Instruction/ maintenance manual of the product FR20KC Exmark
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For Serial Nos. 600,000 & Higher Part No. 109-4288 Rev. A.
i WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment. W HAT CAN HAPPEN ♦ Failure to f ollow safe operating pr act ices can result in serious operator inj ur y or even death.
ii EXMARK PA RTS PLUS ® PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not have the Exmark part in stock, Exmark w ill get the parts to the dealer the next business day or the part will be FREE* Guaranteed! ! How the Program Works 1.
-iii- CONGRAT ULATIONS on the purchase of your Exmark mower. T his product has been caref ully designed and manuf actured to g ive you a max im um amount of dependability and years of tr ouble- f ree operat ion. OPERA TOR'S M ANUA L This manual cont ains oper at ing , maintenance, adj ustment, and saf ety instructi ons for your E xmark mowe r.
iv TA BLE OF CONTENTS 1 . S A F E T Y P A G E 1.1 Safety Alert Sy mbol ....................................................................................... 1 1.2 Trai ning ............................................................................
1 1. SA FETY 1.1 SA FETY A LERT SYMBOL This SAFET Y ALERT SYMBOL is used both in this manual and on t he m achine t o identif y import ant safet y messag es which must be followed to avoid accidents.
2 CA UTION POTENT IAL HAZARD ♦ This machine pr oduces sound levels in excess of 85 dBA at the oper at or’s ear when in operation. W HAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss.
3 DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flamm able and highly explosive. W HAT CAN HAPPEN ♦ A fire or explosion f rom gasoline can bur n you, others, and cause proper t y damage.
4 DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flamm able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g asoline vapors. A fir e or explosion f rom gasoline can burn you, others, and cause pr oper t y damage.
5 WA RNING POTENT IAL HAZARD ♦ Gasoline vapor can collect inside enclosed trailers and m ay be ignited by electrical spark s or hot eng ine/ exhaust components. W HAT CAN HAPPEN ♦ Explosion and fire may occur, r e sult ing in property damag e, personal injury, and/or death.
6 WA RNING POTENT IAL HAZARD ♦ Hands, f eet , hair, clothing , or accessor ies can become entang led in r ot at ing parts. W HAT CAN HAPPEN ♦ Contact with rotating par ts can cause traumat ic am put ation or severe lacera tions.
7 1.4.4 Use EXTREME caution when mowing and/or tur ning on slopes as loss of tr act ion and/or tip-over could occur . T he operator is responsible f or saf e operation on slopes. WA RNING POTENT IAL HAZARD ♦ Mow ing on wet g r ass or st eep slopes can cause sliding and loss of control.
8 • Remove or mark obst acles such as r ock s, tree lim bs, et c. fr om t he m owing area. T all g rass can hide obstacles. • Use extreme care with attachment s.
9 b) connect the negative or ground cabl e (-) from the neg ative post on the booster batt er y to t he eng ine block as f ar away f rom t he bat t ery as possible. c) disconnect batter y cables in the reverse or der af ter st ar t ing . 1.5 MAINTENA NCE A ND STORAGE 1.
10 WA RNING POTENT IAL HAZARD ♦ Hydraulic fluid escaping under pr essur e can penetrate sk in and cause injury. W HAT CAN HAPPEN ♦ Fluid accidentally injected into t he skin must be surg ically removed wi t hin a few hours by a doctor f amiliar with this for m of injury or g ang rene may result.
11 PART NO. 1- 523552 LOCATI ON: Top Sur face of Hy dr aulic Tank PART NO. 1- 643339 LOCATIO N: Inside Hood Support, RH Side PART NO. 103- 5881 LOCATI ON: Inside Surfac e of Hood Support – Each Side PART NO. 103- 7218 LOCATI ON: On Seat Support Plate PART NO.
12 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: FR20KC; FR23KC; FR27KC 2.2 ENGINE 2.2.1 Engine Specifications: See your Engine Owner’s Manual 2.2.2 RPM : Full Speed: 3750 RPM (No Load) I dle: 1500 RPM 2.3 FUEL SYSTEM 2.3.1 Capacity: 8.5 g al ( 32 L) 2.3.2 Type of Fuel: Regular unleaded g asoline, 87 octane or higher 2.
13 2.4.6 Safet y Int er lock System: PTO must be di sengaged , brake engaged , and speed control lever in neut ral positio n to start engi ne . (It is not necessar y for the operat or t o be in the seat to start t he eng ine.
14 2.8 TIRES 20 HP & 23 HP Kohler Units Drive Front Caster Rear Caster (Single T ail Wheel) Pneum atic (Air-F illed) Sem i-Pneumatic Sem i-Pneumatic Quantity 2 2 1 Tread T urf mate Smooth Sm ooth Size 23 x 10.
15 2.11 TORQUE REQUIREMENTS Bolt Location T o r q u e Cutter Housing Spindle Nut (secured with thr eadlock er) 160-185 f t-lbs. ( 217- 251 N- m) Blade Mounting Bolt ............................................................... 55- 60 f t-lbs. (75-81 N-m) Sheav e Mountin g N ut .
16 To make a zero turn to the le ft , pull the left lever back beyond neutral while holding the r ig ht lever slight ly ahead of neutral. To make a zero turn to the right , pull the righ t lever back beyond neutral while holding the lef t lever slight ly ahead of neutral.
17 3.1.8 Hour Meter : Located on t he r ig ht fuel t ank console. The hour m et er is connected to a pressure switch installed in t he eng ine block and it r ecor ds t he number of hours that t he eng ine has run. If the ignit ion switch is lef t on without engine running, hour m eter will not run.
18 3.3.3 Star ting Engine : Brake must be engaged, speed control l ever i n neut ral position and PTO switch “O FF” t o st art engi ne. ( I t is not necessary for t he operator to be in t he seat to star t t he engine.
19 The PTO push-pull switch engages the cut ting blades. Be sur e t hat all persons are clear of the mower deck and dischar g e area before engaging the PTO. IMPORT A NT : Operator must be in seat bef ore t he PTO can be engaged. Set thro ttle to "midw ay" po sition.
20 WA RNING POTENT IAL HAZARD ♦ Loading a unit on a t r ailer or truck increases the possibility of tip-over. W HAT CAN HAPPEN ♦ Tip-over of t he unit could cause serious injury or death. HOW TO AVO ID THE HAZARD ♦ Use extreme caution when operating a unit on a ramp.
21 4. MAINTENA NCE & A DJUSTMENTS WA RNING POTENT IAL HAZARD ♦ W hile maint enance or adj ustments are being made, som eone could st ar t the engine. W HAT CAN HAPPEN ♦ Accidental start ing of the eng ine could seriously injure you or other bystanders.
22 4.1.2 Check batt er y charg e : Service Interval : M ont hl y Allowing batteries to st and f or an extended period of time without recharg ing them will result in reduced per f ormance and ser vice lif e. To preser ve optim um battery perf ormance and lif e, recharg e bat t eries in storage when the open circuit voltag e dr ops t o 12.
23 4.1.4 Check saf ety interlock system . Servic e Interval: Da ily a) Check starting ci rcuit : Starte r should crank wi t h, parking br ak e engaged, PTO disengaged and motion contr ol levers m o ved out in t he neutral lock position. The operator does not need to be in the seat t o start the eng ine.
24 Run the engine at half throt t le and pu ll up on t he PTO engag ement switch. The PTO must not engage . NOT E: If machine does not pass any of these t est s, do not operate.
25 drain, then close t he valve by pushing inward and rotating 1/4 turn clockwise. Remove and retain the hose f or f uture use. e) Replace the oil f ilt er every other oil chang e. Clean around oil filt er and unscrew filter t o r em ove. Bef ore reinst alling new filter , apply a thin coat ing of oil on the surf ace of the r ubber seal.
26 4.1.10 Check tire pr essur es : Service Interval: 40 hrs. a) Stop engine, wait f or all moving part s to stop, and r em ove key. Engag e parking br ak e. b) Check tire pr essure in drive tires. For 20 and 23 HP Kohler Units: T he drive tires should be inflat ed t o 13 psi (90 kpa) .
27 4.1.13 Lubricate rear cast er wheel hub: Service Interval: Once Yearly a) Stop eng ine, wait for all m oving par t s t o stop, and rem ove k ey. Eng ag e parking brake. b) Remove caster wheel fr om cast er f orks. c) Rem ove seal guar ds from t he wheel hub.
28 4.1.15 Lubricate the br ak e rod bushings: Service Interval: 160 hrs. a) Stop eng ine, wait for all m oving par t s to stop, and r em ove key. Engag e parking br ak e.
29 4.1.21 Change f uel filter : Servi ce I nt erval : As Required a) A f uel f ilter is inst alled bet ween the fuel tank and t he engine. Replace when necessary. Replacement Filter s Kohler P/N 2405010 4.1.22 Change hydraulic system f ilter : Service Interval: After First 250 hrs.
30 4.1.23 W heel Hub – lock nut torq ue specificat ion Service Interval: 500 hrs W hen tig htening the lock nut on the wheel motor t aper ed shaf t: a) Torque the lock nut to 125 ft -lbs (169 N-m).
31 d) Locate t he park brak e spring assembly. See Fig ure 7. Ther e should be a gap of 1/8” (3 mm ) bet ween the yoke and thin nyloc nut on the brake bolt .
32 4.2.5 Motion control linkag e adj ustment WA RNING POTENT IAL HAZARD ♦ Engine must be r unning and drive wheels must be tur ning so motion control adjustment can be per f ormed. W HAT CAN HAPPEN ♦ Contact with moving parts or hot sur f aces may cause personal injury.
33 FIGURE 10 h) Move the motion control levers t o t he reverse position. Ret ur n t he motion control levers to neut ral. The wheels must st op t urning (or slig htly creep in reve rse). i) Stop engine and wait f or all moving part s t o stop. Remove jum per wire f rom wire harness connector and plug connector into seat switch.
34 WA RNING POTENT IAL HAZARD ♦ W eig ht t r ansfer spring s may have stored energy. W HAT CAN HAPPEN ♦ Removing the weight tr ansfer spr ing s without releasing the st or ed ener gy can cause ser.
35 5. WA STE DISPOSAL 5.1 MOTOR OIL DISPOSA L Engine oil and hydraulic oil are both pollut ant s to the environment. Dispose of used oil at a certif ied recycling center or accor ding to your state and local reg ulations.
36 6.3 ENGINE W I LL NOT START. a) Make sure the bat t er y has a f ull charge. See sect ion 4. 1.2 for char g ing instructions. b) Be sure the t hrottle contr ol is m idway between the “SLOW ” and “ FAST ” positions, and the chok e is in the “ON” posit ion for a cold eng ine or the “O FF” position f or a warm eng ine.
37 7. ELECTRICA L DIA GRAM.
38 8. HYDRA ULIC DIAGRA M.
39 9. 2-Y ear Limited Warra nty Exmark Tu rf Equipment (For units pur chased on or af ter October 1, 2004) Conditions and Products Covered Exmark M fg.
40 10. Evaporat ive Emission Cont rol Warranty Statement California Evapor ative Emiss ion Control W ar ranty Statem ent Your W arr anty Rights and O bligations Introduction The California A i r Res o.
41 NOTES.
42.
® M FG . CO. IN C. SEE EXMA RK’S COMPLETE LINE OF A CCESSORIES RIDING A CCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT KI T MICRO-MULCH SY ST EM ROLL OVER PROTE.
An important point after buying a device Exmark FR20KC (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Exmark FR20KC yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Exmark FR20KC - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Exmark FR20KC you will learn all the available features of the product, as well as information on its operation. The information that you get Exmark FR20KC will certainly help you make a decision on the purchase.
If you already are a holder of Exmark FR20KC, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Exmark FR20KC.
However, one of the most important roles played by the user manual is to help in solving problems with Exmark FR20KC. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Exmark FR20KC along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
