Exmark Frontrunner 4500-341 User Manual

FRONTRUNNERTM

AIR-COOLED MODELS

For Serial Nos.
790,000 & Higher

Part No. 4500-341 Rev. A

1

READ OPERATOR’S MANUAL BEFORE

OPERATING OR SERVICING EXMARK EQUIPMENT.

TABLE OF CONTENTS

Description Page

Auxiliary Hydraulic Group ................................................. 14

Decals .............................................................................. 22

Electrical Diagram 27HP................................................... 18

Electrical Diagram 31HP................................................... 19

Electrical Logic Schematic 27HP...................................... 20

Electrical Logic Schematic 31HP...................................... 21

Electrical Group ................................................................ 17

Engine Group 27HP ......................................................... 12

Engine Group 31HP.......................................................... 13

Fuel Group........................................................................ 11

Hydraulic Group........................................................... 15-16

Main Frame Group...........................................................3-6

Motion Control Group ....................................................... 10

Park Brake Group............................................................... 9

PTO Drive Group................................................................ 8

Rear Frame Group.............................................................. 7

2

MAIN FRAME GROUP

Item

Part No.

1 1-323142 Nut, Push 1/2 .........................................2

2 109-2365 Bumper .................................................. 4

3 109-3478 Asm, Wheel & Tire (RH) ........................ 1

109-3156 Wheel ....................................................1

103-6771 Tire, 24x12-12 4 Ply ............................... 1

4 1-633859 Frame, Seat ........................................... 1

5 1-803035 Rivet 3/16 x 1/4 ......................................9

6 98-5975 Washer, Spring Disc 3/8 ........................ 8

7 103-0291 Cushion, Armrest LH.............................. 1

8 103-0292 Cushion, Armrest RH ............................. 1

9 103-2882 Decal, Exmark Logo............................... 2

10 103-3520 Seat, Back ............................................. 1

11Q 103-4553 Asm, ROPS Fold Pin ............................. 2

12 1-543401 Spacer, Seat Track ................................ 2

13 103-8383 Screw, HW H 1/4-20 x 3/4 Taptite ........... 11

14 103-5161 Link, Seat Stop ......................................2

15 103-6761 Asm, Seat Frame................................... 1

16 103-6765-03 Latch, Seat ............................................ 1

17 32128-33 Nut, W hizlock 1/4-20 .............................. 2

18 9264964 Bolt, HWH 5/16-18 x 3/4 Tap .................4

19 32128-20 Nut, W hizlock 5/16-18 ............................ 16

20 3296-73 Nut, Nyloc 1/4-20 ...................................2

21 103-8316 Spring .................................................... 1

22 103-8826 Link, Lower Seat Stop ............................ 2

23 103-6761 Plate, Seat Mount .................................. 1

24 1-633080 Bushing.................................................. 2

25X 109-2817 Kit, ROPS .............................................. 1

26 107-2102 Decals, Warning .................................... 1

DESCRIPTION

Qty.

Exmark black touch up spray paint – Gloss black

Q Includes ROPS fold pin plus hairpin, item #27.

X Rollover protection frame is serviced as a complete assembly only. Includes complete ROPS frame, mounting

hardware, fold pivot and locking hardware, seat frame assembly item #15 and seat belt assembly item #39.

O Includes armrests and seat back decal. Does not include seat belt or tracks.
 Does not include item #19 or #48.

Item

Part No.

27 107-3155 Cotter, Hair Pin Double Loop ................. 2

28 109-3633-03 Spacer, Seat Mount............................... 2

29 3296-7 Nut, Nyloc 7/16-20................................. 2

30 109-0768 Skirt, Rubber.......................................... 1

31 109-3547 Asm, Front Console W/Decal ................ 1

32 109-2008 Cushion, Seat Bottom/W Switch............ 1

33 109-2009 Grp, Seat Track ..................................... 1

34O 109-2005 Asm, Seat W/Decal ............................... 1

35 109-2360 Decal, Top Console ............................... 1

36 3256-14 Washer, #10 Std.................................... 9

37 3296-39 Nut, Nyloc 3/8-16 ................................... 4

38 116-1003 Decal, Service Aid ................................. 1

39 110-0883 Kit, Seatbelt........................................... 1

40 242-50 Nut, Lug 1/2-20...................................... 8

41 283-69 Pin, Clevis 1/2 x 3 1/2............................ 2

42 322-5 Screw, HH 5/16-18 x 1........................... 8

43 322-7 Screw, HH 5/16-18 x 1 1/2..................... 2

44 323-6 Screw, HH 3/8-16 x 1............................. 2

45 323-8 Screw, HH 3/8-16 x 1 1/2....................... 8

46 323-9 Screw, HH 3/8-16 x 1 3/4....................... 2

47 3212-4 Screw, HH 7/16-20 x 1........................... 2

48 3296-29 Nut, Nyloc 5/16-18 ................................. 4

49 3256-3 Washer, 5/16 Std................................... 6

50 3256-4 Washer, 3/8 Std..................................... 1

51 3290-357 Nut, Whizlock 3/8-16 ............................. 8

52 109-3479 Asm, Wheel & Tire (LH)......................... 1

109-3156 Wheel .................................................... 1

103-6771 Tire, 24x12-12 4 Ply............................... 1

DESCRIPTION

Qty.

3

MAIN FRAME GROUP

4

MAIN FRAME GROUP (cont.)

Item

Part No.

1 1-513747 Decal, Battery ........................................ 1

2 1-523157 Washer .................................................. 4

3 1-643189 Keeper, Rubber Latch ............................ 2

4 1-643339 Belt Routing, Decal ................................1

5 1-806003 Hairpin, Cotter........................................ 2

6 1-806005 Hairpin, Cotter........................................ 1

7 1-808285 Pin, Clevis 3/8 x 1 1/8 ............................ 2

8 5-0652 Spacer ................................................... 4

9 93-2699 Pin .........................................................2

10 98-4361 Decal, Warning ...................................... 2

11 98-5954 Decal, Danger ........................................ 1

12 100-1663 Pin ......................................................... 2

13 103-1166 Tube, Pump Link Spacer ....................... 2

14 32151-36 Ring, Retaining ......................................4

15 103-3270 Decal, 3750 RPM...................................1

16 103-5881 Decal, Guard..........................................2

17 103-7218 Decal, Pump Fan Warning ..................... 1

18 109-6069 Asm, Frame W/Decals........................... 1

19 103-9727 Latch, Hitch............................................ 2

20 107-2112 Decal, Danger........................................ 1

21 107-8042 Bumper, Rubber..................................... 2

22 109-0075 Asm, Hitch .............................................1

23 109-0080-03 Wld, Hitch .............................................. 1

24 109-0325 Pin, Full Fold.......................................... 1

25 109-0411 Spring .................................................... 2

26 109-0435 Bushing.................................................. 4

27 109-0450 Asm, Spring ...........................................2

28 109-2772 Asm, Floorpan W/Decal .........................1

29 109-2773 Asm, Spring Bellcrank W/Decal (RH) ..... 1

30 109-2774 Asm, Spring Bellcrank W/Decal (LH) ..... 1

DESCRIPTION

Qty.

Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).
Exmark black touch up spray paint – Gloss black

Item

Part No.

31 109-0634 Wld, Spring Anchor................................ 4

32 109-1256-03 Arm, Pivot.............................................. 2

33 109-1257-03 Hook, Hood............................................ 2

34 109-3197 Hood, W/Decal ...................................... 1

35 109-2857 Asm, Hood............................................. 1

36 109-6070 Asm, Hood Support W/Decals .............. 1

37 109-2004 Roller, Lock Lever.................................. 2

38 32128-20 Nut, Whizlock 5/16-18 ........................... 4

39 109-2355 Decal, Spring Loaded ............................ 2

40 109-2356 Decal, Motion Control ............................ 1

41 109-2357 Decal, Motion Cntl/Park Brake............... 1

42 109-2396 Decal, Pump Drive Release................... 1

43 302-19 Zerk, 1/4-28 Str...................................... 2

44 322-3 Screw, HH 5/16-18 x 3/4........................ 4

45 322-4 Screw, HH 5/16-18 x 7/8........................ 8

46 323-11 Screw, HH 3/8-16 x 2 1/4....................... 2

47 323-8 Screw, HH 3/8-16 x 1 1/2....................... 2

48 325-18 Screw, HH 1/2-13 x 4 1/2....................... 2

49 32120-47 Ring, Retaining ......................................4

50 3256-23 Washer, 5/16 SAE ................................. 20

51 3256-24 Washer, 3/8 SAE ................................... 4

52 3256-26 Washer, 1/2 SAE ................................... 8

53 3256-27 Washer, 5/8 SAE ................................... 2

54 3269-24 Rivet...................................................... 4

55 3296-23 Nut, Nyloc 1/2-13 ................................... 2

56 3296-29 Nut, Nyloc 5/16-18 ................................. 8

57 3296-39 Nut, Nyloc 3/8-16 ................................... 4

58 32120-19 E-Ring ................................................... 2

59 109-2114 Decal, FrontRunner ............................... 1

DESCRIPTION

Qty.

5

MAIN FRAME GROUP (cont.)

6

REAR FRAME GROUP

Item

Part No.

1 1-513746 Decal, Muffler......................................... 2

2 1-543508 Cup, Bearing Tapered Roller.................. 4

3 1-543509 Cone, Bearing Tapered Roller................ 4

4 1-543511 Seal, Grease.......................................... 2

5 1-633508 Washer, Spring Disc ..............................6

6 1-633585 Bearing, Cone Tapered Roller................ 4

7 1-643188 Latch...................................................... 2

8 1-811010 Plug ....................................................... 2

9 103-0063 Seal, Double Lip..................................... 4

10 103-2768 Guard, Seal............................................4

11 103-3051 Spacer, Nut............................................ 4

12 923786 Rivet ...................................................... 4

13 109-9127 Asm, Caster Wheel................................ 2

14 103-4882 Cap, Grease .......................................... 2

15 103-5156 Axle, Caster ........................................... 2

16 103-6825 Bearing, Sleeve...................................... 2

17 103-7957-03 Wld, Dual Caster Tube........................... 1

18 103-8347 Asm, Dual Rear Wheels......................... 1

19 103-9045-03 Wld, Rear Frame Dual Wheel ................ 1

20 103-9051 Bearing, Thrust ...................................... 2

21 103-9789-03 Guard, Hose .......................................... 1

Exmark black touch up spray paint – Gloss black

Description

Qty.

Item

Part No.

22 103-9868-03 Wld, Caster Fork ................................... 2

23 103-9974 Washer .................................................. 1

24 105-7699 Strip, Seal .............................................. 2

25 109-2769 Asm, Rear Guard W/Decals (27 HP) ..... 1

109-6071 Asm, Rear Guard W/Decals (31 HP) ..... 1

26 109-0414-03 Cover, Muffler (27 HP) ........................... 1

109-5580-03 Cover, Muffler (31 HP)........................... 1

27 302-19 Zerk, 1/4-28 Str...................................... 1

28 322-3 Screw, HH 5/16-18 x 3/4........................ 5

29 323-6 Screw, HH 3/8-16 x 1............................. 4

30 325-39 Screw, HH 1/2-13 x 9 1/2....................... 2

31 325-5 Screw, HH 1/2-13 x 1 1/4....................... 6

32 327-24 Screw, HH 5/8-11 x 5 3/4....................... 1

33 3256-23 Washer, 5/16 SAE ................................. 5

34 3256-4 Washer, 3/8 Std..................................... 2

35 3290-357 Nut, Whizlock 3/8-16 ............................. 4

36 3296-23 Nut, Nyloc 1/2-13 ................................... 2

37 3296-51 Nut, Nyloc 3/4-10 ................................... 2

38 3296-53 Nut, Nyloc 5/8-11 ................................... 1

39 32128-20 Nut, Whizlock 5/16-18 ........................... 5

40 32128-49 Nut, Whizlock 1/2-13 ............................. 6

Description

7

Qty.

PTO DRIVE GROUP

Item Part No.

1 1-413088 Spacer ................................................... 1

2V 1-803050 Setscrew, 5/16-18 x 3/4 ......................... 2

3 1-807525 Bolt, Carriage 3/8-16 x 2 3/4 .................. 1

4 5-1336 Key, Machine 1/4 x 1/4 x 2..................... 1

5 92-8799 Bearing, Flanged.................................... 2

6 98-5975 Washer, Spring Disc 3/8 ........................ 5

7 103-2916 Guard, Top............................................. 2

8 116-0133 Spring, Extension...................................1

9 103-3504 Bearing, Spherical.................................. 2

10 103-3506 Seal, Single Lip...................................... 2

11 32151-13 Ring, Retaining ......................................2

12 103-6409 Asm, Pump Idler .................................... 1

13 103-6779-03 Shaft, Line ............................................. 1

14 103-6813 Pulley, Idler ............................................ 1

15 103-6814 Sheave ..................................................1

16 103-6836 Spacer ................................................... 1

17 103-8012 Spacer, Spring ....................................... 1

DESCRIPTION

Qty.

Exmark black touch up spray paint – Gloss black

V Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on setscrew, item #2.

Item Part No.

18 103-8073 Asm, Linedrive Idler............................... 1

19 103-8366-03 Guard, Linedrive .................................... 1

20 109-7588 Belts, Matched Pair ............................... 1

21 106-7159 O-Ring ................................................... 2

22 109-0431-03 Arm, Idler............................................... 1

23 251-347 Bearing, Ball Deep Groove .................... 1

24 302-40 Zerk, 90° 1/4-28..................................... 1

25 323-10 Screw, HH 3/8-16 x 2............................. 1

26 323-16 Screw, HH 3/8-16 x 4............................. 1

27 323-6 Screw, HH 3/8-16 x 1............................. 4

28 323-7 Screw, HH 3/8-16 x 1 1/4....................... 3

29 323-8 Screw, HH 3/8-16 x 1 1/2....................... 1

30 323-9 Screw, HH 3/8-16 x 1 3/4....................... 4

31 3218-3 Nut, Jam 3/8-16 ..................................... 1

32 3256-4 Washer, 3/8 Std..................................... 1

33 3290-357 Nut, Whizlock 3/8-16 ............................. 15

34 32120-10 Ring, Retaining ......................................2

DESCRIPTION

Qty.

8

PARK BRAKE GROUP

Item Part No.

1 1-633102 Bearing, Flanged....................................2

2 323-4 Screw, HH 3/8-16 x 3/4.......................... 4

3 3290-357 Nut, Whizlock 3/8-16.............................. 9

4 109-0262 Spacer ................................................... 2

5 3256-4 Washer, 3/8 Std ..................................... 6

6 1-633630 Grommet................................................ 4

7 322-9 Screw, HH 5/16-18 x 1 3/4 .....................2

8 3296-29 Nut, Nyloc 5/16-18 ................................. 4

9 322-6 Screw, HH 5/16-18 x 1 1/4 .....................2

10 103-0126 Bushing.................................................. 2

11 3256-3 Washer, 5/16 Std ................................... 2

12 109-0132 Asm, Brake Linkage............................... 2

13 103-8625-03 Wld, Brake Cross Shaft ......................... 1

14 3296-59 Nut, Nyloc 3/8-16 Thin ........................... 2

Exmark black touch up spray paint – Gloss black

DESCRIPTION

Qty.

Item Part No.

15 1-513140 Bearing .................................................. 2

16 103-0608 Balljoint.................................................. 1

17 103-4399 Rod, Linkage Brake ............................... 1

18 3219-3 Nut, Hex 3/8-24...................................... 1

19 3256-24 Washer, 3/8 SAE ................................... 1

20 3272-10 Pin, Cotter 1/8 x 3/4............................... 1

21 323-7 Screw, HH 3/8-16 x 1 1/4....................... 1

22 32120-47 Ring, Retaining ......................................1

23 1-633268 Grip, Brake Lever................................... 1

24 103-4388 Spring.................................................... 2

25 109-0130 Link, Brake ............................................ 2

26 109-0131 Clevis, Brake ......................................... 2

27 109-1192 Asm, Brake Lever W/Grip & Bearings.... 1

28 323-39 Screw, HH 3/8-16 x 5............................. 2

DESCRIPTION

Qty.

9

MOTION CONTROL GROUP

Item Part No.

1 1-303105 Yoke, Adjustable .................................... 2

2 1-323245 Spring, Compression ............................. 2

3 1-403180 Screw, HH 5/16-18 X 1 1/4 Sp ...............4

4 1-543017 Balljoint .................................................. 2

5 1-603735 Bushing, Flanged ................................... 2

6 1-603737 Bolt, Neutral Return ............................... 2

7 1-603807 Spring .................................................... 2

8 1-633102 Bearing, Flanged....................................4

9 1-633152 Balljoint, (LH) ......................................... 2

10V 1-803022 Setscrew, 5/16-18 X 5/8 ......................... 2

11 1-804524 Nut, Hex 5/16-24 (LH) ............................ 4

12 1-808280 Pin, Clevis 5/16 X 1................................2

13 98-5975 Washer, Spring Disc 3/8 ........................6

14 103-1361 Spacer ................................................... 2

15 103-3457 Asm, Handle W/Grip (LH) ...................... 1

16 103-3458 Asm, Handle W/Grip (RH)......................1

17 103-3456 Grip, Control Lever.................................2

18 109-3623 Wld, Lever Control (LH) ......................... 1

19 109-3622 Wld, Lever Control (RH)......................... 1

20 103-8262 Tab, Motion Cntrl ................................... 2

Description

Qty.

Exmark black touch up spray paint – Gloss black.
V Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on screw, item #10 & screw, item #32 going into control shaft

weldment item #21.

Item Part No.

21 109-3618 Wld, Control Shaft ................................. 2

22 3290-357 Nut, Whizlock 3/8-16 ............................. 8

23 3296-29 Nut, Nyloc 5/16-18 ................................. 4

24 32128-20 Nut, Whizlock 5/16-18 ........................... 8

25 106-5335 Washer, Wave....................................... 6

26 103-8286-03 Wld, Pump Ctrl (RH) ............................. 1

27 103-8285-03 Wld, Pump Ctrl (LH) ..............................1

28 103-8300 Link, Tracking Rod................................. 2

29 109-2339 Damper, Motion Control......................... 2

30 322-12 Screw, HH 5/16-18 X 2 1/2 .................... 2

31 322-6 Screw, HH 5/16-18 X 1 1/4 .................... 2

32 323-4 Screw, HH 3/8-16 X 3/4 ......................... 10

33 323-6 Screw, HH 3/8-16 X 1 ............................ 4

34 3217-6 Nut, Hex 5/16-18.................................... 4

35 3219-2 Nut, Hex 5/16-24.................................... 6

36 3220-2 Nut, Jam 5/16-24 ................................... 6

37 3256-2 Washer, 1/4 Std..................................... 2

38 3272-5 Pin, Cotter 3/32 X 1/2 ............................ 2

39 109-2582 Asm, Tracking Rod ................................ 2

Description

Qty.

10

FUEL GROUP

Item Part No.

5

7Q 1-633023 Stud, Fuel Tank ..................................... 4

10 1-807513 Bolt, Carriage #10-24 x 1/2 .................... 4

11 95-8972 Grommet................................................ 1

12V 103-2605 Fitting, Fuel Bulkhead W/Strainer .......... 1

13 109-7413 Decal, Console ...................................... 1

14 109-7415 Control, Throttle ..................................... 2

1 1-303077 Clamp, Fuel Line....................................4

2 1-303334 Washer, Spring Disc 5/16 ...................... 2

3 1-323385 Knob, 3 Prong........................................ 1

4 109-7416 Control, Choke ....................................... 1

Kohler
Briggs

6 1-603770 Valve, Fuel............................................. 1

8 1-633349 Spring, Compression ............................. 4

9 1-805005 Washer, Lock 5/16 Heavy ...................... 2

103-2784 O-Ring ................................................... 1

Description

Part No. 2405010 Fuel Filter ..................1

Part No. 695327 Fuel Filter .................... 1

Qty.

Item Part No.

15 109-0303 Hose, Fuel Line 7" ................................. 2

16 109-0346 Cap, Fuel (Gas) .....................................1

17 109-4714 Console ................................................. 1

18 3296-2 Nut, Nyloc #10-24.................................. 4

19 3296-47 Nut, Nyloc 5/16-18 Thin .........................6

20 109-1202 Hook, Fender......................................... 1

21 109-1213 Gauge, Fuel ........................................... 1

22 109-1226 Asm, Fender.......................................... 1

23 109-3627 Asm, Fuel Tank .....................................1

24 109-2572 Bracket, Fender..................................... 1

25 109-2652 Bolt, Fender ........................................... 1

26X 109-2661 Screw, PPH #10-24 x 1/2....................... 4

27 322-3 Screw, HH 5/16-18 x 3/4........................ 4

28 109-2358 Decal, Ignition ........................................ 1

29 3256-23 Washer, 5/16 SAE ................................. 11

Exmark black touch up spray paint – Gloss black

Q Use Pro-Lock, Retaining Type (P/N 1-840023, .5ml tube) on stud threads, item #7 going into the tank.
V Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on fuel fitting, item #11.

 Refer to Engine Owner’s Manual (Fuel Filter Must be 15 Micron or smaller).
X Snug fit only on slotted holes, Do Not Overtighten, tank must be able to expand.

Description

Qty.

11

ENGINE GROUP 27HP

(

.

.

.

Item Part No.

1 1-603610 Washer, Spring Disc 7/16 ...................... 2

2 1-633179 Spacer ................................................... 1

3 1-653291 Gasket, Exhaust Manifold ......................2

4V 1-803050 Setscrew, 5/16-18 x 3/4 ......................... 2

5 1-805005 Washer, Lock 5/16 Heavy ...................... 4

6 13-2840 Key, Machine 1/4 x 1/4 x 1 1/4 ............... 1

7 52-4780 Rod, Belt................................................ 1

8 109-1012 Plug, Oil Drain........................................ 1

9 98-5975 Washer, Spring Disc 3/8 ........................ 5

10 103-0152 Keeper, Clutch ....................................... 1

11 103-3535 Kit, Cable Heat Shield ............................ 1

12 109-6627 Kit, Clutch ..............................................1

13 103-6774 Sheave ..................................................1

14X 103-7480 Kit, Muffler ............................................. 1

15 103-8813 Hub, Adapter..........................................1

16 109-2987 Asm, Hose Oil Drain W/Plug.................. 1

Exmark black touch up spray paint – gloss black.

 Use a Teflon Pipe Sealant or equivalent on threads.

V Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on screws, item #4, #20, #21 & #24
X Includes item #3.

O Includes item 29

Replacement Parts List

Refer to Engine Owner’s Manual)

Description

Engine Oil Filter...................................

Engine Air Filter...................................

Safety Filter.........................................

Description

Kohler Part No.

5205002-S
2508301
2508304

Qty.

Item Part No.

17 109-1830-03 Bracket, Air Cleaner............................... 1

18 321-4 Screw, HH 1/4-20 x 3/4.......................... 1

19 322-3 Screw, HH 5/16-18 x 3/4........................ 2

20V 322-5 Screw, HH 5/16-18 x 1........................... 3

21V 323-10 Screw, HH 3/8-16 x 2............................. 4

22 323-6 Screw, HH 3/8-16 x 1............................. 1

23 324-2 Screw, HH 7/16-14 x 3/4........................ 2

24V 3212-5 Screw, HH 7/16-20 x 1 1/4..................... 1

25 3253-6 Washer, Lock 7/16................................. 2

26 3256-4 Washer, 3/8 Std..................................... 1

27 3290-357 Nut, Whizlock 3/8-16 ............................. 4

28 32128-20 Nut, Whizlock 5/16-18 ........................... 2

29 32128-33 Nut, Whizlock 1/4-20 ............................. 1

30 33014-00 Nut, Hex M8-1.25................................... 4

31O 103-3535 Kit, Cable Heat Shield............................ 1

Description

Qty.

12

ENGINE GROUP 31HP

(

.

Item Part No.

1 1-603610 Washer, Spring Disc 7/16 ...................... 2

2 109-6874 Spacer, XP A/C Clutch Inner .................. 1

3 3256-23 Washer, 5/16 SAE .................................2

4V 1-803050 Setscrew, 5/16-18 x 3/4 ......................... 2

5 100-2436 Asm, Hood Air Intake W/Clamp ............. 1

6 13-2840 Key, Machine 1/4 x 1/4 x 1 1/4 ............... 1

7 109-5584 Anchor, Clutch ....................................... 1

8 103-1327 Filter, Air ................................................ 1

9 1-303334 Washer, Spring Disc 5/16 ...................... 4

10 103-0152 Keeper, Clutch .......................................1

11 103-1326 Filter, Safety Air ..................................... 1

12 109-6627 Kit, Clutch .............................................. 1

13 103-6774 Sheave .................................................. 1

14 103-1058 Bracket, Air Filter ................................... 1

15 109-5823 Hub, Adapter.......................................... 1

Exmark black touch up spray paint – gloss black.

 Use a Teflon Pipe Sealant or equivalent on threads.

V Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on screws, item #4, #20, #22 & #24

31HP Briggs & Stratton Replacement Parts List

Refer to Engine Owner’s Manual)

Description

Engine Oil Filter...................................

Description

Briggs Part No.

492932

Qty.

Item Part No.

16 109-1012 Plug, Oil Drain ....................................... 1

17 109-5583-03 Bracket, Air Cleaner............................... 1

18 103-5178 Asm, Canister Air Filter W/Hood............ 1

19 2412-42 Clamp, Hose.......................................... 2

20V 322-5 Screw, HH 5/16-18 x 1........................... 5

21 322-11 Screw, HH 5/16-18 x 2 1/4..................... 1

22V 3212-5 Screw, HH 7/16-20 x 1 1/4..................... 1

23 48-7710 Screw, HH M8-1.25 x 20mm .................. 2

24V 3274-105 Screw, Button Head 7/16-14 x 1 ............ 1

25 98-5975 Washer, Spring Disc 3/8 ........................ 2

26 322-10 Screw, HH 5/16-18 x 2........................... 3

27 32128-20 Nut, Whizlock 5/16-18 ........................... 6

28 109-4324 Asm, Hose Oil Drain ..............................1

29 109-5585 Hose, Air Intake..................................... 1

Description

Qty.

13

AUXILIARY HYDRAULIC GROUP

Item Part No.

1V 109-2853 Asm, Hydraulic Power Unit ....................1

2 109-2015 Hose, Hydraulic...................................... 1

3 109-2016 Hose, Hydraulic...................................... 1

4 109-0760 Adapter, 90°........................................... 2

109-1284 O-Ring (37° Flare #4).............................1

1-603923 O-Ring (SAE #4) .................................... 1

5 323-4 Screw, HH 3/8-16 x 5/8.......................... 2

6 98-5975 Washer, Spring Disc 3/8 ........................ 2

7 109-2812 Asm, Cylinder W/Decal .......................... 1

109-2856 Kit, Hyd Cylinder Seal ............................ 1

V Includes item #8.

Description

Qty.

Item Part No.

8 109-2663 Terminal, Ring 5/16 ............................... 2

9 109-1180 Pin, Cylinder Mount ............................... 1

10 109-2377 Decal, High Pressure Oil ....................... 1

11 1-806005 Hairpin, Cotter ....................................... 1

12 321-4 Screw, HH 1/4-20 x 3/4.......................... 1

13 3296-42 Nut, Nyloc 1/4-20................................... 1

14 103-1193 Clip, Loom ............................................. 2

15 109-2017 Adapter, Straight ................................... 2

109-1284 O-Ring (37° Flare #4) ............................ 1

1-603923 O-Ring (SAE #4).................................... 1

Description

Qty.

14

HYDRAULIC GROUP

Item Part No. Description Qty.

1 1-413088 Spacer ................................................... 1

2 32128-43 Nut, Whizlock 3/8-16.............................. 4

3 109-4076 Sheave, Idler.......................................... 1

4 1-805004 Washer, Lock 1/4 Heavy........................ 2

5 103-2739 Key, 5mm x 5mm x 32mm ..................... 2

6V 30-1710 Setscrew, 5/16-18 x 1 ............................ 4

7 98-5975 Washer, Spring Disc 3/8 ........................ 1

8 103-1828 Adapter, Running Tee............................ 3

1-603921 O-Ring (SAE #6) .................................... 1

9 109-0582 Asm, Hydraulic Reservoir W/Decal ........ 1

10 103-7615 Asm, Cap W/Gasket .............................. 1

11 103-1949 Gasket, Reservoir Cap........................... 1

12 103-1988 Clamp, Hose 11/16 ................................ 6

13 103-2146 Element Hydraulic Oil Filter.................... 1

14 103-2155 Adapter, 90°........................................... 2

15 1-603990 Adapter, Straight .................................... 3

103-1020 O-Ring (37° Flare #6).............................1

1-603920 O-Ring (SAE #8) .................................... 1

16 103-2259 Head, Filter ............................................1

17 103-2916 Guard, Top............................................. 2

18 116-0133 Spring, Extension...................................1

19 103-3504 Bearing, Spherical.................................. 2

20 103-3506 Seal, Single Lip...................................... 2

21 103-6409 Kit, Pump Idler ....................................... 1

22 1-303287 Tie, Cable 5 1/2 (Small) ......................... 1

23 103-8011 Spacer, Spring ....................................... 1

24 103-8357 Pump, Hydro W/Fan (LH) ......................1

25 103-8358 Pump, Hydro W/Fan (RH) ...................... 1

26 106-7159 O-Ring ................................................... 2

27 109-5949-03 Arm, Idler ............................................... 1

28 109-0816 Belt ........................................................ 1

29 109-0899 Hose, Hydraulic...................................... 1

Exmark black touch up spray paint – gloss black.

V Use Prolock, Nut Type (P/N 1-840022, .5ml tube) on setscrews, items #6.

O Wheel Motor Service Kits

Part No. Description Qty.

103-9762 Kit, Seal ....................................................... 1

103-9763 Handle, Actuating......................................... 1

103-9764 Clip, Retaining.............................................. 1

103-9765 Nut, Hex Toplock 1-20UNEF-2B .................. 1

103-4242 Asm, Wheel Hub W/Studs ........................... 1

103-7447 Stud, Wheel 1/2-20 x 1/2.............................. 4

Item Part No. Description Qty.

30 109-0900 Hose, Hydraulic ..................................... 1

31 109-0901 Hose, Hydraulic ..................................... 1

32 109-0902 Hose, Hydraulic ..................................... 1

33 109-1008 Hose, Case Drain .................................. 2

34 109-1009 Hose, Hydraulic ..................................... 1

35 109-1010 Hose, Hydraulic ..................................... 1

36O 103-9519 Motor, Wheel (RH)................................. 1

37O 103-9520 Motor, Wheel (LH) ................................. 1

38 103-2153 Adapter, 90° .......................................... 2

103-1020 O-Ring (37° Flare #6) ............................ 1

1-603920 O-Ring (SAE #8).................................... 1

39 109-2202 Sheave .................................................. 2

40 109-4644 Hose, Hydraulic ..................................... 1

41 109-4645 Hose, Hydraulic ..................................... 1

42 302-40 Zerk, 90° 1/4-28..................................... 1

43 321-3 Screw, HH 1/4-20 x 5/8.......................... 2

44 321-6 Screw, HH 1/4-20 x 1............................. 2

45 323-16 Screw, HH 3/8-16 x 4............................. 1

46 323-7 Screw, HH 3/8-16 x 1 1/4....................... 7

47 325-10 Screw, HH 1/2-13 x 2 1/2....................... 8

48 3231-10 Bolt, Carriage 3/8-16 x 3 ........................ 1

49 3231-6 Bolt, Carriage 3/8-16 x 2........................ 1

50 3256-22 Washer, 1/4 SAE ................................... 2

51 3256-26 Washer, 1/2 SAE ................................... 8

52 3256-4 Washer, 3/8 Std.....................................

53 3290-357 Nut, Whizlock 3/8-16 ............................. 6

54 32120-10 Ring, Retaining ......................................2

55 32128-33 Nut, Whizlock 1/4-20 ............................. 2

56 32128-49 Nut, Whizlock 1/2-13 ............................. 8

57 116-0404 Decal, Hydraulic Tank............................ 1

58 3256-24 Washer.................................................. 1

 Hydro Pump Service Kits

Part No. Description Qty.

109-2863 Bearing, Input Shaft PR ............................... 1

109-2864 Kit, Cylinder Block 16CC PR........................ 1

109-2865 Bearing, Thrust PR ...................................... 1

109-2866 Kit, Overhaul Seal PR.................................. 1

109-2867 Plate, Valve PR............................................ 1

103-7488 Fan, Pump Cooling ...................................... 1

103-7489 Guard, Pump Fan ........................................ 1

As
Req’d.

15

HYDRAULIC GROUP

16

ELECTRICAL GROUP

Item Part No.

1 1-303335 Tie, Cable 7 5/16 (Large) ....................... 14

2 1-513374 Meter, Engine Hours .............................. 1

3■ 109-7608 Cable, Battery (+)................................... 1

4 1-543393 Insulator, Solenoid ................................. 2

5 1-543792 Wingnut, Nyloc 1/4-20............................ 2

6 1-603727 Clip, Loom ............................................. 2

7 1-633110 Switch .................................................... 1

8 1-633111 Switch .................................................... 1

9 1-633181 Plate, Tapped ........................................ 2

10 1-633307 Cable, Ground (-) ................................... 1

11 1-633651 Bolt Battery Hold Down .......................... 2

12 107-9277-03 Strap, Battery Hold Down....................... 1

13 1-643275 Relay, 12VDC 40 Amp (27HP)...............2

1-643275 Relay, 12VDC 40 Amp (31HP) ............... 3

14 109-2589 Harness, Auxiliary Hydraulics.................1

15 1-805005 Washer, Lock 5/16 Heavy ...................... 4

16 1-807513 Bolt, Carriage #10-24 x 1/2 .................... 2

17 82-2190 Switch.................................................... 2

18 109-4813 Switch .................................................... 1

19 109-4736 Asm, Switch W/Nut ................................ 1

20 103-0498 Nut, Ignition............................................ 1

21 103-5218 Module, Seat Delay................................1

22 103-5221 Switch, PTO........................................... 1

23X 103-9268 Harness, Wiring (27HP) ......................... 1

109-5593 Harness Wiring (31HP) .......................... 1

Exmark black touch up spray paint – gloss black.

X Use dielectric grease on all wiring harness connectors.

■ Includes items 4 & 26.
 Not shown.

Description

Qty.

Item Part No.

24 109-0742 Contactor, Reversing Polarity ................ 1

25 109-2398 Breaker, Circuit 40A............................... 1

26 109-2407 Insulator, Battery (+).............................. 1

27 109-2571 Cover, Circuit Breaker ........................... 1

28 240-3 Grommet ............................................... 1

29 321-4 Screw, HH 1/4-20 x 3/4.......................... 2

30 322-5 Screw, HH 5/16-18 x 1........................... 2

31 3219-2 Nut, Hex 5/16-24.................................... 4

32 3229-2 Bolt, Carriage 1/4-20 x 1........................ 2

33 3250-27 Screw, PPH #10-24 x 7/8....................... 2

34 3256-22 Washer, 1/4 SAE ................................... 4

35 3256-23 Washer, 5/16 SAE ................................. 2

36 3290-500 Screw, PPH #10-24 x 5/8....................... 6

37 3296-2 Nut, Nyloc #10-24.................................. 6

38 3296-29 Nut, Nyloc 5/16-18 ................................. 2

39 3296-42 Nut, Nyloc 1/4-20 ................................... 2

40 32128-33 Nut, Whizlock 1/4-20 ............................. 2

41 32149-8 Nut, Keps 10-32 UNF YZ ....................... 2

42 103-2106 Key, Exmark Logo ................................. 1

43 1-816001 Fuse, 20 Amp (27HP)............................ 2

1-816001 Fuse, 20 Amp (31HP) ............................ 1

44 109355 Fuse, 15 Amp ........................................ 1

45 1-816003 Fuse, 30 Amp (31HP)............................ 1

Description

17

Qty.

ELECTRICAL DIAGRAM – 27HP KOHLER

18

ELECTRICAL DIAGRAM – 31HP

19

ELECTRICAL LOGIC SCHEMATIC – 27HP

20

ELECTRICAL LOGIC SCHEMATIC – 31HP

21

Item Part No.

1 116-0404 Decal, Hydraulic Tank ............................ 1

2 103-5881 Decal, Rotating Devices......................... 2

3 103-7218 Decal, Pump Fan Warning..................... 1

4 109-2355 Decal, Spring Loaded ............................ 2

5 103-3270 Decal, 3750 Rpm ................................... 1

6 98-5954 Decal, Missing Cover ............................. 1

7 109-2377 Decal, High Pressure Oil........................ 1

8 109-2360 Decal, Top Console ............................... 1

9 116-1003 Decal, Service Aid ................................. 1

10 107-2102 Decal, Folding Rops Warning ................ 1

11 109-2396 Decal, Pump Drive Release ................... 1

12 1-643339 Decal, Routing Belt ................................ 1

Description

DECALS GROUP

Qty.

Item Part No.

13 109-7413 Decal, Console ...................................... 1

14 103-2882 Decal, Exmark Logo .............................. 2

15 1-513747 Decal, Battery ........................................ 1

16 103-2076 Decal, Caution Hot Surface ................... 2

17 107-2112 Decal, Warning...................................... 1

18 109-2356 Decal, Motion Control ............................ 1

19 109-2357 Decal, Motion Cntl/Park Brk................... 1

20 109-2358 Decal, Ignition ........................................ 1

21 98-4361 Decal, Warning ...................................... 2

22 109-2114 Decal, Frontrunner................................. 2

109-2851 Kit, Decal

Description

Qty.

22

NOTES

23

NOTES

24

SERVICE RECORD

Date

Description of Work Done Service Done By

25

-26-

© 2008 Exmark Mfg. Co., Inc. Part No. 4500-341 Rev. A
Industrial Park Box 808 [phone]
Beatrice, NE 68310 Fax [phone]
All Rights Reserved Printed In USA