Exmark Frontrunner 720, 000 & Higher Serial Nos., Frontrunner Series, Frontrunner FR23KC, Frontrunner FR27KC Operator's Manual

FRONTRUNNERTM

AIR-COOLEDMODELS

ForSerialNos.
720,000&Higher

PartNo.4500-218Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,or
otherreproductiveharm.

Important:Whenthemowerisusedoroperated
onanyCaliforniaforest,brushorgrasscovered
land,aworkingsparkarrestermustbeattached
tothemufer.Ifnot,theoperatorisviolating
statelaw,Section4442PublicResourceCode.To
acquireasparkarresterforyourunit,seeyour
EngineServiceDealer.

ThissparkignitionsystemcomplieswithCanadian
ICES-002Cesystèmed’allumageparètincellede
vèhiculeestconformeàlanormeNMB-002du
Canada

TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.

Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.

©2004–2008—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310

2

Contactusatwww.Exmark.com.

PrintedintheUSA.

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.

Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.

AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

3

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.....................10

Specications.......................................................14

ModelNumbers............................................14

Systems.........................................................14

Dimensions...................................................16

TorqueRequirements....................................17

ProductOverview................................................17

Operation.............................................................18

Controls........................................................18

Pre-Start........................................................19

OperatingInstructions..................................19

Transporting.................................................22

Maintenance.........................................................23

RecommendedMaintenanceSchedule(s)...........23

PeriodicMaintenance.......................................24

CheckEngineOilLevel.................................24

CheckBatteryCharge....................................24

CheckSafetyInterlockSystem.......................25

CheckRolloverProtectionsSystems(Roll

Bar)Pins...................................................26

CheckSeatBelt..............................................26

CheckforLooseHardware............................26

ServiceAirCleaner........................................26

ChangeEngineOil........................................26

CheckHydraulicOilLevel.............................27

CheckTirePressures.....................................27

CheckConditionOfBelts..............................28

LubricateGreaseFittings...............................28

LubricateRearCasterWheelHub(s)...............28

LubricateBrakeHandlePivot........................29

LubricateBrakeRodBushings.......................29

LubricateMotionControlBronze

Bushings...................................................29

LubricateMotionControlShaft.....................29

LubricateSteeringLinkageRodEnds.............29

CheckSparkPlugs.........................................30

ChangeHydraulicSystemFilter.....................30

CheckWheelHubLocknuts..........................30

ThreadLockingAdhesives.............................30

DielectricGrease...........................................31

Adjustments.....................................................31

PumpDriveBeltTension...............................31

PumpDriveBeltReplacement.......................31

ParkBrakeAdjustment..................................31

MotionControlLinkageAdjustment.............32

WeightTransferSpringAdjustment...............33

CasterPivotBearingsPre-Load

Adjustment...............................................34

Cleaning...........................................................34

CleanEngineCoolingSystem........................34

RemoveAccumulatedDebrisfrom

Engine(Briggs&StrattonUnits

Only).........................................................34

RemoveEngineShroudsandCleanCooling

Fins...........................................................35

WasteDisposal..............................................35

Troubleshooting...................................................36

Schematics...........................................................38

4

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Y ellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.

CAUTION

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.

5

Safety

DANGER

Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen
area,whentheengineiscold.Wipeup
anygasolinethatspills.

•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.

•DoNotllthefueltankcompletely
full.Addgasolinetothefueltankuntil
thelevelis1/4to1/2inch(6–13mm)
belowthebottomofthellerneck.This
emptyspaceinthetankallowsgasoline
toexpand.

•Neversmokewhenhandlinggasoline,
andstayawayfromanopenameor
wheregasolinefumesmaybeignitedby
spark.

•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.

•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

DANGER

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.

•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas
tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly .DoNotoperateunlessthey
arefunctioningproperly.

6

Safety

Operation

WARNING

Operatingengineparts,especiallythe
mufer,becomeextremelyhot.Severeburns
canoccuroncontactanddebris,suchas
leaves,grass,brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,
tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer
andenginearea.

•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.

WARNING

Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.

DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.

WARNING

OperatingaFrontRunnertractorwithoutan
approvedExmarkfrontmountattachment
increasesthepossibilityofforwardtipover.
Tip-overcouldcauseseriousinjuryordeath.

WhenoperatingaFrontRunnertractor
withoutanapprovedExmarkfrontmount
attachment,observethefollowing:

•Limitoperationtominimumrequiredto
installadifferentfrontmountattachment.

•Minimizespeedanduseextremecaution.

•Onlyoperateonaatlevelsurface.

•DoNotoperateupordownatrailerramp.

•Avoidsuddenaccelerationordeceleration.

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.Useseatbelts.

•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.

•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly .

•DoNotchangetheenginegovernorsettingor
overspeedtheengine.

•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting

andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:

–Beforerefueling.
–Beforedumpingthegrasscatcher.

WARNING

Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.

•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.

•NEVERcarrypassengers.DONOToperate
themowerwhenpeople,especiallychildren,or
petsareinthearea.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen

7

Safety

transportingthemowertoandfromtheareato
bemowed.

•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.

DANGER

Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Wheels
droppingoveredges,ditches,steepbanks,or
watercancauserollovers,whichmayresult
inseriousinjury,deathordrowning.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15
degrees.

•Reducespeedanduseextremecaution
onslopes.

•Avoidsuddenturnsorrapidspeed
changes.

•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.

•Useawalkbehindmowerand/orahandtrimmer
neardrop-offs,ditches,steepbanksorwater.
(Figure3).

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15
degrees

2.DangerZone-Useawalkbehindmowerand/orhand
trimmerneardrop-offsandwater.

3.Water

•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.

•Avoidsuddenstopswhenmowingdownhill
becausethemowermaytipforwards.

•Beawarethatlossoftractionmayoccurgoing
uphill.Weighttransfertotherearwheelsmay
causedrivewheelstoslipandcauselossof
brakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.

•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem
(ROPS)

ARolloverProtectionSystem(rollbar)isinstalled
ontheunit.

8

Safety

WARNING

Thereisnorolloverprotectionwhentheroll
barisdown.Wheelsdroppingoveredges,
ditches,steepbanks,orwatercancause
rollovers,whichmayresultinseriousinjury,
deathordrowning.

•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.

•Lowertherollbaronlywhenabsolutely
necessary.

•DoNotwearseatbeltwhentherollbar
isdown.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance
permits.

•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,andelectricalwires)before
drivingunderanyobjectsandDoNotcontactthem.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.

•Keepengine,enginearea,andpumpdrivebelt
compartmentfreefromaccumulationofgrass,
leaves,excessivegreaseoroil,andotherdebris
whichcanaccumulateintheseareas.These
materialscanbecomecombustibleandmayresult
inare.

•LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe

negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplaceblades.Neverstraightenor
weldthem.

•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.

•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

WARNING

Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.

•Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.

9

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

103-2076

1-513747

1-523552

1-643339

98-4361

98-5954

103-3270

103-5881

10

Safety

103-7218

107-2102

107-2112

109-2355

109-2356

1.Fast3.Neutral

2.Slow

4.Reverse

11

Safety

109-2357

1.Fast4.Reverse

2.Slow

5.ParkBrake—Release

3.Neutral6.ParkBrake—Engage

109-2358

109-2377

109-2396

109-3637

12

Safety

109-7413

1.Cylinder—extend4.Slow

2.Cylinder—retract5.Choke—on

3.Fast

6.Choke—off

109-7949

109-2360

13

Specications

Specications

ModelNumbers

SerialNos:720,000andHigher

FR23KC;FR27KC;FR31BV

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s
Manual

•RPM:FullSpeed:3750±50RPM(NoLoad)
Idle:1500RPM

FuelSystem

•Capacity:8.5gal.(32L)

•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher.

•FuelFilter:

–Kohler:

In-line15MicronKohlerP/N2405010.

–Briggs&Stratton:

In-line30MicronBriggsP/N695327.

•FuelShut-OffValve:1/4turnincrements(“ON”,
“OFF”).

•Fuelgaugeinrighthandfueltank.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

–Kohler:15amps

–Briggs&Stratton:20amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:

–Kohler:

One15ampandtwo20ampbladetype

–Briggs&Stratton:

One15amp,one20amp,andone30amp
bladetype

SafetyInterlockSystem

•PTOmustbedisengaged,brakeengaged,and
motioncontrolleversout(neutrallock)tostart
engine.(Itisnotnecessaryfortheoperatortobe
intheseattostarttheengine.)

•OperatormustbeinseatwhenPTOisengaged,
brakeisdisengaged,ormotioncontrolleversare
movedinorenginewillstop.

•Enginewillstopifthemotioncontrollevers
aremovedfromneutralpositionwhilebrakeis
engaged.

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto
threeheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe
respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementLever:EngagesdrivetoPTO
(mowerdeck).

•ParkingBrakeLever:Engagesparkingbrakeby
pullingback.

Seat

•Type:Standardseatwithhighback,foampadded
(internalsuspension)andarmrestsandintegral
safetyswitch.

Optionalseataccessories:

–Customridesuspensionsystemtoenhance

StandardSeat.

–Deluxesuspensionseatwithhighback,low

prolefoam-in-placecushion(dampened,
adjustablespringsuspension)andarmrests.

14

Specications

•Mounting:Hingedtotiltupforaccessto
hydraulicpumps,batteryandothercomponents.
Theseatisheldinthetiltedpositionwitha
linkage.Adjustableforeandaftseattrack.

•Armrests:Standardseat:foampaddedip-up
armrests.Optionalsuspensionseat:molded
adjustableip-uparmrests.

•SeatSafetySwitch:Internaltothebottomseat
cushion,nonserviceable.Timedelaymodule
incorporatedintotheSafetyInterlockSystem
eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:

–27HPKohler&31HPBriggs&Stratton

Units:TwoHydroGearPR16ccvariable
displacementpistonpumps.

–23HPKohlerUnits:TwoHydroGearPJ

12ccvariabledisplacementpistonpumps.

•WheelMotors:HydroGearplanetaryreduction
motors.

•HydraulicOilType:UseMobil115W-50
Syntheticmotoroil.

•HydraulicOilCapacity:

–27HPKohler&31HPBriggs&Stratton

Units:5.2qt.(4.9L)

–23HPKohlerUnits:4.0qt.(3.8L)

•HydraulicFilter:Replaceablecartridgetype.

P/N103-2146:25microns,Nobypass

•Speeds:

–27HPKohler&31HPBriggs&Stratton

Units:

0-10.5mph(16.9km/hr)forward

0-6.6mph(10.6km/hr)reverse

–23HPKohlerUnits:

0-8.7mph(14.0km/hr)forward

0-5.7mph(9.2km/hr)reverse

•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.

Tires&Wheels

27HPKohler&31HPBriggs&StrattonUnits

Drive

Front
Caster

RearCaster
(DualTail
Wheel)

Pneumatic
(Air-Filled)

Semi­Pneumatic

Semi­Pneumatic

Quantity

222

TreadAT101

SmoothSmooth

Size24x

12.00-12

9x3.50-413x6.5-6

PlyRating

4

Pressure

9psi
(62kPa)

23HPKohlerUnits

Drive

Front
Caster

RearCaster
(SingleTail
Wheel)

Pneumatic
(Air-Filled)

Semi­Pneumatic

Semi­Pneumatic

Quantity

221

Tread

TurfmateSmoothSmooth

Size23x

10.50-10

9x3.50-413x6.5-6

PlyRating

4

Pressure

13psi
(90kPa)

CuttingDeck

(SoldSeparately)

•ModelNumbers:

–FR524

–FR604

–FR724

•CuttingWidth:

–52inch(132cm)

–60inch(152cm)

–72inch(183cm)

•Discharge:Side

•BladeSize:(3ea.)

–52inchDeck:18.00inches(45.7cm)

15

Specications

–60inchDeck:20.50inches(52.1cm)

–72inchDeck:24.50inches(62.2cm)

•BladeSpindles:Solidsteelspindleswith13/4
inch(4.45cm)I.D .bearings.

•DeckDrive:“B”-Sectionbeltfromjackshafton
decktobladespindles.

•Deck:Fulloatingdeckisattachedtoout-front
supportframe,removableforservice.Six
anti-scalprollersprovidemaximumturf
protection.Deckdesignallowsforbagging,
mulchingorsidedischarge.

•DeckDepth:

–52inchDeck:5.5inches(14.0cm)

–60inchDeck:5.5inches(14.0cm)

–72inchDeck:5.5inches(14.0cm)

•CuttingHeightAdjustment:Adjustsfrom11/2
inches(3.8cm)to5inches(12.7cm)innitely
variable.

•MulchingKit:Optional

•Bagger:Optional

Dimensions

OverallWidth:

52inch
Deck

60inch
Deck

72inch
Deck

Without
Deck

49.0inches
(124.5cm)

49.0inches
(124.5cm)

53.0inches
(135cm)

Deector
Up

53.3inches
(135.4cm)

61.4inches
(156cm)

73.4inches
(186cm)

Deector
Down

64.0inches
(163cm)

72.0inches
(183cm)

84.3inches
(214cm)

OverallLength:

23HPKohler27HPKohler&

31HPBriggs&
Stratton

Withoutdeck
andoorpan
folded

80.4inches
(204.2cm)

82.3inches
(209.0cm)

52inchDeck112.4inches

(285.5cm)

114.3inches
(290.3cm)

23HPKohler27HPKohler&

31HPBriggs&
Stratton

60inchDeck112.4inches

(285.5cm)

114.3inches
(290.3cm)

72inchDeck114.3inches

(290.3cm)

OverallHeight:

RollBar-UpRollBar-Down

69.2inches(175.8cm)50.7inches(128.8cm)

TreadWidth:(CentertoCenterof
Tires,Widthwise)

27HPKohler&31HPBriggs&StrattonUnits

52inchDeck60inchDeck72inchDeck

41.4inches
(105.2cm)

41.4inches
(105.2cm)

45.4inches
(115.3cm)

23HPKohlerUnits

52inchDeck60inchDeck72inchDeck

38.9inches
(98.8cm)

38.9inches
(98.8cm)

WheelBase:(CenterofCasterTireto
CenterofDriveTire)

•27HPKohler&31HPBriggs&StrattonUnits:

51.2inches(130.0cm)

•23HPKohlerUnits:54.1in(137.4cm)

MinimumTurningRadius

•27HPKohler&31HPBriggs&StrattonUnits:

55.25inches(140.3cm)

•23HPKohlerUnits:56.3in(143.0cm)

CurbWeight:

Withoutdeck911lb(413kg)

52inchDeck

1303lb(591kg)

60inchDeck

1348lb(611kg)

72inchDeck

1397lb(634kg)

16

ProductOverview

TorqueRequirements

BoltLocation

Torque

EngineMountingBolts

30-35ft-lb(41-47N-m)

WheelLugNuts

90-95ft-lb(122-129N-m)

WheelMotorMounting
Bolts

72-77ft-lb(98-104N-m)

WheelHubLockNut210-250ft-lb

(285-339N-m)

RolloverProtectionSystem
(RollBar)MountingBolts

30-35ft-lb(41-47N-m)

ClutchRetainingBolt
(securedwiththreadlocker)

55-60ft-lb(75-81N-m)

ProductOverview

Figure4

1.FuelCap4.SeatBelt

2.RollBar

5.MotionControlLever

3.Controls

6.ParkingBrakeLever

17

Operation

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideofthe
consolecontroltheforwardandreversemotionof
themachine.Theleverscontroltheowofhydraulic
oilfromthehydrostaticpumptothedrivewheel
motorforeachside.

Movingtheleversforwardorbackwardturnsthe
wheelonthesamesideforwardorinreverse.Wheel
speedisproportionaltotheamounttheleveris
moved.

Movingtheleversoutwardfromthecenterposition
intotheT-slotlocksthemintheneutralposition
(Figure6).

ChokeControl

Locatedonrightfueltankconsole.

Thechokeisusedtoaidinstartingacoldengine.
Movingthechokeleverforwardwillputthechokein
the“ON”positionandmovingthechokelevertothe
rear,tothedetent,willputthechokeinthe“OFF”
position.DoNotrunawarmenginewithchokein
the“ON”position.

ThrottleControl

Locatedonrightfueltankconsole.

Thethrottleisusedtocontrolenginespeed.Moving
thethrottleleverforwardwillincreaseenginespeed
andmovingthethrottlelevertotherearwilldecrease
enginespeed.Movingthethrottleforwardintothe
detentisfullthrottle.

ParkBrakeLever

Locatedonleftsideofunit,betweentheseatandthe
dummytank.

Thebrakeleverengagesaparkingbrakeonthedrive
wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe
brake.

Theunitmustbetieddownandbrakeengagedwhen
transporting.

IgnitionSwitch

Locatedonrightfueltankconsole.

Theignitionswitchisusedtostartandstopthe
engine.Theswitchhasthreepositions“OFF”,“ON”
and“START”.Insertkeyintoswitchandrotate
clockwisetothe“ON”position.Rotateclockwiseto
thenextpositiontoengagethestarter(keymustbe
heldagainstspringpressureinthisposition).

Note:Brakemustbeengaged,motioncontrollevers
out(neutrallockposition),andPTOswitch“OFF”
tostartengine.(Itisnotnecessaryfortheoperator
tobeintheseattostarttheengine.)

HourMeter

Locatedontherightfueltankconsole.

Thehourmeterisconnectedtoapressureswitch
installedintheengineblockanditrecordsthe
numberofhoursthattheenginehasrun.Ifthe
ignitionswitchisleftonwithoutenginerunning,
hourmeterwillnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot
alerttheoperatoriftheengineoilislow .

FuelShut-OffValve

Locatedinfuellinebyfueltankandfuellter.

Thefuelshut-offvalveisusedtoshutoffthefuel
whenthemachinewillnotbeusedforafewdays,
duringtransporttoandfromthejobsite,andwhen
parkedinsideabuilding.

Rotatethevalve1/4turnclockwisetoshutofffuel.
Rotatethevalve1/4turncounterclockwisetoturn
onfuel.

FuelGauge

Locatedattherearoftherightfueltank.

Thefuelgaugemonitorstheamountoffuelinthe
rightfueltankonly .Thelefttankdoesnotholdfuel.

18

Operation

DriveWheelReleaseValves

Locatedonthetopleftfrontcornerofhydrostatic
pumps.

Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
pushedwithouttheenginerunning.

Withawrench,turnbothvalvesoneturn
counterclockwisetoreleasedrivesystem.Turn
clockwisetoresetsystem.DoNotovertighten.Do

Nottowmachine.

•For27HPKohler&31HPBriggs&Stratton
Units:Usea5/8inchwrenchtoturnthevalves.

•For23HPKohlerUnits:Usea7/16inchwrench
toturnthevalves.

PTOEngagementSwitch

Locatedonrightfueltank.

Switchmustbepulledouttothe“ROTATE”
positiontoengagetheblades.Switchispushedinto
the“STOP”positiontostoptheblades.

HydraulicLiftSwitch

Locatedonrightfueltankconsole.

Thehydraulicliftswitchisusedtoraiseandlower
themowerdeck.

Pushthefrontportionofthehydraulicliftswitch
downtoraisethemowerdecktothedesiredheight.

Pushtherearportionofthehydraulicliftswitch
downtolowerthemowerdecktothedesiredheight.

Pre-Start

Fillfueltanks.Forbestresultsuseonlyclean,fresh
regulargradeunleadedgasolinewithanoctanerating
of87orhigher.Regulargradeleadedgasolinemay
alsobeused;however,combustionchamberand
cylinderheadwillrequiremorefrequentservice.See
EngineOwner’sManual.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

thatthefuellevelrisesabovealevelthatis1/2inch
(13mm)belowthebottomofthellernecktoallow
forfuelexpansionandpreventfuelspillage.

Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.

RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem
(ROPS)

Important:Lowertherollbaronlywhen

absolutelynecessary.

1.Removethehairpincotterpinsandremovethe
tworollbarpins(Figure5).

2.Raisetherollbartotheuprightpositionand
installthetwopinsandsecurethemwiththe
hairpincotterpins(Figure5).

Important:Alwaysusetheseatbeltwiththe
rollbarintheraisedposition.Ensurethatthe
rearpartoftheseatissecuredwiththeseat
latch.

Figure5

1.Rollbar3.Pin

2.Raisedposition4.Hairpincotterpin

19

Operation

OpentheFuelShut-OffValve

Thefuelshut-offvalveislocatedontherightsideof
unitinfuellinenexttothefuellter.Raisetherear
hoodtoaccessfuelshut-offvalve.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral
lockposition.

2.Pullupandbackontheparkingbrakeleverto
engagetheparkingbrake.

3.PushinonthePTOswitchtothe“STOP”
position.

Note:Itisnotnecessaryfortheoperatortobe
intheseattostarttheengine.

4.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.

5.Onacoldengine,pushthechokeleverforward
intothe“ON”position.

Onawarmengine,leavethechokeinthe“OFF”
position.

6.Turnignitionswitchtothe“START”position.
Releasetheswitchassoonastheenginestarts.

Important:DoNotcranktheengine
continuouslyformorethantensecondsata
time.Iftheenginedoesnotstart,allowa60
secondcool-downperiodbetweenstarting
attempts.Failuretofollowtheseguidelines
canburnoutthestartermotor.

7.Ifthechokeisinthe“ON”position,gradually
returnchoketothe“OFF”positionastheengine
warmsup.

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.

DANGER

Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryordeath.

Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunless
thereisagrasscollectionsystemormulch
kitinplaceandworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades.
Besurethatallpersonsareclearofthemowerdeck
anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe
PTOcanbeengaged.

1.Setthethrottletothe“MIDWAY”position.

2.PullthePTOswitchoutwardtothe“ROTATE”
position.

3.Placethethrottleinthe“FAST”positiontobegin
mowing.

DisengagingthePTO

1.Setthethrottletothe“MIDWAY”position.

2.PushthePTOswitchintothe“STOP”position
todisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movethemotioncontrolleversouttotheneutral
lockposition.

4.Engagetheparkingbrake.

5.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.

6.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalvewhenthemachine
willnotbeinuseforafewdays,when
transporting,orwhentheunitisparkedinside
abuilding.

20

Operation

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioning
onelevertoomuchaheadoftheother.
Operatormaylosecontrolofthemachine,
whichmaycausedamagetothemachine
orinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking
sharpturns.

Important:Tobeginmovement(forwardor
backward)theoperatormustbeintheseat,the
brakelevermustbedisengaged(pusheddown)
beforethemotioncontrolleverscanbemovedin
ortheenginewillstop.

WhenleversarecenteredintheT-slotthedrive
systemisintheneutralposition.Withleversmoved
outintheT-slotthedrivesystemisintheneutrallock
position(Figure6).

Figure6

1.HandlesOut(Neutral
Lock)

5.Neutral

2.HandlesIn(Neutral)

6.Reverse

3.FrontofUnit

7.NeutralLock

4.Forward

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe
centertotheneutralunlockedposition.

3.Tomoveforwardinastraightlineapplyequal
forwardpressuretobothlevers.

Toturnleftorright,pullthemotioncontrollever
backtowardneutralinthedirectiondesired.

Themachinewillmovefasterthefartherthe
motioncontrolleversaremovedawayfrom
neutral.

4.Tostop,pullthemotioncontrolleversbackto
theneutralposition.

Figure7

1.HandlesOut(Neutral
Lock)

4.Forward

2.HandlesIn(Neutral)

5.Reverse

3.FrontofUnit

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe
centertotheneutralunlockedposition.

2.Tomoverearwardinastraightlineapplyingequal
pressurepullbothmotioncontrolleversrearward.

Toturnleftorright,releasepressureonthe
motioncontrollevertowardthedirectiondesired.

3.Tostop,pushthemotioncontrolleverstothe
neutralposition.

21

Operation

Transporting

TransportingaUnit

Important:DoNottransportFrontRunner

tractorwithoutanapprovedExmarkfrontmount
attachment.

Useaheavy-dutytrailerortrucktotransportthe
machine.Lockbrakeandblockwheels.Securely
fastenthemachinetothetrailerortruckwithstraps,
chains,cable,orropes.Besurethatthetrailerortruck
hasallnecessarylightingandmarkingasrequiredby
law .Secureatrailerwithasafetychain.

CAUTION

Thisunitdoesnothaveproperturn
signals,lights,reectivemarkings,ora
slowmovingvehicleemblem.Drivingona
streetorroadwaywithoutsuchequipment
isdangerousandcanleadtoaccidents
causingpersonalinjury.Drivingonastreet
orroadwaywithoutsuchequipmentmayalso
beaviolationofStatelawsandtheoperator
maybesubjecttotrafcticketsand/ornes.

DoNotdriveaunitonapublicstreetor
roadway.

WARNING

Loadingaunitonatrailerortruckincreases
thepossibilityoftip-over.Tip-overcould
causeseriousinjuryordeath.

•Useextremecautionwhenoperatinga
unitonaramp.

•Useonlyasingle,fullwidthramp;Do
Notuseindividualrampsforeachside
oftheunit.

•Ifindividualrampsmustbeused,use
enoughrampstocreateanunbroken
rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp
andgroundorbetweenrampandtrailer
ortruck.

•Avoidsuddenaccelerationwhiledriving
unitonaramp.

LoadingaUnit

Useextremecautionwhenloadingunitsontrailers
ortrucks.Onefullwidthrampisrequired.Ifitis
notpossibletouseonefullwidthramp,useenough
individualrampstosimulateafullwidthcontinuous
ramp.

Rampshouldbelongenoughsothattheangles
betweentherampandthegroundandtherampand
thetrailerortruckdonotexceed15°.Asteeperangle
maycausemowerdeckcomponentstogetcaughtas
theunitmovesfromramptotrailerortruck.Steeper
anglesmayalsocausetheunittotip.Ifloadingonor
nearaslope,positionthetrailerortrucksoitison
thedownsideoftheslopeandtherampextendsup
theslope.Thiswillminimizetherampangle.The
trailerortruckshouldbeaslevelaspossible.

Important:DoNotattempttoturntheunit
whileontheramp,youmaylosecontroland
driveofftheside.

Avoidsuddenaccelerationwhendrivingonaramp.

22

Maintenance

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch,
engageparkingbrake,andpullthewire(s)
offthesparkplug(s)beforeyoudoany
maintenance.Alsopushthewire(s)aside
soitdoesnotaccidentallycontactthespark
plug(s).

WARNING

Theenginecanbecomeveryhot.Touching
ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst5hours

•Changetheengineoil.

Aftertherst100hours

•Checkthewheelhublocknutstorquespecication.

Aftertherst250hours

•Changethehydrauliclter.

Beforeeachuseordaily

•Checktheengineoillevel.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)pins.

•Checktheseatbelt.

•Checkforloosehardware.

•Cleantheenginecoolingsystem.

•Removeaccumulateddebrisfromengine.

Every40hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasehitchandcylinderpivots.

•Greasethedualtailwheelpivot(ifapplicable).

Every50hours

•Servicetheaircleaner.(Mayneedmoreoftenundersevereconditions.SeetheEngine
Owner’sManualforadditionalinformation.)

Every80hours

•Removetheengineshroudsandcleanthecoolingns.

Every100hours

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Greasethefoldpivotpin.

Every160hours

•Lubricatethebrakehandlepivot.

•Lubricatethebrakerodbushings.

•Lubricatethemotioncontrolbronzebushings.

•Lubricatethesteeringlinkagerodends.

•Checkthesparkplugs.

Every500hours

•Checkthewheelhublocknutstorquespecication.

23

Maintenance

MaintenanceService

Interval

MaintenanceProcedure

Monthly

•Checkthebatterycharge.

Yearly

•Greasethefoldlockpin.

•Greasetherearcasterpivot.

•Greasethebeltidlers.

•Greasethemotioncontrolpivots.

•Greasethetransferspringends.

•Lubricatethecasterwheelhub(s).

•Lubricatethemotioncontrolshaft.

•Changethehydrauliclter.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.

2.Tiltseatforwardandraisehoodtogainaccess
toaccesstoenginearea.

3.Checkwithenginecold.

4.Cleanareaarounddipstick.Removedipstickand
wipeoiloff.Reinsertthedipstickandpushitall
thewaydownintothetube.Removethedipstick
andreadtheoillevel.

5.Iftheoillevelislow ,wipeofftheareaaroundthe
oilllcap,removecapandlltothe“FULL”
markonthedipstick.Useoilasspeciedin
EngineOwner’ sManual.DoNotoverll.

Important:DoNotoperatetheenginewiththe
oillevelbelowthe“LOW”(or“ADD”)markon
thedipstick,oroverthe“FULL”mark.

CheckBatteryCharge

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof
timewithoutrechargingthemwillresultinreduced
performanceandservicelife.Topreserveoptimum
batteryperformanceandlife,rechargebatteriesin
storagewhentheopencircuitvoltagedropsto12.4
volts.

Note:Topreventdamageduetofreezing,battery
shouldbefullychargedbeforeputtingawayfor
winterstorage.

Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebatteryin
thetableandchargethebatteryfortherecommended
timeintervaltobringthechargeuptoafullcharge
of12.6voltsorgreater.

Important:Makesurethenegativebattery
cablesaredisconnectedandthebatterycharger
usedforchargingthebatteryhasanoutputof
16voltsand7ampsorlesstoavoiddamaging
thebattery(seechartforrecommendedcharger
settings).

24

Maintenance

Voltage
Reading

Percent
Charge

Maximum
Charger
Settings

Charging
Interval

12.6or
greater

100%

16volts/7
amps

No
Charging
Required

12.4–12.675–100%

16volts/7
amps

30Minutes

12.2–12.450–75%

16volts/7
amps

1Hour

12.0–12.225–50%

14.4volts/4
amps

2Hours

11.7–12.00–25%

14.4volts/4
amps

3Hours

11.7orless

0%

14.4volts/2
amps

6Hoursor
More

CheckSafetyInterlock
System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

1.Checkstartingcircuit.Startershouldcrankwith,
parkingbrakeengaged,PTOdisengagedand
motioncontrolleversmovedoutintheneutral
lockposition.Theoperatordoesnotneedtobe
intheseattostarttheengine.

Trytostartwithoperatorinseat,parkingbrake
disengaged,PTOdisengagedandmotioncontrol
leversintheneutrallockposition-startermust
notcrank.

Trytostartwithoperatorinseat,parkingbrake
engaged,PTOengagedandmotioncontrol
leversintheneutrallockposition-startermust
notcrank.

Trytostartwithoperatorinseat,parking
brakeengaged,PTOdisengaged,andtheleft
motioncontrolleverin,startermustnotcrank,
repeatagainwiththerightleverin,thenwith
bothleversin-startermustnotcrank.

2.Checkthekillcircuits.Runengineatone-third
throttle,disengageparkingbrakeandraiseoff
ofseat(butdonotgetoffofmachine)engine
mustinitiateshutdownafterapproximately1/2
secondhaselapsed(seathastimedelaykillswitch
topreventcut-outsonroughterrain).

Runengineatone-thirdthrottle,engagePTO
andraiseoffofseat(butdonotgetoffof
machine)enginemustinitiateshutdownafter
1/2secondhaselapsed.

Runengineatone-thirdthrottle,withbrake
disengaged,moveleversinandraiseoffseat(but
donotgetoffofmachine)enginemustinitiate
shutdownafter1/2secondhaselapsed.

Again,runengineatone-thirdthrottle,brake
engaged,andmoveleftmotioncontrolleverin

-enginemustinitiateshutdown.

Repeatagainmovingtherightleverin,then
movingbothleversin-enginemustinitiate
shutdownwhetheroperatorisonseatornot.

3.CheckthePTOcircuit.SeetheFR524,FR604,
andFR724Operator’ smanualtobecomefamiliar
withthedeckoperation.Openthefolding
decklatches,disengagetheparkbrake,move
themotioncontrolleversintoneutral,and
disengagethePTO.Lowerthedeckuntilthe
PTOswitcharmisnolongerdepressingthePTO
“kill”switch(seeFigure8).

Figure8

LeftSide—InsideofHitchShown

1.PTO“Kill”Switch

2.PTOSwitchArm

3.LowerdeckuntilarmDoesNotcontacttheswitch.

Runtheengineathalfthrottleandpulluponthe
PTOengagementswitch.

ThePTOmustnotengage.

25

Maintenance

Note:Ifmachinedoesnotpassanyofthesetests,

DoNotoperate.ContactyourauthorizedEXMARK
SERVICEDEALER.

Important:Itisessentialthatoperatorsafety
mechanismsbeconnectedandinproper
operatingconditionpriortouseformowing.

CheckRolloverProtections
Systems(RollBar)Pins

ServiceInterval:Beforeeachuseordaily

Makesurelatchpinandhairpinarefullyinstalled
andlanyardisingoodcondition.

CheckSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper
operationofretractorandbuckle.Replacebefore
operatingifdamaged.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every50hours(May

needmoreoftenunder
severeconditions.See
theEngineOwner’s
Manualforadditional
information.)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Tiltseatforwardandraisehoodtogainaccess
totheaircleaner.

•For27HPKohler&31HPBriggs&Stratton
Units:

A.Loosenretainingclipsandremoveair

cleanercompartmentcover.

B.Removepaperelement.Checkthe

conditionofthepaperelement.Replaceif
dirty,bentordamaged.

C.Checktheconditionoftheinnerelement.

Replacewheneveritappearsdirty,typically
everyothertimethepaperelementis
replaced.Cleanthebasearoundtheinner
elementbeforeremoving,sodirtdoesnot
getintotheengine.

D.DoNotwashorusepressurizedairto

cleanpaperelementorinnerelement.

E.Reinstallelements.Positionthecoverso

thattherubberdustejectorispointing
downwardandsecurewithretainingclips.

•For23HPKohlerUnits:

A.Removefoampre-cleanerelementand

washinwarmwaterwithdetergent.Rinse
untilalltracesofdetergentareeliminated
andsqueezeoutexcesswater(DoNot
wring).Airdry.Saturatewithengineoil
andsqueezeoutexcessoil.

B.Checkpaperelement.DoNotwashor

usepressurizedairtocleanpaperelement.
Replaceifdirty,bentordamaged.

C.Reinstallfoampre-cleanertopaper

element,thenreinstallpaperelementand
cover.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours/Yearly
(whichevercomesrst)
(Mayneedmoreoften
undersevereconditions.)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Tiltseatforwardandraisehoodtogainaccess
totheenginearea.

3.Drainoilwhileengineiswarmfromoperation.

4.Fithoseinliteraturepackoveroildrainvalve.
Rotatethevalve1/4counterclockwiseandgently
pulloutwardtoopenthevalve.Allowtheoilto
drain,thenclosethevalvebypushinginwardand
rotating1/4turnclockwise.Removeandretain
thehoseforfutureuse.

26

Maintenance

5.Replacetheoilltereveryotheroilchange.Clean
aroundoillterandunscrewltertoremove.
Beforereinstallingnewlter,applyathincoating
ofoilonthesurfaceoftherubberseal.Turn
lterclockwiseuntilrubbersealcontactsthelter
adapterthentightenlteranadditional2/3to
3/4turn.

6.Cleanaroundoilllcapandremovecap.Fillto
speciedcapacityandreplacecap.

7.Useoilrecommendedinengineowner’smanual.
DoNotoverll.Starttheengineandcheckfor
leaks.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.

2.Tiltseatup.

3.Cleanareaaroundhydraulicreservoircapand
removecap.Oillevelshouldbetothetopofthe
bafeinsidethetank.Ifnot,addoil.Useonly
Mobil115W -50syntheticmotoroil.Replace
hydraulicreservoircapandtightenuntilsnug.Do
Notovertighten.

Note:Thebafeislabeled“HOT”and
“COLD”.Theoillevelvarieswiththe
temperatureoftheoil.The“HOT”levelshows
thelevelofoilwhenitisat225°F(107°C).The
“COLD”levelshowstheleveloftheoilwhen
itisat75°F(24°C).Filltotheappropriatelevel
dependinguponthetemperatureoftheoil.For
example:Iftheoilisabout150°F(65°C),llto
halfwaybetweenthe“HOT”and“COLD”levels.
Iftheoilisatroomtemperature(about75°F
(24°C)),llonlytothe“COLD”level.

CheckAuxiliaryHydraulic
OilLevel

ServiceInterval:Asrequired

Note:Checktheauxiliaryhydraulicoillevelifthere

isevidenceofaleakorthehydrauliccylinderdoes
notperformnormally.

1.Retractthehydrauliccylinder.

2.Stopengineandwaitforallmovingpartstostop.

3.Tilttheseatforward.

4.Locatetheauxiliaryhydraulicpowerunitreservoir
(seeFigure9).

Figure9

1.Auxiliaryhydraulicreservoirplug

5.Cleanareaaroundthereservoirplugandremove.
Oillevelshouldbeuptothereservoirplughole.
Ifnot,addoil.UseonlyMobil115W-50synthetic
motoroil.Replacereservoirplugandtightenuntil
snug.DoNotovertighten.

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

•For23HPKohlerUnits:Thedrivetires
shouldbeinatedto13psi(90kpa).

•For27HPKohler&31HPBriggs&Stratton
Units:Thedrivetiresshouldbeinatedto9
psi(62kpa).

3.Therearcastertire(s)issemi-pneumaticanddoes
notneedtobeinated.

Note:DoNotaddanytypeoftirelinerorfoam
llmaterialtothetires.Excessiveloadscreatedby

foamlledtiresmaycausefailurestothehydrodrive
system,frame,andothercomponents.Foamlling
tireswillvoidthewarranty.

27

Maintenance

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.CheckpumpandPTOdrivebelts.

3.Beltsarespringtensionedandnoadjustmentis
necessary.SeePumpDriveBeltTensionand
ReplacementsectionsinAdjustments.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Lubricatettingswithonetotwopumpsof
NGLIgrade#2multi-purposegungrease.

Refertothefollowingchartforttinglocations
andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.Hitch
andCylinder
Pivots

2

440Hours

2.Fold
PivotPin

22

100Hours

3.Fold
LockPin

22

Yearly

4.Rear
CasterPivot

*0

1

*Yearly

5.Belt
Idlers

12

Yearly

6.Motion
Control
Pivots

12

Yearly

7.Transfer
SpringEnds

1

4

Yearly

8.Dual
TailWheel
Pivot(if
applicable)

21

40Hours

*Seestep3forspeciallubricationinstructions
ontherearcasterpivotsandtheLubricateRear
CasterWheelHubsectionforspeciallubrication
instructionsontherearcasterswheelhub.

3.Lubricatefrontcasterpivotsonceayear.Remove
hexplugandcap.Threadgreasezerkinholeand
pumpwithgreaseuntilitoozesoutaroundtop
bearing.Removegreasezerkandthreadplugback
in.Placecapbackon.

LubricateRearCasterWheel
Hub(s)

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

Figure10

1.Sealguard2.Spacernutwithwrench
ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

4.Removeoneofthespacernutsfromtheaxle
assemblyinthecasterwheel.Notethatthread
lockingadhesivehasbeenappliedtolockthe

28

Maintenance

spacernutstotheaxle.Removetheaxle(with
theotherspacernutstillassembledtoit)from
thewheelassembly .

5.Pryoutseals,andinspectbearingsforwearor
damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1
multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Seals(ExmarkP/N103-0063)mustbe
replaced.

8.Iftheaxleassemblyhashadbothspacernuts
removed(orbrokenloose),applyathreadlocking
adhesivetoonespacernutandthreadontothe
axlewiththewrenchatsfacingoutward.Do
Notthreadspacernutallofthewayontotheend
oftheaxle.Leaveapproximately1/8inch(3mm)
fromtheoutersurfaceofthespacernuttothe
endoftheaxleinsidethenut.

9.Inserttheassemblednutandaxleintothewheel
onthesideofthewheelwiththenewsealand
bearing.

10.Withtheopenendofthewheelfacingup,ll
theareainsidethewheelaroundtheaxlefullof
NGLIgrade#1multi-purposegrease.

11.Insertthesecondbearingandnewsealintothe
wheel.

12.Applyathreadlockingadhesivetothe2ndspacer
nutandthreadontotheaxlewiththewrenchats
facingoutward.

13.T orquethenutto75-80in-lb(8-9N-m),loosen,
thenre-torqueto20-25in-lb(2-3N-m).Make
sureaxledoesnotextendbeyondeithernut.

14.Reinstallthesealguardsoverthewheelhuband
insertwheelintocasterfork.Reinstallcasterbolt
andtightennutfully .

Important:Topreventsealandbearingdamage,
checkthebearingadjustmentoften.Spinthe
castertire.Thetireshouldnotspinfreely
(morethan1or2revolutions)orhaveanyside
play.Ifthewheelspinsfreely,adjusttorqueon
spacernutuntilthereisaslightamountofdrag.
Reapplythreadlockingadhesive.

LubricateBrakeHandlePivot

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Tiltseatforward.

3.Lubricatebronzebushingsonbrakehandlepivot
withaspraytypelubricantorlightoil.

LubricateBrakeRod
Bushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Tiltseatforwardandraisehood.

3.Lubricatebronzebushingsoneachendofthe
brakerodshaftwithaspraytypelubricantor
lightoil(bushingsarelocatedtotheinsideofthe
angebearings).

LubricateMotionControl
BronzeBushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsonangebearings
securingthemotioncontrolarmshaftswitha
lightoiloraspraytypelubricant.

LubricateMotionControl
Shaft

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Tiltseatforward.

3.Removetabatrearofmotioncontrolshaft.

4.Pullmotioncontrolshaftoutandlubricatewith
anNGLIgrade#2multi-purposegungrease.

5.Re-installshaftandtab.

LubricateSteeringLinkage
RodEnds

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

29

Maintenance

2.Tiltseatforward.

3.Lubricateeachendofbothsteeringlinkagerods
withaspraylubricantorlightoil

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps,
orreplacewithnewplugs.SeeEngineOwner’s
Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltanksandthe
engine.Replacewhennecessary.

ReplacementFilters

KohlerKohler

P/N2405010–15Micron

Briggs&Stratton

Briggs&Stratton

P/N695327–30Micron

ChangeHydraulicSystem
Filter

ServiceInterval:Aftertherst250hours

Yearlythereafter

Note:UseonlyExmarkPartNo.103-2146.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Carefullycleanareaaroundlter.Itisimportant
thatnodirtorcontaminationenterhydraulic
system.

3.Unscrewltertoremoveandallowoiltodrain
fromreservoir.

Important:Beforereinstallingnewlter,ll
itwithMobil115W-50andapplyathincoat
ofoilonthesurfaceoftherubberseal.

Turnlterclockwiseuntilrubbersealcontactsthe
lteradapter,thentightenthelteranadditional
2/3to3/4turn.

4.FillreservoirasstatedinCheckHydraulicOil
Levelsection.

5.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely.

CAUTION

Raisingthemowerforserviceormaintenance
relyingsolelyonmechanicalorhydraulic
jackscouldbedangerous.Themechanicalor
hydraulicjacksmaynotbeenoughsupport
ormaymalfunctionallowingtheunittofall,
whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport

6.Startengineandmovethrottlecontrolaheadto
fullthrottleposition.Movethespeedcontrol
leverstothefullspeedandrunforseveral
minutes.Shutdownmachineandrecheckoil
level.

Note:DoNotchangehydraulicsystemoil(except
forwhatcanbedrainedwhenchanginglter),unless
itisfelttheoilhasbeencontaminatedorbeen
extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic
systembyintroducingcontaminatesintothesystem.

CheckWheelHubLocknuts

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningthelocknutonthewheelmotor
taperedshaft:

Torqueto210-250ft-lb(285-339N-m).

Note:DoNotuseantiseizeonwheelhub.

FuelTank—Mounting
HardwareSpecications

ServiceInterval:Asrequired

Wheninstallingthenutsonthefueltankstuds,fully
tightenthenylocnutandbackoff1/2turn.This
allowsfornormalfueltankexpansionandcontraction
withchangesintemperatureandfuellevels.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242”
or“Fel-Pro,Pro-LockNutType”areusedonthe
followingfasteners:

30

Maintenance

•Pumpdrivesheavesetscrews.

•Lineshaftsheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol
arms.

•Sheaveretainingboltintheendofengine
crankshaft.

•Casterwheelspacernuts.

•Fueltankbulkheadttingnuts.

•Motioncontroltabretainingbolt.

Adhesivessuchas“LoctiteRC/609orRC/680”or
“Fel-ProPro-LockRetainingIorRetainingII”are
usedonthefollowing:

Fueltankstuds,wherestudsareinsertedintotank.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical
connectionstopreventcorrosionandlossofcontact.

Adjustments

Note:DisengagePTO,shutoffengine,waitfor
allmovingpartstostop,engageparkingbrake,and
removekeybeforeservicing,cleaning,ormakingany
adjustmentstotheunit.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

PumpDriveBelt
Replacement

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removepumpdrivebelt.

3.Routenewbeltontosheavesasshowninthe
decallocatedontherighthandsideoftheleft
hoodsupport(seeFigure11).

Figure11

ParkBrakeAdjustment

Checktomakesurebrakeisadjustedproperly.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Tiltseatforwardandraisehood.

3.Pullthebrakeleverupintotheengagedposition.

4.Locatetheparkbrakespringassembly(see
Figure12).Thereshouldbeagapof1/8inch(3
mm)betweentheyokeandthinnylocnutonthe
brakebolt.Ifnecessary,rotatethethinnylocnut
toobtainthe1/8inchgap.

31

Maintenance

Figure12

1.Parkbrakeengaged3.Thinnylocnut

2.Yoke

4.1/8inch(3mm)gap
betweennutandyoke.

5.Ifparkbrakedoesnotfullydisengagewhenthe
leverisdisengagedcheckthebrakerodlinkage
assembly.Theassemblyshouldmeasure73/8
inch(18.7cm)fromthecenteroftheballjoint
tothecenterofthelowerendofthelinkagerod
(seeFigure13).

Figure13

1.Balljoint3.Parkbrakelinkagerod

2.Jamnut

4.73/8inch(18.7cm)

6.Ifthelinkagedoesnotmeasure73/8inch
(18.7cm)orstilldoesnotdisengageasdesired,

removetheboltthatsecurestheballjointto
thebrakeleverandloosenthejamnutnextto
theballjoint.Rotatetheballjointinhalf-turns
counterclockwiseuntildesireddisengagementis
obtained.

MotionControlLinkage
Adjustment

WARNING

Enginemustberunninganddrive
wheelsmustbeturningsomotioncontrol
adjustmentcanbeperformed.Contactwith
movingpartsorhotsurfacesmaycause
personalinjury

Keepngers,hands,andclothingclearof
rotatingcomponentsandhotsurfaces.

1.Thisadjustmentmustbemadewiththedrive
wheelsturning.Firstraisetheframeandblockup
sothatdrivewheelscanrotatefreely.

2.Removetheelectricalconnectionfromtheseat
safetyswitch,locateddirectlyinfrontoftheseat
switchassembly.

3.Temporarilyinstallajumperwireacrossthe
terminalsintheconnectorofthemainwiring
harness.

4.Starttheengine.

5.Runtheunitatleast5minuteswiththedrive
leversatfullforwardspeedtobringhydraulic
systemoiluptooperatingtemperature.

6.Toobtaintheneutralposition,adjusttheleftand
rightpumpcontrolrodlinkagesthatconnectthe
steeringcontroltothepumpcontrolarmsuntil
thewheelsstop,orcreepslightlyinreverse.

7.Toadjusteachlinkage,loosenthejamnutnext
theballjointattheupperendofthelinkage
rodassembly.Thenrotatetheassemblyusinga
wrenchtoturnthedoublenutsontheassembly
(seeFigure14).

8.Re-tightenthejamnutagainsttheballjointon
eachside.

32

Maintenance

Figure14

1.Loosenjamnut

2.Pumpcontrolrodlinkage

3.Usewrenchtoturndoublenuts

9.Movethemotioncontrolleverstothereverse
position.Returnthemotioncontrolleversto
neutral.Thewheelsmuststopturning(orslightly
creepinreverse).

10.Stopengineandwaitforallmovingpartstostop.
Removejumperwirefromwireharnessconnector
andplugconnectorintoseatswitch.

11.Lowerfromjackstands.

WeightTransferSpring
Adjustment

Weighttransferspringsareassembledfromthe
factorytoapplythemaximumamountofweightonto
thedrivewheels.Thissettingprovidesthegreatest
amountoftraction.Someconditionsmayrequire
therearwheellifttobereduced.Thiscanbedone
byreducingtheamounttoweighttransfer,which
willincreasetheamountofweightonthefrontand
rearcasters.

1.Rotatetheleftmotioncontrolarmupandinto
theoperationposition.

2.Locateandloosentheknobundertherearofthe
leftfender(seeFigure15).

Figure15

1.Motioncontrollever3.Fenderknob

2.Leftfender

3.Slidethefenderforwardandtwistupwardand
outwardtoremove.

4.Toadjusttheweighttransfersprings,fold
themowerdeckandfrontframeandlockin
serviceposition.SeeDeckManualforcomplete
instructions.

WARNING

Weighttransferspringsmayhavestored
energy.Removingtheweighttransfer
springswithoutreleasingthestoredenergy
cancauseseriousinjury.

Foldmowerdeckandfrontframeandlockin
servicepositiontoremovespringtensionand
releasestoredenergybeforeperformingany
maintenanceoradjustmentsontheweight
transfersprings.(SeeDeckManualforDeck
Raisinginstructions).

5.Removetheretainingringandwasherateither
endoftheweighttransferspringthatretainsitto
thetransferbellcrankpinsand/orweighttransfer
springanchorpins(seeFigure16).

6.Pullthespringoffoffrontorrearpinand
re-installintheouterhole,toreducethespring
force.Re-installthewasherandretainingring.

33

Maintenance

Figure16

Right-HandSideofUnitShown

1.Re-installspringinouter
holestoreducespring
tension.

3.Removee-ringand
washer.

2.Weighttransferspring.

7.Re-installtheleftfender

8.Foradditionalweighttransferadjustment,repeat
steps4through7ontherightsideoftheunit.

CasterPivotBearings
Pre-LoadAdjustment

Removedustcapfromcasterandtightennylocnut
untilwashersareatandbackoff1/4ofaturn
toproperlysetthepre-loadonthebearings.If
disassembled,makesurethespringdiscwashersare
reinstalledasshowninFigure17.

Figure17

1.Springdiscwashers

Cleaning

CleanEngineCooling
System

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore
oftenindryordirty
conditions.)

CAUTION

Excessivedebrisaroundtheenginecooling
airintakeandinsideofthepumpdrive
beltcompartmentanddamagedormissing
rubberbafescancausetheengineand
hydraulicsystemtooverheatwhichcan
createarehazard.

Cleanalldebrisfrominsideofpumpdrive
beltcompartmentdaily.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake
screenandfromaroundengineshrouding.

3.Cleanalldebrisfromaroundtheengineanddrive
belts.

RemoveAccumulatedDebris
fromEngine(Briggs&
StrattonUnitsOnly)

ServiceInterval:Beforeeachuseordaily

Enginepartsshouldbekeptcleantoreducetherisk
ofoverheatingandignitionofaccumulateddebris.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removefrontpanelfromengineandcleanaround
theintakemanifold,fuelpump,andcarburetor.

3.Reinstallthefrontpanel.

Important:DoNotusewatertocleanengine.
Uselowpressurecompressedair.SeeEngine
Owner’sManual.

34

Maintenance

RemoveEngineShroudsand
CleanCoolingFins

ServiceInterval:Every80hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removecoolingshroudclean-outcoversfrom
engineandcleancoolingns.Alsocleandust,
dirt,andoilfromexternalsurfacesofengine,
whichcancauseimpropercooling.

3.Makesurecoolingshroudclean-outcoversare
reinstalled.Operatingtheenginewithoutcooling
shroudclean-outcoverswillcauseenginedamage
duetooverheating.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto
theenvironment.Disposeofusedoilatacertied
recyclingcenteroraccordingtoyourstateandlocal
regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

Federallawstatesthatbatteriesshouldnotbeplaced
inthegarbage.Managementanddisposalpractices
mustbewithinrelevantfederal,state,orlocallaws.

Ifabatteryisbeingreplacedoriftheunitcontaining
thebatteryisnolongeroperatingandisbeing
scrapped,takethebatterytoalocalcertiedrecycling
center.Ifnolocalrecyclingisavailablereturnthe
batterytoanycertiedbatteryreseller.

35

Troubleshooting

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,DoNotoverlookthesimplecauses.Forexample:startingproblemscouldbe
causedbyanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor
itemsoranyitemsthatcallforspecialtimingofadjustmentprocedures(suchasvalves,governor,etc.).Have
thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.PTOisengaged.

1.DisengagethePTO .

2.Parkingbrakeisnot.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock
position.

3.Ensurethedriveleversareintheneutral
lockposition.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.

5.Electricalconnectionsarecorroded,loose
orfaulty.

5.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

6.Fuseisblown.6.Replacetheblownfuse.

Starterdoesnotcrank

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty .1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

2.Openthefuelshutoffvalve.

3.Oillevelinthecrankcaseislow .

3.Addoiltothecrankcase.

4.Thethrottleandchokearenotinthe
correctposition.

4.Besurethethrottlecontrolismidway
betweenthe“SLOW”and“F AST”
positions,andthechokeisinthe“ON”
positionforacoldengineorthe“OFF”
positionforawarmengine.

5.Dirtinfuellter.5.Replacethefuellter.

6.Dirt,water,orstalefuelisinthefuel
system.

6.ContactanAuthorizedServiceDealer.

7.Aircleanerisdirty.

7.Cleanorreplacetheaircleanerelement.

8.Electricalconnectionsarecorroded,loose
orfaulty.

8.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

9.Relayorswitchisdefective.9.ContactanAuthorizedServiceDealer.

10.Faultysparkplug.

10.Clean,adjustorreplacesparkplug.

Enginewillnotstart,startshard,orfailsto
keeprunning

11.Sparkplugwireisnotconnected.

11.Checkthesparkplugwireconnection.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

2.Cleanorreplacetheaircleanerelement.

3.Oillevelinthecrankcaseislow .

3.Addoiltothecrankcase.

4.Coolingnsandairpassagesforthe
engineareplugged.

4.Removetheobstructionsfromthecooling
nsandairpassages.

5.V entholeinthefuelcapisplugged.

5.Cleanorreplacethefuelcap.

6.Dirtinfuellter.6.Replacethefuellter.

Enginelosespower

7.Dirt,water,orstalefuelisinthefuel
system.

7.ContactanAuthorizedServiceDealer.

36

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

2.Addoiltothecrankcase.

Engineoverheats

3.Coolingnsandairpassagesforthe
engineareplugged.

3.Removetheobstructionsfromthecooling
nsandairpassages.

1.Trackingneedsadjustment1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

Mowerpullsleftorright(withleversfully
forward)

3.Reverseindicatorandmotioncontrol
linkageneedadjustment.

3.Adjustthereverseindicatorandthe
motioncontrollinkage.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor
broken.

2.Changethebelt.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.

4.Replacethespring.

Machinedoesnotdrive

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

cooldown.

1.Enginemountingboltsareloose.1.Tightentheenginemountingbolts.

2.Looseenginepulley,idlerpulley,orblade
pulley.

2.Tightentheappropriatepulley.

Abnormalvibration

3.Enginepulleyisdamaged.3.ContactanAuthorizedServiceDealer.

37

Schematics

Schematics

ElectricalDiagram—23HP&27HPKohler

BATT (POS)

CIRCUIT

BREAKER

BATT (NEG)

BLACK

BLACK

ORANGE

ORANGE

MOTOR (FWD)

MOTOR (REV)

RED

RED

BLACK
BLACK

GREY / BLACK

GREY

LT BLUE

YELLOW / BLACK

ORANGE

ORANGE

YELLOW / BLACK

ORANGE

PINK / BLACK

GREY

GREY

RED

BLACK

DK GREEN

DK GREEN
ORANGE / BLACK

YELLOW

TAN

RED

BROWN
BLACK

BROWN

BROWN

GREY

GREY

ORANGE

LT BLUE

YELLOW / BLACK

DK GREEN

WHITE

DK BLUE

ORANGE

ORANGE

ORANGE

YELLOW / BLACK

LT BLUE
LT BLUE

TAN

BROWN

GREY

LT BLUE

LT GREEN

LT GREEN

DK GREEN /

WHITE

BLACK

BLACK

DK GREEN

1

2

3

7

8

9

4

12

4

3

2
1

5

4

3

2

1

5

4

3

2

1

4

3

2

1

2

1

2

1

4

3
2

1

5

4

3

2

1

3

2

1

1 4 3 2

987321546

3

2

1

B

A

1

2

123

4

1

2

21453

1 2

1 2

1 4 2 3

1 2 3 4 5

1

2

CBA

9836527

14

5

2

4

1

3

1
2

AB

A

B

6 5 4 7

3 2 1 8

C

B

A

C

B

A

A

B

2

1

2

1

2

1

GREY / BLACK

GREY

DECK TILT

SAFETY SWITCH

CONTACTOR

AUX. HYDRAULICS

RAISE / LOWER

ORANGE

BLUE / BLACK

WHITE / BLACK

BLACK

GREY

SEAT DELAY

MODULE DIODE

DK GREEN

ENGINE

FUSE

15 AMP

HEADLIGHT

HARNESS

YELLOW / BLACK

YELLOW / BLACK

DK BLUE

WHITE

ORANGE

DK GREEN / WHITE

YELLOW / BLACK

YELLOW / BLACK

BLACK

BLACK

BLACK

PINK / BLACK

LT BLUE

DK GREEN

DK GREEN

ORANGE / BLACK

TAN

TAN

YELLOW

RED

RED

STARTER;

BATTERY (POS)

FUSE

20 AMP

HOUR

METER

IGNITION

SWITCH

RH MOTION

CONTROL

LH MOTION

CONTROL

BRAKE

SWITCH

START

RELAY

KILL

RELAY

STARTER

SOLENOID

SIGNAL

FUSE

20 AMP

GROUND

PTO

SWITCH

PTO

CLUTCH

SEAT

SWITCH

SEAT DELAY

MODULE INPUT

SEAT DELAY

MODULE CONTROL

YBS

A

I

DK GREEN

SWITCH IS CLOSED

WITH OPERATOR

IN THE SEAT

OPEN WITH

BRAKE ENGAGED

CLOSED WITH

BRAKE ENGAGED

BOTH MOTION CONTROL

SWITCHES ARE CLOSED WITH

CONTROL LEVERS IN NEUTRAL

LOCK POSITION

SWITCH IN: ORANGE TO PINK/BLACK

SWITCH OUT: ORANGE TO GRAY

G007220

IGNITION SWITCH

TERMINAL CONNECTIONS

TERMINAL A VOLTAGE REGULATOR

TERMINAL B BATTERY

TERMINAL I HOUR METER, AUX HYD, PTO SWITCH

TERMINAL S START RELAY

TERMINAL X SEAT DELAY

TERMINAL Y HOUR METER, AUX HYD, PTO SWITCH

TERMINAL A

TERMINAL B

TERMINAL Y

TERMINAL X

TERMINAL S

TERMINAL I

NOTE:

CONNECTORS VIEWED FROM WIRE END

NONE

X + Y

CIRCUIT "MAKE"

B + I + S

B + I + A

2. RUN

1. OFF

POSITION

3. START

38

Schematics

ElectricalDiagram–31HPBriggs&Stratton

3

I

ASBXY

SEAT DELAY

MODULE CONTROL

SEAT DELAY

MODULE INPUT

SEAT

SWITCH

PTO

CLUTCH

PTO

SWITCH

GROUND

FUSE

20 AMP

KILL

RELAY

START

RELAY

BRAKE

SWITCH

LH MOTION

CONTROL

RH MOTION

CONTROL

IGNITION

SWITCH

HOUR

METER

FUSE

30 AMP

STARTER;

BATTERY (POS)

RED

YELLOW

TAN

TAN

ORANGE / BLACK

DK GREEN

DK GREEN

LT BLUE

PINK / BLACK

BLACK

BLACK

BLACK

VIOLET

YELLOW / BLACK

DK GREEN / WHITE

ORANGE

WHITE

DK BLUE

YELLOW / BLACK

YELLOW / BLACK

HEADLIGHT

HARNESS

FUSE

15 AMP

ENGINE

SEAT DELAY

MODULE DIODE

GREY

BLACK

WHITE / BLACK

BLUE / BLACK

ORANGE

AUX. HYDRAULICS

RAISE / LOWER

CONTACTOR

DECK TILT

SAFETY SWITCH

GREY

GREY / BLACK

1

2

1

2

1

2

B

A

A

C

A

B

C

6 5 4 7

3 2 1 8

A

B

B A

2

1

3

1
4
2

5

4 1

7 2 5 6 3 8 9

A B C

A B C

2

1

54321

3241

21

21

35412

2

1

764

1

2

1

A

B

1

2

3

6 4 5 1 2 3 7 8 9

2341

1

2

3

1

2

3

4

5

1

2

3

4

1

2

1

2

1

2

3

4

1

2

3

4

5

1

2

3

4

5

4

3

2

1

2 1

4

9

8

7

3

2

1

DK GREEN

BLACK
BLACK

DK GREEN /

WHITE

LT GREEN

LT GREEN
LT BLUE

GREY

BROWN

TAN

LT BLUE

LT BLUE

VIOLET

ORANGE

ORANGE

ORANGE

DK BLUE

WHITE

DK GREEN

TAN

LT BLUE

ORANGE

GREY

GREY

BROWN

BROWN

BLACK

BROWN

RED

TAN

YELLOW

ORANGE / BLACK

DK GREEN

DK GREEN

BLACK

RED

GREY

GREY

PINK / BLACK

ORANGE

YELLOW / BLACK

ORANGE

ORANGE

YELLOW / BLACK

LT BLUE

GREY

GREY / BLACK

BLACK
BLACK

VIOLET

RED

MOTOR (REV)

MOTOR (FWD)

ORANGE

ORANGE

BLACK

BLACK

BATT (NEG)

CIRCUIT

BREAKER

BATT (POS)

DK GREEN
DK GREEN

RED

CHARGE

RELAY

BLACK

54321

BLACK

TAN

VIOLET

YELLOW/BLACK

1

2

3

4

5

8

7

6

5

RED

SWITCH IN: ORANGE TO PINK/BLACK

SWITCH OUT: ORANGE TO GRAY

BOTH MOTION CONTROL

SWITCHES ARE CLOSED WITH

CONTROL LEVERS IN NEUTRAL

LOCK POSITION

CLOSED WITH

BRAKE ENGAGED

OPEN WITH

BRAKE ENGAGED

SWITCH IS CLOSED

WITH OPERATOR

IN THE SEAT

G007221

IGNITION SWITCH

TERMINAL CONNECTIONS

TERMINAL A VOLTAGE REGULATOR

TERMINAL B BATTERY

TERMINAL I HOUR METER, AUX HYD, PTO SWITCH

TERMINAL S START RELAY

TERMINAL X SEAT DELAY

TERMINAL Y HOUR METER, AUX HYD, PTO SWITCH

TERMINAL A

TERMINAL B

TERMINAL Y

TERMINAL X

TERMINAL S

TERMINAL I

NOTE:

CONNECTORS VIEWED FROM WIRE END

NONE

X + Y

CIRCUIT "MAKE"

B + I + S

B + I + A

2. RUN

1. OFF

POSITION

3

. START

39

Schematics

HydraulicDiagram

CASE DRAIN

CHARGE PUMP

HIGH PRESSURE

G007220

BYPASS VALVE

BYPASS VALVE

HIGH
PRESSURE
REVERSE

HIGH PRESSURE
FORWARD

HIGH PRESSURE
REVERSE

HIGH PRESSURE
FORWARD

40

Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty
Company, pursuant to an agreement between them, jointly
warrant on the terms and conditions herein, that we will repair,
replace or adjust any part manufactured by Exmark and found
by us (in the exercise of our reasonable discretion) to be
defective in factory materials or workmanship for a period of
two years.

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

 Products Warranty Period

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 and Metro 26 Series  1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

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

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized 
 Exmark Service Dealer beyond first warrantable service.

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

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

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

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

There are no other express warranties except for engine and
special emission system coverage stated elsewhere herein or
included with the product.

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

Instructions for Obtaining Warranty Service

The product must be registered with original proof of purchase
by an Exmark Service Dealer before obtaining any warranty
service.

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

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
 [e-mail]

Owner’s Responsibilities

The Exmark turf equipment, including any defective part,
must be returned to an authorized Exmark service dealer
within the warranty period. This warranty extends only to turf
equipment operated under normal conditions. You must read
the operator’s manual. You must also 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.

General Conditions

The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair and replacement
of defective components as set forth herein. Neither Exmark

nor Exmark Warranty Company shall have any liability
for any other cost, loss or damage, including but not
limited to, any incidental or consequential loss or damage.

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

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other  
 extraordinary repair charges or charge relating to repairs or 
 replacements outside of normal business hours at the place 
 of business of the authorized Exmark Service Dealer.

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

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that 
 covered by the terms of this warranty.

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

• Attorney's fees.

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

Some states do not allow exclusions of incidental or
consequential damages, so the above exclusions and
limitations may not apply to you.

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

2-Year Limited Warranty

Exmark Turf Equipment

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

G006117

41

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

42

43

MI D-MOUNT RIDING ACCE SSORIES

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES

WALK-BEHIND ACCESSORIES

GRASS CATCHER

LAZERLOCKER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LAZERLOCKER

LIGHT KIT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-F RONT RIDING AC CESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

ROTARY BROOM

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

ModelNo.EngineSerialNo.(E/No)

SerialNo.

©2004–2008ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
AllRightsReserved

PartNo.4500-218Rev .A
[phone]
Fax[phone]
PrintedintheUSA.

www.exmark.com