Exmark Frontrunner Diesel Users Manual

Diesel to the manual d63265fe-02e4-4c58-8057-57fe366f31cd

2015-02-04

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FRONTRUNNER

DIESEL MODELS

For Serial Nos.
720,000 & Higher
Part No. 4500-227 Rev. A

WARNING
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
Important: When the mower is used or operated
on any California forest, brush or grass covered
land, a working spark arrester must be attached
to the muffler. If not, the operator is violating
state law, Section 4442 Public Resource Code. To
acquire a spark arrester for your unit, see your
Engine Service Dealer.
This spark ignition system complies with Canadian
ICES-002 Ce système d’allumage par ètincelle de
vèhicule est conforme à la norme NMB-002 du
Canada
The enclosed Engine Owner’s Manual is
supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and
the California Emission Control Regulation of
emission systems, maintenance and warranty.
Keep this engine Owner’s Manual with your unit.
Should this engine Owner’s Manual become
damaged or illegible, replace immediately.
Replacements may be ordered through the
engine manufacturer.
Exmark reserves the right to make changes or
add improvements to its products at any time
without incurring any obligation to make such
changes to products manufactured previously.
Exmark, or its distributors and dealers, accept
no responsibility for variations which may be
evident in the actual specifications of its products
and the statements and descriptions contained
in this publication.

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.

Contents

Alternator Belt Tension ................................. 33
Park Brake Adjustment.................................. 33
Motion Control Linkage Adjustment ............. 34
Reverse Indicator Adjustment........................ 35
Weight Transfer Spring Adjustment ............... 35
Rear Caster Pivot Bearings Pre-Load
Adjustment ............................................... 36
Cleaning ........................................................... 37
Clean Engine Cooling System ........................ 37
Waste Disposal .............................................. 37
Troubleshooting ................................................... 38
Schematics ........................................................... 40

Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ..................... 10
Specifications ....................................................... 14
Model Numbers ............................................ 14
Systems ......................................................... 14
Dimensions................................................... 16
Torque Requirements .................................... 16
Product Overview ................................................ 17
Operation ............................................................. 17
Controls ........................................................ 17
Pre-Start........................................................ 19
Operating Instructions .................................. 19
Transporting ................................................. 21
Maintenance ......................................................... 23
Recommended Maintenance Schedule(s) ........... 23
Periodic Maintenance ....................................... 24
Check Engine Oil Level ................................. 24
Check Engine Coolant Level.......................... 24
Change Engine Coolant................................. 25
Check Battery Charge .................................... 25
Check Safety Interlock System ....................... 26
Check Rollover Protections Systems (Roll
Bar) Pins ................................................... 27
Check Seat Belt.............................................. 27
Check for Loose Hardware ............................ 27
Service Air Cleaner ........................................ 27
Change Engine Oil ........................................ 27
Check Hydraulic Oil Level ............................. 28
Check Tire Pressures ..................................... 28
Check Condition Of Belts.............................. 28
Lubricate Grease Fittings............................... 29
Lubricate Rear Caster Wheel Hub(s)............... 29
Lubricate Brake Handle Pivot ........................ 30
Lubricate Brake Rod Bushings ....................... 30
Lubricate Motion Control Bronze
Bushings ................................................... 30
Lubricate Motion Control Shaft ..................... 30
Lubricate Steering Linkage Rod Ends............. 31
Change Fuel Filter ......................................... 31
Change Hydraulic System Filter ..................... 31
Check Wheel Hub Locknuts .......................... 32
Thread Locking Adhesives............................. 32
Dielectric Grease........................................... 32
Adjustments ..................................................... 33
Pump Drive Belt Tension............................... 33
Pump Drive Belt Replacement ....................... 33
4

Safety

• Never let children or untrained people operate
or service the equipment. Local regulations may
restrict the age of the operator.

Safety Alert Symbol

• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.

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

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

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 refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.

• Never siphon by mouth.

• 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.

• Never smoke when handling diesel, and
stay away from an open flame or where
diesel fumes may be ignited by spark.

Operation

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.

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.

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.

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.
3. Water

• Drive slowly and carefully.
• 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.

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.
• 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.
• 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.
• 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.
• 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.

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.

WARNING
Fuel system components are under high
pressure. The use of improper components
can result in system failure, fuel leakage and
possible explosion.
Use only approved fuel lines and clamps for
high pressure systems.

Safety

Safety and Instructional Decals
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• Replace all worn, damaged, or missing safety
signs.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• If an attachment or accessory has been installed,
make sure current safety signs are visible.

• New safety signs may be obtained from
your authorized Exmark equipment dealer or
distributor or from Exmark Mfg. Co. Inc.
• 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.
• Familiarize yourself with the following safety signs
and instruction labels. They are critical to the safe
operation of your Exmark commercial mower.

98-4361

103-2076

98-5954
1-513747

1-523552

103-0223

1-643339

Safety

103-1636

103-5881

103-7218

107-2102

107-2112

Safety

109-2355

109-2358

109-2356
1. Fast
2. Slow

109-2377

3. Neutral
4. Reverse

109-2396

109-2357
1. Fast
2. Slow
3. Neutral

4. Reverse
5. Park Brake—Release
6. Park Brake—Engage

Safety

109-7949

19426-87881

109-2698
1. Cylinder—extend
2. Cylinder—retract

3. Fast
4. Slow

19426-87903

109-3637

109-2360

Specifications

Specifications
Model Numbers
Serial Nos: 720,000 and Higher
FR25KD

Systems

Cooling System

Engine

• Fan: Belt driven with continuous operation with
engine running.

• Engine Specifications: See your Engine Owner’s
Manual
• RPM: Full Speed: 3870 +50/-100 RPM (No
Load) Idle: 1400 ±50 RPM (No Load)

• Coolant Liquid: 50/50 mix of DexCool©
extended life antifreeze and water.
• Coolant Capacity: 4 quarts

Fuel System

Operator Controls

• Capacity: 8.5 gal. (32 L)
• 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.
• Fuel gauge at the rear of the right hand fuel tank.

• Steering and Motion Control:
Note: Motion control levers are adjustable to
three heights.
– Separate levers, on each side of the console,
control speed and direction of travel of the
respective drive wheels.
– 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
Polarity: Negative Ground
Fuses: One 15 amp, one 20 amp, and one 40 amp
blade type

• PTO Engagement Switch: Engages drive to PTO
(mower deck).
• Parking Brake Lever: Engages parking brake by
pulling back.

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.)
• Operator must be in seat when PTO is engaged,
brake is disengaged, or motion control levers are
moved in or engine will stop.
• Engine will stop if the motion control levers
are moved from neutral position while brake is
engaged.

Optional seat accessories for units with standard
seats:
– Custom ride suspension system to enhance
Standard Seat.
– Deluxe suspension seat with high back, low
profile foam-in-place cushion (dampened,
adjustable spring suspension), armrests, and
integral safety switch.
14

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

• Armrests: Standard seat: foam padded flip-up
armrests. Optional suspension seat: molded
adjustable flip-up armrests.
• 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.

• Hydraulic Filter: Replaceable cartridge type.
P/N 103-2146: 25 microns, No bypass
• Speeds:
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.

Tires & Wheels
Drive

Tread

AT101

TurfMate

Size

24 x 12.00-12

23 x 10.50-10

Ply Rating

Pressure

9 psi(62 kPa)

13 psi (90 kPa)

Quantity

Tread

Smooth

Size

9 x 3.50-4

13 x 6.5-6

(Sold Separately)
• Model Numbers:
– FR524
– FR604
– FR724
• Cutting Width:
– 52 inch (132 cm)
– 60 inch (152 cm)
– 72 inch (183 cm)
• Discharge: Side
• Blade Size: (3 ea.)
– 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)
• Cutting Height Adjustment: Adjusts from 1 1/2
inches (3.8 cm) to 5 inches (12.7 cm) infinitely
variable.

• Hydraulic Oil Capacity: 5.2 qt (4.9 L)

Semi-Pneumatic

Cutting Deck

• Hydraulic Oil Type: Use Mobil 1 15W-50
Synthetic motor oil.

Quantity

Semi-Pneumatic

Pressure

• Hydrostatic Pumps: Two Hydro Gear PR 16 cc
variable displacement piston pumps.

Pneumatic
(Air-Filled)
(Optional)

Rear Caster
(Dual Tail
Wheel)

Ply Rating

Hydrostatic Ground Drive System

Pneumatic
(Air-Filled)
(Standard)

Front Caster

Specifications
Curb Weight:

• Mulching Kit: Optional
• Bagger: Optional

Dimensions

Without deck

1163 lb (528 kg)

52 inch Deck

1555 lb (705 kg)

60 inch Deck

1600 lb (726 kg)

72 inch Deck

1660 lb (753 kg)

Overall Width:
52 inch
Deck

60 inch
Deck

72 inch
Deck

Without
Deck

49.0 inches
(124.5 cm)

53.0 inches
(135 cm)

Bolt Location

Torque

Wheel Lug Nuts

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

Deflector
Up

53.3 inches
(135.4 cm)

61.4 inches
(156 cm)

73.4 inches
(186 cm)

Wheel Motor Mounting
Bolts

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

Deflector
Down

64.0 inches
(163 cm)

72.0 inches
(183 cm)

84.3 inches
(214 cm)

Wheel Hub Lock Nut

210-250 ft-lb
(285-339 N-m)

Torque Requirements

Rollover Protection System 30-35 ft-lb (41-47 N-m)
(Roll Bar) Mounting Bolts

Overall Length:
Without deck and floor
pan folded

82.3 inches (209.0 cm)

52 inch Deck

114.3 inches (290.3 cm)

60 inch Deck

114.3 inches (290.3 cm)

72 inch Deck

114.3 inches (290.3 cm)

Clutch Retaining Bolt
55-60 ft-lb (75-81 N-m)
(secured with threadlocker)

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)

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)

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”
17

Operation
The hydraulic lift switch is used to raise and lower
the mower deck.

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).

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

Hour Meter

Located on the right fuel tank console.

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.

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.
Note: This switch is not a low oil sensor and will not
alert the operator if the engine oil is low.

Coolant Temperature Light

Fuel Gauge

The light will come on if the engine is overheating
and an alarm will sound. Refer to the Warning
Buzzer in the Troubleshooting section.

Located on the right fuel tank console.

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
Located on the top left front corner of hydrostatic
pumps.

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.

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

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.

Located to the rear of the key switch.

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
Located on the right fuel tank.

Light will come on when engine oil pressure is low
or lost.

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.
18

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
1. Roll bar
2. Raised position

Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.

Operating Instructions

3. Pin
4. Hairpin cotter pin

Starting the Engine
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.

Operation
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.

Glow Plug Chart

Ambient Temperature

Hold Glow Plugs On

Above 50°F (10°C)

NO NEED

Important: Operator must be in seat before the
PTO can be engaged.
1. Set the throttle to the “MIDWAY” position.
2. Pull the PTO switch outward to the “ROTATE”
position.
3. Place the throttle in the “FAST” position to begin
mowing.

50°F (10°C) to 23°F (-5°C) Approximately 5 seconds
Below 23°F (-5°C)

Approximately 10 seconds

Limit of continuous use

20 seconds

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.

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.
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.
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.

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.

Engaging the PTO

DANGER
The rotating blades under the mower deck
are dangerous. Blade contact can cause
serious injury or kill you.

Driving the Machine

Do Not put hands or feet under the mower
or mower deck when the blades are engaged.

CAUTION
DANGER

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.

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)
20

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
Lock)
2. Handles In (Neutral)
3. Front of Unit

Figure 6
1. Handles Out (Neutral
Lock)
2. Handles In (Neutral)
3. Front of Unit
4. Forward

5. Neutral
6. Reverse
7. Neutral Lock

4. Forward
5. Reverse

Driving in Reverse
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.

Driving Forward
1. Release the parking brake.
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.
21

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
22

Maintenance

Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.

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
Interval

Maintenance Procedure

After the first 5 hours

• Change the engine oil.

After the first 100 hours

• Check the wheel hub locknuts torque specification.

After the first 250 hours

• Change the hydraulic filter.

Before each use or daily

•
•
•
•
•
•
•

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.
Check for loose hardware.
Clean the engine cooling system.

Every 40 hours

•
•
•
•
•

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 50 hours

• Service the air cleaner. (May need more often under severe conditions. See the Engine
Owner’s Manual for additional information.)

Every 100 hours

• Change the engine oil. (May need more often under severe conditions.)
• Grease the fold pivot pin.

Every 160 hours

•
•
•
•

Every 400 hours

• Change the fuel filter.

Every 500 hours

• Check the wheel hub locknuts torque specification.

Lubricate the brake handle pivot.
Lubricate the brake rod bushings.
Lubricate the motion control bronze bushings.
Lubricate the steering linkage rod ends.

Maintenance
Maintenance Service
Interval
Every 4,000 hours
Monthly

Yearly

Maintenance Procedure
• 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.

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

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.

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.

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

Check Engine Coolant Level

Engine coolant is toxic. Swallowing coolant
can cause poisoning.

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.

Maintenance

Change Engine Coolant

WARNING

Service Interval: Every 4,000 hours/Every 4
years (whichever comes
© extended
first) Dex-Cool©
life coolant (orange color)

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.

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.

Check Battery Charge

Figure 8
1. Oil dipstick

2. Drain cock

Service Interval: Monthly

WARNING

4. Tighten engine and radiator drain cocks. Reinstall
lower hose (if removed).

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
25

Maintenance
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.

battery performance and life, recharge batteries in
storage when the open circuit voltage drops to 12.4
volts.
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).
Voltage
Reading

Percent
Charge

Maximum
Charger
Settings

Charging
Interval

12.6 or
greater

100%

16 volts/7
amps

No
Charging
Required

12.4 – 12.6

75–100%

16 volts/7
amps

30 Minutes

12.2 – 12.4

50–75%

16 volts/7
amps

1 Hour

12.0–12.2

25–50%

14.4 volts/4 2 Hours
amps

11.7–12.0

0–25%

14.4 volts/4 3 Hours
amps

11.7 or less

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 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.
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.
Again, run engine at one-third throttle, brake
engaged, and move left motion control lever in
- engine must initiate shutdown.
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/2 6 Hours or
More
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.

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.)
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 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.
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.

Figure 9
Left Side—Inside of Hitch Shown
1. PTO “Kill” Switch
2. PTO Switch Arm
3. Lower deck until arm Does Not contact the switch.

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.

Check Rollover Protections
Systems (Roll Bar) Pins
Service Interval: Before each use or daily

Change Engine Oil

Make sure latch pin and hair pin are fully installed
and lanyard is in good condition.

Service Interval: After the first 5 hours
Every 100 hours/Yearly
(whichever comes first)
(May need more often
under severe conditions.)
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.
3. Drain oil while engine is warm from operation.

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.

Maintenance
4. Remove the oil drain plug. Allow oil to drain then
replace the drain plug.
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.

3. Tilt the seat forward.
4. Locate the auxiliary hydraulic power unit reservoir
(see Figure 10).

Figure 10

Check Hydraulic Oil Level

1. Auxiliary hydraulic reservoir plug

Service Interval: Every 40 hours
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.

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.

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
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.
• 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.
1. Retract the hydraulic cylinder.
2. Stop engine and wait for all moving parts to stop.

Check Condition Of Belts
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
28

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
Fitting
Locations

Initial
Pumps

Number of
Places

Service
Interval

1. Hitch
and Cylinder
Pivots

40 Hours

2. Fold
Pivot Pin

100 Hours

3. Fold
Lock Pin

Yearly

4. Rear
Caster Pivot

*Yearly

5. Belt
Idlers

Yearly

6. Motion
Control
Pivots

Yearly

7. Transfer
Spring Ends

Yearly

8. Dual Tail
Wheel Pivot

40 Hours

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.

Lubricate Rear Caster Wheel
Hub(s)
Service Interval: Yearly
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.

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
29

Maintenance

Lubricate Brake Handle Pivot

the other spacer nut still assembled to it) from
the wheel assembly.

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.
30

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

Change Hydraulic System
Filter

Drain Water from Fuel Tank
Service Interval: As required
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

2. Place a drain pan under the fuel tank and loosen
the drain cock approximately 1 turn.

Note: Use only Exmark Part No. 103-2146.

Yearly thereafter

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.

Maintenance
• Pump drive sheave set screws.

CAUTION

• Line shaft sheave setscrews.

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.

Dielectric Grease

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.

Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.

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:
32

Maintenance

Adjustments

Park Brake Adjustment

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.

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.

Pump Drive Belt Tension

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.

Self-tensioning - No adjustment necessary.

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

Alternator Belt Tension
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.

3. Thin nyloc nut
4. 1/8 inch (3 mm) gap
between nut and yoke.

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

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,

Maintenance

Figure 18
1. Motion control lever
2. End of slot
3. Yoke

4. Loosen here
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).

Maintenance

Figure 20
Right-Hand Side of Unit Shown
1. Re-install spring in outer
holes to reduce spring
tension.
2. Weight transfer spring.

Figure 19
1. Motion control lever
2. Left fender

3. Fender knob

3. Remove e-ring and
washer.

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

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.
37

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.

Engine will not start, starts hard, or fails to
keep running.

Possible Cause
1. PTO is engaged.

1. Disengage the PTO.

2. Parking brake is not.
3. Drive levers are not in neutral lock
position.
4. Battery does not have a full charge.
5. Electrical connections are corroded, loose
or faulty.

6. Fuse is blown.
7. Relay or switch is defective.

2. Set the parking brake.
3. Ensure the drive levers are in the neutral
lock position.
4. Charge the battery.
5. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
6. Replace the blown fuse.
7. Contact an Authorized Service Dealer.

1. Fuel tank is empty.

1. Fill the fuel tank.

2. Fuel shutoff valve is closed.
3. Oil level in the crankcase is low.
4. The throttle and choke are not in the
correct position.

2. Open the fuel shutoff valve.
3. Add oil to the crankcase.
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. Replace the fuel filter.
6. Contact an Authorized Service Dealer.

5. Dirt in fuel filter.
6. Dirt, water, or stale fuel is in the fuel
system.
7. Air cleaner is dirty.
8. Electrical connections are corroded, loose
or faulty.

Engine loses power.

Corrective Action

9. Relay or switch is defective.

7. Clean or replace the air cleaner element.
8. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
9. Contact an Authorized Service Dealer.

1. Engine load is excessive

1. Reduce the ground speed.

2.
3.
4.
5.
6.

Air cleaner is dirty.
Oil level in the crankcase is low.
Vent hole in the fuel cap is plugged.
Dirt in fuel filter.
Dirt, water, or stale fuel is in the fuel
system.

Clean or replace the air cleaner element.
Add oil to the crankcase.
Clean or replace the fuel cap.
Replace the fuel filter.
Contact an Authorized Service Dealer.

Troubleshooting
Problem
Engine overheats.

Possible Cause

Corrective Action

1. Engine load is excessive.

1. Reduce the ground speed.

2.
3.
4.
5.
6.

Oil level in the crankcase is low.
Dirty air filter.
Coolant level is low.
Debris on or around radiator.
Water pump or alternator belt is worn,
loose, or broken.

Add oil to the crankcase.
Clean or replace the air cleaner element.
Add coolant.
Remove debris.
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.
3. Reverse indicator and motion control
linkage need adjustment.

2. Adjust tire pressure in the drive tires.
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. 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.

2. Change the belt.

Abnormal vibration.

Warning buzzer emits continuous beep. (See
also Engine overheats).

Warning buzzer emits intermittent beep.

3. Change the belt.
4. Replace the spring.
5. Add hydraulic fluid to reservoir or let it
cool down.

1. Engine mounting bolts are loose.

1. Tighten the engine mounting bolts.

2. Loose engine pulley, idler pulley, or blade
pulley.
3. Engine pulley is damaged.

2. Tighten the appropriate pulley.

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.
3. Debris on or around radiator.
4. Water pump or alternator belt is worn,
loose or broken.

2. Add coolant.
3. Remove debris.
4. Contact Authorized Service Dealer.

1. Oil level is low.

1. Check oil level.

2. Oil leaking from engine.

2. Contact Authorized Service Dealer.

3. Contact an Authorized Service Dealer.

TERMINAL X

TERMINAL I

3. START

2. RUN

1. OFF

POSITION

B+I+S

B+I+ A

GROUND

CIRCUIT
BREAKER

CONNECTIONS

BATTERY

HOUR METER, AUX HYD, PTO SWITCH

START RELAY

SEAT DELAY

HOUR METER, AUX HYD, PTO SWITCH

TERMINAL S

TERMINAL X

TERMINAL Y

YELLOW
YELLOW/BLACK

3
YELLOW/BLACK

RED

TAN

ORANGE

RED

BLACK
RED

BLACK

RED

ORANGE

BLACK

TERMINAL I

2
3

TERMINAL B

VOLTAGE REGULATOR

TERMINAL A

5
4

BATTERY (POS)

BATTERY (NEG)

20 AMP FUSE
(IGN. SWITCH)

IGNITION
SWITCH

WHITE/BLACK

BLUE/BLACK

YELLOW/BLACK
YELLOW/BLACK

1
5

WHITE/BLACK

MOTOR (FWD)

MOTOR (REV)

STARTER;
BATTERY (POS)

IGNITION SWITCH

TERMINAL

TERMINAL Y

TERMINAL A

TERMINAL B

TERMINAL S

X +Y

NONE

CIRCUIT "MAKE"

NOTE:
CONNECTORS VIEWED FROM TERMINAL END

CONTACTOR

G007979
4

3
3

GRAY

GRAY
2

GRAY

DECK LIFT
SAFETY SWITCH

GRAY/BLACK

AUXILLARY
HYDRAULICS
RAISE/LOWER

GRAY/BLACK

BLACK
YELLOW/BLACK

TAN
TAN
BLACK

BLACK

HEADLIGHT
HARNESS

A B

LT. BLUE
2

YELLOW/BLACK
1

ORANGE

15 AMP FUSE
(HEADLIGHTS)

RED
1

LT.GREEN

LT. BLUE

B A

BLACK

BOTH MOTION CONTROL
SWITCHES ARE CLOSED WITH
CONTROL LEVERS IN NEUTRAL
LOCK POSITION

RH MOTION
CONTROL

LT. GREEN
2

DK. GREEN
2

GRAY
CLOSED WITH
BRAKE
ENGAGED

LH MOTION
CONTROL

BRAKE
SWITCH

3
4

4 1

ORANGE
ORANGE
VIOLET
ORANGE
LT. BLUE

ORANGE
LT. BLUE

9 87

GRAY
VIOLET

1 B
2

A B C

BROWN
RED

40 AMP FUSE
(GLOW)

GRAY/BLACK

TAN

BROWN
LT. BLUE

A B

YELLOW/RED
YELLOW/BLACK

BLACK

GRAY

DK. GREEN

DK. GREEN
LT. BLUE

2
5

DK. GREEN

A B
DIODE

BLACK
8

3 2 1 8

6 5 4 7

GLOW SWITCH

1A 1B 2A 2B

2
5

GLOW
RELAY

A B

2B
1B

BROWN/BLACK
START
RELAY

1A 1B 2A 2B

FUEL
PUMP

BLACK
BLACK
2

2B
1B

OIL PRES AND
ALT CHARGE LED

PINK/BLACK
2

OPEN WITH
BRAKE
ENGAGED

SEAT DELAY
MODULE DIODE

GRAY
YELLOW
BLACK
BLACK
ORANGE/BLACK
ORANGE/BLACK

DK. GREEN

TEMP AND
GLOW LED

YELLOW/BLACK
ORANGE/BLACK

32 1

BLACK/GREEN
BROWN/BLACK

PTO
SWITCH

BLACK

SEAT
PTO
SWITCH CLUTCH

PINK/BLACK

PINK

SEAT DELAY
MODULE INPUT

BLACK/WHITE

TEMP
GAUGE

YELLOW/BLACK
YELLOW/BLACK
YELLOW/BLACK

SEAT DELAY
MODULE CONTROL

VIOLET
YELLOW/BLACK

BLACK

SWITCH IN: ORANGE TO PINK/BLACK
SWITCH OUT: ORANGETO GRAY

ORANGE
RED

GRAY/BLACK

BROWN/BLACK
5

1
BLACK/WHITE

DUAL
TONE
ALARM

2
1

VIOLET

BLACK

YELLOW/BLACK

PINK/BLACK

ORANGE/BLACK

WHITE

FUEL
SOLENOID

ALTERNATOR
CONNECTOR

GLOW
PLUG
RAIL

STARTER
SOLENOID
SIGNAL

STARTER
MOTOR

RED

GROUND

TEMP.
SWITCH
ALT "B"
TERMINAL

BLACK/GREEN
RED

BLACK/GREEN

TEMP
SENDER

HOUR
METER

OIL
SWITCH

DK. BLUE

YELLOW/RED

BLACK/WHITE

BLACK/GREEN

YELLOW/BLACK

BLACK/WHITE

2
PINK

5
BLACK

DK. BLUE

BLACK

YELLOW/BLACK

PINK
PINK
VIOLET
VIOLET
YELLOW/BLACK

YELLOW/BLACK

PINK
PINK

YELLOW/BLACK

BLACK
BLACK

DK. GREEN

BROWN/BLACK

SWITCH IS CLOSED
WITH OPERATOR
IN THE SEAT

ENGINE

OIL
PRESSURE
RELAY

ALTERNATOR
RELAY

Schematics

Schematics
Electrical Diagram

Schematics
Hydraulic Diagram

BYPASS VALVE

HIGH PRESSURE
FORWARD

HIGH PRESSURE
REVERSE
HIGH PRESSURE
FORWARD

HIGH
PRESSURE
REVERSE

G007220

HIGH PRESSURE
CHARGE PUMP
CASE DRAIN

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
dealership. To locate a dealer convenient to you, access our
website at www.exmark.com. U.S. Customers may also call
402-223-6375.

Conditions and Products Covered
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty
Company, pursuant to an agreement between them, jointly
warrant on the terms and conditions herein, that we will repair,
replace or adjust any part manufactured by Exmark and found
by us (in the exercise of our reasonable discretion) to be
defective in factory materials or workmanship for a period of
two years.
This warranty applies to Exmark turf equipment purchased on
or after October 1, 2004 sold in the US or Canada. This
warranty may only be assigned or transferred to a second (or
third) owner by an authorized Exmark dealer. The warranty
period commences upon the date of the original retail
purchase.
Products
Warranty Period
• All Products (except as noted below)
2 years
• All Attachments and Accessories
1 year
• Metro 21 and Metro 26 Series
1 year
• Belts and Tires
90 days
• Battery
1 Year Prorated
• Engine*
Warranty is covered by engine manufacturer
* Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet. We are not authorized
to handle warranty adjustments on engines.
This warranty only includes the cost of parts and labor.

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
service@exmark.com
Owner’s Responsibilities
The Exmark turf equipment, including any defective part,
must be returned to an authorized Exmark service dealer
within the warranty period. This warranty extends only to turf
equipment operated under normal conditions. You must read
the operator’s manual. You must also properly service and
maintain your Exmark product as described in the operator’s
manual. Such routine maintenance, whether performed by a
dealer or by you, is at your expense.
General Conditions
The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair and replacement
of defective components as set forth herein. Neither Exmark
nor Exmark Warranty Company shall have any liability
for any other cost, loss or damage, including but not
limited to, any incidental or consequential loss or damage.
In particular, we shall have no liability or responsibility for:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other
extraordinary repair charges or charge relating to repairs or
replacements outside of normal business hours at the place
of business of the authorized Exmark Service Dealer.
• Rental of like or similar replacement equipment during the
period of any warranty, repair or replacement work.
• Any telephone or telegram charges or travel charges.
• Loss or damage to person or property other than that
covered by the terms of this warranty.
• Any claims for lost revenue, lost profit or additional cost as
a result of a claim of breach of warranty.
• Attorney's fees.

Items and Conditions Not Covered
This warranty does not cover the following:
• Pickup and delivery charges to and from any authorized
Exmark Service Dealer beyond first warrantable service.
• Any damage or deterioration due to normal use, wear and
tear, or exposure.
• Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune-up parts, and adjustments.
• Any product or part which has been altered or misused or
required replacement or repair due to normal wear,
accidents, or lack of proper maintenance.
• Any repairs necessary due to use of parts, accessories or
supplies, including gasoline, oil or lubricants, incompatible
with the turf equipment or other than as recommended in
the operator's manual or other operational instructions
provided by Exmark.
There are no other express warranties except for engine and
special emission system coverage stated elsewhere herein or
included with the product.
All warranty work must be performed by an authorized
Exmark Service Dealer using Exmark approved replacement
parts.

No Claim of breach of warranty shall be cause for cancellation
or rescission of the contract of sale of any Exmark mower.
Some states do not allow exclusions of incidental or
consequential damages, so the above exclusions and
limitations may not apply to you.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.

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.

G006117

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES
MID-MOUNT RIDING ACCESSORIES
CUSTOM RIDE SEAT SUSPENSION SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

DECK LIFT ASSIST KIT

SNOW BLADE

HITCH KIT

SUN SHADE

LAZERLOCKER

TRASH CONTAINER

LIGHT KIT

TURF STRIPER

MICRO-MULCH SYSTEM

ULTRA VAC COLLECTION SYSTEM

OPERATOR CONTROLLED DISCHARGE

ULTRA VAC QUICK DISPOSAL SYSTEM

OUT-FRONT RIDING ACCESSORIES
CUSTOM RIDE SEAT SUSPENSION SYSTEM

SNOW BLADE

DUAL-TAIL WHEEL

SNOWBLOWER

FLOOR PAN EXTENDER

SUN SHADE

HITCH KIT

TRASH CONTAINER

LIGHT KIT

ULTRA VAC COLLECTION SYSTEM

MICRO-MULCH SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

WEATHER CAB

ROTARY BROOM

WALK-BEHIND ACCESSORIES
GRASS CATCHER

TURF STRIPER

LAZERLOCKER

STANDON

MICRO-MULCH SYSTEM

Place Model No. and Serial No.
Label Here (Included in the Literature
Pack) or Fill in Below
Model No.

Date Purchased
Engine Model No. and Spec. No.
Engine Serial No. (E/No)

Serial No.

Part No. 4500-227 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed in the USA.

www.exmark.com

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Exmark Frontrunner Diesel Users Manual

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