Exmark Lawn Mower 4500 497 User Manual

FRONTRUNNERTM  
AIR-COOLED MODELS  
For Serial Nos.  
790,000 & Higher  
Part No. 4500-497 Rev. A  
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Mower. This product has been carefully  
designed and manufactured to give you a maximum  
amount of dependability and years of trouble-free  
operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
Figure 1  
1. Model and serial number location  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Model No.  
Serial No.  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
All Exmark equipment dealers and distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Contents  
Introduction ........................................................... 3  
Torque Requirements .................................... 17  
Periodic Maintenance ....................................... 25  
4
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Safety  
• Never let children or untrained people operate  
Safety  
Safety Alert Symbol  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
Preparation  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and  
safely perform the job. Only use accessories and  
attachments approved by Exmark.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
Figure 2  
1. Safety alert symbol  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
CAUTION  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
This machine produces sound levels in  
excess of 85 dBA at the operator’s ear and  
can cause hearing loss through extended  
periods of exposure.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
Wear hearing protection when operating this  
machine.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
Safe Operating Practices  
Training  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
not read English it is the owner’s responsibility to  
explain this material to them.  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
5
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Safety  
DANGER  
DANGER  
In certain conditions gasoline is extremely  
flammable and vapors are explosive.  
In certain conditions during fueling, static  
electricity can be released causing a spark  
which can ignite gasoline vapors. A fire or  
explosion from gasoline can burn you and  
others and cause property damage.  
A fire or explosion from gasoline can burn  
you, others, and cause property damage.  
• Fill the fuel tank outdoors in an open  
area, when the engine is cold. Wipe up  
any gasoline that spills.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• Do Not fill gasoline containers inside a  
vehicle or on a truck or trailer bed because  
interior carpets or plastic truck bed liners  
may insulate the container and slow the  
loss of any static charge.  
• Do Not fill the fuel tank completely  
full. Add gasoline to the fuel tank until  
the level is 1/4 to 1/2 inch (6–13 mm)  
below the bottom of the filler neck. This  
empty space in the tank allows gasoline  
to expand.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Never smoke when handling gasoline,  
and stay away from an open flame or  
where gasoline fumes may be ignited by  
spark.  
• If this is not possible, then refuel such  
equipment on a truck or trailer from a  
portable container, rather than from a  
gasoline dispenser nozzle.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
• If a gasoline dispenser nozzle must be  
used, keep the nozzle in contact with the  
rim of the fuel tank or container opening  
at all times until fueling is complete.  
• Add fuel before starting the engine.  
Never remove the cap of the fuel tank or  
add fuel when engine is running or when  
the engine is hot.  
WARNING  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
6
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Safety  
• Be sure all drives are in neutral and parking brake  
is engaged before starting engine. Use seat belts  
with the roll bar in the raised and locked position.  
Operation  
WARNING  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
Operating engine parts, especially the  
muffler, become extremely hot. Severe burns  
can occur on contact and debris, such as  
leaves, grass, brush, etc. can catch fire.  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
• Allow engine parts, especially the muffler,  
to cool before touching.  
• Remove accumulated debris from muffler  
and engine area.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
• Stop engine, wait for all moving parts to stop,  
remove key and engage parking brake:  
– Before checking, cleaning or working on the  
mower.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating the mower).  
WARNING  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can  
kill you.  
– Before clearing blockages.  
– Whenever you leave the mower.  
Do Not run engine indoors or in a small  
confined area where dangerous carbon  
monoxide fumes can collect.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
– Before refueling.  
– Before dumping the grass catcher.  
WARNING  
Operating a FrontRunner tractor without an  
approved Exmark front mount attachment  
increases the possibility of forward tip over.  
Tip-over could cause serious injury or death.  
WARNING  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
When operating a FrontRunner tractor  
without an approved Exmark front mount  
attachment, observe the following:  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
• Limit operation to minimum required to  
install a different front mount attachment.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
• Minimize speed and use extreme caution.  
• Only operate on a flat level surface.  
NEVER carry passengers. DO NOT operate  
the mower when people, especially children, or  
pets are in the area.  
• Do Not operate up or down a trailer ramp.  
• Avoid sudden acceleration or deceleration.  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
7
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Safety  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
Figure 3  
Slope Operation  
1. Safe Zone-Use the mower here on slopes less than 15  
degrees  
2. Danger Zone-Use a walk behind mower and/or hand  
trimmer on slopes greater than 15 degrees, near  
drop-offs and water.  
Use Extreme caution when mowing and/or turning  
on slopes as loss of traction and/or tip-over could  
occur. The operator is responsible for safe operation  
on slopes.  
3. Water  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
DANGER  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. Wheels  
dropping over edges, ditches, steep banks, or  
water can cause rollovers, which may result  
in serious injury, death or drowning.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
• Avoid sudden stops when mowing downhill  
because the mower may tip forwards.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Be aware that operating on wet grass, across steep  
slopes or down hill may cause the mower to lose  
traction. Loss of traction to the drive wheels may  
result in sliding and loss of braking and steering.  
• Do Not mow slopes greater than 15  
degrees.  
• Reduce speed and use extreme caution  
on slopes.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
• Avoid sudden turns or rapid speed  
changes.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
• Use a walk behind mower and/or a hand trimmer  
near drop-offs, ditches, steep banks or water.  
(Figure 3).  
Using the Rollover Protection System  
(ROPS)  
A Rollover Protection System (roll bar) is installed  
on the unit.  
8
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Safety  
• Carefully release pressure from components with  
stored energy.  
WARNING  
There is no rollover protection when the roll  
bar is down. Wheels dropping over edges,  
ditches, steep banks, or water can cause  
rollovers, which may result in serious injury,  
death or drowning.  
• Disconnect battery or remove spark plug wire  
before making any repairs. Disconnect the  
negative terminal first and the positive last.  
Reconnect positive first and negative last.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
• Lower the roll bar only when absolutely  
necessary.  
• Keep hands and feet away from moving parts.  
If possible, Do Not make adjustments with the  
engine running.  
• Do Not wear seat belt when the roll bar  
is down.  
• Charge batteries in an open well ventilated area,  
away from spark and flames. Unplug charger  
before connecting or disconnecting from battery.  
Wear protective clothing and use insulated tools.  
• Drive slowly and carefully.  
• Raise the roll bar as soon as clearance  
permits.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Check carefully for overhead clearances (i.e.  
branches, doorways, and electrical wires) before  
driving under any objects and Do Not contact  
them.  
• Check all bolts frequently to maintain proper  
tightness.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• In the event of a rollover, take the unit to an  
Authorized Service Dealer to have the ROPS  
inspected.  
• All replacement parts must be the same as  
or equivalent to the parts supplied as original  
equipment.  
Maintenance and Storage  
• Disengage drives, lower implement, set parking  
brake, stop engine and remove key or disconnect  
spark plug wire. Wait for all movement to stop  
before adjusting, cleaning or repairing.  
• Keep engine, engine area, and pump drive belt  
compartment free from accumulation of grass,  
leaves, excessive grease or oil, and other debris  
which can accumulate in these areas. These  
materials can become combustible and may result  
in a fire.  
• Let engine cool before storing and Do Not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
• Use jack stands to support components when  
required.  
9
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Safety  
WARNING  
Hydraulic fluid escaping under pressure  
can penetrate skin and cause injury. Fluid  
accidentally injected into the skin must be  
surgically removed within a few hours by a  
doctor familiar with this form of injury or  
gangrene may result.  
• Make sure all hydraulic fluid hoses  
and lines are in good condition and  
all hydraulic connections and fittings  
are tight before applying pressure to  
hydraulic system.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
• Use cardboard or paper, not your hands,  
to find hydraulic leaks.  
• Safely relieve all pressure in the hydraulic  
system by placing the motion control  
levers in neutral and shutting off the  
engine before performing any work on  
the hydraulic system.  
10  
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• Safety signs may be affixed by peeling off the  
backing to expose the adhesive surface. Apply  
only to a clean, dry surface. Smooth to remove  
any air bubbles.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
1-513747  
103-3270  
1-643339  
98-4361  
103-5881  
103-7218  
98-5954  
103-2076  
11  
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Safety  
109-2355  
109-2356  
3. Neutral  
1. Fast  
2. Slow  
4. Reverse  
107-2102  
109-2357  
1. Fast  
2. Slow  
3. Neutral  
4. Reverse  
5. Park Brake—Release  
6. Park Brake—Engage  
107-2112  
12  
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Safety  
109-2358  
109-2377  
109-7413  
4. Slow  
1. Cylinder—extend  
2. Cylinder—retract  
3. Fast  
5. Choke—on  
6. Choke—off  
109-7949  
109-2396  
116-0404  
13  
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Safety  
116-1003  
109-2360  
14  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 790,000 and Higher  
FR27KC; FR31BV  
Systems  
Safety Interlock System  
• PTO must be disengaged, brake engaged, and  
motion control levers out (neutral lock) to start  
engine. (It is not necessary for the operator to be  
in the seat to start the engine.)  
Engine  
• Engine Specifications: See your Engine Owner’s  
Manual  
• Operator must be in seat when PTO is engaged,  
brake is disengaged, or motion control levers are  
moved in or engine will stop.  
• RPM: Full Speed: 3750 ±50 RPM (No Load)  
Idle: 1500 RPM  
• Engine will stop if the motion control levers  
are moved from neutral position while brake is  
engaged.  
Fuel System  
• Capacity: 8.5 gal. (32 L)  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher.  
Operator Controls  
• Steering and Motion Control:  
• Fuel Filter:  
– Kohler:  
Note: Motion control levers are adjustable to  
three heights.  
In-line 15 Micron Kohler P/N 2405010.  
– Briggs & Stratton:  
– Separate levers, on each side of the console,  
control speed and direction of travel of the  
respective drive wheels.  
In-line 30 Micron Briggs P/N 695327.  
• Fuel Shut-Off Valve: 1/4 turn increments (“ON”,  
“OFF”).  
– Steering is controlled by varying the position  
of the levers relative to each other.  
• Fuel gauge in right hand fuel tank.  
– Moving motion control levers outward (in  
slots) locks the drive system in neutral.  
Electrical System  
• Charging System: Flywheel Alternator  
• Charging Capacity:  
• PTO Engagement Lever: Engages drive to PTO  
(mower deck).  
• Parking Brake Lever: Engages parking brake by  
pulling back.  
– Kohler: 15 amps  
– Briggs & Stratton: 20 amps  
• Battery Type: BCI Group U1  
• Battery Voltage: 12 Volt  
• Polarity: Negative Ground  
• Fuses:  
Seat  
• Type: Standard seat with high back, foam padded  
(internal suspension) and armrests and integral  
safety switch.  
Optional seat accessories:  
– Kohler:  
– Custom ride suspension system to enhance  
Standard Seat.  
One 15 amp and two 20 amp blade type  
– Briggs & Stratton:  
– Deluxe suspension seat with high back, low  
profile foam-in-place cushion (dampened,  
adjustable spring suspension) and armrests.  
One 15 amp, one 20 amp, and one 30 amp  
blade type  
15  
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Specifications  
• Mounting: Hinged to tilt up for access to  
hydraulic pumps, battery and other components.  
The seat is held in the tilted position with a  
linkage. Adjustable fore and aft seat track.  
Tires & Wheels  
Drive  
Front  
Caster  
Rear Caster  
(Dual Tail  
Wheel)  
• Armrests: Standard seat: foam padded flip-up  
armrests. Optional suspension seat: molded  
adjustable flip-up armrests.  
Pneumatic  
(Air-Filled) Pneumatic  
Semi-  
Semi-  
Pneumatic  
Quantity  
Tread  
Size  
2
2
2
• Seat Safety Switch: Internal to the bottom seat  
cushion, non serviceable. Time delay module  
incorporated into the Safety Interlock System  
eliminates rough ground cut-outs.  
AT101  
Smooth  
9 x 3.50-4  
Smooth  
13 x 6.5-6  
24 x  
12.00-12  
Ply Rating  
Pressure  
4
9 psi  
(62 kPa)  
Hydrostatic Ground Drive System  
• Hydrostatic Pumps: Two Hydro Gear PR 16 cc  
variable displacement piston pumps.  
Cutting Deck  
• Wheel Motors: Hydro Gear planetary reduction  
motors.  
(Sold Separately)  
• Model Numbers:  
– FR524  
• Hydraulic Oil Type: Use Exmark Premium Hydro  
oil.  
– FR604  
• Hydraulic Oil Capacity: 5.2 qt. (4.9 L)  
• Hydraulic Filter: Replaceable cartridge type.  
P/N 103-2146: 25 microns, No bypass  
• Speeds:  
– FR724  
• Cutting Width:  
– 52 inch (132 cm)  
– 60 inch (152 cm)  
– 72 inch (183 cm)  
• Discharge: Side  
• Blade Size: (3 ea.)  
0-10.5 mph (16.9 km/hr) forward  
0-6.6mph (10.6 km/hr) reverse  
• Drive wheel release valves allow machine to be  
moved when engine is not running.  
– 52 inch Deck: 18.00 inches (45.7 cm)  
– 60 inch Deck: 20.50 inches (52.1 cm)  
– 72 inch Deck: 24.50 inches (62.2 cm)  
• Blade Spindles: Solid steel spindles with 1 3/4  
inch (4.45 cm) I.D. bearings.  
• Deck Drive: “B”-Section belt from jackshaft on  
deck to blade spindles.  
• Deck: Full floating deck is attached to out-front  
support frame, removable for service. Six  
anti-scalp rollers provide maximum turf  
protection. Deck design allows for bagging,  
mulching or side discharge.  
• Deck Depth:  
– 52 inch Deck: 5.5 inches (14.0 cm)  
– 60 inch Deck: 5.5 inches (14.0 cm)  
– 72 inch Deck: 5.5 inches (14.0 cm)  
16  
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Specifications  
• Cutting Height Adjustment: Adjusts from 1 1/2  
inches (3.8 cm) to 5 inches (12.7 cm) infinitely  
variable.  
Minimum Turning Radius  
55.25 inches (140.3 cm)  
• Mulching Kit: Optional  
• Bagger: Optional  
Curb Weight:  
Without deck  
52 inch Deck  
60 inch Deck  
72 inch Deck  
911 lb (413 kg)  
1303 lb (591 kg)  
1348 lb (611 kg)  
1397 lb (634 kg)  
Dimensions  
Overall Width:  
52 inch  
Deck  
60 inch  
Deck  
72 inch  
Deck  
Torque Requirements  
Without  
Deck  
49.0 inches 49.0 inches 53.0 inches  
(124.5 cm) (124.5 cm) (135 cm)  
Bolt Location  
Torque  
Engine Mounting Bolts  
Wheel Lug Nuts  
30-35 ft-lb (41-47 N-m)  
90-95 ft-lb (122-129 N-m)  
72-77 ft-lb (98-104 N-m)  
Deflector  
Up  
53.3 inches 61.4 inches 73.4 inches  
(135.4 cm) (156 cm)  
64.0 inches 72.0 inches 84.3 inches  
(163 cm) (183 cm) (214 cm)  
(186 cm)  
Deflector  
Down  
Wheel Motor Mounting  
Bolts  
Wheel Hub Lock Nut  
210-250 ft-lb  
(285-339 N-m)  
Overall Length:  
Rollover Protection System 30-35 ft-lb (41-47 N-m)  
(Roll Bar) Mounting Bolts  
27HP Kohler & 31HP  
Briggs & Stratton  
Clutch Retaining Bolt  
55-60 ft-lb (75-81 N-m)  
Without deck and floor  
pan folded  
82.3 inches (209.0 cm)  
(secured with threadlocker)  
52 inch Deck  
60 inch Deck  
72 inch Deck  
114.3 inches (290.3 cm)  
114.3 inches (290.3 cm)  
114.3 inches (290.3 cm)  
Overall Height:  
Roll Bar - Up  
Roll Bar - Down  
69.2 inches (175.8 cm)  
50.7 inches (128.8 cm)  
Tread Width: (Center to Center of  
Tires, Widthwise)  
52 inch Deck  
60 inch Deck  
72 inch Deck  
41.4 inches  
(105.2 cm)  
41.4 inches  
(105.2 cm)  
45.4 inches  
(115.3 cm)  
Wheel Base: (Center of Caster Tire to  
Center of Drive Tire)  
51.2 inches (130.0 cm)  
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Operation  
Product Overview  
Operation  
Note: Determine the left and right sides of the  
machine from the normal operating position.  
Controls  
Motion Control Levers  
The motion control levers located on each side of the  
console control the forward and reverse motion of  
the machine. The levers control the flow of hydraulic  
oil from the hydrostatic pump to the drive wheel  
motor for each side.  
Moving the levers forward or backward turns the  
wheel on the same side forward or in reverse. Wheel  
speed is proportional to the amount the lever is  
moved.  
Figure 4  
Moving the levers outward from the center position  
into the T-slot locks them in the neutral position  
(Figure 6).  
1. Fuel Cap  
2. Roll Bar  
3. Controls  
4. Seat Belt  
5. Motion Control Lever  
6. Parking Brake Lever  
Choke Control  
Located on right fuel tank console.  
The choke is used to aid in starting a cold engine.  
Moving the choke lever forward will put the choke in  
the “ON” position and moving the choke lever to the  
rear, to the detent, will put the choke in the “OFF”  
position. Do Not run a warm engine with choke in  
the “ON” position.  
Throttle Control  
Located on right fuel tank console.  
The throttle is used to control engine speed. Moving  
the throttle lever forward will increase engine speed  
and moving the throttle lever to the rear will decrease  
engine speed. Moving the throttle forward into the  
detent is full throttle.  
Park Brake Lever  
Located on left side of unit, between the seat and the  
dummy tank.  
The brake lever engages a parking brake on the drive  
wheels.  
Pull the lever up and rearward to engage the brake.  
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Operation  
Push the lever forward and down to disengage the  
brake.  
Drive Wheel Release Valves  
Located on the top left front corner of hydrostatic  
pumps.  
The unit must be tied down and brake engaged when  
transporting.  
Drive wheel release valves are used to release the  
hydrostatic drive system to allow the machine to be  
pushed without the engine running.  
Ignition Switch  
Located on right fuel tank console.  
With a 5/8 inch wrench, turn both valves one turn  
counterclockwise to release drive system. Turn  
clockwise to reset system. Do Not overtighten. Do  
Not tow machine.  
The ignition switch is used to start and stop the  
engine. The switch has three positions “OFF”, “ON”  
and “START”. Insert key into switch and rotate  
clockwise to the “ON” position. Rotate clockwise to  
the next position to engage the starter (key must be  
held against spring pressure in this position).  
PTO Engagement Switch  
Located on right fuel tank.  
Note: Brake must be engaged, motion control levers  
out (neutral lock position), and PTO switch “OFF”  
to start engine. (It is not necessary for the operator  
to be in the seat to start the engine.)  
Switch must be pulled out to the “ROTATE”  
position to engage the blades. Switch is pushed in to  
the “STOP” position to stop the blades.  
Hydraulic Lift Switch  
Hour Meter  
Located on right fuel tank console.  
Located on the right fuel tank console.  
The hydraulic lift switch is used to raise and lower  
the mower deck.  
The hour meter is connected to a pressure switch  
installed in the engine block and it records the  
number of hours that the engine has run. If the  
ignition switch is left on without engine running,  
hour meter will not run.  
Push the front portion of the hydraulic lift switch  
down to raise the mower deck to the desired height.  
Push the rear portion of the hydraulic lift switch  
down to lower the mower deck to the desired height.  
Note: This switch is not a low oil sensor and will not  
alert the operator if the engine oil is low.  
Pre-Start  
Fuel Shut-Off Valve  
Fill fuel tanks. For best results use only clean, fresh  
regular grade unleaded gasoline with an octane rating  
of 87 or higher. Regular grade leaded gasoline may  
also be used; however, combustion chamber and  
cylinder head will require more frequent service. See  
Engine Owner’s Manual.  
Located in fuel line by fuel tank and fuel filter.  
The fuel shut-off valve is used to shut off the fuel  
when the machine will not be used for a few days,  
during transport to and from the jobsite, and when  
parked inside a building.  
Do Not add oil to gasoline.  
Rotate the valve 1/4 turn clockwise to shut off fuel.  
Rotate the valve 1/4 turn counterclockwise to turn  
on fuel.  
Do Not overfill fuel tank. Never fill the fuel tank so  
that the fuel level rises above a level that is 1/2 inch  
(13 mm) below the bottom of the filler neck to allow  
for fuel expansion and prevent fuel spillage.  
Fuel Gauge  
Located at the rear of the right fuel tank.  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
The fuel gauge monitors the amount of fuel in the  
right fuel tank only. The left tank does not hold fuel.  
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Operation  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Starting the Engine  
1. Move the motion control levers out to the neutral  
lock position.  
Operating Instructions  
2. Pull up and back on the parking brake lever to  
engage the parking brake.  
Raise the Rollover Protection System  
(ROPS)  
3. Push in on the PTO switch to the “STOP”  
position.  
Important: Lower the roll bar only when  
absolutely necessary.  
Note: It is not necessary for the operator to be  
in the seat to start the engine.  
1. Remove the hairpin cotter pins and remove the  
two roll bar pins (Figure 5).  
4. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
2. Raise the roll bar to the upright position and  
install the two pins and secure them with the  
hairpin cotter pins (Figure 5).  
5. On a cold engine, push the choke lever forward  
into the “ON” position.  
On a warm engine, leave the choke in the “OFF”  
position.  
Important: Always use the seat belt with the  
roll bar in the raised position. Ensure that the  
rear part of the seat is secured with the seat  
latch.  
6. Turn ignition switch to the “START” position.  
Release the switch as soon as the engine starts.  
Important: Do Not crank the engine  
continuously for more than ten seconds at a  
time. If the engine does not start, allow a 60  
second cool-down period between starting  
attempts. Failure to follow these guidelines  
can burn out the starter motor.  
7. If the choke is in the “ON” position, gradually  
return choke to the “OFF” position as the engine  
warms up.  
Engaging the PTO  
DANGER  
The rotating blades under the mower deck  
are dangerous. Blade contact can cause  
serious injury or kill you.  
Do Not put hands or feet under the mower  
or mower deck when the blades are engaged.  
Figure 5  
1. Roll bar  
2. Raised position  
3. Pin  
4. Hairpin cotter pin  
Open the Fuel Shut-Off Valve  
The fuel shut-off valve is located on the right side of  
unit in fuel line next to the fuel filter. Raise the rear  
hood to access fuel shut-off valve.  
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Operation  
Driving the Machine  
DANGER  
An uncovered discharge opening will allow  
objects to be thrown in an operator’s or  
bystander’s direction. Also, contact with the  
blade could occur. Thrown objects or blade  
contact can cause serious injury or death.  
CAUTION  
Machine can spin very rapidly by positioning  
one lever too much ahead of the other.  
Operator may lose control of the machine,  
which may cause damage to the machine  
or injury.  
Never operate the mower with the discharge  
deflector raised, removed, or altered unless  
there is a grass collection system or mulch  
kit in place and working properly.  
• Use caution when making turns.  
• Slow the machine down before making  
sharp turns.  
The PTO push-pull switch engages the cutting blades.  
Be sure that all persons are clear of the mower deck  
and discharge area before engaging PTO.  
Important: To begin movement (forward or  
backward) the operator must be in the seat, the  
brake lever must be disengaged (pushed down)  
before the motion control levers can be moved in  
or the engine will stop.  
Important: Operator must be in seat before the  
PTO can be engaged.  
1. Set the throttle to the “MIDWAY” position.  
When levers are centered in the T-slot the drive  
system is in the neutral position. With levers moved  
out in the T-slot the drive system is in the neutral lock  
position (Figure 6).  
2. Pull the PTO switch outward to the “ROTATE”  
position.  
3. Place the throttle in the “FAST” position to begin  
mowing.  
Disengaging the PTO  
1. Set the throttle to the “MIDWAY” position.  
2. Push the PTO switch in to the “STOP” position  
to disengage the blades.  
Stopping the Engine  
1. Bring the unit to a full stop.  
2. Disengage the PTO.  
3. Move the motion control levers out to the neutral  
lock position.  
4. Engage the parking brake.  
Figure 6  
5. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
1. Handles Out (Neutral  
Lock)  
2. Handles In (Neutral)  
3. Front of Unit  
4. Forward  
5. Neutral  
6. Reverse  
7. Neutral Lock  
6. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
7. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
Driving Forward  
1. Release the parking brake.  
8. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
2. Move the motion control levers inward to the  
center to the neutral unlocked position.  
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Operation  
3. To move forward in a straight line apply equal  
forward pressure to both levers.  
Transporting  
To turn left or right, pull the motion control lever  
back toward neutral in the direction desired.  
Transporting a Unit  
Important: Do Not transport FrontRunner  
tractor without an approved Exmark front mount  
attachment.  
The machine will move faster the farther the  
motion control levers are moved away from  
neutral.  
Use a heavy-duty trailer or truck to transport the  
machine. Lock brake and block wheels. Securely  
fasten the machine to the trailer or truck with straps,  
chains, cable, or ropes. Be sure that the trailer or truck  
has all necessary lighting and marking as required by  
law. Secure a trailer with a safety chain.  
4. To stop, pull the motion control levers back to  
the neutral position.  
CAUTION  
This unit does not have proper turn  
signals, lights, reflective markings, or a  
slow moving vehicle emblem. Driving on a  
street or roadway without such equipment  
is dangerous and can lead to accidents  
causing personal injury. Driving on a street  
or roadway without such equipment may also  
be a violation of State laws and the operator  
may be subject to traffic tickets and/or fines.  
Do Not drive a unit on a public street or  
roadway.  
Figure 7  
WARNING  
Loading a unit on a trailer or truck increases  
the possibility of tip-over. Tip-over could  
cause serious injury or death.  
1. Handles Out (Neutral  
Lock)  
2. Handles In (Neutral)  
3. Front of Unit  
4. Forward  
5. Reverse  
• Use extreme caution when operating a  
unit on a ramp.  
Driving in Reverse  
• Use only a single, full width ramp; Do  
Not use individual ramps for each side  
of the unit.  
1. Move the motion control levers inward to the  
center to the neutral unlocked position.  
2. To move rearward in a straight line applying equal  
pressure pull both motion control levers rearward.  
• If individual ramps must be used, use  
enough ramps to create an unbroken  
ramp surface wider than the unit.  
To turn left or right, release pressure on the  
motion control lever toward the direction desired.  
• Do Not exceed a 15° angle between ramp  
and ground or between ramp and trailer  
or truck.  
3. To stop, push the motion control levers to the  
neutral position.  
• Avoid sudden acceleration while driving  
unit on a ramp.  
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Operation  
Loading a Unit  
Use extreme caution when loading units on trailers  
or trucks. One full width ramp is required. If it is  
not possible to use one full width ramp, use enough  
individual ramps to simulate a full width continuous  
ramp.  
Ramp should be long enough so that the angles  
between the ramp and the ground and the ramp and  
the trailer or truck do not exceed 15°. A steeper angle  
may cause mower deck components to get caught as  
the unit moves from ramp to trailer or truck. Steeper  
angles may also cause the unit to tip. If loading on or  
near a slope, position the trailer or truck so it is on  
the down side of the slope and the ramp extends up  
the slope. This will minimize the ramp angle. The  
trailer or truck should be as level as possible.  
Important: Do Not attempt to turn the unit  
while on the ramp, you may lose control and  
drive off the side.  
Avoid sudden acceleration when driving on a ramp.  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could  
seriously injure you or other bystanders.  
The engine can become very hot. Touching  
a hot engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine  
area.  
Remove the key from the ignition switch,  
engage parking brake, and pull the wire(s)  
off the spark plug(s) before you do any  
maintenance. Also push the wire(s) aside  
so it does not accidentally contact the spark  
plug(s).  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
After the first 100 hours  
After the first 250 hours  
• Check the wheel hub locknuts torque specification.  
• Change the hydraulic filter.  
• Check the engine oil level.  
• Check the safety interlock system.  
• Check the rollover protections systems (roll bar) pins.  
• Check the seat belt.  
Before each use or daily  
• Check for loose hardware.  
• Clean the engine cooling system.  
• Remove accumulated debris from engine.  
• Check the hydraulic oil level.  
• Check the tire pressures.  
• Check the condition of the belts.  
• Grease hitch and cylinder pivots.  
• Grease the dual tail wheel pivot (if applicable).  
Every 40 hours  
• Service the air cleaner. (May need more often under severe conditions. See the Engine  
Owner’s Manual for additional information.)  
Every 50 hours  
Every 80 hours  
Every 100 hours  
• Remove the engine shrouds and clean the cooling fins.  
• Change the engine oil. (May need more often under severe conditions.)  
• Grease the fold pivot pin.  
• Lubricate the brake handle pivot.  
• Lubricate the brake rod bushings.  
• Lubricate the motion control bronze bushings.  
• Lubricate the steering linkage rod ends.  
• Check the spark plugs.  
Every 160 hours  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)  
• Check the wheel hub locknuts torque specification.  
Every 500 hours  
Monthly  
• Check the battery charge.  
• Grease the fold lock pin.  
• Grease the rear caster pivot.  
• Grease the belt idlers.  
• Grease the motion control pivots.  
• Grease the transfer spring ends.  
• Lubricate the caster wheel hub(s).  
• Lubricate the motion control shaft.  
Yearly  
WARNING  
CALIFORNIA  
Proposition 65 Warning  
Periodic Maintenance  
Check Engine Oil Level  
Battery posts, terminals, and related  
accessories contain lead and lead  
compounds, chemicals known to the State of  
California to cause cancer and reproductive  
harm. Wash hands after handling.  
Service Interval: Before each use or daily  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
2. Tilt seat forward and raise hood to gain access  
to access to engine area.  
Allowing batteries to stand for an extended period of  
time without recharging them will result in reduced  
performance and service life. To preserve optimum  
battery performance and life, recharge batteries in  
storage when the open circuit voltage drops to 12.4  
volts.  
3. Check with engine cold.  
4. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick and push it all  
the way down into the tube. Remove the dipstick  
and read the oil level.  
5. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Use oil as specified in  
Engine Owner’s Manual. Do Not overfill.  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
Check the voltage of the battery with a digital  
voltmeter. Locate the voltage reading of the battery in  
the table and charge the battery for the recommended  
time interval to bring the charge up to a full charge  
of 12.6 volts or greater.  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
Check Battery Charge  
Service Interval: Monthly  
Important: Make sure the negative battery  
cables are disconnected and the battery charger  
used for charging the battery has an output of  
16 volts and 7 amps or less to avoid damaging  
the battery (see chart for recommended charger  
settings).  
25  
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Maintenance  
Run engine at one-third throttle, engage PTO  
and raise off of seat (but do not get off of  
machine) engine must initiate shutdown after  
1/2 second has elapsed.  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
Charger  
Settings  
Interval  
12.6 or  
greater  
100%  
No  
Charging  
Required  
16 volts/7  
amps  
Run engine at one-third throttle, with brake  
disengaged, move levers in and raise off seat (but  
do not get off of machine) engine must initiate  
shutdown after 1/2 second has elapsed.  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
1 Hour  
16 volts/7  
amps  
Again, run engine at one-third throttle, brake  
engaged, and move left motion control lever in  
- engine must initiate shutdown.  
12.0–12.2  
11.7–12.0  
25–50%  
0–25%  
2 Hours  
3 Hours  
14.4 volts/4  
amps  
Repeat again moving the right lever in, then  
moving both levers in - engine must initiate  
shutdown whether operator is on seat or not.  
14.4 volts/4  
amps  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
3. Check the PTO circuit. See the FR524, FR604,  
and FR724 Operator’s manual to become familiar  
with the deck operation. Open the folding  
deck latches, disengage the park brake, move  
the motion control levers in to neutral, and  
disengage the PTO. Lower the deck until the  
PTO switch arm is no longer depressing the PTO  
“kill” switch (see Figure 8).  
Check Safety Interlock  
System  
Service Interval: Before each use or daily  
Note: To prevent engine cut-outs on rough terrain  
the seat kill switch has a 1/2 second delay.  
1. Check starting circuit. Starter should crank with,  
parking brake engaged, PTO disengaged and  
motion control levers moved out in the neutral  
lock position. The operator does not need to be  
in the seat to start the engine.  
Try to start with operator in seat, parking brake  
disengaged, PTO disengaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Try to start with operator in seat, parking brake  
engaged, PTO engaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Try to start with operator in seat, parking  
brake engaged, PTO disengaged, and the left  
motion control lever in, starter must not crank,  
repeat again with the right lever in, then with  
both levers in - starter must not crank.  
Figure 8  
Left Side—Inside of Hitch Shown  
1. PTO “Kill” Switch  
2. PTO Switch Arm  
3. Lower deck until arm Does Not contact the switch.  
2. Check the kill circuits. Run engine at one-third  
throttle, disengage parking brake and raise off  
of seat (but do not get off of machine) engine  
must initiate shutdown after approximately 1/2  
second has elapsed (seat has time delay kill switch  
to prevent cut-outs on rough terrain).  
Run the engine at half throttle and pull up on the  
PTO engagement switch.  
The PTO must not engage.  
26  
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Maintenance  
Note: If machine does not pass any of these tests,  
Do Not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
5. Check the condition of the inner element. Replace  
whenever it appears dirty, typically every other  
time the paper element is replaced. Clean the base  
around the inner element before removing, so  
dirt does not get into the engine.  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
6. Do Not wash or use pressurized air to clean  
paper element or inner element.  
7. Reinstall elements. Position the cover so that the  
rubber dust ejector is pointing downward and  
secure with retaining clips.  
Check Rollover Protections  
Systems (Roll Bar) Pins  
Service Interval: Before each use or daily  
Change Engine Oil  
Service Interval: After the first 5 hours  
Make sure latch pin and hair pin are fully installed  
and lanyard is in good condition.  
Every 100 hours/Yearly  
(whichever comes first)  
(May need more often  
under severe conditions.)  
Check Seat Belt  
Service Interval: Before each use or daily  
Visually inspect seat belt for wear, cuts, and proper  
operation of retractor and buckle. Replace before  
operating if damaged.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Tilt seat forward and raise hood to gain access  
to the engine area.  
Check for Loose Hardware  
Service Interval: Before each use or daily  
3. Drain oil while engine is warm from operation.  
4. Fit hose in literature pack over oil drain valve.  
Rotate the valve 1/4 counterclockwise and gently  
pull outward to open the valve. Allow the oil to  
drain, then close the valve by pushing inward and  
rotating 1/4 turn clockwise. Remove and retain  
the hose for future use.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
5. Replace the oil filter every other oil change. Clean  
around oil filter and unscrew filter to remove.  
Before reinstalling new filter, apply a thin coating  
of oil on the surface of the rubber seal. Turn  
filter clockwise until rubber seal contacts the filter  
adapter then tighten filter an additional 2/3 to  
3/4 turn.  
Service Air Cleaner  
Service Interval: Every 50 hours (May  
need more often under  
severe conditions. See  
the Engine Owner’s  
Manual for additional  
information.)  
6. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
7. Use oil recommended in engine owner’s manual.  
Do Not overfill. Start the engine and check for  
leaks.  
2. Tilt seat forward and raise hood to gain access  
to the air cleaner.  
3. Loosen retaining clips and remove air cleaner  
compartment cover.  
Check Hydraulic Oil Level  
Service Interval: Every 40 hours  
4. Remove paper element. Check the condition  
of the paper element. Replace if dirty, bent or  
damaged.  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
27  
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Maintenance  
2. Tilt seat up.  
If not, add oil. Use only Exmark Premium Hydro  
oil. Replace reservoir plug and tighten until snug.  
Do Not overtighten.  
3. Clean area around hydraulic reservoir cap and  
remove cap. Oil level should be to the top of the  
baffle inside the tank. If not, add oil. Use Exmark  
Premium Hydro oil. Replace hydraulic reservoir  
cap and tighten until snug. Do Not overtighten.  
Check Tire Pressures  
Service Interval: Every 40 hours  
Note: The baffle is labeled “HOT” and  
“COLD”. The oil level varies with the  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
temperature of the oil. The “HOT” level shows  
the level of oil when it is at 225°F (107°C). The  
“COLD” level shows the level of the oil when  
it is at 75°F (24°C). Fill to the appropriate level  
depending upon the temperature of the oil. For  
example: If the oil is about 150°F (65°C), fill to  
halfway between the “HOT” and “COLD” levels.  
If the oil is at room temperature (about 75°F  
(24°C)), fill only to the “COLD” level.  
2. Check tire pressure in drive tires.  
Bar lug drive tires should be inflated to 9 psi (62  
kpa).  
Turf drive tires should be inflated to 13 psi (90  
kpa).  
3. The rear caster tires are semi-pneumatic and Do  
Not need to be inflated.  
Note: Do Not add any type of tire liner or foam  
fill material to the tires. Excessive loads created by  
foam filled tires may cause failures to the hydro drive  
system, frame, and other components. Foam filling  
tires will void the warranty.  
Check Auxiliary Hydraulic  
Oil Level  
Service Interval: As required  
Note: Check the auxiliary hydraulic oil level if there  
is evidence of a leak or the hydraulic cylinder does  
not perform normally.  
Check Condition Of Belts  
Service Interval: Every 40 hours  
1. Retract the hydraulic cylinder.  
2. Stop engine and wait for all moving parts to stop.  
3. Tilt the seat forward.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
4. Locate the auxiliary hydraulic power unit reservoir  
(see Figure 9).  
2. Check pump and PTO drive belts.  
3. Belts are spring tensioned and no adjustment is  
necessary. See Pump Drive Belt Tension and  
Replacement sections in Adjustments.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate fittings with one to two pumps of  
NGLI grade #2 multi-purpose gun grease.  
Refer to the following chart for fitting locations  
and lubrication schedule.  
Figure 9  
1. Auxiliary hydraulic reservoir plug  
5. Clean area around the reservoir plug and remove.  
Oil level should be up to the reservoir plug hole.  
28  
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Maintenance  
Lubrication Chart  
Lubricate Rear Caster Wheel  
Hub(s)  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Service  
Interval  
Places  
Service Interval: Yearly  
2
4
40 Hours  
1. Hitch  
and Cylinder  
Pivots  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2
2
2
2
1
2
2
100 Hours  
Yearly  
2. Fold  
Pivot Pin  
3. Fold  
Lock Pin  
4. Rear  
Caster Pivot  
*0  
1
*Yearly  
Yearly  
5. Belt  
Idlers  
6. Motion  
Control  
Pivots  
1
Yearly  
Figure 10  
1. Seal guard  
2. Spacer nut with wrench  
flats  
1
2
4
1
7. Transfer  
Spring Ends  
Yearly  
8. Dual Tail  
Wheel Pivot  
40 Hours  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the wheel hub.  
* See step 3 for special lubrication instructions  
on the rear caster pivots and the Lubricate Rear  
Caster Wheel Hub section for special lubrication  
instructions on the rear casters wheel hub.  
4. Remove one of the spacer nuts from the axle  
assembly in the caster wheel. Note that thread  
locking adhesive has been applied to lock the  
spacer nuts to the axle. Remove the axle (with  
the other spacer nut still assembled to it) from  
the wheel assembly.  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
7. Insert one bearing, one new seal into the wheel.  
Note: Seals (Exmark P/N 103-0063) must be  
replaced.  
8. If the axle assembly has had both spacer nuts  
removed (or broken loose), apply a thread locking  
adhesive to one spacer nut and thread onto the  
axle with the wrench flats facing outward. Do  
Not thread spacer nut all of the way onto the end  
of the axle. Leave approximately 1/8 inch (3 mm)  
from the outer surface of the spacer nut to the  
end of the axle inside the nut.  
3. Lubricate front caster pivots once a year. Remove  
hex plug and cap. Thread grease zerk in hole and  
pump with grease until it oozes out around top  
bearing. Remove grease zerk and thread plug back  
in. Place cap back on.  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
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Maintenance  
10. With the open end of the wheel facing up, fill  
the area inside the wheel around the axle full of  
NGLI grade #1 multi-purpose grease.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Unhook seat latch and tilt seat up.  
11. Insert the second bearing and new seal into the  
wheel.  
3. Lubricate bronze bushings on flange bearings  
securing the motion control arm shafts with a  
light oil or a spray type lubricant.  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
Lubricate Motion Control  
Shaft  
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,  
then re-torque to 20-25 in-lb (2-3 N-m). Make  
sure axle does not extend beyond either nut.  
Service Interval: Yearly  
14. Reinstall the seal guards over the wheel hub and  
insert wheel into caster fork. Reinstall caster bolt  
and tighten nut fully.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Tilt seat forward.  
Important: To prevent seal and bearing damage,  
check the bearing adjustment often. Spin the  
caster tire. The tire should not spin freely  
(more than 1 or 2 revolutions) or have any side  
play. If the wheel spins freely, adjust torque on  
spacer nut until there is a slight amount of drag.  
Reapply thread locking adhesive.  
3. Remove tab at rear of motion control shaft.  
4. Pull motion control shaft out and lubricate with  
an NGLI grade #2 multi-purpose gun grease.  
5. Re-install shaft and tab.  
Lubricate Steering Linkage  
Rod Ends  
Lubricate Brake Handle Pivot  
Service Interval: Every 160 hours  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Tilt seat forward.  
3. Lubricate bronze bushings on brake handle pivot  
with a spray type lubricant or light oil.  
2. Tilt seat forward.  
3. Lubricate each end of both steering linkage rods  
with a spray lubricant or light oil  
Lubricate Brake Rod  
Bushings  
Check Spark Plugs  
Service Interval: Every 160 hours  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owner’s  
Manual.  
2. Tilt seat forward and raise hood.  
3. Lubricate bronze bushings on each end of the  
brake rod shaft with a spray type lubricant or  
light oil (bushings are located to the inside of the  
flange bearings).  
Change Fuel Filter  
Service Interval: As required  
A fuel filter is installed between the fuel tanks and the  
engine. Replace when necessary.  
Lubricate Motion Control  
Bronze Bushings  
Service Interval: Every 160 hours  
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Maintenance  
Replacement Filters  
CAUTION  
Kohler  
Kohler  
Raising the mower for service or maintenance  
relying solely on mechanical or hydraulic  
jacks could be dangerous. The mechanical or  
hydraulic jacks may not be enough support  
or may malfunction allowing the unit to fall,  
which could cause injury.  
P/N 2405010–15 Micron  
Briggs & Stratton  
Briggs & Stratton  
P/N 695327– 30 Micron  
Change Hydraulic System  
Filter  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support  
Service Interval: After the first 250 hours  
Every 500 hours/Yearly  
(whichever comes  
first) thereafter  
(Every 250 hours/Yearly if  
using Mobil 1 15W50)  
6. Start engine and move throttle control ahead to  
full throttle position. Move the speed control  
levers to the full speed and run for several  
minutes. Shut down machine and recheck oil  
level.  
Note: Use only Exmark Part No. 103-2146.  
Note: Do Not change hydraulic system oil (except  
for what can be drained when changing filter), unless  
it is felt the oil has been contaminated or been  
extremely hot.  
Changing oil unnecessarily could damage hydraulic  
system by introducing contaminates into the system.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Carefully clean area around filter. It is important  
that no dirt or contamination enter hydraulic  
system.  
3. Unscrew filter to remove and allow oil to drain  
from reservoir.  
Check Wheel Hub Locknuts  
Service Interval: After the first 100 hours  
Important: Before reinstalling new filter, fill  
it with Exmark Premium Hydro oil and apply  
a thin coat of oil on the surface of the rubber  
seal.  
Every 500 hours thereafter  
When tightening the lock nut on the wheel motor  
tapered shaft:  
Turn filter clockwise until rubber seal contacts the  
filter adapter, then tighten the filter an additional  
2/3 to 3/4 turn.  
Torque to 210-250 ft-lb (285-339 N-m).  
Note: Do Not use antiseize on wheel hub.  
4. Fill reservoir as stated in Check Hydraulic Oil  
Level section.  
Fuel Tank — Mounting  
Hardware Specifications  
Service Interval: As required  
Exmark Premium Hydro Oil is recommended.  
Refer to the chart for an acceptable alternative:  
Hydro Oil  
Change Interval  
500 Hours  
When installing the nuts on the fuel tank studs, fully  
tighten the nyloc nut and back off 1/2 turn. This  
allows for normal fuel tank expansion and contraction  
with changes in temperature and fuel levels.  
Exmark Premium Hydro  
Oil (Preferred)  
250 Hours  
Mobil 1 15W50  
5. Raise the rear of machine up and support with  
jack stands (or equivalent support) just high  
enough to allow drive wheels to turn freely.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
31  
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Maintenance  
• Pump drive sheave set screws.  
• Line shaft sheave setscrews.  
Adjustments  
Note: Disengage PTO, shut off engine, wait for  
all moving parts to stop, engage parking brake, and  
remove key before servicing, cleaning, or making any  
adjustments to the unit.  
• Square head setscrews on Hydro pump control  
arms.  
• Sheave retaining bolt in the end of engine  
crankshaft.  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
• Caster wheel spacer nuts.  
• Fuel tank bulkhead fitting nuts.  
• Motion control tab retaining bolt.  
Pump Drive Belt  
Replacement  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Adhesives such as “Loctite RC/609 or RC/680” or  
“Fel-Pro Pro-Lock Retaining I or Retaining II” are  
used on the following:  
Fuel tank studs, where studs are inserted into tank.  
2. Remove pump drive belt.  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
3. Route new belt onto sheaves as shown in the  
decal located on the right hand side of the left  
hood support (see Figure 11).  
Figure 11  
Park Brake Adjustment  
Check to make sure brake is adjusted properly.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Tilt seat forward and raise hood.  
3. Pull the brake lever up into the engaged position.  
4. Locate the park brake spring assembly (see  
Figure 12). There should be a gap of 1/8 inch (3  
mm) between the yoke and thin nyloc nut on the  
brake bolt. If necessary, rotate the thin nyloc nut  
to obtain the 1/8 inch gap.  
32  
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Maintenance  
remove the bolt that secures the ball joint to  
the brake lever and loosen the jam nut next to  
the ball joint. Rotate the ball joint in half-turns  
counterclockwise until desired disengagement is  
obtained.  
Motion Control Linkage  
Adjustment  
WARNING  
Engine must be running and drive  
wheels must be turning so motion control  
adjustment can be performed. Contact with  
moving parts or hot surfaces may cause  
personal injury  
Figure 12  
3. Thin nyloc nut  
Keep fingers, hands, and clothing clear of  
rotating components and hot surfaces.  
1. Park brake engaged  
2. Yoke  
4. 1/8 inch (3 mm) gap  
between nut and yoke.  
1. This adjustment must be made with the drive  
wheels turning. First raise the frame and block up  
so that drive wheels can rotate freely.  
5. If park brake does not fully disengage when the  
lever is disengaged check the brake rod linkage  
assembly. The assembly should measure 7 3/8  
inch (18.7 cm) from the center of the ball joint  
to the center of the lower end of the linkage rod  
(see Figure 13).  
2. Remove the electrical connection from the seat  
safety switch, located directly in front of the seat  
switch assembly.  
3. Temporarily install a jumper wire across the  
terminals in the connector of the main wiring  
harness.  
4. Start the engine.  
5. Run the unit at least 5 minutes with the drive  
levers at full forward speed to bring hydraulic  
system oil up to operating temperature.  
6. To obtain the neutral position, adjust the left and  
right pump control rod linkages that connect the  
steering control to the pump control arms until  
the wheels stop, or creep slightly in reverse.  
7. To adjust each linkage, loosen the jam nut next  
the ball joint at the upper end of the linkage  
rod assembly. Then rotate the assembly using a  
wrench to turn the double nuts on the assembly  
(see Figure 14).  
Figure 13  
1. Ball joint  
2. Jam nut  
3. Park brake linkage rod  
4. 7 3/8 inch (18.7 cm)  
8. Re-tighten the jam nut against the ball joint on  
each side.  
6. If the linkage does not measure 7 3/8 inch  
(18.7 cm) or still does not disengage as desired,  
33  
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Maintenance  
Figure 14  
Figure 15  
3. Fender knob  
1. Loosen jam nut  
1. Motion control lever  
2. Left fender  
2. Pump control rod linkage  
3. Use wrench to turn double nuts  
3. Slide the fender forward and twist upward and  
outward to remove.  
9. Move the motion control levers to the reverse  
position. Return the motion control levers to  
neutral. The wheels must stop turning (or slightly  
creep in reverse).  
4. To adjust the weight transfer springs, fold  
the mower deck and front frame and lock in  
service position. See Deck Manual for complete  
instructions.  
10. Stop engine and wait for all moving parts to stop.  
Remove jumper wire from wire harness connector  
and plug connector into seat switch.  
WARNING  
11. Lower from jackstands.  
Weight transfer springs may have stored  
energy. Removing the weight transfer  
springs without releasing the stored energy  
can cause serious injury.  
Weight Transfer Spring  
Adjustment  
Fold mower deck and front frame and lock in  
service position to remove spring tension and  
release stored energy before performing any  
maintenance or adjustments on the weight  
transfer springs. (See Deck Manual for Deck  
Raising instructions).  
Weight transfer springs are assembled from the  
factory to apply the maximum amount of weight onto  
the drive wheels. This setting provides the greatest  
amount of traction. Some conditions may require  
the rear wheel lift to be reduced. This can be done  
by reducing the amount to weight transfer, which  
will increase the amount of weight on the front and  
rear casters.  
5. Remove the retaining ring and washer at either  
end of the weight transfer spring that retains it to  
the transfer bellcrank pins and/or weight transfer  
spring anchor pins (see Figure 16).  
1. Rotate the left motion control arm up and into  
the operation position.  
2. Locate and loosen the knob under the rear of the  
left fender (see Figure 15).  
6. Pull the spring off of front or rear pin and  
re-install in the outer hole, to reduce the spring  
force. Re-install the washer and retaining ring.  
34  
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Maintenance  
Clutch Shim  
Some later model year units have been built with  
clutches that contain a brake shim. When the clutch  
brake has worn to the point where the clutch no  
longer engages consistently, the shim can be removed  
to extend the clutch life.  
Figure 16  
Right-Hand Side of Unit Shown  
1. Re-install spring in outer 3. Remove e-ring and  
holes to reduce spring  
washer.  
tension.  
2. Weight transfer spring.  
7. Re-install the left fender.  
Figure 18  
8. For additional weight transfer adjustment, repeat  
steps 4 through 7 on the right side of the unit.  
1. Armature  
2. Field shell  
3. Rotor  
5. Brake spacer  
6. Re-gap shim  
7. Brake pole  
4. Brake mounting bolt  
Caster Pivot Bearings  
Pre-Load Adjustment  
Removing the Shim:  
Remove dust cap from caster and tighten nyloc nut  
until washers are flat and back off 1/4 of a turn  
to properly set the pre-load on the bearings. If  
disassembled, make sure the spring disc washers are  
reinstalled as shown in Figure 17.  
1. Stop engine, wait for all moving parts to stop,  
and remove key. Engage parking brake. Allow  
the machine to cool completely before starting  
these instructions.  
2. Using a pneumatic line, blow out any debris  
from under the brake pole and around the brake  
spacers.  
Figure 19  
Figure 17  
1. Spring disc washers  
35  
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Maintenance  
3. Check the condition of the wire harness leads,  
connectors, and terminals. Clean or repair as  
necessary.  
C. Using a pneumatic line, blow out any debris  
from under the brake pole and around the  
brake spacers.  
D. Re-torque each bolt (M6 x 1) to 10 ft-lb (13  
N-m) +/-0.5 ft-lb (0.7 N-m).  
4. Verify that 12V is present at the clutch connector  
when the PTO switch is engaged.  
E. Using a 0.010 inch thick feeler gauge, verify  
that a gap is present between the rotor and  
armature face on both sides of the brake pole  
as shown. (Due to the way the rotor and  
armature faces wear (peaks and valleys) it is  
sometimes difficult to measure the true gap.)  
5. Measure the gap between the rotor and armature.  
If the gap is greater than .04 inch (1 mm), proceed  
with the following steps:  
A. Loosen both brake mounting bolts one-half  
to one full turn as shown below.  
Note: Do Not remove the brake pole from  
the field shell/armature. The brake pole has  
worn to match the armature and needs to  
continue to match after the shim is removed  
to ensure proper brake torque.  
Figure 22  
1. Feeler gauge  
Figure 20  
1. Brake mounting bolt  
B. Using needle nose pliers, or by hand, take  
hold of the tab and remove the shim (Do Not  
discard the shim until proper clutch function  
has been confirmed).  
Figure 23  
1. Feeler gauge  
• If the gap is less than 0.010 inch, then  
reinstall the shim and reference the  
Troubleshooting section.  
• If the gap is sufficient, proceed to the  
safety check in step F.  
F. Perform the following safety check:  
a. Sit on the seat and start the engine.  
Figure 21  
b. Make sure the blades Do Not engage  
with the PTO switch “off ” and the clutch  
disengaged.  
1. Shim  
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Maintenance  
If the clutch does not disengage,  
reinstall the shim and reference the  
Troubleshooting section.  
Cleaning  
Clean Engine Cooling  
System  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
c. Engage and disengage the PTO switch  
ten consecutive times to ensure the clutch  
is functioning properly. If the clutch  
does not engage properly, reference the  
Troubleshooting section.  
conditions.)  
CAUTION  
Excessive debris around the engine cooling  
air intake and inside of the pump drive  
belt compartment and damaged or missing  
rubber baffles can cause the engine and  
hydraulic system to overheat which can  
create a fire hazard.  
Clean all debris from inside of pump drive  
belt compartment daily.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Clean all debris from rotating engine air intake  
screen and from around engine shrouding.  
3. Clean all debris from around the engine and drive  
belts.  
Remove Accumulated Debris  
from Engine (Briggs &  
Stratton Units Only)  
Service Interval: Before each use or daily  
Engine parts should be kept clean to reduce the risk  
of overheating and ignition of accumulated debris.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove front panel from engine and clean around  
the intake manifold, fuel pump, and carburetor.  
3. Reinstall the front panel.  
Important: Do Not use water to clean engine.  
Use low pressure compressed air. See Engine  
Owner’s Manual.  
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Maintenance  
Remove Engine Shrouds and  
Clean Cooling Fins  
Service Interval: Every 80 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove cooling shroud clean-out covers from  
engine and clean cooling fins. Also clean dust,  
dirt, and oil from external surfaces of engine,  
which can cause improper cooling.  
3. Make sure cooling shroud clean-out covers are  
reinstalled. Operating the engine without cooling  
shroud clean-out covers will cause engine damage  
due to overheating.  
Waste Disposal  
Motor Oil Disposal  
Engine oil and hydraulic oil are both pollutants to  
the environment. Dispose of used oil at a certified  
recycling center or according to your state and local  
regulations.  
Battery Disposal  
DANGER  
Battery electrolyte contains sulfuric acid,  
which is poisonous and can cause severe  
burns. Swallowing electrolyte can be fatal or  
if it touches skin can cause severe burns.  
• Wear safety glasses to shield eyes, and  
rubber gloves to protect skin and clothing  
when handling electrolyte.  
• Do Not swallow electrolyte.  
Federal law states that batteries should not be placed  
in the garbage. Management and disposal practices  
must be within relevant federal, state, or local laws.  
If a battery is being replaced or if the unit containing  
the battery is no longer operating and is being  
scrapped, take the battery to a local certified recycling  
center. If no local recycling is available return the  
battery to any certified battery reseller.  
38  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, Do Not overlook the simple causes. For example: starting problems could be  
caused by an empty fuel tank.  
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major  
items or any items that call for special timing of adjustment procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.  
Problem  
Starter does not crank  
Possible Cause  
1. PTO is engaged.  
Corrective Action  
1. Disengage the PTO.  
2. Parking brake is not.  
2. Set the parking brake.  
3. Drive levers are not in neutral lock  
position.  
3. Ensure the drive levers are in the neutral  
lock position.  
4. Battery does not have a full charge.  
4. Charge the battery.  
5. Electrical connections are corroded, loose 5. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
6. Fuse is blown.  
6. Replace the blown fuse.  
7. Relay or switch is defective.  
7. Contact an Authorized Service Dealer.  
Engine will not start, starts hard, or fails to  
keep running  
1. Fuel tank is empty.  
1. Fill the fuel tank.  
2. Fuel shutoff valve is closed.  
3. Oil level in the crankcase is low.  
2. Open the fuel shutoff valve.  
3. Add oil to the crankcase.  
4. The throttle and choke are not in the  
correct position.  
4. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions, and the choke is in the “ON”  
position for a cold engine or the “OFF”  
position for a warm engine.  
5. Dirt in fuel filter.  
5. Replace the fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
7. Air cleaner is dirty.  
7. Clean or replace the air cleaner element.  
8. Electrical connections are corroded, loose 8. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
9. Relay or switch is defective.  
10. Faulty spark plug.  
11. Spark plug wire is not connected.  
9. Contact an Authorized Service Dealer.  
10. Clean, adjust or replace spark plug.  
11. Check the spark plug wire connection.  
Engine loses power  
1. Engine load is excessive  
1. Reduce the ground speed.  
2. Air cleaner is dirty.  
3. Oil level in the crankcase is low.  
2. Clean or replace the air cleaner element.  
3. Add oil to the crankcase.  
4. Cooling fins and air passages for the  
engine are plugged.  
4. Remove the obstructions from the cooling  
fins and air passages.  
5. Vent hole in the fuel cap is plugged.  
6. Dirt in fuel filter.  
5. Clean or replace the fuel cap.  
6. Replace the fuel filter.  
7. Dirt, water, or stale fuel is in the fuel  
system.  
7. Contact an Authorized Service Dealer.  
39  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Engine overheats  
1. Engine load is excessive  
1. Reduce the ground speed.  
2. Add oil to the crankcase.  
2. Oil level in the crankcase is low.  
3. Cooling fins and air passages for the  
engine are plugged.  
3. Remove the obstructions from the cooling  
fins and air passages.  
Mower pulls left or right (with levers fully  
forward)  
1. Tracking needs adjustment  
1. Adjust the tracking.  
2. Tire pressure in drive tires not correct.  
2. Adjust tire pressure in the drive tires.  
3. Reverse indicator and motion control  
linkage need adjustment.  
3. Adjust the reverse indicator and the  
motion control linkage.  
Machine does not drive  
1. Bypass valve is not closed tight.  
1. Tighten the bypass valve.  
2. Change the belt.  
2. Drive or pump belt is worn, loose or  
broken.  
3. Drive or pump belt is off a pulley.  
4. Broken or missing idler spring.  
5. Hydraulic fluid level is low or too hot.  
3. Change the belt.  
4. Replace the spring.  
5. Add hydraulic fluid to reservoir or let it  
cool down.  
Abnormal vibration  
1. Engine mounting bolts are loose.  
1. Tighten the engine mounting bolts.  
2. Tighten the appropriate pulley.  
2. Loose engine pulley, idler pulley, or blade  
pulley.  
3. Engine pulley is damaged.  
3. Contact an Authorized Service Dealer.  
Clutch will not engage.  
1. Fuse is blown.  
1. Replace fuse. Check coil resistance,  
battery charge, charging system, and  
wiring connections and replace if  
necessary.  
2. Low voltage supply at the clutch.  
2. Check coil resistance, battery charge,  
charging system, and wiring connections  
and replace if necessary.  
3. Damaged coil.  
3. Replace clutch.  
4. Inadequate current supply.  
4. Repair or replace clutch lead wire or  
electrical system. Clean connector  
contacts.  
5. Remove shim or replace clutch.  
5. Rotor/armature airgap is too large.  
40  
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Schematics  
Schematics  
Electrical Diagram —27HP Kohler  
G R E Y  
W H I T E  
C A K B L  
C A K B L  
D K G R E E N /  
C A K B L  
C A K B L  
W H I T E  
G R E Y  
G R E Y  
D K G R E E N  
D K G R E E N  
O R A N G E  
P I N K / B L  
C A K  
O R A N G E  
G R E Y  
G R E Y  
D K G R E E N  
D K G R E E N  
K C A  
W H I T E  
O R A N G E / B L  
W O N R B  
D K G R E E N /  
C A K B L  
W O Y E L L  
A T N  
W O N R B  
D K G R E E N  
D K G R E E N  
C A K  
P I N K / B L  
T L B L U E  
T L B L U E  
T L B L U E  
W O N R B  
D K G R E E N  
T L G R E E N  
T L B L U E  
T L B L U E  
C A K B L  
A T N  
T L G R E E N  
T L B L U E  
A T N  
G R E Y  
O R A N G E  
G R E Y  
G R E Y  
C A K  
C A K  
G R E Y / B L  
G R E Y / B L  
W O N R B  
G007220  
41  
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Schematics  
Electrical Diagram – 31HP Briggs & Stratton  
C A K L B / W O Y E L L  
V I O L E T  
C A K B L  
C A K B L  
A T N  
G R E Y  
W H I T E  
C A K B L  
C A K B L  
W H I T E  
D K G R E E N /  
C A K B L  
C A K B L  
G R E Y  
G R E Y  
D K G R E E N  
O R A N G E  
P I N K / B L  
D K G R E E N  
C A K  
O R A N G E  
G R E Y  
G R E Y  
D K G R E E N  
D K G R E E N  
K C A  
W H I T E  
O R A N G E / B L  
W O N R B  
D K G R E E N /  
C A K B L  
W O Y E L L  
D K G R E E N  
D K G R E E N  
A T N  
W O N R B  
C A K  
P I N K / B L  
T L B L U E  
T L B L U E  
T L B L U E  
W O N R B  
D K G R E E N  
T L G R E E N  
T L B L U E  
T L B L U E  
C A K B L  
A T N  
T L G R E E N  
T L B L U E  
A T N  
G R E Y  
O R A N G E  
G R E Y  
G R E Y  
C A K  
C A K  
G R E Y / B L  
G R E Y / B L  
W O N R B  
G007221  
42  
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Schematics  
Electrical Logic Schematic – 27HP Kohler  
. G R E E N D K  
. G R E E N D K  
C A K  
C A K  
B L  
B L  
G R E Y  
G R E Y  
W H I T E . G R D E K E N /  
W H I T E  
C A K  
P I N K / B L  
G R E Y  
C A K  
C A K  
B L  
B L  
G R E Y  
O R A N G E  
. G R E E N D K  
. G R E E N D K  
W H I T E . G R D E K E N /  
W O N R B  
C A K  
O R A N G E / B L  
C A K B L  
W O Y E L L  
A T N  
. B T L L U E  
. G R E E N D K  
. G R E E N D K  
P I N K / B L  
W O N R B  
C A K  
. G R E E N D K  
. G T R L E E N  
W O N R B  
G R E Y  
. G T R L E E N  
. B T L L U E  
C A K B L  
. B T L L U E  
G R E Y  
. B T L L U E  
G R E Y  
G R E Y  
A T N  
A T N  
O R A N G E  
C A K  
C A K  
G R E Y / B L  
G R E Y / B L  
C A K  
C A K  
B L U E / B L  
W H I T E / B L  
W O N R B  
R E D  
O R A N G E  
43  
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Schematics  
Electrical Logic Schematic – 31HP Briggs & Stratton  
K C A W O / B L Y E L L  
C A K  
C A K  
B L  
B L  
V I O L E T  
A T N  
N E E R G .  
N E E R G .  
D K  
D K  
B L  
B L  
C A K  
C A K  
G R E Y  
G R E Y  
W H I T E . G R D E K E N /  
W H I T E  
C A K  
P I N K / B L  
G R E Y  
G R E Y  
C A K  
C A K  
B L  
B L  
O R A N G E  
N E E R G .  
N E E R G .  
D K  
D K  
W H I T E . G R D E K E N /  
O R A N G E / B L  
W O N R B  
C A K  
C A K B L  
W O Y E L L  
N A T  
E U L B . T L  
N E E R G .  
D K  
D K  
N E E R G .  
C A K  
W O N R B  
P I N K / B L  
N E E R G .  
D K  
N E E R G . T L  
W O N R B  
G R E Y  
N E E R G . T L  
E U L B . T L  
C A K B L  
. B T L L U E  
. B T L L U E  
G R E Y  
G R E Y  
G R E Y  
N A T  
N A T  
O R A N G E  
C A K  
C A K  
G R E Y / B L  
G R E Y / B L  
K C A  
C A K  
B L U E / B L  
W H I T E / B L  
W O N R B  
R E D  
O R A N G E  
44  
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Schematics  
Hydraulic Diagram  
BYPASS VALVE  
BYPASS VALVE  
HIGH PRESSURE  
FORWARD  
HIGH PRESSURE  
REVERSE  
HIGH  
HIGH PRESSURE  
FORWARD  
PRESSURE  
REVERSE  
G007220  
HIGH PRESSURE  
CHARGE PUMP  
CASE DRAIN  
45  
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Exmark Commercial Turf Equipment  
2Year Limited Warranty  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
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.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
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.  
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.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
2 years*  
• Engine  
* 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.  
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.  
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.  
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 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.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
There are no other express warranties except for engine and  
special emission system coverage.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark mower.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
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.  
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.  
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.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G4500-425  
46  
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Notes:  
47  
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Notes:  
48  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
49  
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50  
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51  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
© 2008 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-497 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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