For Serial Nos.
600,000 & Higher
Part No. 109-4288 Rev. A
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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
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.
2.
Distributor ships part(s) to dealer or customer, as
requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.
3.
4.
5.
6.
If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus® order, he contacts Exmark by 3:00 p.m.,
central time, with an Exmark Parts Plus® order of six (6) line items or less.
If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by
distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.
The customer pays for the part and freight if it is shipped under the Exmark Parts Plus® and if it arrives in
accordance to the program.
Who pays for the part and freight if it fails to arrive overnight in accordance to the program?
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:
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.
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus® order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
Exmark pays for the part and freight.
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
pays for the part.
The following restrictions apply -- The Exmark Parts Plus® Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available
only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental
United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air
charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no
responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by
3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus® Program are:
Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and
5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United
Parcel Service size and weight restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day
or Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be
ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
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CONGRATULATIONS on the purchase of your Exmark mower. This product has
been carefully designed and manufactured to give you a maximum amount of
dependability and years of trouble-free operation.
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, maintenance, and safety instructions, you will prolong
the life of your mower, maintain its maximum efficiency, and promote safe operation.
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 distributors are kept informed of the latest
methods of servicing and are equipped to provide prompt and efficient service in the
field or at their service stations. They carry ample stock of service parts or can
secure them promptly for you from the factory.
All Exmark parts are thoroughly tested and inspected before leaving the factory,
however, attention is required on your part if you are to obtain the fullest measure of
satisfaction and performance.
-iii-
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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
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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 imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
WARNING: Black lettering / Orange background. Indicates a potentially hazardous
situation which, if not avoided, COULD result in death 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. Familiarize yourself with the controls and the
proper use of the equipment. If the operator(s) or mechanic(s) can not read
English, it is the owner’s responsibility to explain this material to 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 attachments are needed to
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) protection
for the eyes, ears, feet, and head is recommended.
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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 footwear 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 to be used and remove all
stones, sticks, wires, bones, and other foreign objects which may damage the
equipment or cause personal injury to the operator or bystanders.
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.
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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 starting the engine.
Never remove the cap of the fuel tank or
add fuel when engine is running or when
the engine is hot.
♦ Never fill the fuel tank so that the gasoline
level rises above a level that is 1/2” below
the bottom of the filler neck to allow for
gasoline expansion and prevent fuel
spillage.
♦ If fuel is spilled, DO NOT attempt to start
the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.
♦ Do not operate without entire exhaust
system in place and in proper working
condition.
3
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DANGER
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely
flammable and highly explosive.
WHAT CAN HAPPEN
♦ A static charge can ignite gasoline
vapors. A fire or explosion from gasoline
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, remove gas-powered
equipment from the truck 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 trailer 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 complete.
4
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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 the personnel involved in
the operation, transport, maintenance, and storage of the equipment. It is essential
that all Operator Safety Mechanisms be connected and in operating 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 muffler,
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 brush-
covered unimproved land.
5
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WARNING
POTENTIAL HAZARD
♦ Hands, feet, hair, clothing, or accessories
can become entangled in rotating parts.
WHAT CAN HAPPEN
♦ Contact with rotating parts can cause
traumatic amputation or severe
lacerations.
HOW TO AVOID THE HAZARD
♦ Do not operate the machine without
guards, shields, and safety devices in
place and working.
♦ Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
1.4.1
1.4.2
Give complete, undivided attention to the job at hand.
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 feasible, avoid operating the equipment in wet grass.
WARNING
POTENTIAL HAZARD
♦ Operating a FrontRunner tractor 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.
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1.4.4
Use EXTREME caution when mowing and/or turning on slopes as loss of traction
and/or tip-over could occur. The operator is responsible for safe operation on
slopes.
WARNING
POTENTIAL HAZARD
♦ Mowing on wet grass or steep slopes can
cause sliding and loss of control.
WHAT CAN HAPPEN
♦ Wheels 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 rises that change the operating
angle, as rough terrain could overturn the machine.
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•
•
•
Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing
area. Tall grass can hide obstacles.
Use extreme care with attachments. These can change the stability of the
machine and cause loss of control.
Follow the manufacturer’s recommendations for wheel weights or
counterweights to improve stability.
1.4.5
1.4.6
Use EXTREME caution when backing up. LOOK BEHIND YOU!
Stop the blades when crossing surfaces other than grass and when transporting
the mower to and from the area to be mowed.
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
1.4.9
DO NOT change the engine governor settings or overspeed the engine. Operating
an engine at excessive speed may increase the hazard of personal injury.
Disengage PTO before 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 parts 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 working on the mower.
• After striking a foreign object (inspect the mower for damage and make
repairs before restarting and operating the mower).
• Before clearing blockages.
• Whenever you leave the mower.
Stop the engine and wait for all moving parts to stop:
• Before refueling.
• Before dumping the grass catcher.
1.4.13 Before stopping the engine, place the throttle control midway between the “slow”
and “fast” positions. Allow the engine to run a minimum of 15 seconds; then stop
the engine.
1.4.14 The fuel system is provided 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 for one operator only. Keep all others away from
mower during operation.
1.4.16 DO NOT mow with the discharge deflector raised, removed or altered unless
there is a grass collection system or mulch kit in place and working properly.
1.4.17 DO NOT operate mower under the influence of alcohol or drugs.
1.4.18 Use extra care when approaching blind corners, shrubs, 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 starter solenoid switch (this post
has the positive battery cable attached to it).
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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 manufacturer’s recommendations
precisely as stated in the engine manual.
1.5.2 Disconnect the battery cable from the 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 service life. To preserve optimum
battery performance and life, 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 storage.
1.5.4 Keep engine, engine area, and pump drive belt compartment free from
accumulation of grass, leaves, excessive grease or oil, and other debris which
can accumulate in these areas. These materials can become combustible and
may result in a fire.
1.5.5 Store fuel in a container specifically designed 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 isproperly
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 condition.
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 equivalent to the parts supplied as
original equipment.
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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 form 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 performing any work on
the hydraulic system.
1.6 SAFETY SIGNS
1.6.1
Keep all safety signs legible. Remove all grease, dirt and debris from safety
signs and instructional labels.
1.6.2
1.6.3
Safety signs must be replaced if they are missing or illegible.
When new components are installed, be sure that current safety signs are
affixed to the replaced components.
1.6.4
1.6.5
New safety signs may be obtained from Exmark Mfg. Co. Inc.
Safety signs may be affixed by peeling off the backing 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 following safety signs and instruction labels. They
are critical to the safe operation of your Exmark commercial mower.
PART NO. 1-513746
LOCATION: Outside of Rear
Muffler Guard
PART NO. 1-513747
LOCATION: LH Side of Battery Holder
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PART NO. 1-643339
LOCATION: Inside Hood
PART NO. 1-523552
LOCATION: Top Surface of
Hydraulic Tank
Support, RH Side
PART NO. 103-7218
LOCATION: On Seat Support Plate
PART NO. 103-5881
LOCATION: Inside Surface of Hood
Support – Each Side
PART NO. 109-2355
LOCATION: Outside of each
Bell Crank
PART NO. 107-2112
LOCATION: Top of Floor Pan
PART NO. 107-2102
LOCATION: Inside
Surface of
Upper Roll
bar
PART NO. 109-2356
LOCATION: Top of
Console,
PART NO. 109-2358
LOCATION: On Control
Panel
PART NO. 109-2357
LOCATION: Top of Console,
LH Side
RH Side
PART NO. 109-2360
LOCATION: Front of Console
PART NO. 109-2377
PART NO. 109-2396
LOCATION: On Hydraulic Cylinder
LOCATION: Top of Seat Support Plate
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PART NO. 98-5954
LOCATION: Top Surface of Hood
Support
PART NO. 103-3270
LOCATION: Top Surface of
Hood Support
PART NO. 109-3637
LOCATION: Back of Seat
PART NO. 109-2699
LOCATION: On Control Panel
PART NO. 93-4361
LOCATION: On LH and RH Side, Near
Back of Unit
2. SPECIFICATIONS
2.1 MODEL NUMBER: FR20KC; FR23KC; FR27KC
2.2 ENGINE
2.2.1
2.2.2
Engine Specifications: See your Engine Owner’s Manual
RPM: Full Speed: 3750 RPM (No Load) Idle: 1500 RPM
2.3 FUEL SYSTEM
2.3.1
2.3.2
2.3.3
2.3.4
Capacity: 8.5 gal (32 L)
Type of Fuel: Regular unleaded gasoline, 87 octane or higher
Fuel Filter: In-line 15 Micron Kohler P/N 2405010.
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
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2.4.6 Safety Interlock System:
PTO must be disengaged, brake engaged, and speed control lever in neutral
position to start engine. (It is not necessary for the operator to be in the seat to
start the engine.)
Operator must be in seat when PTO is engaged, brake is disengaged, or speed
control lever is moved out of neutral or engine will stop.
Engine will stop if the motion control levers are moved from neutral position while
brake is engaged.
2.5 OPERATOR CONTROLS
2.5.1 Steering and Motion Control:
Separate levers, on each side of the console, control speed and direction 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 (in slots) locks the drive system in neutral.
NOTE: Motion control levers are adjustable to three heights.
2.5.2 PTO Engagement Lever: Engages drive to PTO (mower deck).
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 fore and
aft seat track.
2.6.3 Seat Safety Switch: Internal to the bottom seat cushion, non serviceable. Time delay
module incorporated into the Safety Interlock System eliminates rough ground cut-outs.
2.6.4 Armrests: Standard seat: foam padded flip-up armrests.
Optional suspension seat: molded adjustable flip-uparmrests.
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 Synthetic Motor Oil.
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) forward
0-6.6mph (10.6 km/hr) reverse
20 HP & 23 HP Kohler Units: 0-8.7 mph (14.0 km/hr) forward
0-5.7mph (9.2 km/hr) reverse
2.7.7 Drive wheel release valves allow machine to be moved when engine is not running.
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20 HP & 23 HP Kohler Units
Front Caster
2.8 TIRES
Rear Caster
(Single Tail Wheel)
Semi-Pneumatic
1
Drive
Pneumatic (Air-Filled)
Semi-Pneumatic
2
Quantity
Tread
2
Turfmate
23 x 10.50-10
4
Smooth
Smooth
Size
9 x 3.50-4
13 x 6.5-6
Ply Rating
Pressure
13 psi (90 kPa)
27 HP Kohler Units
Front Caster
Rear Casters
(Dual Tail Wheel)
Semi-Pneumatic
2
Drive
Pneumatic (Air-Filled)
Semi-Pneumatic
2
Quantity
Tread
2
AT101
Smooth
Smooth
Size
24 x 12.00-12
4
9 x 3.50-4
13 x 6.5-6
Ply Rating
Pressure
9 psi (62 kPa)
2.9 MOWER DECK (Sold Separately)
FR524
FR604
2.9.1
Models
Discharge
Cutting Width
Side Discharge
52 in. (132 cm)
Side Discharge
60 in. (152 cm)
2.10 DIMENSIONS
2.10.1 Overall Width:
without deck
w/52” Deck
w/60” Deck
49.0 in. (124.5 cm)
53.3 in. (135.4 cm)
64.0 in. (163 cm)
49.0 in. (124 cm)
61.4 in. (156 cm)
72.0 in. (183 cm)
deflector up
deflector down
2.10.2 Overall Length:
20 & 23 HP Kohler
27 HP Kohler
without deck & floor pan folded
80.4 in. (204.2 cm)
82.3 in. (209.0 cm)
w/52” Deck
w/60” Deck
112.4 in. (285.5 cm) 114.3 in. (290.3 cm)
112.4 in. (285.5 cm) 114.3 in. (290.3 cm)
2.10.3 Overall Height:
2.10.4 Curb Weight:
Roll Bar - Up
Roll Bar - Down
69.2 in. (175.8 cm) 50.7 in. (128.8 cm)
without Deck
w/52” Deck
w/60” Deck
911 lbs. (413 kg)
1303 lbs. (591 kg)
1348 lbs. (611 kg)
2.10.5 Tread Width (Center to 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”
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2.11 TORQUE REQUIREMENTS
Bolt Location
Torque
Cutter Housing Spindle Nut (secured with threadlocker) 160-185 ft-lbs. (217-251 N-m)
Blade Mounting Bolt...............................................................55-60 ft-lbs. (75-81 N-m)
Sheave Mounting Nut ...................................................... 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)
3. OPERATION INSTRUCTIONS
3.1 CONTROLS
3.1.1 Familiarize yourself with all controls before operating the mower.
3.1.2 Motion Control Levers: Located on each side of the console. The left lever
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 right
hydrostatic pump to the right drive wheel motor.
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 position.
With levers moved out in the T-slot the drive system is in the neutral lock position
See Figure 2.
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 forward 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 to
slow the right drive wheel.
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To make a zero turn to the left, pull the left lever back beyond neutral while
holding the right lever slightly ahead of neutral.
To make a zero turn to the right, pull the right lever back beyond neutral while
holding the left lever slightly ahead of neutral.
Pulling the levers back from the neutral position will cause the respective drive
wheels to rotate in a reverse direction (spring tension can be felt when moving
into reverse from neutral).
To turn to the left while backing, move the left lever forward toward neutral. To
turn to the right while backing, move 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
3.1.4
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.
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 to the rear
will put the choke in the “OFF” position. DO NOT run a warm engine with choke
in the “ON” position.
3.1.5
3.1.6
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.
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 transporting.
Ignition Switch: Located on the right fuel tank console.
3.1.7
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. Rotate clockwise to the next position to engage the starter
(key must be held against spring pressure in this position).
Brake must be engaged, speed control lever in neutral and PTO switch
“OFF” to start engine. (It is not necessary for the operator to be in the seat to
start the engine.)
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3.1.8
3.1.9
Hour Meter: Located on the right fuel tank console. The hour meter is connected
to a pressure switch installed in the engine block and it records the number of
hours that the engine has run. If the ignition switch is left on without engine
running, hour meter will not run.
NOTE: This switch is not a low oil sensor and will not alert the operator if the
engine oil is low.
Hydraulic Lift Switch: Located on the right fuel tank console. The hydraulic lift
switch is used to raise and lower the mower deck.
Push the front portion of the hydraulic lift switch down to raise the mower deck
to the desired height.
Push the rear portion of the hydraulic lift switch down to lower the mower deck
to the desired height.
3.1.10 Fuel Shut-Off Valve: Located in fuel line by fuel tank and fuel filter. The fuel shut-
off valve is used to shut off the fuel when the machine will not be used for a few
days, during transport to and from the job site, and when parked inside a building.
3.1.11 Fuel Gauge: Located at the rear of the right fuel tank.
The fuel gauge monitors the amount of fuel left in the right fuel tank only. The left
tank does not hold fuel.
3.1.12 Drive Wheel Release Valves: Located on the top left front corner of hydrostatic
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, turn both 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.
3.2 PRE-START
3.2.1 Fill fuel tank. For best results use only clean, fresh regular grade unleaded
gasoline with an octane rating of 87 or higher. Regular grade leaded gasoline may
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 tank. Never fill the fuel tank so that the fuel level rises above
a level that is 1/2” below the bottom of the filler neck to allow for fuel 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 perform 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-off valve is located on the right side of unit in fuel line next to the fuel
filter. Raise the rear hood to access fuel shut-off valve.
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3.3.3 Starting Engine:
Brake must be engaged, speed control lever in neutral position and PTO
switch “OFF” to start engine. (It is not necessary for the operator to be in the
seat to start the engine.)
On a cold engine, place the throttle midway between the “SLOW” and “FAST”
positions and push choke lever forward into the “ON” position. Turn ignition switch to
the “start” position. Release the switch as soon as the engine starts.
IMPORTANT: DO NOT crank the engine continuously for more then ten (10)
seconds at a time. If the engine does not start, allow a 60 second cool-down
period between starting attempts. Failure to follow these guidelines 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:
DANGER
POTENTIAL HAZARD
♦ The rotating blades under the mower
deck are dangerous.
WHAT CAN HAPPEN
♦ Blade contact can cause serious injury or
kill you.
HOW TO AVOID THE HAZARD
♦ DO NOT put hands or feet under the
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, removed, or
altered unless there is a grass collection
system or mulch kit in place and working
properly.
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The PTO push-pull switch engages the cutting blades. Be sure that all persons
are clear of the mower deck and discharge area before engaging the PTO.
IMPORTANT: Operator must be in seat before the PTO can be engaged.
Set throttle to "midway" position. Pull the switch out to the “ROTATE” position.
Accelerate to full throttle to begin mowing.
3.3.5
3.3.6
Stopping PTO: Set throttle to the “midway” position. Push the switch in to the
“STOP” position to stop the PTO.
Stopping Engine: Bring unit to a full stop. Disengage the PTO, move motion
control levers to the neutral position and set the parking brake.
Before stopping the engine, place the throttle control midway between the “slow”
and “fast” positions. Allow the engine to run a minimum of 15 seconds; then
stop the engine.
Rotate ignition switch to “OFF” position. Remove the key to prevent children or
other unauthorized persons from starting engine.
Close fuel shut-off valve when machine will not be used for a few days, when
transporting, and when the unit is parked inside a building.
3.4 TRANSPORTING
IMPORTANT: Do not transport FrontRunner tractor without an approved Exmark front
mount attachment.
3.4.1 Transporting a Unit: Use a heavy-duty trailer or truck to transport the machine.
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 truck
has all necessary lighting and marking as required by law. Secure the trailer with a
safety chain.
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 traffic tickets and/or fines.
HOW TO AVOID THE HAZARD
♦ Do not drive a unit on a public street or
roadway.
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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 trailers or trucks. One
full width ramp is required. If 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 truck do not exceed 15°. A steeper angle may
cause mower deck components to get caught as the unit moves from ramp to
trailer or truck. Steeper angles may also cause the unit to tip. If loading on or
near a slope, position the trailer or truck so it is on the down side of the slope and
the ramp extends up the slope. This will minimize the ramp angle. The trailer or
truck should be as level as possible.
DO NOT attempt to turn the unit while on the ramp, you may lose control and drive
off the side.
Avoid sudden acceleration when driving on a ramp.
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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 stop. Make sure unit is on a
level surface.
b) Tilt seat forward and raise hood to gain access to access to engine area.
c) Check with engine cold.
d) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert 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.
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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 service life. To preserve optimum
battery performance and life, 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 storage.
a) Check the voltage of the battery with a digital voltmeter. Locate the voltage
reading of the battery in the table below and charge the battery for the
recommended time interval to bring the 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 charging the battery has an output of 16
volts and 7 amps or less to avoid damaging the battery (see chart below for
recommended charger settings).
Maximum
Charger Settings
16 volts/7 amps
Voltage
Reading
Percent
Charge
Charging Interval
12.6 or greater 100%
No Charging Required
30 Minutes
1 Hour
2 Hours
3 Hours
12.4 – 12.6
12.2 – 12.4
12.0 – 12.2
11.7 – 12.0
11.7 or less
75 – 100% 16 volts/7 amps
50 – 75%
25 – 50%
0 – 25%
0%
16 volts/7 amps
14.4 volts/4 amps
14.4 volts/4 amps
14.4 volts/2 amps
6 Hours or More
4.1.3
Clean engine cooling system:
Service Interval: Daily or more often 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.
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4.1.4
Check safety interlock system.
Service Interval: Daily
Check starting circuit:
a)
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 position - 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 levers in -
starter must not crank.
b)
Check the kill circuits:
Run engine at one-third throttle, disengage parking brake and raise off of
seat (but do not get off 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 after 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 machine) engine must stop after 1/2
second has elapsed.
Again, run engine at one-third throttle, brake engaged, and move left
motion control lever in - engine must stop.
Repeat again moving the right lever in, then moving both levers 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 folding deck latches, disengage the park brake,
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
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Run the engine at half throttle and pull up on the PTO engagement switch.
The PTO must not engage.
NOTE: If machine does not pass any of these tests, do not operate.
Contact your authorized EXMARK SERVICE DEALER.
IMPORTANT: It is essential that operator safety mechanisms be
connected and in proper operating condition prior to use for mowing.
4.1.5
4.1.6
Check for loose hardware.
Service Interval: Daily
a) Stop engine, wait for all moving parts to stop, and remove 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.
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 remove 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 remove air cleaner compartment cover.
d) Remove paper element. Check the condition of the paper element.
Replace if dirty, bent or damaged.
e) Check the condition 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 removing, so dirt does not get into the engine.
f) DO NOT wash or use pressurized air to clean paper element 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 pre-cleaner element and wash in warm water with detergent.
Rinse until all traces of detergent are eliminated and squeeze out excess
water (DO NOT wring). Air dry. Saturate with engine oil and squeeze out
excess oil.
i) Check paper element. DO NOT wash or use pressurized air to clean paper
element. Replace if dirty, bent or damaged.
j) Reinstall foam 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 remove 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 from 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
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drain, then close the valve by pushing inward and rotating 1/4 turn
clockwise. Remove and retain the hose for future use.
e) Replace the oil filter every other oil change. Clean around oil filter and
unscrew filter to remove. Before reinstalling new filter, apply a thin coating of
oil on the surface of the rubber seal. Turn filter clockwise until rubber seal
contacts the filter adapter then 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 NOT overfill.
g) Lower the hood and seat.
h) Start the engine and check for leaks.
Check hydraulic oil level:
4.1.8
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 remove cap. Oil level should
be to the top of the baffle 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 appropriate 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 temperature
(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 hydraulic
cylinder does not perform normally.
a) Retract the 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 reservoir 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.
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4.1.10 Check tire pressures:
Service Interval: 40 hrs.
a) Stop engine, wait for all moving parts to stop, and remove key. Engage
parking brake.
b) Check tire pressure in drive tires.
For 20 and 23 HP Kohler Units: The drive tires should be inflated to 13 psi
(90 kpa).
For 27 HP Koher Units: The drive tires should be inflated to 9 psi (62 kpa)
c) The rear caster tire(s) is semi-pneumatic and does not need to be inflated.
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 remove key. Engage
parking brake.
b) Check pump and PTO drive belts.
c) Belts are spring tensioned and no adjustment is necessary. See section
4.2.2 and 4.2.3 for belt replacement.
4.1.12 Lubricate grease fittings:
Service Interval: Refer to chart.
a) Stop engine, wait for all moving parts to stop, and remove key. Engage
parking brake.
b) Lubricate fittings with one to two pumps of NGLI grade #2 multi-purpose
gun grease.
Refer to the following chart for fitting locations and lubrication schedule.
LUBRICATION CHART
Initial No. of Service
Fitting Locations
Pumps Places Interval
1. Hitch and Cylinder Pivots
2. Fold Pivot Pin
2
2
4
2
2
1
2
2
4
1
40 hrs
100 hrs
yearly
*yearly
yearly
yearly
yearly
40 hrs
3. Fold Lock Pin
2
4. Rear Caster Pivot
5. Belt Idlers
*0
1
6. Motion Control Pivots
7. Transfer Spring Ends
1
1
8. Dual Tail Wheel Pivot
(if applicable)
2
* See Section 4.1.12 c) for special lubrication
instructions on the rear caster pivots and Section
4.1.13 for special lubrication instructions on the rear
caster wheel hub.
c) Lubricate caster pivots once a year. Remove hex plug and cap. Thread
grease zerk in hole and pump with grease until it oozes out around top
bearing. Remove grease zerk and thread plug back in. Place cap back on.
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4.1.13 Lubricate rear caster wheel hub:
Service Interval: Once Yearly
a) Stop engine, wait for all moving parts to
stop, and remove key. Engage parking
brake.
b) Remove caster wheel from caster forks.
c) Remove seal guards from the wheel hub.
d) Remove one of the spacer nuts from the
axle 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) from the wheel
assembly.
FIGURE 5
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-purpose grease.
g) Insert (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 thread onto the axle
with the wrench flats facing outward. Do not thread 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 the assembled 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 2nd 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-install the seal guards over the wheel hub and insert wheel into caster
fork. Re-install caster bolt and tighten nut fully.
IMPORTANT: To prevent seal and bearing damage, check the bearing
adjustment often. Spin the 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 brake 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 bushings on brake handle pivot with a spray type lubricant
or light oil.
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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 motion control bronze 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.
c) Lubricate bronze bushings on the flange bearings securing the motion
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 motion control shaft out and lubricate with an NGLI grade #2 multi-
purpose gun grease.
e) Re-install shaft and tab.
4.1.18 Lubricate steering linkage rod ends:
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 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 to stop, and remove key. Engage
parking brake.
b) Remove cooling shroud clean-out covers from engine and clean cooling fins.
Also clean dust, dirt, and oil from external surfaces of engine, which can cause
improper cooling.
c) Make sure cooling shroud clean-out covers are reinstalled. 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 replace with new
plugs. See Engine Owners Manual.
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4.1.21 Change fuel filter:
Service Interval: As Required
a) A fuel filter is installed between the fuel tank and the engine. Replace when
necessary.
Replacement Filters
Kohler P/N 2405010
4.1.22 Change hydraulic system filter:
Service Interval: After First 250 hrs.
Then yearly thereafter
NOTE: Use only Exmark Part No.103-2146
a) Stop engine, wait for all moving parts to stop, and remove key. Engage
parking brake.
b) Carefully clean area around filter. It is important that no dirt or
contamination enter hydraulic system.
c) Unscrew filter to remove 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 clockwise until rubber seal contacts the filter adapter, then
tighten the filter an additional 2/3 to 3/4 turn.
d) Fill reservoir as stated in Section 4.1.8.
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 to full throttle position. Move
the motion control levers to the full 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 contaminated or been
extremely hot.
Changing oil unnecessarily could damage hydraulic system by
introducing contaminates into the system.
29
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4.1.23 Wheel Hub – lock nut torque specification
Service Interval: 500 hrs
When tightening the lock nut on the wheel motor tapered shaft:
a)
Torque the lock nut to 125 ft-lbs (169 N-m).
NOTE: Do not use antisieze on wheel hub.
4.1.24 Fuel Tank – mounting hardware specification
When installing the nuts on the fuel tank studs, fully tighten the nyloc nut and
back off 1/2 turn. This allows for normal fuel tank expansion and contraction with
changes in temperature and fuel levels.
4.1.25 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type”
are used on the following fasteners:
a)
b)
c)
d)
e)
f)
Pump drive sheave set screws.
Line shaft sheave setscrews.
Square head setscrews on Hydro pump control arms.
Sheave retaining bolt in the end of engine crankshaft.
Caster wheel spacer nuts.
Fuel tank bulkhead fitting nuts.
g)
Motion control tab retaining bolt.
4.1.26 Dielectric grease is used on blade type electrical connections to prevent corrosion
and loss of contact.
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.
Pump Drive Belt Replacement.
4.2.2
a)
Stop engine, wait for all moving parts to stop, and remove key. Engage
parking brake.
b)
c)
Remove pump drive belt.
Route new belt onto sheaves as shown in the decal located on the right
hand side of the left hood support. See Figure 6.
FIGURE 6
4.2.3
Park Brake Adjustment.
Check to make sure each brake is adjusted properly.
a) Stop engine, wait for all moving parts to stop, and remove key. Engage
parking brake.
b) Tilt seat forward and raise hood.
c) Pull the brake lever up into the engaged position.
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d) Locate the park brake spring assembly. See Figure 7. There should be a
gap of 1/8” (3 mm) between the yoke and thin nyloc nut on the brake bolt. If
necessary, rotate the thin nyloc nut to obtain the 1/8” gap.
FIGURE 7
e) If park brake does not fully disengage when the lever is disengaged check the
brake rod linkage assembly. The assembly 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 still 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-turns
counter-clockwise until desired disengagement is obtained.
4.2.4
Adjust Throttle Lever Tension.
a) Stop engine, wait for all moving parts to stop, and remove 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
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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 surfaces.
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 electrical connection from the seat safety switch, located directly
in front of the seat switch assembly.
b) The neutral adjustment must be made with the drive wheels turning. Raise the
frame and place on jack stands so that drive 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 forward speed to
bring hydraulic system oil up to operating temperature.
e) To obtain the neutral position, adjust the left and right pump control rod
linkages that connect the steering control to the pump control arms until the
wheels stop, or creep slightly in reverse.
f) To adjust each linkage, loosen the jam nut next the ball joint at the upper
end of the linkage rod assembly. Then rotate the assembly using a wrench
to turn the double nuts on the assembly. See Figure 10.
g) Re-tighten the jam nut against the ball joint on each side.
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FIGURE 10
h) Move the motion control levers to the reverse 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. Remove jumper wire from
wire harness connector and plug connector into seat switch.
j) Lower from jackstands.
4.2.6
Weight transfer spring adjustment:
Weight transfer springs are assembled from the factory to apply the maximum
amount of weight onto the drive wheels. This setting provides the greatest
amount of traction. Some conditions may 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)
b)
Rotate the left motion control arm up and into the operation position.
Locate and loosen the knob under the rear of the left fender. See Figure 11.
FIGURE 11
c)
d)
Slide the fender forward and twist upward and outward to remove.
To adjust the weight transfer springs, fold the mower deck and front frame
and lock in service position. See Deck Manual for complete instructions.
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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 frame 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)
f)
Remove the retaining ring and washer at either end of the weight transfer
spring that retains it to the transfer bellcrank pins and/or weight transfer
spring anchor pins. See Figure 12.
Pull the spring off of front or rear pin and re-install in the outer hole, to
reduce the spring force. Re-install the washer and retaining ring.
FIGURE 12
g)
h)
Re-install the left fender.
For additional weight transfer adjustment, repeat steps steps d) through g)
on the right side of the unit.
4.2.7
Rear caster pivot bearings pre-load adjustment.
a) Remove dust cap from caster and tighten
nyloc nut until washers are flat. Back the
nyloc off 1/4 of a turn to properly set the pre-
load on the bearings.
Note: If disassembled, make sure the
spring washers are reinstalled as shown in
Figure 13.
FIGURE 13
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5. WASTE DISPOSAL
5.1 MOTOR OIL DISPOSAL
Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at
a certified recycling center or according to your state and local regulations.
5.2 BATTERY DISPOSAL
DANGER
POTENTIAL HAZARD
♦ Battery electrolyte contains sulfuric 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 batteries 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. If 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)
b)
Refer to Tracking Adjustment Section 4.2.5
Check air pressure in drive tires.
For 20 and 23 HP Kohler Units: The drive tires should be inflated to
13 psi (90 kpa).
For 27 HP Koher Units: The drive tires should be inflated to 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 inflated to
13 psi (90 kpa).
For 27 HP Koher Units: The drive tires should be inflated to 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 flotation.
b)
c)
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. This is the “rake” of the deck.
Check the distance from the bottom edge of the deck skirt to the tip of each
blade. Measurement should be consistent between all blade tips.
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6.3 ENGINE WILL NOT START.
a) Make sure the battery has a full charge. See section 4.1.2 for charging
instructions.
b) Be sure the throttle control is midway between the “SLOW” and “FAST”
positions, and the choke is in the “ON” position for a cold engine or the “OFF”
position for a warm engine.
c) Make sure there is fuel in the fuel tank and that the fuel valve is open.
d) Make sure the parking brake is set and motion control levers in the neutral
position.
e) Check that the PTO is disengaged, park brake is engaged and motion
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 corrosion may
cause a faulty connection. Clean connector terminals thoroughly with
electrical contact cleaner, apply dielectric grease and reconnect.
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, contact 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 occurs, do not overlook the simple causes. For example:
starting problems could be caused by an empty fuel tank.
The following table lists some of the common causes of trouble. Do not attempt
to service or replace major items or any items that call for special timing of
adjustments procedures (such as valves, governor, etc.). Have this work done
by your Engine Service Dealer.
ENGINE TROUBLESHOOTING TABLE
FAULTY
SPARK
PLUG
BLOCKED
FUEL
FILTER
INCORRECT
OIL
LEVEL
DIRTY
AIR
SCREEN
INSUFFICIENT
BATTERY
CHARGE
NO
FUEL
IMPROPER
FUEL
DIRT IN
FUEL LINE
DIRTY AIR
FILTER
ENGINE
OVERLOADED
PROBLEM
Will not start
Hard starting
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
Stops suddenly
Lacks power
X
X
X
X
X
X
X
X
X
X
Operates erratically
Knocks or pings
Skips or misfires
Backfires
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Overheats
X
High fuel
consumption
X
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7. ELECTRICAL DIAGRAM
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8. HYDRAULIC DIAGRAM
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9.
2-Year Limited Warranty
Exmark Turf Equipment
(For units purchased on or after October 1, 2004)
Owner’s Responsibilities
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.
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.
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.
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.
Products
Warranty Period
2 years
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.
• All Products (except as noted below)
• All Attachments and Accessories
• Metro 21 and Metro 26 Series
• Belts and Tires
1 year
1 year
90 days
• Battery
1 Year Prorated
• Engine*
Warranty is covered by engine manufacturer
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.
*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.
Items and Conditions Not Covered
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 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.
•
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.
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.
All warranty work must be performed by an authorized Exmark
Service Dealer using Exmark approved replacement parts.
Instructions for Obtaining Warranty Service
1. Contact any Exmark Service Dealer to arrange service at
their dealership. To locate a dealer convenient to you,
may also call 402-223-6375.
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.
2. Bring the product and your proof of purchase (sales
receipt) to the Exmark Service Dealer.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
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 Warranty Company
2101 Ashland Avenue
Beatrice, NE 68310
402-223-6375 or
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10.
Evaporative Emission Control Warranty Statement
California Evaporative Emission Control Warranty Statement
Your Warranty Rights and Obligations
Introduction
The California Air Resources Board and Exmark Manufacturing Company are pleased to explain the evaporative emission control
system’s warranty on your 2006 model year equipment. In California, new equipment that uses small off-road engines must be
designed, built, and equipped to meet the State’s stringent anti-smog standards. Exmark Manufacturing Company must warrant the
evaporative emission control system on your equipment for two years provided there has been no abuse, neglect or improper
maintenance of your equipment.
Your evaporative emission control system may include parts such as: fuel lines, fuel line fittings, and clamps.
Manufacturer’s Warranty Coverage:
This evaporative emission control system is warranted for two years. If any evaporative emission-related part on your equipment is
defective, the part will be repaired or replaced by Exmark Manufacturing Company.
Owner’s Warranty Responsibilities:
As the equipment owner, you are responsible for performance of the required maintenance listed in your Operator’s Manual.
Exmark Manufacturing Company recommends that you retain all receipts covering maintenance on your equipment, but Exmark
Manufacturing Company cannot deny warranty solely for the lack of receipts.
ƒ
ƒ
ƒ
As the equipment owner, you should however be aware that Exmark Manufacturing Company may deny you warranty coverage if
your emission warranty parts have failed due to abuse, neglect, or improper maintenance or unapproved modifications.
You are responsible for presenting your equipment to an Authorized Service Dealer as soon as the problem exists. The warranty
repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your
warranty coverage, you should contact Exmark Manufacturing Company at 1-402-223-6375.
Defects Warranty Requirements:
1. The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser.
2. General Evaporative Emissions Warranty Coverage. The emission warranty parts must be warranted to the ultimate purchaser
and any subsequent owner that the evaporative emission control system when installed was:
A. Designed, built, 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 emissions-related parts will be interpreted as follows:
A. Any warranted part that is not scheduled for replacement as required maintenance in the written instructions must be
warranted for the warranty period of two years. If any such part fails during the period of warranty coverage, it must be
repaired or replaced by Exmark Manufacturing Company. Any such part repaired or replaced 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 inspection in the written instructions must be warranted for the
warranty period of two years. A statement in such written instructions to the effect of “repair or replace as necessary” will not
reduce the period of warranty coverage. Any such part repaired or replaced under warranty must be warranted for a time not
less than the remaining warranty period.
C. Any warranted part that is scheduled for replacement as required maintenance in the written instructions must be warranted
for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to 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 the part.
D. Repair or replacement of any warranted part under the warranty provisions of this article must be performed at no charge to
the owner at an Authorized Service Dealer.
E. Notwithstanding 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 the determination that a warranted part is in fact defective,
provided that such diagnostic work is performed at an Authorized Service 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 meet the expected demand for such parts.
H. Manufacturer approved replacement parts must be used in the performance of any warranty maintenance or repairs and
must be provided without charge to the owner. Such use will not reduce the warranty obligations of Exmark Manufacturing
Company.
I.
The use of any add-on or modified parts will be grounds for disallowing a warranty claim made in accordance with this
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 the warranty procedures 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
40
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NOTES
41
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42
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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
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WARNING
The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.
©2005-2006
EXMARK MFG. CO. INC.
PART NO. 109-4288 Rev. A
(402) 223-6300
INDUSTRIAL PARK BOX 808
BEATRICE, NE 68310
ALL RIGHTS RESERVED
FAX (402) 223-5489
®
PRINTED IN U.S.A.
MFG. CO. INC.
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