark Manufacturing Company. Any such part repaired or replaced under warranty must be warranted for a time not less than the remainder of the period prior to the first scheduled replacement point for t he part .

D. Repair or replacement of any warranted part under the warranty provisions of this artic l e must be performed at no c harge to

the owner at an Authorized Service Dealer.

E. Notwithst andi ng the provisions of subsection (D) above, warranty services or repairs must be provided at an Authorized

Service Dealer.

F. The owner must not be charged for diagnostic labor that leads to t he determination that a warranted part is i n fact defective,

provided that such diagnosti c work is performed at an Authorized S ervi ce Dealer.

G. Throughout the evaporative emission control system's two year warranty period, Exmark Manufacturing Company must

maintain a supply of warranted parts sufficient to m eet the expected demand for such parts .

H. Manufacturer approved replacement part s must be used in the performance of any warranty maintenance or repai rs and

must be provided without charge to the owner. Such us e will not reduc e the warranty obligations of Exmark Manufacturing Company.

I. The use of any add-on or m odif i ed parts will be grounds for disallowing a warranty claim made in accordance with t his

article. Exmark Manufacturing Company will not be liable under this Article to warrant failures of warranted parts caused by the use of an add-on or modified part .

J. Exmark Manufacturing Company shall provide any documents that describe t he warranty proc edures or policies within five

working days of request by the Air Resources Board.

Emission Warranty Parts List:

The following list includes the parts covered under this warranty:

• Fuel Lines

• Fuel Line Fittings

• Clamps

NOTES

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.com

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

FG. CO. INC.

Exmark FR23KC, FR27KC, FR20KC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual