Exmark Frontrunner 4500-497 User Manual

FRONTRUNNERTM

AIR-COOLEDMODELS

ForSerialNos.
790,000&Higher

PartNo.4500-497Rev.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.

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

Contactusatwww.Exmark.com.

2

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.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

3

Contents

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

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

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

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

SafetyandInstructionalDecals.....................11

Specications.......................................................15

ModelNumbers............................................15

Systems.........................................................15

Dimensions...................................................17

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

ProductOverview................................................18

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

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

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

OperatingInstructions..................................20

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

Maintenance.........................................................24

RecommendedMaintenanceSchedule(s)...........24

PeriodicMaintenance.......................................25

CheckEngineOilLevel.................................25

CheckBatteryCharge....................................25

CheckSafetyInterlockSystem.......................26

CheckRolloverProtectionsSystems(Roll

Bar)Pins...................................................27

CheckSeatBelt..............................................27

CheckforLooseHardware............................27

ServiceAirCleaner........................................27

ChangeEngineOil........................................27

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

CheckTirePressures.....................................28

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

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

LubricateRearCasterWheelHub(s)...............29

LubricateBrakeHandlePivot........................30

LubricateBrakeRodBushings.......................30

LubricateMotionControlBronze

Bushings...................................................30

LubricateMotionControlShaft.....................30

LubricateSteeringLinkageRodEnds.............30

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

ChangeHydraulicSystemFilter.....................31

CheckWheelHubLocknuts..........................31

ThreadLockingAdhesives.............................31

DielectricGrease...........................................32

Adjustments.....................................................32

PumpDriveBeltTension...............................32

PumpDriveBeltReplacement.......................32

ParkBrakeAdjustment..................................32

MotionControlLinkageAdjustment.............33

WeightTransferSpringAdjustment...............34

CasterPivotBearingsPre-Load

Adjustment...............................................35

ClutchShim..................................................35

Cleaning...........................................................37

CleanEngineCoolingSystem........................37

RemoveAccumulatedDebrisfrom

Engine(Briggs&StrattonUnits

Only).........................................................37

RemoveEngineShroudsandCleanCooling

Fins...........................................................38

WasteDisposal..............................................38

Troubleshooting...................................................39

Schematics...........................................................41

4

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.

•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

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.

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

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

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

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.

•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.Useseatbelts
withtherollbarintheraisedandlockedposition.

•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.

DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.

WARNING

OperatingaFrontRunnertractorwithoutan
approvedExmarkfrontmountattachment
increasesthepossibilityofforwardtipover.
Tip-overcouldcauseseriousinjuryordeath.

WhenoperatingaFrontRunnertractor
withoutanapprovedExmarkfrontmount
attachment,observethefollowing:

•Limitoperationtominimumrequiredto
installadifferentfrontmountattachment.

•Minimizespeedanduseextremecaution.

•Onlyoperateonaatlevelsurface.

•DoNotoperateupordownatrailerramp.

•Avoidsuddenaccelerationordeceleration.

–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.

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.

7

Safety

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
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.

•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15
degrees

2.DangerZone-Useawalkbehindmowerand/orhand
trimmeronslopesgreaterthan15degrees,near
drop-offsandwater.

3.Water

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

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

•Avoidsuddenstopswhenmowingdownhill
becausethemowermaytipforwards.

•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandlossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.

•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.

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

•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
drivingunderanyobjectsandDoNotcontact
them.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.

•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.

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

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Intheeventofarollover,taketheunittoan
AuthorizedServiceDealertohavetheROPS
inspected.

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.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

9

Safety

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.

10

SafetyandInstructionalDecals

Safety

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

1-513747

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

103-3270

1-643339

103-5881

98-4361

103-7218

98-5954

103-2076

11

Safety

109-2355

109-2356

1.Fast3.Neutral

2.Slow

4.Reverse

107-2102

107-2112

109-2357

1.Fast4.Reverse

2.Slow

3.Neutral6.ParkBrake—Engage

5.ParkBrake—Release

12

Safety

109-2358

109-2377

109-7413

1.Cylinder—extend4.Slow

2.Cylinder—retract5.Choke—on

3.Fast

109-2396

6.Choke—off

109-7949

116-0404

13

Safety

116-1003

109-2360

14

Specications

ModelNumbers

SerialNos:790,000andHigher

FR27KC;FR31BV

Specications

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.

15

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:TwoHydroGearPR16cc
variabledisplacementpistonpumps.

•WheelMotors:HydroGearplanetaryreduction
motors.

•HydraulicOilType:UseExmarkPremiumHydro
oil.

•HydraulicOilCapacity:5.2qt.(4.9L)

•HydraulicFilter:Replaceablecartridgetype.

P/N103-2146:25microns,Nobypass

•Speeds:

0-10.5mph(16.9km/hr)forward

0-6.6mph(10.6km/hr)reverse

•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.

Tires&Wheels

Drive

Pneumatic
(Air-Filled)

Quantity

TreadAT101

Size24x

PlyRating

Pressure

222

12.00-12

4

9psi
(62kPa)

Front
Caster

Semi­Pneumatic

SmoothSmooth

9x3.50-413x6.5-6

CuttingDeck

(SoldSeparately)

•ModelNumbers:

–FR524

–FR604

–FR724

•CuttingWidth:

–52inch(132cm)

–60inch(152cm)

–72inch(183cm)

•Discharge:Side

•BladeSize:(3ea.)

–52inchDeck:18.00inches(45.7cm)

RearCaster
(DualTail
Wheel)

Semi­Pneumatic

–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)

16

Specications

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

•MulchingKit:Optional

•Bagger:Optional

Dimensions

OverallWidth:

Without
Deck

Deector
Up

Deector
Down

OverallLength:

Withoutdeckandoor
panfolded

52inch
Deck

49.0inches
(124.5cm)

53.3inches
(135.4cm)

64.0inches
(163cm)

60inch
Deck

49.0inches
(124.5cm)

61.4inches
(156cm)

72.0inches
(183cm)

27HPKohler&31HP
Briggs&Stratton

82.3inches(209.0cm)

72inch
Deck

53.0inches
(135cm)

73.4inches
(186cm)

84.3inches
(214cm)

MinimumTurningRadius

55.25inches(140.3cm)

CurbWeight:

Withoutdeck911lb(413kg)

52inchDeck

60inchDeck

72inchDeck

1303lb(591kg)

1348lb(611kg)

1397lb(634kg)

TorqueRequirements

BoltLocation

EngineMountingBolts

WheelLugNuts

WheelMotorMounting
Bolts

WheelHubLockNut210-250ft-lb

RolloverProtectionSystem
(RollBar)MountingBolts

ClutchRetainingBolt
(securedwiththreadlocker)

Torque

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

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

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

(285-339N-m)

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

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

52inchDeck114.3inches(290.3cm)

60inchDeck114.3inches(290.3cm)

72inchDeck114.3inches(290.3cm)

OverallHeight:

RollBar-UpRollBar-Down

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

TreadWidth:(CentertoCenterof
Tires,Widthwise)

52inchDeck60inchDeck72inchDeck

41.4inches
(105.2cm)

41.4inches
(105.2cm)

45.4inches
(115.3cm)

WheelBase:(CenterofCasterTireto
CenterofDriveTire)

51.2inches(130.0cm)

17

Operation

ProductOverview

Figure4

1.FuelCap4.SeatBelt

2.RollBar

3.Controls

5.MotionControlLever

6.ParkingBrakeLever

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.

18

Operation

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 .

DriveWheelReleaseValves

Locatedonthetopleftfrontcornerofhydrostatic
pumps.

Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
pushedwithouttheenginerunning.

Witha5/8inchwrench,turnbothvalvesoneturn
counterclockwisetoreleasedrivesystem.Turn
clockwisetoresetsystem.DoNotovertighten.Do

Nottowmachine.

PTOEngagementSwitch

Locatedonrightfueltank.

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

HydraulicLiftSwitch

Locatedonrightfueltankconsole.

Thehydraulicliftswitchisusedtoraiseandlower
themowerdeck.

Pushthefrontportionofthehydraulicliftswitch
downtoraisethemowerdecktothedesiredheight.

Pushtherearportionofthehydraulicliftswitch
downtolowerthemowerdecktothedesiredheight.

FuelShut-OffValve

Locatedinfuellinebyfueltankandfuellter.

Thefuelshut-offvalveisusedtoshutoffthefuel
whenthemachinewillnotbeusedforafewdays,
duringtransporttoandfromthejobsite,andwhen
parkedinsideabuilding.

Rotatethevalve1/4turnclockwisetoshutofffuel.
Rotatethevalve1/4turncounterclockwisetoturn
onfuel.

FuelGauge

Locatedattherearoftherightfueltank.

Thefuelgaugemonitorstheamountoffuelinthe
rightfueltankonly .Thelefttankdoesnotholdfuel.

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.

19

Operation

RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem
(ROPS)

Important:Lowertherollbaronlywhen

absolutelynecessary.

1.Removethehairpincotterpinsandremovethe
tworollbarpins(Figure5).

2.Raisetherollbartotheuprightpositionand
installthetwopinsandsecurethemwiththe
hairpincotterpins(Figure5).

Important:Alwaysusetheseatbeltwiththe
rollbarintheraisedposition.Ensurethatthe
rearpartoftheseatissecuredwiththeseat
latch.

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.

Figure5

1.Rollbar3.Pin

2.Raisedposition4.Hairpincotterpin

OpentheFuelShut-OffValve

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

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

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.

20

Operation

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.

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).

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.

Figure6

1.HandlesOut(Neutral
Lock)

2.HandlesIn(Neutral)

3.FrontofUnit

4.Forward

5.Neutral

6.Reverse

7.NeutralLock

DrivingForward

1.Releasetheparkingbrake.

2.Movethemotioncontrolleversinwardtothe
centertotheneutralunlockedposition.

21

Operation

3.Tomoveforwardinastraightlineapplyequal
forwardpressuretobothlevers.

Toturnleftorright,pullthemotioncontrollever
backtowardneutralinthedirectiondesired.

Themachinewillmovefasterthefartherthe
motioncontrolleversaremovedawayfrom
neutral.

4.Tostop,pullthemotioncontrolleversbackto
theneutralposition.

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.

Figure7

1.HandlesOut(Neutral
Lock)

2.HandlesIn(Neutral)

3.FrontofUnit

DrivinginReverse

1.Movethemotioncontrolleversinwardtothe
centertotheneutralunlockedposition.

2.Tomoverearwardinastraightlineapplyingequal
pressurepullbothmotioncontrolleversrearward.

Toturnleftorright,releasepressureonthe
motioncontrollevertowardthedirectiondesired.

3.Tostop,pushthemotioncontrolleverstothe
neutralposition.

4.Forward

5.Reverse

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.

22

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.

Operation

Avoidsuddenaccelerationwhendrivingonaramp.

23

Maintenance

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.

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

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhublocknutstorquespecication.

WARNING

Theenginecanbecomeveryhot.Touching
ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

Aftertherst250hours

Beforeeachuseordaily

Every40hours

Every50hours

Every80hours

Every100hours

Every160hours

•Changethehydrauliclter.

•Checktheengineoillevel.

•Checkthesafetyinterlocksystem.

•Checktherolloverprotectionssystems(rollbar)pins.

•Checktheseatbelt.

•Checkforloosehardware.

•Cleantheenginecoolingsystem.

•Removeaccumulateddebrisfromengine.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasehitchandcylinderpivots.

•Greasethedualtailwheelpivot(ifapplicable).

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

•Removetheengineshroudsandcleanthecoolingns.

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Greasethefoldpivotpin.

•Lubricatethebrakehandlepivot.

•Lubricatethebrakerodbushings.

•Lubricatethemotioncontrolbronzebushings.

•Lubricatethesteeringlinkagerodends.

•Checkthesparkplugs.

24

Maintenance

MaintenanceService

Interval

Every500hours

Monthly

Yearly

MaintenanceProcedure

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Checkthewheelhublocknutstorquespecication.

•Checkthebatterycharge.

•Greasethefoldlockpin.

•Greasetherearcasterpivot.

•Greasethebeltidlers.

•Greasethemotioncontrolpivots.

•Greasethetransferspringends.

•Lubricatethecasterwheelhub(s).

•Lubricatethemotioncontrolshaft.

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.

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.

CheckBatteryCharge

ServiceInterval:Monthly

Important:Makesurethenegativebattery

cablesaredisconnectedandthebatterycharger
usedforchargingthebatteryhasanoutputof
16voltsand7ampsorlesstoavoiddamaging
thebattery(seechartforrecommendedcharger
settings).

25

Maintenance

Voltage
Reading

12.6or
greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent
Charge

100%

0%

Maximum
Charger
Settings

16volts/7
amps

16volts/7
amps

16volts/7
amps

14.4volts/4
amps

14.4volts/4
amps

14.4volts/2
amps

Charging
Interval

No
Charging
Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor
More

CheckSafetyInterlock
System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

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

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).

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).

Figure8

LeftSide—InsideofHitchShown

1.PTO“Kill”Switch

2.PTOSwitchArm

3.LowerdeckuntilarmDoesNotcontacttheswitch.

Runtheengineathalfthrottleandpulluponthe
PTOengagementswitch.

ThePTOmustnotengage.

26

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.

5.Checktheconditionoftheinnerelement.Replace
wheneveritappearsdirty,typicallyeveryother
timethepaperelementisreplaced.Cleanthebase
aroundtheinnerelementbeforeremoving,so
dirtdoesnotgetintotheengine.

6.DoNotwashorusepressurizedairtoclean
paperelementorinnerelement.

7.Reinstallelements.Positionthecoversothatthe
rubberdustejectorispointingdownwardand
securewithretainingclips.

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.

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.

3.Loosenretainingclipsandremoveaircleaner
compartmentcover.

4.Removepaperelement.Checkthecondition
ofthepaperelement.Replaceifdirty,bentor
damaged.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.

27

Maintenance

2.Tiltseatup.

3.Cleanareaaroundhydraulicreservoircapand
removecap.Oillevelshouldbetothetopofthe
bafeinsidethetank.Ifnot,addoil.UseExmark
PremiumHydrooil.Replacehydraulicreservoir
capandtightenuntilsnug.DoNotovertighten.

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).

Ifnot,addoil.UseonlyExmarkPremiumHydro
oil.Replacereservoirplugandtightenuntilsnug.
DoNotovertighten.

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

Barlugdrivetiresshouldbeinatedto9psi(62
kpa).

Turfdrivetiresshouldbeinatedto13psi(90
kpa).

3.Therearcastertiresaresemi-pneumaticandDo
Notneedtobeinated.

Note:DoNotaddanytypeoftirelinerorfoam
llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.CheckpumpandPTOdrivebelts.

3.Beltsarespringtensionedandnoadjustmentis
necessary.SeePumpDriveBeltTensionand
ReplacementsectionsinAdjustments.

Figure9

1.Auxiliaryhydraulicreservoirplug

5.Cleanareaaroundthereservoirplugandremove.
Oillevelshouldbeuptothereservoirplughole.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations
andlubricationschedule.

28

Maintenance

LubricationChart

Fitting

Locations

1.Hitch
andCylinder
Pivots

2.Fold
PivotPin

3.Fold
LockPin

4.Rear
CasterPivot

5.Belt
Idlers

6.Motion
Control
Pivots

7.Transfer
SpringEnds

8.DualTail
WheelPivot

Initial

Pumps

2

22

22

*0

12

12

1

21

Numberof

Places

440Hours

1

4

*Seestep3forspeciallubricationinstructions
ontherearcasterpivotsandtheLubricateRear
CasterWheelHubsectionforspeciallubrication
instructionsontherearcasterswheelhub.

Service

Interval

100Hours

40Hours

LubricateRearCasterWheel
Hub(s)

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

Yearly

*Yearly

Yearly

Yearly

Figure10

1.Sealguard2.Spacernutwithwrench

Yearly

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

4.Removeoneofthespacernutsfromtheaxle
assemblyinthecasterwheel.Notethatthread
lockingadhesivehasbeenappliedtolockthe
spacernutstotheaxle.Removetheaxle(with
theotherspacernutstillassembledtoit)from
thewheelassembly .

ats

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

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.

29

Maintenance

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.

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.

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).

LubricateSteeringLinkage
RodEnds

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Tiltseatforward.

3.Lubricateeachendofbothsteeringlinkagerods
withaspraylubricantorlightoil

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps,
orreplacewithnewplugs.SeeEngineOwner’s
Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

LubricateMotionControl
BronzeBushings

ServiceInterval:Every160hours

Afuellterisinstalledbetweenthefueltanksandthe
engine.Replacewhennecessary.

30

Maintenance

ReplacementFilters

KohlerKohler

P/N2405010–15Micron

Briggs&Stratton

Briggs&Stratton

P/N695327–30Micron

ChangeHydraulicSystem
Filter

ServiceInterval:Aftertherst250hours

Every500hours/Yearly
(whichevercomes
rst)thereafter
(Every250hours/Yearlyif
usingMobil115W50)

Note:UseonlyExmarkPartNo.103-2146.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Carefullycleanareaaroundlter.Itisimportant
thatnodirtorcontaminationenterhydraulic
system.

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.

3.Unscrewltertoremoveandallowoiltodrain
fromreservoir.

Important:Beforereinstallingnewlter,ll
itwithExmarkPremiumHydrooilandapply
athincoatofoilonthesurfaceoftherubber
seal.

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

4.FillreservoirasstatedinCheckHydraulicOil
Levelsection.

ExmarkPremiumHydroOilisrecommended.
Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro
Oil(Preferred)

Mobil115W50

5.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely.

ChangeInterval

500Hours

250Hours

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:

31

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.

32

Figure12

1.Parkbrakeengaged3.Thinnylocnut

2.Yoke

4.1/8inch(3mm)gap
betweennutandyoke.

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

Maintenance

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.

Figure13

1.Balljoint3.Parkbrakelinkagerod

2.Jamnut

4.73/8inch(18.7cm)

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

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.

33

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.

34

Figure16

Right-HandSideofUnitShown

Maintenance

ClutchShim

Somelatermodelyearunitshavebeenbuiltwith
clutchesthatcontainabrakeshim.Whentheclutch
brakehasworntothepointwheretheclutchno
longerengagesconsistently,theshimcanberemoved
toextendtheclutchlife.

1.Re-installspringinouter
holestoreducespring
tension.

2.Weighttransferspring.

3.Removee-ringand
washer.

7.Re-installtheleftfender.

8.Foradditionalweighttransferadjustment,repeat
steps4through7ontherightsideoftheunit.

CasterPivotBearings
Pre-LoadAdjustment

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

Figure18

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheShim:

1.Stopengine,waitforallmovingpartstostop,
andremovekey.Engageparkingbrake.Allow
themachinetocoolcompletelybeforestarting
theseinstructions.

2.Usingapneumaticline,blowoutanydebris
fromunderthebrakepoleandaroundthebrake
spacers.

1.Springdiscwashers

Figure17

Figure19

35

Maintenance

3.Checktheconditionofthewireharnessleads,
connectors,andterminals.Cleanorrepairas
necessary.

4.Verifythat12Vispresentattheclutchconnector
whenthePTOswitchisengaged.

5.Measurethegapbetweentherotorandarmature.
Ifthegapisgreaterthan.04inch(1mm),proceed
withthefollowingsteps:

A.Loosenbothbrakemountingboltsone-half

toonefullturnasshownbelow.

Note:DoNotremovethebrakepolefrom
theeldshell/armature.Thebrakepolehas
worntomatchthearmatureandneedsto
continuetomatchaftertheshimisremoved
toensureproperbraketorque.

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthe
brakespacers.

D.Re-torqueeachbolt(M6x1)to10ft-lb(13

N-m)+/-0.5ft-lb(0.7N-m).

E.Usinga0.010inchthickfeelergauge,verify

thatagapispresentbetweentherotorand
armaturefaceonbothsidesofthebrakepole
asshown.(Duetothewaytherotorand
armaturefaceswear(peaksandvalleys)itis
sometimesdifculttomeasurethetruegap.)

Figure20

1.Brakemountingbolt

B.Usingneedlenosepliers,orbyhand,take

holdofthetabandremovetheshim(DoNot
discardtheshimuntilproperclutchfunction
hasbeenconrmed).

Figure21

1.Shim

Figure22

1.Feelergauge

Figure23

1.Feelergauge

•Ifthegapislessthan0.010inch,then
reinstalltheshimandreferencethe
Troubleshootingsection.

•Ifthegapissufcient,proceedtothe
safetycheckinstepF.

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.
b.MakesurethebladesDoNotengage

withthePTOswitch“off”andtheclutch
disengaged.

36

Maintenance

Iftheclutchdoesnotdisengage,
reinstalltheshimandreferencethe
Troubleshootingsection.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch
isfunctioningproperly .Iftheclutch
doesnotengageproperly ,referencethe
Troubleshootingsection.

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.

37

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.

38

Troubleshooting

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,DoNotoverlookthesimplecauses.Forexample:startingproblemscouldbe
causedbyanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank

Enginewillnotstart,startshard,orfailsto
keeprunning

1.PTOisengaged.

2.Parkingbrakeisnot.2.Settheparkingbrake.

3.Driveleversarenotinneutrallock
position.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.

5.Electricalconnectionsarecorroded,loose
orfaulty.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty .1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Oillevelinthecrankcaseislow .

4.Thethrottleandchokearenotinthe
correctposition.

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

6.Dirt,water,orstalefuelisinthefuel
system.

7.Aircleanerisdirty.

8.Electricalconnectionsarecorroded,loose
orfaulty.

9.Relayorswitchisdefective.9.ContactanAuthorizedServiceDealer.

10.Faultysparkplug.

11.Sparkplugwireisnotconnected.

1.DisengagethePTO .

3.Ensurethedriveleversareintheneutral
lockposition.

5.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Addoiltothecrankcase.

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

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleanerelement.

8.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

10.Clean,adjustorreplacesparkplug.

11.Checkthesparkplugwireconnection.

Enginelosespower

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe
engineareplugged.

5.V entholeinthefuelcapisplugged.

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

7.Dirt,water,orstalefuelisinthefuel
system.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling
nsandairpassages.

5.Cleanorreplacethefuelcap.

7.ContactanAuthorizedServiceDealer.

39

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Engineoverheats

Mowerpullsleftorright(withleversfully
forward)

Machinedoesnotdrive

Abnormalvibration

Clutchwillnotengage.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

3.Coolingnsandairpassagesforthe
engineareplugged.

1.Trackingneedsadjustment1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

3.Reverseindicatorandmotioncontrol
linkageneedadjustment.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor
broken.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

1.Enginemountingboltsareloose.1.Tightentheenginemountingbolts.

2.Looseenginepulley,idlerpulley,orblade
pulley.

3.Enginepulleyisdamaged.3.ContactanAuthorizedServiceDealer.

1.Fuseisblown.

2.Lowvoltagesupplyattheclutch.

3.Damagedcoil.

4.Inadequatecurrentsupply.4.Repairorreplaceclutchleadwireor

5.Rotor/armatureairgapistoolarge.

2.Addoiltothecrankcase.

3.Removetheobstructionsfromthecooling
nsandairpassages.

3.Adjustthereverseindicatorandthe
motioncontrollinkage.

2.Changethebelt.

4.Replacethespring.

cooldown.

2.Tightentheappropriatepulley.

1.Replacefuse.Checkcoilresistance,
batterycharge,chargingsystem,and
wiringconnectionsandreplaceif
necessary.

2.Checkcoilresistance,batterycharge,
chargingsystem,andwiringconnections
andreplaceifnecessary.

3.Replaceclutch.

electricalsystem.Cleanconnector
contacts.

5.Removeshimorreplaceclutch.

40

Schematics

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

Schematics

ElectricalDiagram—27HPKohler

41

Schematics

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

ElectricalDiagram–31HPBriggs&Stratton

42

DK. GREEN

FUEL SOLENOID

REGULATOR

ENGINE KILL

OIL PRESSURE

STARTER

SOLENOID

DK. GREEN

DK. GREEN

TAN

BLACK

BLACK

WHITE

DK. GREEN / WHITE

BLACK

BLACK

DK. GREEN / WHITE

ORANGE / BLACK

YELLOW

PINK / BLACK

DK. GREEN

DK. GREEN

DK. GREEN

DK. GREEN

LT. GREEN

LT. GREEN

LT. BLUE

LT. BLUE

BLACK

BLACK

BROWN

BLACK

TAN

BROWN

BROWN

BLACK

LT. BLUE

LT. BLUE

TAN

SEAT DELAY

MODULE

SEAT

SWITCH

ELECTRIC

CLUTCH

(PTO)

GROUND

20 AMP

FUSE

20 AMP

FUSE

RH MOTION

CONTROL

LH MOTION

CONTROL

BRAKE

START

RELAY

IGNITION

SWITCH

-

HOUR

METER

+

PTO

SWITCH

KILL

REL

AY

3. START

POSITION

1. OFF

2. RUN

B + I + S

CIRCUIT "MAKE"

X + Y

NONE

B + I + A

WIRES CROSSING

(NOT CONNECTED)

WIRES CONNECTED

YXSIB

A

STARTRUNOFF

GREY

GREY

GREY

GREY

GREY / BLACK

GREY / BLACK

BROWN

DECK TILT

SAFETY SWITCH

DK BLUE

ORANGE

ORANGE

AUX. HYDRAULIC

RAISE / LOWER

RED

RED

RED

YELLOW / BLACK

YELLOW / BLACK

YELLOW / BLACK

YELLOW / BLACK

15 AMP

FUSE

ORANGE

ORANGE

TAN

YELLOW

ORANGE

ORANGE

RED

YELLOW / BLACK

YELLOW / BLACK

ORANGE

BLUE / BLACK

WHITE / BLACK

AUXILARY

HYDRAULIC

PUMP

ORANGE

GREY

GREY

PINK / BLACK

GREY

GREY

DK BLUE

WHITE

YELLOW / BLACK

DK GREEN

ORANGE / BL

ACK

BLACK

WHITE / BLACK

BLUE / BLACK

AUX 15A - 12V OUTLET

ACCY PLUG

(HEADLIGHT)

BLACK

YELLOW / BLACK

BLACK

40 AMP

CIRCUIT

BREAKER

RED

ORANGE

RED

SHOWN WITH PTO

DISENGAGED (SWITCH IN)

SHOWN WITH

BRAKE ENGAGED

+ 12V

SHOWN WITH OPERATOR

IN SEAT

TERMINAL X

TERMINAL Y

TERMINAL A

TERMINAL B

TERMINAL S

TERMINAL I

SHOWN WITH CONTROL

LEVERS IN NEUTRAL

LOCK POSITION

(HANDLES OUT)

G009845

Schematics

ElectricalLogicSchematic–27HPKohler

43

START SOLENOID

5

1

2

4

3

RED

ORANGE

RED

40 AMP

CIRCUIT

BREAKER

BLACK

YELLOW / BLACK

BLACK

AUX 15A - 12V OUTLET

ACCY PLUG

(HEADLIGHT)

BLUE / BLACK

WHITE / BLACK

BLACK

ORANGE / BLACK

DK GREEN

TANWHITE

DK BLUE

GREY

GREY

PINK / BLACK

GREY

GREY

ORANGE

AUXILARY

HYDRAULIC

PUMP

WHITE / BLACK

BLUE / BLACK

ORANGE

YELLOW / BLACK

YELLOW / BLACK

RED

ORANGE

ORANGE

YELLOW

TAN

ORANGE

ORANGE

15 AMP

FUSE

YELLOW / BLACK

YELLOW / BLACK

VIOLET

VIOLET

RED

RED

RED

AUX. HYDRAULIC

RAISE / LOWER

ORANGE

ORANGE

DK BLUE

DECK TILT

SAFETY SWITCH

BROWN

GREY / BLACK

GREY / BLACK

GREY

GREY

GREY

GREY

OFF RUN START

ABISX

Y

WIRES CONNECTED

WIRES CROSSING

(NOT CONNECTED)

B + I + A

NONE

X + Y

CIRCUIT "MAKE"

B + I + S

2. RUN

1. OFF

POSITION

3

. START

KILL

REL

AY

PTO

SWITCH

-

HOUR

METER

+

IGNITION

SWITCH

START

RELAY

BRAKE

LH MOTION

CONTROL

RH MOTION

CONTROL

30 AMP

FUSE

20 AMP

FUSE

GROUND

ELECTRIC

CLUTCH

(PTO)

SEAT

SWITCH

SEAT DELAY

MODULE

TAN

LT. BLUE

LT. BLUE

BLACK

BROWN

BROWN

TAN

BLACK

BROWN

BLACK

BLACK

LT. BLUE

LT. BLUE

LT. GREEN

LT. GREEN

DK. GREEN

DK. GREEN

DK. GREEN

DK. GREEN

PINK / BLACK

YELLOW

ORANGE / BLACK

DK. GREEN / WHITE

BLACK

BLACK

DK. GREEN / WHITE

WHITE

BLACK

BLACK

TAN

DK. GREEN

DK. GREEN

STARTER

SOLENOID

OIL PRESSURE

ENGINE KILL

REGULATOR

FUEL SOLENOID

DK. GREEN

CHARGE

RELAY

BLACK
BLACK

VIOLET

TAN

YELLOW/BLACK

5

4

3

1

2

3

4

2

1

VIOLET

SHOWN WITH CONTROL

LEVERS IN NEUTRAL

LOCK POSITION

(HANDLES OUT)

TERMINAL I

TERMINAL S

TERMINAL B

TERMINAL A

TERMINAL Y

TERMINAL X

SHOWN WITH OPERATOR

IN SEAT

+ 12V

SHOWN WITH

BRAKE ENGAGED

SHOWN WITH PTO

DISENGAGED (SWITCH IN)

G009846

Schematics

ElectricalLogicSchematic–31HPBriggs&Stratton

44

HydraulicDiagram

CASE DRAIN

CHARGE PUMP

HIGH PRESSURE

G007220

BYPASS VALVE

BYPASS VALVE

HIGH
PRESSURE
REVERSE

HIGH PRESSURE
FORWARD

HIGH PRESSURE
REVERSE

HIGH PRESSURE
FORWARD

Schematics

45

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 on these products 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 commercial turf equipment
sold in the U.S. 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.

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine 2 years*

* The Engine warranty is covered by the engine manufacturer.
Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet.

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized 
 Exmark Service Dealer.

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

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

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

• Any 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.

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. or Canada 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 or replacement of
defective components as set forth herein. Neither Exmark

nor Exmark Warranty Company shall be liable for any
incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other  
 extraordinary repair charges or charges 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.

All implied warranties of merchantability (that the
product is fit for ordinary use) and fitness for use (that the
product is fit for a particular purpose) are limited to the
duration of the express warranty.

Some states do not allow exclusions of incidental or
consequential damages, or limitations on how long an
implied warranty lasts, so the above exclusions and
limitations may not apply to you.

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

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-425

46

Notes:

47

Notes:

48

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

495051

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

12

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-F RONT RIDING AC CESSORIES A ND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

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

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-497Rev .A
[phone]
Fax[phone]
PrintedintheUSA

www.exmark.com