Exmark Lawn Mower Diesel User Manual

FRONTRUNNERTM  
DIESEL MODELS  
For Serial Nos.  
720,000 & Higher  
Part No. 4500-227 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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Reverse Indicator Adjustment........................ 35  
Contents  
Introduction ........................................................... 3  
Torque Requirements .................................... 16  
Periodic Maintenance ....................................... 24  
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  
WARNING  
In certain conditions diesel is extremely  
flammable and vapors are explosive.  
Diesel fuel 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.  
A fire or explosion from diesel can burn you,  
others, and cause property damage.  
• Avoid prolonged breathing of vapors.  
• Fill the fuel tank outdoors in an open  
area, when the engine is cold. Wipe up  
any diesel that spills.  
• Keep face away from nozzle and diesel  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• Do Not fill the fuel tank completely full.  
Add diesel 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 diesel to expand.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
Operation  
• Never smoke when handling diesel, and  
stay away from an open flame or where  
diesel fumes may be ignited by spark.  
WARNING  
• Store diesel in an approved container and  
keep it out of the reach of children.  
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.  
• 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.  
• Allow engine parts, especially the muffler,  
to cool before touching.  
• 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.  
• Remove accumulated debris from muffler  
and engine area.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
WARNING  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can  
kill you.  
Do Not run engine indoors or in a small  
confined area where dangerous carbon  
monoxide fumes can collect.  
6
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Safety  
– 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.  
• Be sure all drives are in neutral and parking brake  
is engaged before starting engine. Use seat belts.  
• 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.  
• 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.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• 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.  
• 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.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
• Stop engine, wait for all moving parts to stop,  
remove key and engage parking brake:  
Slope Operation  
– Before checking, cleaning or working on the  
mower.  
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.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating the mower).  
– Before clearing blockages.  
– Whenever you leave the mower.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
– Before refueling.  
7
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Safety  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
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.  
• Avoid sudden stops when mowing downhill  
because the mower may tip forwards.  
• Be aware that loss of traction may occur going  
uphill. Weight transfer to the rear wheels may  
cause drive wheels to slip and cause loss of  
braking and steering.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
• Do Not mow slopes greater than 15  
degrees.  
• Reduce speed and use extreme caution  
on slopes.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Avoid sudden turns or rapid speed  
changes.  
• 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.  
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.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
• Lower the roll bar only when absolutely  
necessary.  
Figure 3  
• Do Not wear seat belt when the roll bar  
is down.  
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 near drop-offs and water.  
• Drive slowly and carefully.  
3. Water  
• Raise the roll bar as soon as clearance  
permits.  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• Check carefully for overhead clearances (i.e.  
branches, doorways, and electrical wires) before  
driving under any objects and do not contact them.  
8
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Safety  
Maintenance and Storage  
WARNING  
• 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.  
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.  
• 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.  
• 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.  
• Let engine cool before storing and Do Not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Use cardboard or paper, not your hands,  
to find hydraulic leaks.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
• 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.  
• Use jack stands to support components when  
required.  
• Carefully release pressure from components with  
stored energy.  
• 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.  
WARNING  
Fuel system components are under high  
pressure. The use of improper components  
can result in system failure, fuel leakage and  
possible explosion.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace blades. Never straighten or  
weld them.  
Use only approved fuel lines and clamps for  
high pressure systems.  
• Keep hands and feet away from moving parts.  
If possible, Do Not make adjustments with the  
engine running.  
• 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.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Check all bolts frequently to maintain proper  
tightness.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• All replacement parts must be the same as  
or equivalent to the parts supplied as original  
equipment.  
9
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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.  
98-4361  
98-5954  
103-2076  
1-513747  
1-523552  
103-0223  
1-643339  
10  
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Safety  
103-1636  
103-5881  
103-7218  
107-2102  
107-2112  
11  
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Safety  
109-2355  
109-2358  
109-2356  
3. Neutral  
109-2377  
1. Fast  
2. Slow  
4. Reverse  
109-2396  
109-2357  
1. Fast  
2. Slow  
3. Neutral  
4. Reverse  
5. Park Brake—Release  
6. Park Brake—Engage  
12  
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Safety  
109-7949  
19426-87881  
109-2698  
3. Fast  
4. Slow  
1. Cylinder—extend  
2. Cylinder—retract  
19426-87903  
109-3637  
109-2360  
13  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 720,000 and Higher  
FR25KD  
Systems  
Cooling System  
• Fan: Belt driven with continuous operation with  
engine running.  
Engine  
• Engine Specifications: See your Engine Owner’s  
Manual  
• Coolant Liquid: 50/50 mix of DexCool©  
extended life antifreeze and water.  
• RPM: Full Speed: 3870 +50/-100 RPM (No  
Load) Idle: 1400 ±50 RPM (No Load)  
• Coolant Capacity: 4 quarts  
Operator Controls  
Fuel System  
• Capacity: 8.5 gal. (32 L)  
• Steering and Motion Control:  
Note: Motion control levers are adjustable to  
three heights.  
• Type of Fuel: Diesel fuel, 40 cetane or higher.  
• Fuel Filter: Two In-line 15 Micron Kubota P/N  
12581-43012, before and after the electric fuel  
pump.  
– Separate levers, on each side of the console,  
control speed and direction of travel of the  
respective drive wheels.  
• Fuel gauge at the rear of the right hand fuel tank.  
– Steering is controlled by varying the position  
of the levers relative to each other.  
Electrical System  
– Moving motion control levers outward (in  
slots) locks the drive system in neutral.  
• Charging System: External Alternator  
• Charging Capacity: 60 amps  
• Battery Type: BCI Group 26  
• Battery Voltage: 12 Volt  
• PTO Engagement Switch: Engages drive to PTO  
(mower deck).  
• Parking Brake Lever: Engages parking brake by  
pulling back.  
• Polarity: Negative Ground  
• Fuses: One 15 amp, one 20 amp, and one 40 amp  
blade type  
Seat  
• Type: Standard seat with high back, foam padded  
(internal suspension) and armrests and integral  
safety switch.  
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.)  
Optional seat accessories for units with standard  
seats:  
– Custom ride suspension system to enhance  
Standard Seat.  
• Operator must be in seat when PTO is engaged,  
brake is disengaged, or motion control levers are  
moved in or engine will stop.  
– Deluxe suspension seat with high back, low  
profile foam-in-place cushion (dampened,  
adjustable spring suspension), armrests, and  
integral safety switch.  
• Engine will stop if the motion control levers  
are moved from neutral position while brake is  
engaged.  
14  
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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.  
Caster  
Front Caster  
Rear Caster  
(Dual Tail  
Wheel)  
• Armrests: Standard seat: foam padded flip-up  
armrests. Optional suspension seat: molded  
adjustable flip-up armrests.  
Semi-Pneumatic Semi-Pneumatic  
Quantity  
Tread  
2
2
Smooth  
9 x 3.50-4  
Smooth  
13 x 6.5-6  
• 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.  
Size  
Ply Rating  
Pressure  
Hydrostatic Ground Drive System  
Cutting Deck  
• Hydrostatic Pumps: Two Hydro Gear PR 16 cc  
variable displacement piston pumps.  
(Sold Separately)  
• Model Numbers:  
– FR524  
• Hydraulic Oil Type: Use Mobil 1 15W-50  
Synthetic motor 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)  
Tires & Wheels  
Drive  
• Blade Spindles: Solid steel spindles with 1 3/4  
inch (4.45 cm) I.D. bearings.  
Pneumatic  
(Air-Filled)  
(Standard)  
Pneumatic  
(Air-Filled)  
(Optional)  
• 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.  
Quantity  
Tread  
2
2
AT101  
TurfMate  
23 x 10.50-10  
4
Size  
24 x 12.00-12  
4
Ply Rating  
Pressure  
• Deck Depth:  
9 psi(62 kPa)  
13 psi (90 kPa)  
– 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)  
• Cutting Height Adjustment: Adjusts from 1 1/2  
inches (3.8 cm) to 5 inches (12.7 cm) infinitely  
variable.  
15  
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Specifications  
• Mulching Kit: Optional  
• Bagger: Optional  
Curb Weight:  
Without deck  
52 inch Deck  
60 inch Deck  
72 inch Deck  
1163 lb (528 kg)  
1555 lb (705 kg)  
1600 lb (726 kg)  
1660 lb (753 kg)  
Dimensions  
Overall Width:  
52 inch  
Deck  
60 inch  
Deck  
72 inch  
Deck  
Torque Requirements  
Bolt Location  
Torque  
Without  
Deck  
49.0 inches 49.0 inches 53.0 inches  
(124.5 cm) (124.5 cm) (135 cm)  
Wheel Lug Nuts  
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  
Wheel Motor Mounting  
Bolts  
(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 Hub Lock Nut  
210-250 ft-lb  
(285-339 N-m)  
Rollover Protection System 30-35 ft-lb (41-47 N-m)  
(Roll Bar) Mounting Bolts  
Overall Length:  
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)  
Minimum Turning Radius  
55.25 inches (140.3 cm)  
16  
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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  
1. Fuel Cap  
2. Roll Bar  
3. Controls  
4. Seat Belt  
5. Motion Control Lever  
6. Parking Brake Lever  
Moving the levers outward from the center position  
into the T-slot locks them in the neutral position  
(Figure 6).  
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.  
Push the lever forward and down to disengage the  
brake.  
The unit must be tied down and brake engaged when  
transporting.  
Ignition Switch  
Located on right fuel tank console.  
The ignition switch is used to start and stop the  
engine. The switch has three positions “OFF”, “ON”  
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Operation  
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).  
The hydraulic lift switch is used to raise and lower  
the mower deck.  
Push the front portion of the hydraulic lift switch  
down to raise the mower deck to the desired height.  
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.)  
Push the rear portion of the hydraulic lift switch  
down to lower the mower deck to the desired height.  
Coolant Temperature Gauge  
Located on the right fuel tank console.  
Hour Meter  
The coolant temperature gauge monitors the  
temperature of the engine coolant. An engine  
overheating condition is indicated by the red area  
on the gauge and an alarm will sound. Refer to the  
Warning Buzzer in the Troubleshooting section.  
Located on the right fuel tank console.  
The hour meter runs when the alternator is charging  
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.  
Coolant Temperature Light  
Note: This switch is not a low oil sensor and will not  
alert the operator if the engine oil is low.  
Located on the right fuel tank console.  
The light will come on if the engine is overheating  
and an alarm will sound. Refer to the Warning  
Buzzer in the Troubleshooting section.  
Fuel Gauge  
Located at the rear of the right fuel tank.  
The fuel gauge monitors the amount of fuel in the  
right fuel tank only. The left tank does not hold fuel.  
Glow Plug Switch and Light  
Located on the right fuel tank console.  
Drive Wheel Release Valves  
Depress and hold the switch to heat the glow plugs.  
The glow plug light comes on when the glow plug  
switch is depressed. The glow plug light indicates the  
glow plugs are preheating the combustion chamber.  
Located on the top left front corner of hydrostatic  
pumps.  
Drive wheel release valves are used to release the  
hydrostatic drive system to allow the machine to be  
pushed without the engine running.  
Alternator Charging Light  
Located to the rear of the key switch.  
With a wrench, turn both valves one turn  
counterclockwise to release drive system. Turn  
clockwise to reset system. Do Not overtighten. Do  
Not tow machine.  
Light will come on when the alternator is not  
charging.  
Low Oil Pressure Light  
Use a 5/8 inch wrench to turn the valves.  
Located to the rear of the key switch with the  
alternator light.  
PTO Engagement Switch  
Light will come on when engine oil pressure is low  
or lost.  
Located on the right fuel tank.  
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.  
Note: This switch is not a low oil level sensor and  
will not alert the operator if the engine oil level is low.  
Warning Buzzer  
Hydraulic Lift Switch  
Located behind the seat under the engine cover on  
the right hand side of the engine fan shroud.  
Located on the right fuel tank console.  
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Operation  
The buzzer is a warning signal that the engine  
is overheating or the oil pressure is low. See the  
Troubleshooting section.  
Pre-Start  
Fill fuel tank. For best results use only clean, fresh  
diesel fuel, with a cetane rating of 40 higher  
Note: Do Not use kerosene or gasoline instead  
of diesel fuel. Failure to observe this caution will  
damage the engine.  
Do Not add oil to 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.  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Figure 5  
3. Pin  
1. Roll bar  
2. Raised position  
4. Hairpin cotter pin  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Starting the Engine  
Operating Instructions  
1. Move the motion control levers out to the neutral  
lock position.  
Raise the Rollover Protection System  
(ROPS)  
2. Pull up and back on the parking brake lever to  
engage the parking brake.  
Important: Lower the roll bar only when  
absolutely necessary.  
3. Push in on the PTO switch to the “STOP”  
position.  
1. Remove the hairpin cotter pins and remove the  
two roll bar pins (Figure 5).  
Note: It is not necessary for the operator to be  
in the seat to start the engine.  
2. Raise the roll bar to the upright position and  
install the two pins and secure them with the  
hairpin cotter pins (Figure 5).  
4. On a warm engine, place the throttle in the  
“SLOW” 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.  
5. On a cold engine, (below 14°F (-10°C)), place the  
throttle in the “MIDWAY” position.  
Note: Do Not use fuel left over from summer.  
6. Turn ignition switch to the “ON” position.  
Depress the glow plug switch and the glow plug  
light will turn on. Hold switch as required by  
chart below. Turn the ignition switch to the  
“START” position. Release the ignition switch as  
soon as the engine starts.  
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Operation  
Glow Plug Chart  
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.  
Ambient Temperature  
Above 50°F (10°C)  
Hold Glow Plugs On  
NO NEED  
Important: Operator must be in seat before the  
PTO can be engaged.  
Approximately 5 seconds  
Approximately 10 seconds  
20 seconds  
50°F (10°C) to 23°F (-5°C)  
Below 23°F (-5°C)  
1. Set the throttle to the “MIDWAY” position.  
2. Pull the PTO switch outward to the “ROTATE”  
position.  
Limit of continuous use  
The glow plug light, located near the glow  
plug switch, will illuminate when the switch is  
depressed. The glow plug light indicates the glow  
plugs are preheating the combustion chamber.  
3. Place the throttle in the “FAST” position to begin  
mowing.  
Disengaging the PTO  
Important: Do Not crank the engine  
continuously for more then ten seconds at a  
time. If the engine does not start, allow a 30  
second cool-down period between starting  
attempts. Failure to follow these guidelines  
can burn out the starter motor and/or fuel  
solenoid.  
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.  
7. Move the throttle to the “SLOW” (if in  
“MIDWAY”) and let the engine warm up a few  
minutes before moving the throttle to the “FAST”  
position.  
3. Move the motion control levers out to the neutral  
lock position.  
4. Engage the parking brake.  
5. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
Engaging the PTO  
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.  
DANGER  
The rotating blades under the mower deck  
are dangerous. Blade contact can cause  
serious injury or kill you.  
7. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
Driving the Machine  
Do Not put hands or feet under the mower  
or mower deck when the blades are engaged.  
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.  
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.  
• Use caution when making turns.  
• Slow the machine down before making  
sharp turns.  
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.  
Important: To begin movement (forward or  
backward) the operator must be in the seat, the  
brake lever must be disengaged (pushed down)  
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Operation  
before the motion control levers can be moved in  
or the engine will stop.  
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).  
Figure 7  
1. Handles Out (Neutral  
4. Forward  
Figure 6  
Lock)  
1. Handles Out (Neutral  
Lock)  
2. Handles In (Neutral)  
5. Neutral  
2. Handles In (Neutral)  
3. Front of Unit  
5. Reverse  
6. Reverse  
3. Front of Unit  
4. Forward  
7. Neutral Lock  
Driving in Reverse  
1. Move the motion control levers inward to the  
center to the neutral unlocked position.  
Driving Forward  
1. Release the parking brake.  
2. To move rearward in a straight line applying equal  
pressure pull both motion control levers rearward.  
2. Move the motion control levers inward to the  
center to the neutral unlocked position.  
To turn left or right, release pressure on the  
motion control lever toward the direction desired.  
3. To move forward in a straight line apply equal  
forward pressure to both levers.  
3. To stop, push the motion control levers to the  
neutral position.  
To turn left or right, pull the motion control lever  
back toward neutral in the direction desired.  
Transporting  
The machine will move faster the farther the  
motion control levers are moved away from  
neutral.  
Transporting a Unit  
Important: Do Not transport FrontRunner  
tractor without an approved Exmark front mount  
attachment.  
4. To stop, pull the motion control levers back to  
the neutral position.  
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.  
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Operation  
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.  
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.  
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.  
Do Not drive a unit on a public street or  
roadway.  
WARNING  
Loading a unit on a trailer or truck increases  
the possibility of tip-over. Tip-over could  
cause serious injury or death.  
• Use extreme caution when operating a  
unit on a ramp.  
• Use only a single, full width ramp; Do  
Not use individual ramps for each side  
of the unit.  
• If individual ramps must be used, use  
enough ramps to create an unbroken  
ramp surface wider than the unit.  
• Do Not exceed a 15° angle between ramp  
and ground or between ramp and trailer  
or truck.  
• Avoid sudden acceleration while driving  
unit on a ramp.  
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  
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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 engine coolant 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.  
• 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.  
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 100 hours  
• 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.  
Every 160 hours  
• Change the fuel filter.  
Every 400 hours  
Every 500 hours  
• Check the wheel hub locknuts torque specification.  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
Every 4,000 hours  
Monthly  
Change engine coolant. Dex-Cool© extended life coolant (orange color)  
• 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.  
• Change the hydraulic filter.  
Yearly  
Periodic Maintenance  
4. View coolant level in overflow bottle on the left  
side of the engine. Coolant level should be at the  
indicator line on the overflow bottle.  
Check Engine Oil Level  
Service Interval: Before each use or daily  
5. If the coolant level is low, remove the cap to the  
overflow bottle and fill to the indicator line. Use  
coolant specified in Specifications section.  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
Note: Units should only be filled with  
Dex-Cool© extended life coolant, which can be  
identified by its orange color.  
2. Tilt seat forward and raise hood to gain access  
to access to engine area.  
3. Check with engine cold.  
WARNING  
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.  
Engine coolant is hot and pressurized and  
radiator and surrounding parts are hot. Spray  
or steam from hot, pressurized liquid in the  
engine cooling system and touching a hot  
radiator may cause severe burns.  
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.  
Allow the engine to cool completely before  
removing the radiator cap or servicing any  
component of the cooling system.  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
CAUTION  
Engine coolant is toxic. Swallowing coolant  
can cause poisoning.  
Check Engine Coolant Level  
Service Interval: Before each use or daily  
• Do Not swallow.  
1. Stop engine and wait for all moving parts to stop.  
Make sure machine is on a level surface.  
• Keep out of reach of children and pets.  
2. Tilt seat up and tilt hood forward to gain access  
to the cooling area.  
3. Check with engine cold.  
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Maintenance  
Change Engine Coolant  
Service Interval: Every 4,000 hours/Every 4  
years (whichever comes  
WARNING  
Engine compartment contains open belt  
drives, fans, and other rotating components  
that can cause injury. Fingers, hands, loose  
clothing, or jewelry can get caught by the  
rotating fan and drive shaft.  
©
first) Dex-Cool extended  
life coolant (orange color)  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake. Machine must  
be positioned on level surface.  
• Do Not operate machine without the  
covers in place.  
2. Tilt seat forward and raise the hood up to gain  
access to the cooling area.  
• Keep fingers, hands, and clothing clear of  
rotating components.  
3. Drain coolant when engine is cool. Coolant may  
be drained from the radiator by removing the  
drain plug in the right rear corner. The engine  
block may be drained by removing the rear  
radiator hose and/or by opening the drain cock  
on the right-hand side of the engine block.  
• Shut off engine, wait for moving parts to  
stop, engage parking brake and remove  
key, before performing maintenance.  
6. With the cap off the radiator, tilt hood closed and  
put the seat down. Start the engine as stated in  
the Operation Section. Return the seat up and  
hood forward to the open position.  
7. Operate engine until the engine thermostat opens  
and coolant is circulating through the radiator  
core. As air is purged from the engine block and  
the coolant level drops, add additional coolant to  
the radiator.  
8. When the radiator is completely full and no  
additional coolant can be added, continue running  
and install the radiator cap. Make sure that the  
cap is completely seated by pressing down firmly  
while turning until the cap stops. Once the cap is  
installed, the engine may be stopped.  
Figure 8  
Check Battery Charge  
Service Interval: Monthly  
1. Oil dipstick  
2. Drain cock  
4. Tighten engine and radiator drain cocks. Reinstall  
lower hose (if removed).  
WARNING  
CALIFORNIA  
Proposition 65 Warning  
5. Fill radiator with a 50/50 mix of water and  
Dex-Cool© coolant as specified in the Check  
Engine Coolant Level Section, allowing some  
room (approximately 1/2 inch (12.7 mm)) for  
expansion. Add 50/50 coolant mix to overflow  
bottle on the left side of the engine as required  
to bring the level up to the indicator line on the  
bottle.  
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.  
Allowing batteries to stand for an extended period of  
time without recharging them will result in reduced  
performance and service life. To preserve optimum  
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Maintenance  
battery performance and life, recharge batteries in  
storage when the open circuit voltage drops to 12.4  
volts.  
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.  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
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.  
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.  
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.  
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).  
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).  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
Charger  
Settings  
Interval  
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.  
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  
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.  
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 9).  
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.  
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Maintenance  
Check for Loose Hardware  
Service Interval: Before each use or daily  
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.  
Service Air Cleaner  
Service Interval: Every 50 hours (May  
need more often under  
severe conditions. See  
the Engine Owner’s  
Manual for additional  
information.)  
Figure 9  
Left Side—Inside of Hitch Shown  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
1. PTO “Kill” Switch  
2. PTO Switch Arm  
3. Lower deck until arm Does Not contact the switch.  
2. Tilt seat forward and raise hood to gain access  
to the air cleaner.  
3. Loosen retaining clips and remove air cleaner  
compartment cover.  
4. Remove paper element. Check the condition  
of the paper element. Replace if dirty, bent or  
damaged.  
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.  
Run the engine at half throttle and pull up on the  
PTO engagement switch.  
The PTO must not engage.  
Note: If machine does not pass any of these tests,  
Do Not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
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  
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.  
Visually inspect seat belt for wear, cuts, and proper  
operation of retractor and buckle. Replace before  
operating if damaged.  
3. Drain oil while engine is warm from operation.  
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Maintenance  
4. Remove the oil drain plug. Allow oil to drain then  
replace the drain plug.  
3. Tilt the seat forward.  
4. Locate the auxiliary hydraulic power unit reservoir  
(see Figure 10).  
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.  
6. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
7. Use oil recommended in engine owner’s manual.  
Do Not overfill. Start the engine and check for  
leaks.  
Figure 10  
1. Auxiliary hydraulic reservoir plug  
Check Hydraulic Oil Level  
Service Interval: Every 40 hours  
5. Clean area around the reservoir plug and remove.  
Oil level should be up to the reservoir plug hole.  
If not, add oil. Use only Mobil 1 15W-50 synthetic  
motor oil. Replace reservoir plug and tighten until  
snug. Do Not overtighten.  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
2. Tilt seat up.  
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 only  
Mobil 1 15W-50 synthetic motor oil. Replace  
hydraulic reservoir cap and tighten until snug. Do  
Not overtighten.  
Check Tire Pressures  
Service Interval: Every 40 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Note: The baffle is labeled “HOT” and  
“COLD”. The oil level varies with the  
2. Check tire pressure in drive tires.  
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.  
• TurfMate drive tires should be inflated to 13  
psi (90 kpa).  
• AT101 (Bar Lug) drive tires should be inflated  
to 9 psi (62 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.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Stop engine and wait for all moving parts to stop.  
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Maintenance  
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.  
Lubrication Chart  
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.  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
2
4
40 Hours  
1. Hitch  
and Cylinder  
Pivots  
2
2
2
2
1
2
2
100 Hours  
Yearly  
2. Fold  
Pivot Pin  
Lubricate Rear Caster Wheel  
Hub(s)  
3. Fold  
Lock Pin  
Service Interval: Yearly  
4. Rear  
Caster Pivot  
*0  
1
*Yearly  
Yearly  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
5. Belt  
Idlers  
6. Motion  
Control  
Pivots  
1
Yearly  
1
2
4
1
7. Transfer  
Spring Ends  
Yearly  
8. Dual Tail  
Wheel Pivot  
40 Hours  
Figure 11  
* 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.  
1. Seal guard  
2. Spacer nut with wrench  
flats  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the 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  
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Maintenance  
the other spacer nut still assembled to it) from  
the wheel assembly.  
Lubricate Brake Handle Pivot  
Service Interval: Every 160 hours  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
2. Tilt seat forward.  
3. Lubricate bronze bushings on brake handle pivot  
with a spray type lubricant or light oil.  
7. Insert one bearing, one new seal into the wheel.  
Note: Seals (Exmark P/N 103-0063) must be  
replaced.  
Lubricate Brake Rod  
Bushings  
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.  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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).  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
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.  
Lubricate Motion Control  
Bronze Bushings  
11. Insert the second bearing and new seal into the  
wheel.  
Service Interval: Every 160 hours  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Unhook seat latch and tilt seat up.  
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.  
3. Lubricate bronze bushings on flange bearings  
securing the motion control arm shafts with a  
light oil or a spray type lubricant.  
14. Reinstall the seal guards over the wheel hub and  
insert wheel into caster fork. Reinstall caster bolt  
and tighten nut fully.  
Lubricate Motion Control  
Shaft  
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.  
Service Interval: Yearly  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Tilt seat forward.  
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.  
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Maintenance  
Lubricate Steering Linkage  
Rod Ends  
Change Fuel Filter  
Service Interval: Every 400 hours or as  
required.  
Service Interval: Every 160 hours  
A fuel filter is installed between the fuel tank and fuel  
pump, and between the fuel pump and the engine.  
Replace when necessary.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Tilt seat forward.  
Replacement Filters  
3. Lubricate each end of both steering linkage rods  
with a spray lubricant or light oil  
Kubota  
Kubota P/N 12581-43012  
Drain Water from Fuel Tank  
Service Interval: As required  
Change Hydraulic System  
Filter  
1. Park on level ground. Stop engine, wait for all  
moving parts to stop, and remove key. Engage  
parking brake.  
Service Interval: After the first 250 hours  
Yearly thereafter  
Note: Use only Exmark Part No. 103-2146.  
2. Place a drain pan under the fuel tank and loosen  
the drain cock approximately 1 turn.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Drain out any water.  
2. Carefully clean area around filter. It is important  
that no dirt or contamination enter hydraulic  
system.  
4. When fuel begins to flow from the tank, tighten  
the drain cock.  
5. Prime the fuel system.  
3. Unscrew filter to remove and allow oil to drain  
from reservoir.  
Fuel System Procedure:  
A. Unit is equipped with an electric priming  
pump. Turn key on to let electric pump run  
for at least 30 seconds before starting.  
Important: Before reinstalling new filter, fill  
it with Mobil 1 15W-50 and apply a thin coat  
of oil on the surface of the rubber seal.  
B. Start engine as stated in Starting the Engine  
in the Operation section.  
Turn filter clockwise until rubber seal contacts the  
filter adapter, then tighten the filter an additional  
2/3 to 3/4 turn.  
Important: Do Not over crank engine.  
Over cranking engine can damage the  
starter and/or the fuel solenoid. If engine  
does not start within 10 seconds allow  
electric pump to run for 30 seconds before  
cranking again.  
4. Fill reservoir as stated in Check Hydraulic Oil  
Level section.  
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.  
6. Check for leaks.  
Important: Water or other contaminants in  
fuel can severely damage fuel pump and/or  
the other engine components.  
7. If any water was drained, run engine for  
approximately two minutes to flush any remaining  
water out of the engine and fuel system.  
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Maintenance  
• Pump drive sheave set screws.  
• Line shaft sheave setscrews.  
CAUTION  
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.  
• Square head setscrews on Hydro pump control  
arms.  
• Sheave retaining bolt in the end of engine  
crankshaft.  
• Caster wheel spacer nuts.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support  
• Fuel tank bulkhead fitting nuts.  
• Motion control tab retaining bolt.  
Adhesives such as “Loctite RC/609 or RC/680” or  
“Fel-Pro Pro-Lock Retaining I or Retaining II” are  
used on the following:  
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.  
Fuel tank studs, where studs are inserted into tank.  
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.  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
Changing oil unnecessarily could damage hydraulic  
system by introducing contaminates into the system.  
Check Wheel Hub Locknuts  
Service Interval: After the first 100 hours  
Every 500 hours thereafter  
When tightening the lock nut on the wheel motor  
tapered shaft:  
Torque to 210-250 ft-lb (285-339 N-m).  
Note: Do Not use antiseize on wheel hub.  
Fuel Tank — Mounting  
Hardware Specifications  
Service Interval: As required  
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.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
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Maintenance  
Park Brake Adjustment  
Check to make sure brake is adjusted properly.  
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.  
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.  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
4. Locate the park brake spring assembly (see  
Figure 13). 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.  
Pump Drive Belt  
Replacement  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove pump drive belt.  
3. Route new belt onto sheaves as shown in the  
decal located on the right hand side of the left  
hood support (see Figure 12).  
Figure 12  
Figure 13  
1. Park brake engaged  
2. Yoke  
3. Thin nyloc nut  
4. 1/8 inch (3 mm) gap  
between nut and yoke.  
Alternator Belt Tension  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
5. Disengage the park brake. Measure the length of  
the park brake spring. The spring should measure  
2 1/2 inches (6.4 cm) (see Figure 14).  
2. Tilt seat forward and raise hood.  
3. To tighten alternator belt, loosen both upper and  
lower alternator mounting bolts. Rotate alternator  
out, away from engine and re-tighten hardware  
to secure in place.  
4. When properly tensioned, the alternator belt will  
deflect 1/4–3/8 inches (7-9 mm) while applying  
22 pounds of force to the belt midway between  
alternator and crankshaft pulley.  
Figure 14  
1. Yoke  
2. Park brake spring  
3. 2 1/2 inches (6.4 cm)  
4. Thin nyloc nut  
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Maintenance  
6. If necessary, turn the thin nyloc nut to obtain the  
2 1/2 inches (6.4 cm) spring length.  
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.  
7. Engage the park brake. Measure the gap between  
the thin nyloc nut and the park brake clevis.  
The gap should measure 1/8 inch (3.2 mm) (see  
Figure 15).  
11. Repeat procedure for other side.  
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 15  
1. Yoke  
2. Park brake spring  
3. 1/8 inch (3.2 mm)  
4. Thin nyloc nut  
5. Inner flange nut  
6. Outer flange nut  
Keep fingers, hands, and clothing clear of  
rotating components and hot surfaces.  
8. If necessary, loosen the inner flanged nut and turn  
the outer nut to obtain the 1/8 inch (3.2 mm) gap.  
Re-tigten the inner flanged nut.  
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.  
9. 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  
inches (18.7 cm) from the center of the ball joint  
to the center of the lower end of the linkage rod  
(see Figure 16).  
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 17).  
Figure 16  
1. Ball joint  
2. Jam nut  
3. Park brake linkage rod  
4. 7 3/8 inches (18.7 cm)  
8. Re-tighten the jam nut against the ball joint on  
each side.  
10. If the linkage does not measure 7 3/8 inch  
(18.7 cm) or still does not disengage as desired,  
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Maintenance  
Figure 18  
4. Loosen here  
1. Motion control lever  
2. End of slot  
3. Yoke  
5. Turn bolt here  
4. Check where lever is relative to notch in neutral  
plate (should be centered allowing lever to pivot  
outward to the neutral lock position).  
Figure 17  
5. If adjustment is needed, loosen the nut against the  
yoke and while applying slight rearward pressure  
on the motion control lever, turn the head of the  
adjustment bolt in the appropriate direction until  
lever is centered (keeping rearward pressure on  
the lever will keep the pin at the end of the slot  
and allow the adjustment bolt to move the lever  
to the appropriate position). Tighten lock nut.  
1. Loosen jam nut  
2. Pump control rod linkage  
3. Use wrench to turn double nuts  
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).  
6. Repeat on opposite side of unit.  
10. Stop engine and wait for all moving parts to stop.  
Remove jumper wire from wire harness connector  
and plug connector into seat switch.  
Weight Transfer Spring  
Adjustment  
11. Lower from jackstands.  
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.  
Reverse Indicator  
Adjustment  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Tilt seat forward.  
3. Begin with either the left or right motion control  
lever. Move lever to the neutral position and pull  
lever back until the clevis pin (on arm below pivot  
shaft) contacts the end of the slot (just beginning  
to put pressure on spring), (see Figure 18).  
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 19).  
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Maintenance  
Figure 20  
Right-Hand Side of Unit Shown  
1. Re-install spring in outer 3. Remove e-ring and  
Figure 19  
3. Fender knob  
holes to reduce spring  
washer.  
tension.  
1. Motion control lever  
2. Left fender  
2. Weight transfer spring.  
7. Re-install the left fender.  
3. Slide the fender forward and twist upward and  
outward to remove.  
8. For additional weight transfer adjustment, repeat  
steps 4 through 7 on the right side of the unit.  
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.  
Rear Caster Pivot Bearings  
Pre-Load Adjustment  
WARNING  
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 21.  
Weight transfer springs may have stored  
energy. Removing the weight transfer  
springs without releasing the stored energy  
can cause serious injury.  
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).  
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 20).  
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.  
Figure 21  
1. Spring disc washers  
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Maintenance  
Cleaning  
Clean Engine Cooling  
System  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
conditions.)  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Wipe debris from radiator screen in front of  
radiator. Rotate engine cover forward, pull out  
radiator screen, and wipe debris from radiator  
core as required.  
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.  
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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.  
1. Engine load is excessive  
9. Contact an Authorized Service Dealer.  
Engine loses power.  
1. Reduce the ground speed.  
2. Air cleaner is dirty.  
2. Clean or replace the air cleaner element.  
3. Add oil to the crankcase.  
4. Clean or replace the fuel cap.  
5. Replace the fuel filter.  
3. Oil level in the crankcase is low.  
4. Vent hole in the fuel cap is plugged.  
5. Dirt in fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
38  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Engine overheats.  
1. Engine load is excessive.  
1. Reduce the ground speed.  
2. Oil level in the crankcase is low.  
3. Dirty air filter.  
4. Coolant level is low.  
2. Add oil to the crankcase.  
3. Clean or replace the air cleaner element.  
4. Add coolant.  
5. Debris on or around radiator.  
5. Remove debris.  
6. Water pump or alternator belt is worn,  
loose, or broken.  
6. Contact an Authorized Service Dealer.  
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.  
Warning buzzer emits continuous beep. (See  
also Engine overheats).  
1. Temperature is increasing on coolant  
temperature gauge.  
1. Turn unit off and allow engine and engine  
components to cool.  
2. Coolant level is low.  
2. Add coolant.  
3. Debris on or around radiator.  
3. Remove debris.  
4. Water pump or alternator belt is worn,  
loose or broken.  
4. Contact Authorized Service Dealer.  
Warning buzzer emits intermittent beep.  
1. Oil level is low.  
1. Check oil level.  
2. Oil leaking from engine.  
2. Contact Authorized Service Dealer.  
39  
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Schematics  
Schematics  
Electrical Diagram  
C A K  
C A K  
W O N R / B B L  
W O N R / B B L  
C A K  
P I N K / B L  
C A K B L  
C A K B L  
O R A N G E  
V I O L E T  
R E D  
C A K  
W O N R / B B L  
C A K  
C A K  
W O / B L Y E L L  
W O / B L Y E L L  
C A K  
C A K  
W O / B L Y E L L  
W O / B L Y E L L  
C A K / W B H L I T E  
P I N K  
C A K B L  
C A K B L  
C A K  
P I N K / B L  
C A K / G B R L E E N  
C A K  
W O N R / B B L  
C A K  
O R A N G E / B L  
C A K  
W O / B L Y E L L  
. G R D E K E N  
. G R D E K E N  
C A K  
C A K  
O R A N G E / B L  
O R A N G E / B L  
C A K B L  
C A K B L  
W O Y E L L  
Y A G R  
. G R D E K E N  
. G R D E K E N  
V I O L E T  
. B T L U E  
. B T L U E  
. B T L U E  
Y A G R  
O R A N G E  
L
L
O R A N G E  
V I O L E T  
O R A N G E  
O R A N G E  
L
Y A G R  
Y A G R  
. G R D E K E N  
. G R L E E N  
T
C A K  
Y A / B L G R  
C A K B L  
. G T L R E E N  
. B T L U E  
A T N  
L
W O N R B  
W O N R B  
R E D  
R E D  
C A K B L  
C A K B L  
O R A N G E  
C A K  
C A K  
W O / B L Y E L L  
W O / B L Y E L L  
W O / R E D Y E L L  
. B T L U E  
. B T L U E  
L
L
C A K B L  
C A K B L  
C A K  
W O / B L Y E L L  
C A K B L  
A T N  
A T N  
Y A G R  
Y A G R  
Y A G R  
Y A / B L G R  
Y A / B L G R  
Y A / B L G R  
C A K  
C A K  
C A K  
G007979  
40  
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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  
41  
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2-Year Limited Warranty  
Exmark Turf Equipment  
(For units purchased on or after October 1, 2004)  
Contact any Exmark Service Dealer to arrange service at their  
Conditions and Products Covered  
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty  
Company, pursuant to an agreement between them, jointly  
warrant on the terms and conditions herein, that we will repair,  
replace or adjust any part manufactured by Exmark and found  
by us (in the exercise of our reasonable discretion) to be  
defective in factory materials or workmanship for a period of  
two years.  
dealership. To locate a dealer convenient to you, access our  
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  
This warranty applies to Exmark turf equipment purchased on  
or after October 1, 2004 sold in the US or Canada. This  
warranty may only be assigned or transferred to a second (or  
third) owner by an authorized Exmark dealer. The warranty  
period commences upon the date of the original retail  
purchase.  
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.  
Products  
Warranty Period  
2 years  
1 year  
1 year  
90 days  
1 Year Prorated  
• All Products (except as noted below)  
• All Attachments and Accessories  
• Metro 21 and Metro 26 Series  
• Belts and Tires  
• Battery  
• Engine*  
Warranty is covered by engine manufacturer  
* Please refer to the engine manufacturer’s warranty statement  
that is included in the literature packet. We are not authorized  
to handle warranty adjustments on engines.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company  
with respect to this warranty shall be repair and replacement  
of defective components as set forth herein. Neither Exmark  
nor Exmark Warranty Company shall have any liability  
for any other cost, loss or damage, including but not  
limited to, any incidental or consequential loss or damage.  
This warranty only includes the cost of parts and labor.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Pickup and delivery charges to and from any authorized  
Exmark Service Dealer beyond first warrantable service.  
• Any damage or deterioration due to normal use, wear and  
tear, or exposure.  
• Cost of regular maintenance service or parts, such as filters,  
fuel, lubricants, tune-up parts, and adjustments.  
• Any product or part which has been altered or misused or  
required replacement or repair due to normal wear,  
accidents, or lack of proper maintenance.  
• Any repairs necessary due to use of parts, accessories or  
supplies, including gasoline, oil or lubricants, incompatible  
with the turf equipment or other than as recommended in  
the operator's manual or other operational instructions  
provided by Exmark.  
In particular, we shall have no liability or responsibility for:  
• Expenses related to gasoline, oil or lubricants.  
• Travel time, overtime, after hours time or other  
extraordinary repair charges or charge relating to repairs or  
replacements outside of normal business hours at the place  
of business of the authorized Exmark Service Dealer.  
• Rental of like or similar replacement equipment during the  
period of any warranty, repair or replacement work.  
• Any telephone or telegram charges or travel charges.  
• Loss or damage to person or property other than that  
covered by the terms of this warranty.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
There are no other express warranties except for engine and  
special emission system coverage stated elsewhere herein or  
included with the product.  
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.  
Some states do not allow exclusions of incidental or  
consequential damages, so the above exclusions and  
limitations may not apply to you.  
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.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G006117  
42  
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43  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES  
MID-MOUNT RIDING ACCESSORIES  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DECK LIFT ASSIST KIT  
HITCH KIT  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SNOW BLADE  
SUN SHADE  
LAZERLOCKER  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
MICRO-MULCH SYSTEM  
OPERATOR CONTROLLED DISCHARGE  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
OUT-FRONT RIDING ACCESSORIES  
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)  
ROTARY BROOM  
WALK-BEHIND ACCESSORIES  
GRASS CATCHER  
LAZERLOCKER  
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.  
© 2006–2008 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-227 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA.  
All Rights Reserved  
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