Exmark FR524, FR724, FR604 User Manual

FR524/FR604/

FR724

ForSerialNos.
720,000&Higher

PartNo.4500-230Rev.A

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

©2005–2008—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310

Contactusatwww.Exmark.com.

2

PrintedintheUSA.

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkCuttingDeck.Thisproducthasbeen
carefullydesignedandmanufacturedtogiveyou
amaximumamountofdependabilityandyearsof
trouble-freeoperation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

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

Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

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.

3

Contents

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

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

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

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

SafetyandInstructionalDecals.......................7

Specications.........................................................9

ModelNumbers..............................................9

Systems...........................................................9

Dimensions.....................................................9

TorqueRequirements....................................10

Setup....................................................................11

AssembleDecktoFrontRunner.....................11

DeckRemoval...............................................13

ProductOverview................................................14

Operation.............................................................14

DeckRaisingandLowering...........................14

Maintenance.........................................................17

RecommendedMaintenanceSchedule(s)...........17

PeriodicMaintenance.......................................17

CheckMowerBlades.....................................17

CheckforLooseHardware............................18

CheckTirePressures.....................................18

ChangeGearboxOil......................................18

LubricateGreaseFittings...............................19

ThreadLockingAdhesives.............................19

Adjustments.....................................................20

DeckLeveling...............................................20

CasterPivotBearingsPre-load

Adjustment...............................................20

Cleaning...........................................................21

CleanGrassBuild-UpUnderDeck................21

Troubleshooting...................................................22

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/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.

•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.

Preparation

•DoNotmodifytheFrontRunnercuttingdeck.

•OnlyuseonmachinesapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.

CAUTION

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

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

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadthetractorandcuttingdeckOperator’s
Manualsandothertrainingmaterial.Ifthe
operator(s)ormechanic(s)cannotreadEnglish
itistheowner’sresponsibilitytoexplainthis
materialtothem.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

Operation

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

•Neverfoldthedeckwithbladesrunning.

•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

5

Safety

WARNING

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

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.

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

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.

MaintenanceandStorage

•DisengagePTO ,setparkingbrake,stopengine
andremovekeyordisconnectsparkplugwire.
Waitforallmovementtostopbeforeadjusting,
cleaningorrepairing.

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

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

6

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

Safety

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

1-303508

1-633922

1-403005

1-643222

98–5954

7

Safety

103-8425

109-2376

109-2354

109-2359

109-2993

109-3148

8

Specications

ModelNumbers

SerialNos:720,000andHigher

FR524;FR604;FR724

Specications

Systems

Tires&Wheels

FrontCaster

Type

Quantity

Tread

Size9x3.50–4

CuttingDeck

•ModelNumbers:

–FR524

–FR604

–FR724

•CuttingWidth:

–52inchDeck:52inch(132cm)

–60inchDeck:60inch(152cm)

–72inchDeck:72inch(183cm)

•Discharge:Side

•BladeSize:(3ea.)

–52inchDeck:18.00inches(45.7cm)

Semi-Pneumatic

2

Smooth

•Deck:

Fulloatingdeckisattachedtoout-frontsupport
frame.Sixanti-scalprollersprovidemaximum
turfprotection.Deckdesignallowsforbagging,
mulching,orsidedischarge.

•DeckDepth:

–52inchDeck:51/2inches(14cm)

–60inchDeck:51/2inches(14cm)

–72inchDeck:51/2inches(14cm)

•CuttingHeightAdjustment:

Adjustsfrom1inch(2.5cm)to5inches(12.7cm)
innitelyvariable

•MulchingKit:Optional

Dimensions

OverallWidth:

52inch
Deck

Deector
Down

Deector
Up

64.6inches
(164.1cm)

53.9inches
(136.9cm)

60inch
Deck

72.7inches
(184.7cm)

61.4inches
(156.0cm)

72inch
Deck

84.4inches
(214.4cm)

73.3inches
(186.2cm)

–60inchDeck:20.50inches(52.1cm)

–72inchDeck:24.50inches(62.2cm)

•DeckDrive:

–Shaftdrivetogearboxatrearofdeck.

–Beltdrivefromgearboxtobladespindles.

OverallLength:

52inchDeck60inchDeck72inchDeck

42.5inches
(108.0cm)

42.3inches
(107.4cm)

OverallHeight:

52inchDeck60inchDeck72inchDeck

18.0inches
(45.7cm)

9

18.0inches
(45.7cm)

45.5inches
(115.6cm)

18.0inches
(45.7cm)

Specications

CurbWeight:

52inchDeck60inchDeck72inchDeck

393lb(178kg)434lb(197kg)514lb(233kg)

TorqueRequirements

BoltLocation

BladeMountingBolt
(lubricatewithanti-seize)

GearboxMountingBolts16-18ft-lb(22-24N-m)

DriveShaftSetScrew

DriveShaftPinchBolt

CutterHousingSpindle
Nut

Anti-ScalpRollerNyloc
NutSeeFigure12

Anti-ScalpRollerWhizlock
NutSeeFigure12

Torque

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

18ft-lb(24N-m)

44ft-lb(60N-m)

140-145ft-lb
(190-197N-m)

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

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

10

Setup

WARNING

OperatingaFrontRunnertractorwithoutan
approvedExmarkfrontmountattachment
increasesthepossibilityofforwardtipover.
Tip-overcouldcauseseriousinjuryordeath.

WhenoperatingaFrontRunnertractor
withoutanapprovedExmarkfrontmount
attachment,observethefollowing:

•Limitoperationtominimumrequiredto
installadifferentfrontmountattachment.

Setup

•Minimizespeedanduseextremecaution.

•Onlyoperateonaatlevelsurface.

•DoNotoperateupordownatrailerramp.

•Avoidsuddenaccelerationordeceleration.

AssembleDeckto
FrontRunner

Important:DoNottransportFrontrunner

tractorwithoutandapprovedExmarkfront
mountattachment.

1.Stoptheengine,waitforallmovingpartstostop,
engagetheparkingbrake,andremovethekey.

2.Rotatethefoldlocklever,locatedonthedeck,in
theunlockedposition(Figure3).

Figure3

1.Foldlocklevershownintheunlockedposition

3.Onthetractor,removethetworetainingpins
onhitchlatchessothelatchescanactuatefreely.
Raisetheoorpanandlockinuprightposition
(Figure4).

Figure4

1.Removetheretainingpinsfrombothhitchlatches

2.Floorpanshownlockedintheuprightposition

4.Alignthefrontframeofthemowerdecktothe
Frontrunnertractorhitch.

5.Manuallyliftuponthehitchtogetthebarsonthe
frontframestartedintothereceiversofthehitch.

6.Pushthefrontframetowardsthetractoruntilthe
twohitchlatchesseatintothe“secure”position.

11

Setup

7.Insertthehitchlatchretainingpinsintothehitch
pinlock.Thedeckisnowlockedontothetractor.

8.Reinstallthekeyandturntheswitchtothe“run”
position.DoNotstarttheengine.

9.Alignthecylinderrodendtothetopholeofthe
oatlinkbracketandinsertthepinasshownin
Figure5.Insertthecotterhairpintolockthe
cylinderpinintoplace.

1.Retainingpin

2.Cotterhairpin

Figure6

3.Weighttransferchains

Figure5

1.Floatlinkbracket

2.Cylinderpin

3.Cylinder

4.Besuregreasezerkis
pointedupward

WARNING

Incorrectlyraisingorloweringamowerdeck
canbedangerous.Adroppedmowerdeck
canresultinaseriousinjuryorproperty
damage.

•Alwaysraiseandlowerdeckonat,dry
ground,freeofanyobstructions.

•Alwaysmakesurethedeckissecurely
latchedinthe“up”or“down”position.

10.Retractthecylindertofoldthedeckupward.
Attachtheweighttransferchains.Itisvery
importantnottotwistthechains.Lockthe
chainsontothepinbyinsertingthecotterhairpin
(Figure6).

WARNING

Operatingthemowerdeckintheraised
servicepositioncanbedangerous.Engaging
thePTOwithadeckintheraisedposition
canresultinaseriousinjuryorproperty
damage.

Alwayslowerandlockmowerdeckinthe
operationpositionbeforeengagingthePTO.

11.Extendthecylinderfullyuntilthecasterwheels
contactthegroundandthedeckisinthefully
raisedposition.Thefoldlockleversshouldhave
resetandsnappedintothe“locked”position.
Lowertheoorpan.

Figure7

1.Floorpan

12

2.Rotatefoldlockleverto
uprightposition.

Setup

WARNING

Operatingmowerwithoutfoldlocklevers
securelylatchedcanresultinthemower
deckfoldingupunexpectedlyandcancause
seriousinjury.

Alwaysoperatemowerwiththefoldlock
leverssecurelylatched.

12.Connectthedriveshaftbypushingbackthe
springloadedcollar.Alignandcouplethedrive
shafttothesplineddriveshaftandreleasethe
collar(Figure8).

5.Retractthecylinderandpartiallyfoldthedeck
justtothepointwheretheweighttransferchains
goslack.

6.Pulloutthehairpinsandchainpinsfromthe
clevisbracket.Placethepinandcotterhairpinon
thechainandsetaside.

7.Lowerthedeckbyextendingthecylinderuntilthe
deckfoldsdown.Thecastertiresshouldtouch
theground.

8.Theoatlinkbracketswillstarttorotateforward
andatthispoint,thecylindercanbedetachedat
therodendbypullingthepinoutofthebracket.
Liftthecylinderoutofthewayandpositionthe
rodendsothatitrestsonthebuckleoftheheight
indicatorbracket.

9.Removethehitchlatchpinsfromthehitch
brackets.Raisethehitchlatchabovetheholeand
insertpin.Thetopofthehitchlatchshouldrest
underthepin(seeFigure9).

Figure8

Viewedfrombelowthemachine

1.Pushspringloadedcollartowardsdeck

DeckRemoval

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Disconnectthedriveshaftbypullingbackonthe
springloadedcollarandpullingawayfromthe
splinedshaft(seeFigure8).Laythedriveshaft
ontheground.

3.Insertkeyandturntothe“run”position.Do
Notstarttheengine.

4.Extendthecylinderuntilthefoldlocklatches
areunloaded,andthenrotatethemtowardthe
tractor.

Figure9

1.Floorpanlockedin
uprightposition

2.Hitchlatchpins

3.Hitchlatchesin“up”
position

10.Standinfrontofthedeckandpulltheunitaway
fromthetractororbackthetractorawayfrom
thedeck.

Important:DoNottransportFrontRunner
tractorwithoutanapprovedExmarkfrontmount
attachment.

13

Operation

ProductOverview

1.Foldlocklever

2.Anti-scalprollers

Figure10

3.Casterwheel

Operation

DeckRaisingandLowering

SettingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted
from1to5inches(2.5cmto12.7cm)innitely
variable.

1.Thekeymustbeinthe“run”positiontosetthe
cutheight.

2.Extendorretractcylinderuntilthecuttingheight
indicatorpointstothedesiredcutheight.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller
position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol
leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe
anti-scalprollersbyremovingthewhizlocknut
andthespringdiscwasher.

6.Placetherollersinoneofthepositionsshown
(Figure11).Rollerswillmaintain3/4inch(19
mm)clearancetothegroundtominimizegouging
androllerwearordamage.

Figure11

Forcuttingheightsabove3.5inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

14

1.Anti-scalproller
mountingbracket

2.Cuttingheight

Operation

ForMaximumDeckFlotation,placetherollers
oneholepositionlower.Rollersshouldmaintain
1/4inch(6.4mm)clearancetotheground.Do
Notadjusttherollerstosupportthedeck.

7.Besurethewhizlocknutsareinstalledwiththe
springdiscwasherbetweentheangeofthenut
andthemountingbracket(seeFigure12).

8.Torquethe3/8-16whizlocknutto30-35ft-lb
(41-47N-m)(Figure12).

9.Ifthe3/8nylocnuthasbeenremoved,re-install
andtorqueitto30–35ft-lb(41-47N-m)
(Figure12).

2.Fullyextendthecylindertounloadthefoldlock
levers.

3.Rotatethefoldlocklevers,locatedoneachside
ofthedeck,totheunlockedposition(Figure3).

4.Retractthecylinderandthedeckwillfoldto
approximately50degrees.

WARNING

Operatingthemowerdeckintheraised
servicepositioncanbedangerous.Engaging
thePTOwithadeckintheraisedposition
canresultinaseriousinjuryorproperty
damage.

Alwayslowerandlockmowerdeckinthe
operationpositionbeforeengagingthePTO.

RaisingtheMowerDeckintothe
StoragePosition

Figure12

1.Springdiscwasher
(conetowardsnut)

2.Frontrightanti-scalp
bracketshown

3.3/8nyloc-torqueto30-35
ft-lb(41-47N-m)

4.3/8-16whizlocknut
torqueto30-35ft-lb
(41-47N-m)

RaisingtheMowerDeckintoService
Position

1.Stopengine,waitforallmovingpartstostop,
engageparkingbrake,andturnkeyto“run”
position.DoNotstarttheengine.

WARNING

Incorrectlyraisingorloweringamowerdeck
canbedangerous.Adroppedmowerdeck
canresultinaseriousinjuryorproperty
damage.

1.Stopengine,waitforallmovingpartstostop,
engageparkingbrake,andturnkeyto“run”
position.DoNotstarttheengine.

2.Flipuptheoorpanandremovefullfoldpin.
Retractthecylindertoalignholesinoatlink
bracketwithholesinfrontframe.(Deckwillbe
atornearlowestheight.)Insertintothebottom
holeoftheoatlinkbracket(seeFigure13).
Lowertheoorpan.

•Alwaysraiseandlowerdeckonat,dry
ground,freeofanyobstructions.

•Alwaysmakesurethedeckissecurely
latchedinthe“up”or“down”position.

15

Operation

4.Ifthefullfoldpinwasusedwhenthedeckwas
folded,removeitfromtheoatlinkandplaceit
inthestoragelocationundertheoorpan.

5.Fullyextendthecylinderuntilitstops.Conrm
thatthelatchesareinthelockedposition.

6.Retractthecylinderuntilthedecklowerstothe
desiredcutheightreadingshownontheheight
indicatorbar.

WARNING

Figure13

1.Removethehairpinand
fullfoldpin

2.Floatlinkbrackets

3.Insertpinhere

4.Hairpin

5.Fullfoldpin

WARNING

Foldingthemowerdeckwiththeoorpanin
lockedpositionmaybedangerous.Hooks
willnotautomaticallydropintheslotsonthe
frontcover.

Makesuretheoorpanisnotlockedinthe
uprightposition.

3.Fullyretractcylinder.Thedeckwillfoldtoan
approximate70degreeangle.

WARNING

Drivingthemowerdeckinthefoldedservice
positioncanbedangerous.Themowercan
tipforward.

Operatingmowerwithoutlockinglatches
securelylatchedcanresultinthemowerdeck
foldingupunexpectedly.Themowerdeck
foldingupunexpectedlycancauseserious
injury.

Alwaysoperatemowerwithlockinglatches
securelylatched.

Alwayslowerandlockmowerdeckinthe
operationpositionbeforedriving.

LoweringtheMowerDecktothe
OperatingPosition

1.Makecertainthatyouandanyobserversareclear
ofthedeck.

2.Raisetheoorpantothelockedpositionas
showninFigure13.

3.Extendthecylinderuntilthefrontcasterwheels
justtouchtheground.

16

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.

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

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst50hours

Beforeeachuseordaily

Every40hours

Every100hours

Yearly

MaintenanceProcedure

•Changeoilinallthreegearboxhousings.Addoilasneededuntillevelwithoildrainplug.

•Checkthemowerblades.

•Checkforloosehardware.

•Greasethefrontcasterwheelhub.

•Cleanthegrassbuild-upfromunderthedeck.

•Checktheconditionofthebelts.

•Greasethedriveshaft.

•Greasetheheightadjustmentshaftbearings.

•Changeoilinallthreegearboxhousings.Addoilasneededuntillevelwithoildrainplug.

•Greasethedeckip-up.

•Greasethefrontcasterpivots.

•Greasethedeckdrivebeltidlerarm.

PeriodicMaintenance

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Inspectbladesandsharpenorreplaceasrequired.

3.Reinstalltheblades(iftheywereremoved)inthe
followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure14

1.Installbushinginbladepriortoinstallingbushingin
spindle.

17

Maintenance

B.Installbushing/bladeassemblyintospindle.

Figure15

1.Usewrenchherefor
bladeinstallation.This
nuthasbeentorquedto
90–110ft-lb(122–149
N-m)

2.Torqueto55-60ft-lb
(75-81N-m)Apply
lubricanttothreads
asneededtoprevent
seizing.Copper-based
anti-seizepreferable.
Greaseacceptable
substitute.

C.Applylubricanttothreadsofbladeboltas

neededtopreventseizing.Copper-based
anti-seizepreferable.Greaseacceptable
substitute.Installbladeboltngertight.Place
wrenchonthetopspindlenutthentorquethe
bladeboltsto55-60ft-lb(75-81N-m).

CheckTirePressures

ServiceInterval:Every40hours

Thefrontcastertiresaresemi-pneumaticandDo
Notneedtobeinated.

ChangeGearboxOil

ServiceInterval:Aftertherst50hours

Every100hoursthereafter

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Placeunitonalevelsurface.

3.Removethegearboxanddriveshaftassembly
fromthemowerdeck.Retainhardwareforre-use.

4.Removetheoildrainplugonthesideofthe
gearboxsectionanddrainoil(Figure16).

WARNING

Incorrectinstallationofthebladeor
componentsusedtoretainthebladecan
bedangerous.Failuretousealloriginal
componentsandassembledasshowncould
allowabladeorbladecomponenttobe
thrownoutfromunderthedeckresultingin
seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades,
bladebushings,andbladeboltsasshown.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.

Figure16

1.Oildrain/llplug

5.Reinstallthegearboxanddriveshaftassemblyto
themowerdeck.

6.FillgearboxwithMobilSHC(synthetic)75W -90
gearlubeoiluntillevelwithoildrain/llplug.

Note:Mowerdeckshouldremainleveltothe
groundwhenllinggearboxwithoil.DoNotll
gearboxwithdeckraisedintheserviceposition.

7.ApplyaTeonpipesealanttotheoilplugand
re-installintothegearbox.

18

Maintenance

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.LubricatettingswithNGLIgrade#2
multi-purposegungrease.

Refertothefollowingchartforttinglocations
andlubricationschedule.

LubricationChart

Fitting

Locations

1.Front
Caster
WheelHub

2.Drive
Shaft

3.Height
Adjustment
Shaft
Bearings

4.Deck
Flip-Up

5.Front
Caster
Pivots

6.Deck
DriveBelt
IdlerArm

Initial

Pumps

128Hours

1

1

12

*0

11

Numberof

Places

340Hours

440Hours

2

Service

Interval

100Hours

*Yearly

Yearly

3.Lubricatecasterpivotsonceayear.Removehex
plugandcap.Threadgreasezerkinholeand
pumpwithgreaseuntilitoozesoutaroundtop
bearing.Removegreasezerkandthreadplugback
in.Placecapbackon.

ThreadLockingAdhesives

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

•Spindletopnut.

•Driveshaftsetscrewatthegearbox.

•Largenutsattheendsofthedeckliftlinks.

•Setscrewsonthegearboxsheave.

*Seestep3forspeciallubricationinstructionson
thefrontcasterpivots.

19

Maintenance

Adjustments

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

DeckLeveling

1.Positionmoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

3.Checktirepressureindrivetires.

ForUnitsEquippedWithTurfTires:Thedrive
tiresshouldbeinatedto13psi(90kpa).

ForUnitsEquippedWithBar-LugTires:The
drivetiresshouldbeinatedto9psi(62kpa).

4.Fullyextendthecylindertoraisethedeckashigh
asitwillgo(thisisalsothetransportposition).
Notethepositionofthecutheightindicator.
Adjusttheindicatorifnecessarysothatthe
indicatorispointingtothe5inchcutheightmark
(seeFigure17).

measure41/4inchestogivetherecommended
1/4inchpositiverake(seeFigure18).

Figure18

1.41/4inches

2.4inches

6.Ifadjustmentsarenecessary,foursockethead
5/16-18x1-1/4inchscrewshavebeenprovided
intheliteraturebag.Installthesescrewsintothe
deckliftarmsuntiltheytouchthehexheaddeck
chainscrews.Loosenthetopchainscrewsin
slotsinthedeckliftarms(seeFigure19).Turn
thesocketheadscrewstomovethedeckchain
screwsupanddowntocorrectthecutheights
measuredabove.Tightenthechainboltsinthe
deckliftarmsmakingsuretheydon’tmovewhile
tightening.

Figure17

1.Cutheightindicator

2.Adjustindicatorusing
thesescrews

5.Lowerthedecktothe4inchcutheightposition
andremoveignitionkey.Orienttheblades
longitudinallywithrespecttothemachine.Stand
awoodenblockapproximately5inchestallnext
tothefrontbladetipofthecenterblade;markthe
locationofthebladetipontheblock.Removethe
blockandmeasureheightontheblock,itshould
be4inches.Repeatthisprocessfortherearblade
tipofboththeleftandrightblades,thoseshould

Figure19

1.Socketheadscrew

2.Deckliftarms

3.Adjustscrewandlocknut

CasterPivotBearings
Pre-loadAdjustment

Removedustcapfromcasterandtightennylocnut
untilwashersareat.Backthenylocoff1/4ofa
turntoproperlysetthepre-loadonthebearings.

Note:Ifdisassembled,makesurethespringwashers
arereinstalledasshowninFigure20.

20

1.Springdiscwashers

Figure20

Maintenance

Cleaning

CleanGrassBuild-UpUnder
Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Foldmowerdeckandsecureinlatchedposition.
SeeRaisingtheMowerDecktotheService
PositionsectioninOperation.

3.Cleanoutanygrassbuild-upfromundersideof
deckandindischargechute.

4.Lowerdecktocuttingpositionandlockdeck
lockingpins.SeeLoweringtheMowerDeckto
theOperationPositionsectioninOperation.

21

Troubleshooting

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused
byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Unevencuttingheight.

Abnormalvibration.

BladesDoNotrotate.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

7.Tipsofadjacentbladesareatanuneven
cuttingheight.Bladestipsshouldbeeven
within3/16inchwhichisapproximately
onebladethickness.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Enginepulleyisdamaged.4.ContactanAuthorizedServiceDealer.

5.Bladespindleisbent.5.ContactanAuthorizedServiceDealer.

6.Beltisdamaged.6.Installnewbelt.

1.PTObeltisworn,loose,orbroken.1.Checkbelttensionorreplacebelt

2.PTOshaftisnotconnected.

3.PTObeltisoffpulley .3.Checkbeltandpulleysfordamage.Install

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check
fordamagetomowerdeck.

1.Installnewcuttingblade(s).

2.ConnectPTOshaft.

beltandcheckadjustingshaftsandbelt
guidesforcorrectposition.

22

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

23

Notes:

24

Notes:

25

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

26

27

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-FRO NT RIDING ACCESSORI ES

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

ModelNo.

SerialNo.

Pack)orFillinBelow

DatePurchased

©2005–2008ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
AllRightsReserved

PartNo.4500-230Rev.A
[phone]
Fax[phone]
PrintedintheUSA.

www.exmark.com