Exmark Frontrunner Users Manual 109 4334

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Engine Model No. and Spec. No. (Code)

Engine Serial No. (E/No)

Date Purchased

Place Model No. and Serial No. Label Here

(Included in Literature Pack)

or Fill in Below

Model No.

Serial No.

CONGRATULATIONS

on the purchase of your new Exmark mower. This product has been carefully designed and manufactured to give you

a maximum amount of dependability and years of trouble-free operation. If additional information is needed, or should you require trained

mechanic service, contact your authorized Exmark equipment dealer or distributor. If you need to order replacement parts from your dealer,

always give the model number and serial number of your mower as well as the part number, description and quantity of the part needed.

The Serial No. Plate on the right side of the unit under the fuel tank. For ease of ordering and reference, we suggest that you record the

information requested in the following identification table.

TM

For Serial Nos.

670,000 & Higher

Part No. 109-4334 Rev. A

i

WARNING

POTENTIAL HAZARD

♦ This product is a piece of power equipment.

WHAT CAN HAPPEN

♦ Failure to follow safe operating practices can result in serious

operator injury or even death.

HOW TO AVOID THE HAZARD

♦ Keep all shields, guards, and safety devices (especially the grass

discharge system) in place and in proper working condition.

♦ Stop engine, wait for all moving parts to stop and engage parking

brake. Disconnect battery ground or remove key before

adjusting, servicing, or performing maintenance.

♦ If mower deck becomes clogged, stop engine, wait for all moving

parts to stop and engage parking brake. Disconnect battery

ground or remove key before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts.

♦ Keep off mower unless seat platform is provided.

♦ Keep others off mower.

WARNING

POTENTIAL HAZARD

♦ Diesel fuel is harmful or fatal if swallowed. Long-term exposure

to vapors has caused cancer in laboratory animals.

WHAT CAN HAPPEN

♦ Failure to use caution may cause serious injury or illness.

HOW TO AVOID THE HAZARD

♦ Avoid prolonged breathing of vapors.

♦ Keep face away from nozzle and fuel tank/container opening.

♦ Keep away from eyes and skin.

♦ Never siphon by mouth.

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.

ii

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995

Program

If your Exmark dealer does not have the Exmark part in stock,

Exmark will get the parts to the dealer the next business day or

the part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

the time of request by customer, the dealer contacts his

distributor by 1:00 p.m., local time, and requests Exmark

Parts Plus® shipment of six (6) line items or less.

2. Distributor ships part(s) to dealer or customer, as

requested by dealer, same day, overnight UPS

Distributor bills dealer for part and freight charges where

applicable.

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus® order, he contacts Exmark by 3:00 p.m.,

central time, with an Exmark Parts Plus® order of six (6) line items or less.

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by

distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.

5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus® and if it arrives in

accordance to the program.

6. Who pays for the part and freight if it fails to arrive overnight in accordance to the program?

A. Under any circumstance the customer does not pay.

B. If the part does not arrive overnight due to:

1. The dealer not submitting the Exmark Parts Plus® order to his Exmark distributor by 1:00 p.m., the dealer

pays for the part and freight.

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus® order

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,

Exmark pays for the part and freight.

4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark

pays for the part.

The following restrictions apply -- The Exmark Parts Plus® Program is available only through participating Exmark

Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available

only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental

United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air

charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no

responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by

3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus® Program are:

Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and

5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United

Parcel Service size and weight restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day

or Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be

ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

iii

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.

OPERATOR'S MANUAL

This manual contains operating, maintenance, adjustment, and safety

instructions for your Exmark mower.

BEFORE OPERATING YOUR MOWER,

CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.

By following the operating, maintenance, and safety instructions, you will prolong

the life of your mower, maintain its maximum efficiency, and promote safe operation.

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.

iv

TABLE OF CONTENTS

1. SAFETY PAGE

1.1 Safety Alert Symbol....................................................................................... 1

1.2 Training ......................................................................................................... 1

1.3 Preparation................................................................................................. 1-3

1.4 Operation ................................................................................................... 4-7

1.5 Maintenance & Storage .............................................................................. 8-9

1.6 Safety Signs............................................................................................. 9-11

2. SPECIFICATIONS

2.1 Model Number............................................................................................. 12

2.2 Engine......................................................................................................... 12

2.3 Fuel System ................................................................................................ 12

2.4 Electrical System......................................................................................... 12

2.5 Cooling System ........................................................................................... 12

2.6 Operator Controls........................................................................................ 12

2.7 Seat........................................................................................................ 12-13

2.8 Hydrostatic Ground Drive System ............................................................... 13

2.9 Tires............................................................................................................ 13

2.10 Mower Deck ................................................................................................ 13

2.11 Dimensions.................................................................................................. 13

2.12 Torque Requirements.................................................................................. 14

3. OPERATION INSTRUCTIONS

3.1 Controls.................................................................................................. 14-17

3.2 Pre-Start...................................................................................................... 17

3.3 Operating Instructions ............................................................................ 17-18

3.4 Transporting........................................................................................... 19-20

4. MAINTENANCE & ADJUSTMENTS

4.1 Periodic Maintenance ............................................................................. 21-32

4.2 Adjustments ........................................................................................... 32-38

5. WASTE DISPOSAL

5.1 Motor Oil Disposal ....................................................................................... 38

5.2 Battery Disposal ..................................................................................... 38-39

6. TROUBLESHOOTING

6.1 Mower Pulls Left or Right ............................................................................ 39

6.2 Mower Cuts Unevenly.................................................................................. 39

6.3 Engine Will Not Start .............................................................................. 39-40

6.4 Engine Warning Systems............................................................................ 40

7. ELECTRICAL DIAGRAM ................................................................................... 41

8. HYDRAULIC DIAGRAM .................................................................................... 42

9. WARRANTY ........................................................................................................ 43

1

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is used both in this manual and on the machine to

identify important safety messages which must be followed to avoid accidents. This

symbol means:

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

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.

DANGER: White lettering / Red background. Indicates an imminently hazardous situation

which, if not avoided, WILL result in death or serious injury.

WARNING: Black lettering / Orange background. Indicates a potentially hazardous

situation which, if not avoided, COULD result in death or serious injury.

CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous

situation which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard

to all who operate this unit.

1.2.2 Read the instructions carefully. Familiarize yourself with the controls and the

proper use of the equipment. If the operator(s) or mechanic(s) can not read

English, it is the owner’s responsibility to explain this material to them.

1.2.3 Do not allow operation of this machine by untrained personnel. Never allow

children, teenagers, or people unfamiliar with these instructions to use the

mower. Local regulations may restrict the age of the operator.

1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in

mind that the operator or user is responsible for accidents or hazards occurring

to other people or their property.

1.3 PREPARATION

1.3.1 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.

1.3.2 The use of personal protective equipment, such as (but not limited to) protection

for the eyes, ears, feet, and head is recommended.

2

CAUTION

POTENTIAL HAZARD

♦ This machine produces sound levels in

excess of 85 dBA at the operator’s ear

when in operation.

WHAT CAN HAPPEN

♦ Exposure to sound levels of 85 dBA or

above for extended periods of time can

cause hearing loss.

HOW TO AVOID THE HAZARD

♦ Wear hearing protection when operating

this machine.

1.3.3 While mowing, always wear substantial footwear and long trousers. Do not

operate equipment when barefoot or when wearing open sandals.

1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all

stones, sticks, wires, bones, and other foreign objects which may damage the

equipment or cause personal injury to the operator or bystanders.

WARNING

POTENTIAL HAZARD

♦ Engine exhaust contains carbon

monoxide, which is an odorless deadly

poison.

WHAT CAN HAPPEN

♦ Carbon monoxide can kill you.

HOW TO AVOID THE HAZARD

♦ Do not run engine indoors or in a small

confined area where dangerous carbon

monoxide fumes can collect.

3

DANGER

POTENTIAL HAZARD

♦ Diesel fuel is flammable.

WHAT CAN HAPPEN

♦ A fire from diesel fuel can burn you,

others, and cause property damage.

HOW TO AVOID THE HAZARD

♦ DO NOT smoke while refueling, and stay

away from an open flame or where fuel

fumes may be ignited by spark.

♦ Refuel only outdoors.

♦ Store fuel in an approved container and

keep it out of the reach of children.

♦ 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.

♦ Never fill the fuel tank so that the fuel

level rises above a level that is 1/2” below

the bottom of the filler neck to allow for

fuel expansion and prevent fuel spillage.

♦ 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.

♦ Do not operate without entire exhaust

system in place and in proper working

condition.

4

1.4 OPERATION

Although hazard control and accident prevention are partially dependent upon the

design and configuration of the equipment, these factors are also dependent upon

the awareness, concern, prudence, and proper training of the personnel involved in

the operation, transport, maintenance, and storage of the equipment. It is essential

that all Operator Safety Mechanisms be connected and in operating condition prior

to use for mowing.

WARNING

POTENTIAL HAZARD

♦ Operating engine parts, especially the

muffler, become extremely hot.

WHAT CAN HAPPEN

♦ Severe burns can occur on contact.

♦ Debris, such as leaves, grass, brush, etc.

can catch fire.

HOW TO AVOID THE HAZARD

♦ Allow engine parts, especially the muffler,

to cool before touching.

♦ 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.

WARNING

POTENTIAL HAZARD

♦ Hands, feet, hair, clothing, or accessories

can become entangled in rotating parts.

WHAT CAN HAPPEN

♦ Contact with rotating parts can cause

traumatic amputation or severe

lacerations.

HOW TO AVOID THE HAZARD

♦ Do not operate the machine without

guards, shields, and safety devices in

place and working.

♦ Keep hands, feet, hair, jewelry, or clothing

away from rotating parts.

1.4.1 Give complete, undivided attention to the job at hand.

1.4.2 Mow only in daylight or good artificial light, keeping away from holes and hidden

hazards. NEVER carry passengers. DO NOT operate the mower when children

or others are in the area.

5

1.4.3 When feasible, avoid operating the equipment in wet grass.

WARNING

POTENTIAL HAZARD

♦ Operating a FrontRunner tractor without

an approved Exmark front mount

attachment increases the possibility of

forward tip over.

WHAT CAN HAPPEN

♦ Tip-over could cause serious injury or

death.

HOW TO AVOID THE HAZARD

♦ When operating a FrontRunner tractor

without an approved Exmark front mount

attachment, observe the following:

9 Limit operation to minimum required to

install a different front mount

attachment.

9 Minimize speed and use extreme

caution.

9 Only operate on a flat level surface.

9 Do not operate up or down a trailer

ramp.

9 Avoid sudden acceleration or

deceleration.

1.4.4 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.

DANGER

POTENTIAL HAZARD

♦ Mowing on wet grass or steep slopes can

cause sliding and loss of control.

WHAT CAN HAPPEN

♦ Wheels dropping over edges, ditches,

steep banks, or water can cause

rollovers, which may result in serious

injury, death or drowning.

HOW TO AVOID THE HAZARD

♦ Do not mow slopes when grass is wet.

♦ Do not mow near drop-offs or near water.

♦ Do not mow slopes greater than 15

degrees.

♦ Reduce speed and use extreme caution

on slopes.

♦ Avoid sudden turns or rapid speed

changes.

6

• 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. This area can be dangerous, see Figure 1.

FIGURE 1

• Progressively greater care is needed as the slope increases.

• Always avoid sudden starting or stopping on a slope. If tires lose traction,

disengage the blades and proceed slowly off the slope.

• Avoid sudden stops when mowing downhill. Tractor 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.

• Watch for ditches, holes, rocks, dips, and rises that change the operating

angle, as rough terrain could overturn the machine.

• Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing

area. Tall grass can hide obstacles.

• Use extreme care with attachments. These can change the stability of the

machine and cause loss of control.

• Follow the manufacturer’s recommendations for wheel weights or

counterweights to improve stability.

1.4.5 A Rollover Protection System (roll bar) is installed on the unit.

DANGER

POTENTIAL HAZARD

♦ There is no rollover protection when the

roll bar is down.

WHAT CAN HAPPEN

♦ Wheels dropping over edges, ditches,

steep banks, or water can cause

rollovers, which may result in serious

injury, death or drowning.

HOW TO AVOID THE HAZARD

♦ Keep the roll bar in the raised and locked

position and use seat belt.

♦ Lower the roll bar only when absolutely

necessary.

♦ Do not wear seat belt when the roll bar is

down.

♦ Drive slowly and carefully.

♦ Raise the roll bar as soon as clearance

permits.

7

• Be certain that the seat belt can be released quickly if the machine is driven or

rolls into ponds of water.

• Check carefully for overhead clearances (i.e. branches, doorways, and

electrical wires) before driving under any objects and do not contact them.

1.4.6 Use EXTREME caution when backing up. LOOK BEHIND YOU!

1.4.7 Stop the blades when crossing surfaces other than grass and when transporting

the mower to and from the area to be mowed.

1.4.8 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.

1.4.9 DO NOT change the engine governor settings or overspeed the engine.

Operating an engine at excessive speed may increase the hazard of personal

injury.

1.4.10 Disengage PTO before starting engine.

1.4.11 Start the engine carefully with feet well away from the blades.

1.4.12 Keep hands, feet, and clothing away from rotating parts while the mower is being

operated.

1.4.13 Stop engine, wait for all moving parts to stop, and remove key. Engage parking

brake:

• Before checking, cleaning or working on the mower.

• After striking a foreign object (inspect the mower for damage and make

repairs before restarting and operating the mower).

• Before clearing blockages.

• Whenever you leave the mower.

Stop the engine and wait for all moving parts to stop. Engage parking brake:

• Before refueling.

• Before dumping the grass catcher.

1.4.14 Before stopping the engine, place the throttle control to the “slow” position.

Allow the engine to run a minimum of 15 seconds; then stop the engine.

1.4.15 This mower was designed for one operator only. Keep all others away from

mower during operation.

1.4.16 DO NOT mow with the discharge deflector raised, removed or altered unless

there is a grass collection system or mulch kit in place and working properly.

1.4.17 DO NOT operate mower under the influence of alcohol or drugs.

1.4.18 Use extra care when approaching blind corners, shrubs, trees, or other objects

that may obscure vision.

1.4.19 If jump starting is required:

a) connect the positive (+) power cable from the positive post on the booster

battery to the positive terminal post on the starter solenoid switch (this post

has the positive battery cable attached to it).

b) connect the negative or ground cable (-) from the negative post on the

booster battery to the engine block as far away from the battery as

possible.

c) disconnect battery cables in the reverse order after starting.

8

1.5 MAINTENANCE AND STORAGE

1.5.1 For engine maintenance, follow the engine manufacturer’s recommendations

precisely as stated in the engine manual.

1.5.2 Disconnect the battery cable from the negative battery post when the unit will be

allowed to sit for more than 30 days without use.

1.5.3 Allowing batteries to stand for an extended period of time without recharging

them will result in reduced performance and service life. To preserve optimum

battery performance and life, recharge batteries in storage when the open circuit

voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged

before putting away for winter storage.

1.5.4 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.

1.5.5 Store fuel in a container specifically designed for this purpose in a cool, dry place.

1.5.6 Keep the mower and fuel container in locked storage to prevent children from

playing or tampering with them.

1.5.7 Diesel powered equipment or fuel containers should not be stored in a basement or

any enclosed area where open pilot lights or heat appliances are present.

1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly

maintained and operated correctly.

1.5.9 Check all bolts frequently to maintain proper tightness.

1.5.10 Keep all guards, shields, and all safety devices in place and in safe working condition.

1.5.11 Frequently check for worn or deteriorating components that could create a hazard.

1.5.12 All replacement parts must be the same as or equivalent to the parts supplied as

original equipment.

9

WARNING

POTENTIAL HAZARD

♦ Hydraulic fluid escaping under pressure

can penetrate skin and cause injury.

WHAT CAN HAPPEN

♦ 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.

HOW TO AVOID THE HAZARD

♦ Make sure all hydraulic fluid hoses and

lines are in good condition an all hydraulic

connections and fittings are tight before

applying pressure to hydraulic system.

♦ The woven guards that protect the

hydraulic hoses may deteriorate and wear

over time. Check the guards frequently

and replace if necessary.

♦ 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

POTENTIAL HAZARD

♦ Fuel system components are under high

pressure.

WHAT CAN HAPPEN

♦ The use of improper components can

result in system failure, fuel leakage and

possible explosion.

HOW TO AVOID THE HAZARD

♦ Use only approved fuel lines and clamps

for high pressure systems.

1.6 SAFETY SIGNS

1.6.1 Keep all safety signs legible. Remove all grease, dirt and debris from safety

signs and instructional labels.

1.6.2 Safety signs must be replaced if they are missing or illegible.

10

1.6.3 When new components are installed, be sure that current safety signs are

affixed to the replaced components.

1.6.4 New safety signs may be obtained from Exmark Mfg. Co. Inc.

1.6.5 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.

1.6.6 Familiarize yourself with the following safety signs and instruction labels. They

are critical to the safe operation of your Exmark commercial mower.

PART NO. 1-513746

LOCATION: Outside of Rear

Muffler Guard

PART NO. 1-513747

LOCATION: LH Side of Batter

y

Holder

PART NO. 1-523552

LOCATION: Top Surface of

Hydraulic Tank

PART NO. 1-643339

LOCATION: On Top of Radiator

PART NO. 103-2076

LOCATION: On Top of

Radiator

PART NO. 103-7218

LOCATION: On Seat Support Plate

PART NO. 103-0233

LOCATION: On Front of the

Fan Shroud

PART NO. 109-2358

LOCATION: On Control

Panel PART NO. 109-2356

LOCATION: Top of

Console,

RH Side

PART NO. 98-5954

LOCATION: Top of Radiator

PART NO. 103-5881

LOCATION: On top of Radiator

PART NO. 103-1636

LOCATION: On Top of

Fuel Tank

PART NO. 93-4361

LOCATION: On LH and RH Side,

Near Back of Unit

11

PART NO. 107-2102

LOCATION: Inside

Surface of

Upper Roll

Bar PART NO. 109-2355

LOCATION: Outside of each

Weight Transfer

Bell Crank

PART NO. 109-2357

LOCATION: Top of Console,

LH Side

PART NO. 109-2360

LOCATION: Front of Console

PART NO. 109-2377

LOCATION: On Hydraulic Cylinder

PART NO. 109-2396

LOCATION: Top of Seat Support

Plate

PART NO. 109-3637

LOCATION: Back of Seat PART NO. 109-2698

LOCATION: On Control Panel

PART NO. 107-2112

LOCATION: Top of Floor Pan

12

2. SPECIFICATIONS

2.1 MODEL NUMBER: FR25KD

2.2 ENGINE

2.2.1 Engine Specifications: See your Engine Owner’s Manual

2.2.2 RPM: Full Speed: 3870 RPM (No Load) +50/-100 RPM

Idle: 1400 RPM (No Load) ±50 RPM

2.3 FUEL SYSTEM

2.3.1 Capacity: 8.5 gal (32 L)

2.3.2 Type of Fuel: Diesel fuel, 40 cetane or higher.

2.3.3 Fuel Filter: 2 In-line 15 Micron Kubota P/N 12581-43012, before and after the

electric fuel pump.

2.4 ELECTRICAL SYSTEM

2.4.1 Charging System: External Alternator

2.4.2 Charging Capacity: 60 amps

2.4.3 Battery Type: BCI Group 26

2.4.4 Battery Voltage: 12 Volt

2.4.5 Polarity: Negative Ground

2.4.6 Safety Interlock System:

PTO must be disengaged, brake engaged, and speed control lever in neutral

position 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 speed

control lever is moved out of neutral or engine will stop.

Engine will stop if the motion control levers are moved from neutral position while

brake is engaged.

2.5 COOLING SYSTEM

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

2.5.2 Coolant Liquid: 50/50 mix of DexCool© extended life antifreeze and water.

2.5.3 Coolant Capacity: 4 quarts

2.6 OPERATOR CONTROLS

2.6.1 Steering and Motion Control:

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.

Moving motion control levers outward (in slots) locks the drive system in neutral.

NOTE: Motion control levers are adjustable to three (3) heights.

2.6.2 PTO Engagement Switch: Engages drive to PTO (mower deck).

2.6.3 Parking Brake Lever: Pull back to engage parking brake.

2.7 SEAT

2.7.1 Type: Standard seat with high back, foam padded (internal suspension).

2.7.2 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.

13

2.7.3 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.

2.7.4 Armrests: Standard seat: foam padded flip-up armrests.

Optional suspension seat: molded adjustable flip-up armrests.

2.8 HYDROSTATIC GROUND DRIVE SYSTEM

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

2.8.2 Wheel Motors: Hydro Gear planetary reduction motors.

2.8.3 Hydraulic Oil Type: Use Mobil 1 15W-50 Synthetic Motor Oil.

2.8.4 Hydraulic Oil Capacity: 5.2 qt. (4.9 L.)

2.8.5 Hydraulic Filter: Replaceable cartridge type.

P/N 103-2146: 25 microns, No bypass

2.8.6 Speeds: 0-10.5 mph (16.9 km/hr) forward

0-6.6mph (10.6 km/hr) reverse

2.8.7 Drive wheel release valves allow machine to be moved when engine is not running.

2.9 TIRES Drive Front Caster

Rear Caster

(Dual Tail Wheel)

Pneumatic (Air-Filled) Pneumatic (Air-Filled) Semi-Pneumatic Semi-Pneumatic

Quantity 2 2 2 2

Tread AT101 Turfmate Smooth Smooth

Size 24 x 12.00-12 23 x 10.50-10 9 x 3.50-4 13 x 6.5-6

Ply Rating 4 4

Pressure 9 psi (62 kPa) 13 psi (90 kPa)

2.10 MOWER DECK (Sold Separately)

2.10.1 Models FR524 FR604

Discharge Side Discharge Side Discharge

Cutting Width 52 in. (132 cm) 60 in. (152 cm)

2.11 DIMENSIONS

2.11.1 Overall Width: w/52” Deck w/60” Deck

without deck 49.0 in. (124.5 cm) 49.0 in. (124 cm)

deflector up 53.3 in. (135.4 cm) 61.4 in. (156 cm)

deflector down 64.0 in. (163 cm) 72.0 in. (183 cm)

2.11.2 Overall Length:

without deck & floor pan folded 82.3 in. (209.0 cm)

w/52” Deck 114.3 in. (290.3 cm)

w/60” Deck 114.3 in. (290.3 cm)

2.11.3 Overall Height: Roll Bar - Up Roll Bar - Down

69.2 in. (175.8 cm) 50.7 in. (128.8 cm)

2.11.4 Curb Weight: without Deck 1163 lbs. (528 kg)

w/52” Deck 1555 lbs. (705 kg)

w/60” Deck 1600 lbs. (726 kg)

2.11.5 Tread Width (Center to Center of Drive Wheels): 41.4 in. (105.2 cm)

2.11.6 Wheel Base (Center of Drive Wheel to Center of Rear Caster Wheel):

51.2 in. (130.0 cm)

2.11.7 Minimum Turning Radius: 55.25”

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2.12 TORQUE REQUIREMENTS

Bolt Location Torque

Wheel Lug Nuts.............................................................90-95 ft-lbs. (122-129 N-m)

Wheel Motor Mounting Bolts............................................72-77 ft-lbs. (98-104 N-m)

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

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

Wheel Hub Slotted Nut .............................................minimum 125 ft-lbs. (169 N-m)

3. OPERATION INSTRUCTIONS

3.1 CONTROLS

3.1.1 Familiarize yourself with all controls before operating the mower.

3.1.2 Motion Control Levers: Located on each side of the console. The left lever

controls the flow of hydraulic oil from the left hydrostatic pump to the left drive

wheel motor. The right lever controls the flow of hydraulic oil from the right

hydrostatic pump to the right drive wheel motor.

IMPORTANT: To begin movement (forward or backward) the operator must

be in the seat, the brake lever must be disengaged (pushed down) before

the motion control levers can be moved in or the engine will kill.

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

See Figure 2.

FIGURE 2

By moving both levers an equal amount forward or back from the neutral position

the machine can be caused to move forward or backward in a straight line.

Movement of the left lever forward will cause the left drive wheel to rotate in a

forward direction. Movement of the right lever forward will cause the right

drive wheel to rotate in a forward direction. To stop forward travel, pull the

levers back to the neutral position.

To turn left while moving forward, move the left lever back toward neutral to

slow the left drive wheel.

To turn right while moving forward, move the right lever back toward neutral to

slow the right drive wheel.

To make a zero turn to the left, pull the left lever back beyond neutral while

holding the right lever slightly ahead of neutral.

To make a zero turn to the right, pull the right lever back beyond neutral while

holding the left lever slightly ahead of neutral.

15

Pulling the levers back from the neutral position will cause the respective drive

wheels to rotate in a reverse direction (spring tension can be felt when moving

into reverse from neutral).

To turn to the left while backing, move the left lever forward toward neutral. To

turn to the right while backing, move the right lever forward toward neutral.

CAUTION

POTENTIAL HAZARD

♦ Machine can spin very rapidly by

positioning one lever too much ahead of

the other.

WHAT CAN HAPPEN

♦ Operator may lose control of the

machine, which may cause damage to

the machine or injury.

HOW TO AVOID THE HAZARD

♦ Use caution when making turns.

♦ Slow the machine down before making

sharp turns.

3.1.3 PTO Engagement Switch: Located on the right fuel tank console.

Switch must be pulled out to the “ROTATE” position to engage the PTO. The

Switch is pushed in to the “STOP” position to stop the PTO.

3.1.4 Throttle Control: Located on right fuel tank console.

Throttle is used to control engine speed. Moving throttle lever forward will increase

engine speed and moving throttle lever to the rear will decrease engine speed.

3.1.5 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 to engage the brake.

Push the lever down to disengage the brake.

The unit must be tied down and brake engaged when transporting.

3.1.6 Ignition Switch: Located on the right fuel tank console.

The ignition switch is used to start and stop the engine. The switch has three

positions “OFF”, “ON” and “START”. Insert key into switch and rotate clockwise

to the “ON” position. Rotate clockwise to the next position to engage the starter

(key must be held against spring pressure in this position).

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.)

3.1.7 Glow Plug Switch: Located on the right fuel tank. Depress and hold switch to

heat glow plugs as required by chart below prior to starting engine.

GLOW PLUG CHART

Ambient Temperature Hold Glow Plugs On

Above 50°F (10°C) NO NEED

50°F (10°C) to 23°F (-5°C) Approx. 5 seconds

Below 23°F (-5°C) Approx. 10 seconds

Limit of continuous use 20 seconds

16

NOTE: A glow plug light, located to the rear of the glow plug switch, will

illuminate when the switch is depressed. The glow plug light indicates the glow

plugs are preheating the combustion chamber.

3.1.8 Hour Meter: 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.

3.1.9 Hydraulic Lift Switch: Located on the right fuel tank console. 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.

Push the rear portion of the hydraulic lift switch down to lower the mower deck

to the desired height.

3.1.10 Fuel Gauge: Located at the rear of the right fuel tank.

The fuel gauge monitors the amount of fuel left in the right fuel tank only. The left

tank does not hold fuel.

3.1.11 Coolant Temperature Gauge: 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.

3.1.12 Coolant Temperature Light: Located on the right fuel tank console. The light will

come on if the engine is overheating and an alarm will sound (See Section

3.1.13).

3.1.13 Glow Plug Light: Located on the right fuel tank console. The glow plug light

comes on when the glow plugs are preheating the combustion chamber. This

happens when the glow switch is depressed and while the engine is cranking.

3.1.14 Warning Buzzer: Located behind the seat under the engine cover on the right

hand side of the engine fan shroud. The buzzer is a warning signal for the

following circumstances:

a) When the engine is running and the buzzer emits a continuous beep, the

buzzer is warning the user that the engine is overheating. Perform the

following steps.

1. Disengage the mower blades, and idle down the engine.

2. Look at the temperature gauge to determine if temperature continues to

increase. If it does, turn the unit off and allow the engine and engine

components to cool.

3. Check the coolant level. If necessary fill with coolant as described in

Section 4.1.2.

4. Remove any debris on or around the radiator that may restrict airflow.

5. Check to see if the water pump/alternator belt is intact. If belt is missing,

do not run unit, as unit can overheat and damage the engine. See Engine

Service Dealer.

b) When the engine is running and the buzzer emits intermittent beeps, the

buzzer is warning the user that the engine oil pressure is low. Perform the

following steps.

1. Turn the unit off, allow the engine and engine components to cool.

2. Check the oil level and fill, if necessary, as described in Section 4.1.1.

3. Check for oil leaking from engine. If the engine is leaking, see Engine

Service Dealer.

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3.1.15 Alternator Charging Light: Located to the rear of the key switch. Light will come on

when the alternator is not charging.

3.1.16 Low Oil Pressure Light: Located to the rear of the key switch with the alternator

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

NOTE: This switch is not a low oil level sensor and will not alert the operator if

the engine oil level is low.

3.1.17 Drive Wheel Release Valves: 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.

With a wrench, turn both valves one turn counter-clockwise to release drive system.

Turn clockwise to reset system. DO NOT overtighten. DO NOT tow machine.

Use a 5/8 wrench to turn the valves.

3.2 PRE-START

3.2.1 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” below the bottom of the filler neck to allow for fuel

expansion and prevent fuel spillage.

3.2.2 Make sure you understand the controls, their locations, their functions, and their

safety requirements.

3.2.3 Refer to Maintenance, Section 4, and perform all the necessary inspection and

maintenance steps.

3.3 OPERATING INSTRUCTIONS

3.3.1 Raise roll bar:

Operate the unit with the roll bar in the raised and locked position and use seat

belt. There is no rollover protection when the roll bar is down. If it is necessary to

lower the roll bar, do not wear the seat belt. Raise the roll bar as soon as

clearance permits.

3.3.2 Starting Engine:

a) 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.)

b) On a warm engine, place the throttle in the “SLOW” position.

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.

c) Turn the ignition switch to the “ON” position. Depress the glow plug switch

and the glow plug light will turn on. Hold switch according to chart in section

3.1.6. Turn the ignition switch to the “START” position. Release the ignition

switch as soon as the engine starts.

IMPORTANT: DO NOT crank the engine continuously for more then ten

(10) 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.

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d) 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.

3.3.3 Engaging PTO:

DANGER

POTENTIAL HAZARD

♦ The rotating blades under the mower

deck are dangerous.

WHAT CAN HAPPEN

♦ Blade contact can cause serious injury or

kill you.

HOW TO AVOID THE HAZARD

♦ DO NOT put hands or feet under the

mower or mower deck when the blades

are engaged.

DANGER

POTENTIAL HAZARD

♦ 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.

WHAT CAN HAPPEN

♦ Thrown objects or blade contact can

cause serious injury or death.

HOW TO AVOID THE HAZARD

♦ 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.

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 the PTO.

IMPORTANT: Operator must be in seat before the PTO can be engaged.

Set throttle to "midway" position. Pull the switch out to the “ROTATE” position.

Accelerate to full throttle to begin mowing.

3.3.4 Stopping PTO: Set throttle to the “midway” position. Push the switch in to the

“STOP” position to stop the PTO.

3.3.5 Stopping Engine: Bring unit to a full stop. Disengage the PTO, move motion

control levers to the neutral position and set the parking brake.

Before stopping the engine, move the throttle control to the “SLOW” position.

Keep on running at idle for a short time, (approximately one minute) then stop

the engine.

Rotate ignition switch to “OFF” position. Remove the key to prevent children or

other unauthorized persons from starting engine.

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3.4 TRANSPORTING

IMPORTANT: Do not transport FrontRunner tractor without an approved Exmark front

mount attachment.

3.4.1 Transporting a Unit: Use a heavy-duty trailer or truck to transport the machine.

Engage the park brake and block the 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 the trailer with a safety

chain.

CAUTION

POTENTIAL HAZARD

♦ This unit does not have proper turn

signals, lights, reflective markings, or a

slow moving vehicle emblem. These

items are required to drive on a public

street or roadway.

WHAT CAN HAPPEN

♦ 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.

HOW TO AVOID THE HAZARD

♦ Do not drive a unit on a public street or

roadway.

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WARNING

POTENTIAL HAZARD

♦ Loading a unit on a trailer or truck

increases the possibility of tip-over.

WHAT CAN HAPPEN

♦ Tip-over of the unit could cause serious

injury or death.

HOW TO AVOID THE HAZARD

♦ 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.

3.4.2 Loading a Unit: Use extreme caution when loading units on trailers or trucks. One

full width ramp is required. If it is not possible to use one full width ramp, use

enough individual ramps to simulate a full width continuous ramp.

Ramp should be long enough so that the angles between the ramp and the ground

and the ramp and the trailer or truck do not exceed 15°. A steeper angle may

cause mower deck components to get caught as the unit moves from ramp to

trailer or truck. Steeper angles may also cause the unit to tip. If loading on or

near a slope, position the trailer or truck so it is on the down side of the slope and

the ramp extends up the slope. This will minimize the ramp angle. The trailer or

truck should be as level as possible.

DO NOT attempt to turn the unit while on the ramp, you may lose control and drive

off the side.

Avoid sudden acceleration when driving on a ramp.

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4. MAINTENANCE & ADJUSTMENTS

WARNING

POTENTIAL HAZARD

♦ While maintenance or adjustments are

being made, someone could start the

engine.

WHAT CAN HAPPEN

♦ Accidental starting of the engine could

seriously injure you or other bystanders.

HOW TO AVOID THE HAZARD

♦ Remove the key from the ignition switch

and engage parking brake. Disconnect

the negative battery cable before you do

any maintenance.

WARNING

POTENTIAL HAZARD

♦ The engine can become very hot.

WHAT CAN HAPPEN

♦ Touching a hot engine can cause severe

burns.

HOW TO AVOID THE HAZARD

♦ Allow the engine to cool completely before

service or making repairs around the

engine area.

4.1 PERIODIC MAINTENANCE

4.1.1 Check engine oil level:

Service Interval: Daily

a) Stop engine and wait for all moving parts to stop. Make sure unit is on a

level surface.

b) Tilt seat forward and raise hood to gain access to access to engine area.

c) Check with engine cold.

d) 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.

e) 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.

IMPORTANT: DO NOT operate the engine with the oil level below the

“LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

22

4.1.2 Check engine coolant level:

Service Interval: Daily

a) Stop engine and wait for all moving parts to stop. Make sure machine is on

a level surface.

b) Tilt seat up and tilt hood forward to gain access to the cooling area.

c) Check with engine cold.

d) 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.

e) If the coolant level is low, remove the cap to the overflow bottle and fill to

the indicator line. Use coolant specified in Section 2.5.2.

NOTE: Units should only be filled with Dex-Cool© extended life coolant, which

can be identified by its orange color.

WARNING

POTENTIAL HAZARD

♦ Engine coolant is hot and pressurized.

♦ Radiator and surrounding parts are hot.

WHAT CAN HAPPEN

♦ Spray or steam from hot, pressurized

liquid in the engine cooling system or

touching a hot radiator may cause severe

burns.

HOW TO AVOID THE HAZARD

♦ Allow the engine to cool completely before

removing the radiator cap or servicing any

component of the cooling system.

CAUTION

POTENTIAL HAZARD

♦ Engine coolant is toxic.

WHAT CAN HAPPEN

♦ Swallowing coolant can cause poisoning.

HOW TO AVOID THE HAZARD

♦ Do not swallow

♦ Keep out of reach of children and pets.

4.1.3 Check battery charge:

Service Interval: Monthly

Allowing batteries to stand for an extended period of time without recharging

them will result in reduced performance and service life. To preserve optimum

battery performance and life, recharge batteries in storage when the open

circuit voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged

before putting away for winter storage.

a) Check the voltage of the battery with a digital voltmeter. Locate the voltage

reading of the battery in the table below and charge the battery for the

23

recommended time interval to bring the charge up to a full charge of 12.6

volts or greater.

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 below 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 amps 2 Hours

11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours

11.7 or less 0% 14.4 volts/2 amps 6 Hours or More

4.1.4 Clean engine cooling system:

Service Interval: Daily or more often in dry conditions

a) 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.

4.1.5 Check safety interlock system:

Service Interval: Daily

NOTE: To prevent engine cut-outs on rough terrain the seat kill

switch has a 1/2 second delay.

a) Check starting circuit:

Starter should crank with, parking brake engaged, PTO disengaged and

motion control levers moved out in the neutral lock position. The operator

does not need to be in the seat to start the engine.

Try to start with operator in seat, parking brake disengaged, PTO

disengaged and motion control levers in the neutral lock position - starter

must not crank.

Try to start with operator in seat, parking brake engaged, PTO engaged and

motion control levers in the neutral lock position - starter must not crank.

Try to start with operator in seat, parking brake engaged, PTO disengaged,

and the left motion control lever in, starter must not crank, repeat again

with the right lever in, then with both levers in - starter must not crank.

b) 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

approx. 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

rise 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 initiate shutdown stop.

24

Repeat again moving the right lever in, then moving both levers in - engine

must initiate shutdown whether operator is on seat or not.

c) Check the PTO circuit:

See the FR524 and FR604 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 3.

FIGURE 3

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.

4.1.6 Check for loose hardware:

Service Interval: Daily

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Visually inspect machine for any loose hardware or any other possible

problem. Tighten hardware or correct the problem before operating.

4.1.7 Check rollover protections system (roll bar) pins:

Service Interval: Daily

c) Make sure latch pin and hair pin are fully installed and lanyard is in good

condition.

4.1.8 Check seat belt:

Service Interval: Daily

a) Visually inspect seat for wear, cuts, and proper operation of retractor and

buckle. Replace before operating if damaged.

25

4.1.9 Service air cleaner:

First Service Interval: 50 hrs.

Normal Interval: 100 hrs

Replacement Interval: 600 hrs

(More often under severe conditions.)

See Engine manual for additional information.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Tilt seat forward and raise hood to gain access to the air cleaner.

c) Loosen retaining clips and remove air cleaner compartment cover.

d) Remove outer paper element. Check the condition of the paper element.

Replace if dirty, bent or damaged.

e) 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.

f) DO NOT wash or use pressurized air to clean paper element or inner element.

g) Reinstall elements. Position the cover so that the rubber dust ejector is

pointing downward and secure with retaining clips.

4.1.10 Change engine oil:

Service Intervals:

First service interval – 50 hrs.

Normal service interval – 100 hrs.

(yearly if operated less than 100 hrs.)

(more often under heavy load or high temperatures).

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Tilt seat up and tilt hood forward to gain access to the engine area.

c) Drain oil while engine is warm from operation.

d) Remove the oil drain plug. Allow oil to drain then replace the drain plug.

e) Replace the oil filter every other oil change.

f) Clean around oil filter and unscrew filter to remove.

g) Before reinstalling a new filter, apply a thin coating of fresh clean oil on the

surface of the gasket.

h) Turn filter clockwise until rubber seal contacts the filter adapter, then tighten

filter an additional 1 full turn.

i) Clean around oil fill cap and remove cap. Fill to specified capacity and replace

cap. Use oil recommended in engine owner’s manual. DO NOT overfill.

j) Start the engine at idle for 5 minutes. Stop engine and wait three minutes, then

check the oil level. If required, add oil to bring level to the “FULL” mark on the

dipstick. DO NOT overfill.

k) Check for leaks, including around the oil filter.

4.1.11 Change engine coolant:

Service Interval: 4 years/4000 hours* - Dex-Cool© extended

life coolant (orange color)

* It is recommended to service at whichever interval happens first.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake. Machine must be positioned on level surface.

b) Tilt seat up and tilt hood forward to gain access to the cooling area.

26

Drain coolant when engine is cool. Coolant may be drained from the radiator

by loosening the drain cock in the left rear corner. The engine block may be

drained by removing the lower radiator hose and/or by opening the drain cock

from the engine block. The engine drain cock may be accessed on the right

side of the unit and is located as shown in Figure 4.

FIGURE 4

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

d) Fill radiator with a 50/50 mix of water and Dex-Cool © coolant, allowing some

room (approximately 1/2” (1.27 cm)) 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.

WARNING

POTENTIAL HAZARD

♦ Engine compartment contains open belt

drives and fans.

♦ Rotating components can cause injury

WHAT CAN HAPPEN

♦ Fingers, hands, loose clothing or jewelry

can get caught by the rotating fan and

drive shaft.

HOW TO AVOID THE HAZARD

♦ Do not operate machine without the

covers in place.

♦ Keep fingers, hands, and clothing clear of

rotating components.

♦ Shut off engine, wait for all moving parts

to stop, and engage parking brake.

Remove the ignition key before

performing maintenance.

e) With the cap off the radiator, start the engine. Refer to Section 3.3.2.

27

f) 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.

g) When the radiator is completely full and no additional coolant can be added,

continue running the engine 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.

4.1.12 Check hydraulic oil level:

Service Interval: 40 hr.

a) Stop engine and wait for all moving parts to stop.

b) Tilt seat up.

c) 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.

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.

4.1.13 Check auxiliary hydraulic oil level:

Service Interval: If there is evidence of a leak or the hydraulic

cylinder does not perform normally.

a) Retract the hydraulic cylinder.

b) Stop engine and wait for all moving parts to stop.

c) Tilt the seat forward.

d) Locate the auxiliary hydraulic power unit reservoir. See Figure 5.

FIGURE 5

e) 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.

4.1.14 Check tire pressures:

Service Interval: 40 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Check tire pressure in drive tires.

28

c) AT101 (Bar Lug) drive tires should be inflated to 9 psi (62 kpa).

d) Turfmate drive tires should be inflated to 13 psi (90 kpa).

e) 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.

4.1.15 Check condition of belts:

Service Interval: 40 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Check pump and PTO drive belts and check alternator belt.

c) Pump and PTO drive belts are spring tensioned and no adjustment is

necessary. See section 4.2.2 and 4.2.3 for belt replacement.

4.1.16 Lubricate grease fittings:

Service Interval: Refer to chart.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) 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 No. of

Places Service

Interval

1. Hitch and Cylinder Pivots 2 4 40 hrs

2. Fold Pivot Pin 2 2 100 hrs

3. Fold Lock Pin 2 2 yearly

4. Rear Caster Pivot *0 1 *yearly

5. Belt Idlers 1 2 yearly

6. Motion Control Pivots 1 2 yearly

7. Transfer Spring Ends 1 4 yearly

8. Dual Tail Wheel Pivot 2 1 40 hrs

* See Section 4.1.15 c) for special lubrication

instructions on the rear caster pivots and Section

4.1.16 for special lubrication instructions on the rear

caster wheel hubs.

FIGURE 6

c) Lubricate 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.

4.1.17 Lubricate rear caster wheel hubs:

Service Interval: Once Yearly

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Remove caster wheel from caster forks.

c) Remove seal guards from the wheel hub.

29

d) Remove one of the spacer nuts from the

axle assembly in the caster wheel. Note

that thread locking adhesive has been

applied to lock the spacer nuts to the

axle. Remove the axle (with the other

spacer nut still assembled to it) from the

wheel assembly.

e) Pry out seals, and inspect bearings for

wear or damage and replace if necessary.

f) Pack the bearings with a NGLI grade #1 multi-purpose grease.

g) Insert (1) bearing, (1) new seal into the wheel.

NOTE: Seals (Exmark PN 103-0063) must be replaced.

h) If the axle assembly has had both spacer nuts removed (or broken loose),

apply a thread locking adhesive to (1) 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” (3 mm) from the outer

surface of the spacer nut to the end of the axle inside the nut.

i) Insert the assembled nut and axle into the wheel on the side of the wheel

with the new seal and bearing.

j) 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.

k) Insert the second bearing and new seal into the wheel.

l) Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle

with the wrench flats facing outward.

m) Torque the nut to 75-80 in-lbs. (8-9 N-m), loosen, then re-torque to

20-25 in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut.

n) Re-install the seal guards over the wheel hub and insert wheel into caster

fork. Re-install caster bolt and tighten nut fully.

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.

Re-apply threadlocking adhesive.

4.1.18 Lubricate the brake handle pivot:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Tilt seat forward.

c) Lubricate bronze bushings on brake handle pivot with a spray type lubricant

or light oil.

4.1.19 Lubricate the brake rod bushings:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Tilt seat forward and raise hood.

c) 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).

FI

GU

RE 7

30

4.1.20 Lubricate the motion control bronze bushings:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Tilt seat forward.

c) Lubricate bronze bushings on the flange bearings securing the motion

control arm shafts with a light oil or a spray type lubricant.

4.1.21 Lubricate the motion control shaft:

Service Interval: Yearly.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Tilt seat forward.

c) Remove tab at rear of motion control shaft.

d) Pull motion control shaft out and lubricate with an NGLI grade #2 multi-

purpose gun grease.

e) Re-install shaft and tab.

4.1.22 Lubricate steering linkage rod ends:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking

brake.

b) Tilt seat forward.

c) Lubricate each end of both steering linkage rods with a spray lubricant or light

oil.

4.1.23 Drain water from fuel tank:

Service Interval: 160 hrs.

a) Park on level ground. Stop engine, wait for all moving parts to stop, and

remove key. Engage parking brake.

b) Place a drain pan under the fuel tank and loosen the drain cock

approximately 1 turn.

c) Drain out any water.

d) When fuel begins to flow from the tank, tighten the drain cock.

e) Prime the fuel system (See Section 4.1.24).

f) Start engine. Check for leaks.

IMPORTANT: Water or other contaminants in fuel can severely damage

fuel pump and/or the other engine components.

g) If any water was drained, run engine for approximately 2 minutes to flush

any remaining water out of the engine and fuel system.

4.1.24 Change fuel filter:

Service Interval: 400 hrs. or as required.

a) A fuel filter is installed between the fuel tank and fuel pump, and between

the fuel pump and the engine. Replace when necessary.

Replacement Filters Kubota P/N 12581-43012

31

4.1.25 Fuel priming 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.

b) Start engine using procedure in Section 3.3.2.

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.

4.1.26 Change hydraulic system filter:

First Interval: 250 hrs.

Normal Interval: Yearly.

NOTE: Use only Exmark Part No.103-2146

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Carefully clean area around filter. It is important that no dirt or

contamination enter hydraulic system.

c) Unscrew filter to remove and allow oil to drain from reservoir.

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.

Turn filter clockwise until rubber seal contacts the filter adapter, then tighten

the filter an additional 2/3 to 3/4 turn.

d) Fill reservoir as stated in Section 4.1.11.

CAUTION

POTENTIAL HAZARD

♦ Raising the mower deck for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous.

WHAT CAN HAPPEN

♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

could cause injury.

HOW TO AVOID THE HAZARD

♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

jack stands or equivalent support.

e) Raise the drive wheels off of the ground and support with jack stands (or

equivalent support) just high enough to allow drive wheels to turn freely.

f) Start engine and move throttle control ahead to full throttle position. Move

the motion control levers to the full speed and run for several minutes.

Shut down machine and recheck oil level.

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.

32

4.1.27 Wheel Hub – lock nut torque specification

Service Interval: After First 100 hrs

Then every 500 hrs thereafter

When tightening the lock nut on the wheel motor tapered shaft:

a) Torque the lock nut to 125 ft-lbs (169 N-m).

NOTE: Do not use antisieze on wheel hub.

4.1.28 Fuel Tank – mounting hardware specification

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.

4.1.29 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type”

are used on the following fasteners:

a) Pump drive sheave set screws.

b) Line shaft sheave setscrews.

c) Square head setscrews on Hydro pump control arms.

d) Sheave retaining bolt in the end of engine crankshaft.

e) Caster wheel spacer nuts.

f) Fuel tank bulkhead fitting nuts.

g) Motion control tab retaining bolt.

4.1.30 Dielectric grease is used on blade type electrical connections to prevent corrosion

and loss of contact.

4.2 ADJUSTMENTS

IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop,

remove key, and engage parking brake before servicing, cleaning, or making any

adjustments to the unit.

4.2.1 Pump Drive Belt Tension:

Spring Tensioned - No adjustment necessary.

4.2.2 Pump Drive Belt Replacement:

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Remove pump drive belt.

c) Route new belt onto sheaves as shown in the decal located on the top of

the radiator. See Figure 8.

FIGURE 8

4.2.3 Alternator belt tension:

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Tilt seat forward and raise hood.

33

c) 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.

d) When properly tensioned, the alternator belt will deflect 1/4”-3/8” (7-9 mm)

while applying 22 pounds of force to the belt midway between alternator

and crankshaft pulley.

4.2.4 Park Brake Adjustment:

Check to make sure each brake is adjusted properly.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Tilt seat forward and raise hood.

FIGURE 9

c) Disengage the park brake. Measure the length of the park brake spring.

The spring should measure 2.5” (6.4cm). See Figure 10.

FIGURE 10

d) If necessary, turn the thin nyloc nut to obtain the 2.5” (6.4cm) spring length.

e) Engage the park brake. Measure the gap between the thin nyloc nut and the

park brake clevis. The gap should measure 1/8” (3.2mm)

FIGURE 11

f) If necessary, loosen the inner flanged nut and turn the outer nut to obtain the

1/8” (3.2mm) gap. Re-tighten the inner flanged nut. See Figure 11

g) 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” (18.7 cm)

from the center of the ball joint to the center of the lower end of the linkage rod.

See Figure 12.

34

FIGURE 12

h) If the linkage does not measure 7-3/8” (18.7 cm) or still does not disengage as

desired, 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

counter-clockwise until desired disengagement is obtained.

i) Repeat procedure for other side.

4.2.5 Motion control linkage adjustment:

WARNING

POTENTIAL HAZARD

♦ Engine must be running and drive wheels

must be turning so motion control

adjustment can be performed.

WHAT CAN HAPPEN

♦ Contact with moving parts or hot surfaces

may cause personal injury.

HOW TO AVOID THE HAZARD

♦ Keep fingers, hands, and clothing clear of

rotating components and hot surfaces.

CAUTION

POTENTIAL HAZARD

♦ Raising the unit for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous.

WHAT CAN HAPPEN

♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

could cause injury.

HOW TO AVOID THE HAZARD

♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

jack stands or equivalent

35

Set neutral:

a) Remove the electrical connection from the seat safety switch, located directly

in front of the seat switch assembly.

b) The neutral adjustment must be made with the drive wheels turning. Raise the

frame and place on jack stands so that drive wheels can rotate freely.

Temporarily install a jumper wire across the terminals in the connector of the

wiring harness.

c) Start the engine.

d) Run the unit at least 5 minutes with the drive levers at full forward speed to

bring hydraulic system oil up to operating temperature.

e) 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.

f) 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 13.

g) Re-tighten the jam nut against the ball joint on each side.

FIGURE 13

h) 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).

i) Stop engine and wait for all moving parts to stop. Remove jumper wire

from wire harness connector and plug connector into seat switch.

j) Lower from jackstands.

4.2.6 Reverse Indicator Adjustment:

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Tilt seat forward.

c) 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 14.

36

FIGURE 14

d) Check where lever is relative to notch in neutral plate (should be centered

allowing lever to pivot outward to the neutral lock position).

e) 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.

f) Repeat on opposite side of unit.

4.2.7 Weight transfer spring adjustment:

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 castors.

a) To adjust the left weight transfer spring, rotate the left motion control arm

up and into the operation position.

b) Locate and loosen the knob under the rear of the left fender. See Figure 15.

FIGURE 15

c) Slide the fender forward and twist upward and outward to remove.

d) To adjust the weight transfer springs, fold the mower deck and front frame

and lock in service position. See Deck Manual for complete instructions.

37

WARNING

POTENTIAL HAZARD

♦ Weight transfer springs may have stored

energy.

WHAT CAN HAPPEN

♦ Removing the weight transfer springs

without releasing the stored energy can

cause serious injury

HOW TO AVOID THE HAZARD

♦ 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)

e) Remove the retaining ring and washer at either end of the weight transfer

spring that retains it to the transfer bellcrank pins and/or weight transfer

spring anchor pins. See Figure 16.

f) 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 16

g) Re-install the left fender.

h) To adjust right side, raise the unit and place on jackstands, remove wheel

and repeat steps steps d) through f).

38

CAUTION

POTENTIAL HAZARD

♦ Raising the unit for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous.

WHAT CAN HAPPEN

♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

could cause injury.

HOW TO AVOID THE HAZARD

♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

jack stands or equivalent

4.2.8 Rear caster pivot bearings pre-load adjustment:

a) Remove dust cap from caster and tighten

nyloc nut until washers are flat. Back the

nyloc off 1/4 of a turn to properly set the

pre-load on the bearings.

Note: If disassembled, make sure the spring

washers are reinstalled as shown in Figure 17.

5. WASTE DISPOSAL

5.1 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.

5.2 BATTERY DISPOSAL

DANGER

POTENTIAL HAZARD

♦ Battery electrolyte contains sulfuric acid,

which is poisonous and can cause severe

burns

WHAT CAN HAPPEN

♦ Swallowing electrolyte can be fatal or if it

touches skin can cause severe burns.

HOW TO AVOID THE HAZARD

♦ 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.

FIGURE 17

39

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.

6. TROUBLE SHOOTING

6.1 MOWER PULLS LEFT OR RIGHT (W/LEVERS FULLY FORWARD).

a) Refer to Tracking Adjustment Section 4.2.5.

b) Check air pressure in drive tires.

AT101 (Bar Lug) drive tires should be inflated to 9 psi (62 kpa).

Turf Mate drive tires should be inflated to 13 psi (90 kpa).

Semi-pneumatic casters do not require inflation.

6.2 MOWER CUTS UNEVENLY.

a) Check air pressure in drive tires.

AT101 (Bar Lug) drive tires should be inflated to 9 psi (62 kpa).

Turf Mate drive tires should be inflated to 13 psi (90 kpa).

Semi-pneumatic casters do not require inflation.

A more uniform cutting height may be obtained with higher tire pressure on rough

terrain. A lower tire pressure provides more flotation.

b) Check deck leveling (See Adjustments in Deck Manual).

Note: The front of the mower deck will be approximately 1/4” lower than the back

of the mower deck. This is the “rake” of the deck.

c) Check the distance from the bottom edge of the deck skirt to the tip of each

blade. Measurement should be consistent between all blade tips.

6.3 ENGINE WILL NOT START.

a) Make sure the battery has a full charge. See section 4.1.3 for charging

instructions.

b) Be sure the throttle control is in the correct position. See section 3.3.2.

c) Make sure there is fuel in the fuel tank.

d) Make sure the parking brake is set and motion control levers in the neutral

position.

e) Check that the PTO is disengaged.

f) Check for loose or faulty wiring connections.

g) Check for corrosion at all wiring connections. Even minor corrosion may cause a

faulty connection. Clean connector terminals thoroughly with electrical contact

cleaner, apply dielectric grease and reconnect.

NOTE: When disconnecting electrical connectors DO NOT pull on the

wires to separate the connectors.

NOTE: After carefully checking the above steps, attempt to start the

engine. If it does not start, contact your authorized Exmark service dealer.

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

adjustments procedures (such as valves, governor, etc.). Have this work done

by your Engine Service Dealer.

40

TROUBLESHOOTING TABLE

PROBLEM

NO

FUEL

IMPROPER

FUEL

WATER OR DIRT IN

FUEL LINE

DIRTY AIR

FILTER

ENGINE

OVERLOADED

BLOCKED

FUEL

FILTERS

INCORRECT

OIL LEVEL

INSUFFICIENT

BATTERY CHARGE

FAN PUMP

BELT MISSING

DIRTY RADIATOR

CORE

Will not start X X X X X X

Hard starting X X X X X X

Stops suddenly X X X X X

Lacks power X X X X X

Operates erratically X X X X X

Skips or misfires X X X

Overheats X X X X X

High fuel consumption X X

6.4 ENGINE WARNING SYSTEMS

6.4.1 Alternator Charging Light: Located to the rear of the key switch. Light will come on

when the alternator is not charging.

6.4.2 Low Oil Pressure Light: Located to the rear of the key switch with the alternator

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

6.4.3 Glow Plug Light: Located on the right fuel tank console. The glow plug light

comes on when the glow plugs are preheating the combustion chamber. This

happens when the glow switch is depressed and while the engine is cranking.

6.4.4 Coolant Temperature Light: Located on the right fuel tank console. The light will

come on if the engine is overheating.

6.4.5 Warning Buzzer: Located behind the seat under the engine cover on the right

hand side of the engine fan shroud. The buzzer is a warning signal for the

following circumstances:

a) When the engine is running and the buzzer emits a continuous beep, the

buzzer is warning the user that the engine is overheating. Perform the

following steps.

1. Disengage the mower blades, and idle down the engine.

2. Look at the temperature gauge to determine if temperature continues to

increase. If it does, turn the unit off and allow the engine and engine

components to cool.

3. Check the coolant level. If necessary fill with coolant as described in

Section 4.1.2.

4. Remove any debris on or around the radiator that may restrict airflow.

5. Check to see if the water pump/alternator belt is intact. If belt is missing,

do not run unit, as unit can overheat and damage the engine. See Engine

Service Dealer.

b) When the engine is running and the buzzer emits intermittent beeps, the

buzzer is warning the user that the engine oil pressure is low. Perform the

following steps.

1. Turn the unit off, allow the engine and engine components to cool.

2. Check the oil level and fill, if necessary, as described in Section 4.1.1.

3. Check for oil leaking from engine. If the engine is leaking, see Engine

Service Dealer.

41

7. ELECTRICAL DIAGRAM

42

8. HYDRAULIC DIAGRAM

43

9. 2-Year Limited Warranty

Exmark Turf Equipment

(For units purchased on or after October 1, 2004)

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.

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized

Exmark Service Dealer.

• Any damage or deterioration due to normal use, wear and

tear, or exposure.

• Cost of regular maintenance service or parts, such as

filters, fuel, lubricants, tune-up parts, and adjustments.

• Any product or part which has been altered or misused or

required replacement or repair due to normal wear,

accidents, or lack of proper maintenance.

• Any repairs necessary due to use of parts, accessories or

supplies, including gasoline, oil or lubricants, incompatible

with the turf equipment or other than as recommended in

the operator's manual or other operational instructions

provided by Exmark.

All warranty work must be performed by an authorized Exmark

Service Dealer using Exmark approved replacement parts.

Instructions for Obtaining Warranty Service

1. 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.

2. Bring the product and your proof of purchase (sales

receipt) to the Exmark Service Dealer.

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 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.

As a condition to this warranty, customer shall have read

the operator's manual and shall have completed and

submitted to Exmark Warranty Company, within the

prescribed time, the Exmark warranty registration.

General Conditions

The sole liability of Exmark and Exmark Warranty Company

with respect to this warranty shall be repair and replacement

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.

No Claim of breach of warranty shall be cause for

cancellation or rescission of the contract of sale of any

Exmark mower.

There are no understandings, agreements, representations,

or warranties, express or implied, including but not limited to

any regarding the merchantability (that product is fit for

ordinary use) or fitness for use (that product is fit for a

particular purpose), not specified herein, respecting the

equipment which is the subject of this warranty.

Some states do not allow exclusions of incidental or

consequential damages, or limitations on how long an

implied warranty lasts, so the above exclusions and

limitations may not apply to you.

This warranty gives you specific legal rights, and you may

also have other rights which vary from state to state.

44

NOTES

45

NOTES

46

®

M

FG. CO. INC.

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

STANDON

WARNING WARNING

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects, or other reproductive harm.

CALIFORNIA

Proposition 65

Diesel engine exhaust and some of its constituents

are known to the State of California to cause cancer,

birth defects, and other reproductive harm.

©2006-2007 PART NO. 109-4334 Rev. A

EXMARK MFG. CO. INC. (402) 223-6300

INDUSTRIAL PARK BOX 808 FAX (402) 223-5489

BEATRICE, NE 68310

ALL RIGHTS RESERVED PRINTED IN U.S.A.

Check us out on the Web:

www.exmark.com