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Exmark Frontrunner User's Manual

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3. 17 2 Operating teret 17 18 3 4 Transport uc to eoa Rad e 19 20 4 MAINTENANCE amp ADJUSTMENTS 4 1 Periodic Maintenance reto ep MERE KR ELA 21 32 4 2 Adjustments e Aiea Shae ae ie ii 32 38 5 WASTE DISPOSAL 8 1 _Mot r Qil Disposal Mr 38 5 2 Disposal pet orb peto dte eoe a 38 39 6 TROUBLESHOOTING 6 1 Mower Pulls Left or Right sanete 39 6 2 Mower Cuts Unevenly ec pte pta tas Ne ot um dE 39 6 35 Engine ds eite 39 40 6 4 Engine Warning SystemS dee ntt Mane A dust 40 7 ELECTRICAL DIAGRAM 22 2 41 8 HYDRAULIC DIAGRAM qe d tans 42 9 WARRANTY iub sod drei taht te db ds 43 1 SAFETY 1 1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL A 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 avo
4. YOKE Com 08 2 il UM GA AHH lt FIGURE 10 THIN NYLOC NUT 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 YOKE INNER FLANGE NUT 1 8 GAP ARA cop aaa x LN OUTER FLANGE NUT THIN NYLOC NUT 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 33 BALL JOINT JAMNUT Ky PARK BRAKE om LINKAGE ROD 738 ld 60573 FIGURE 12 h If the linkage does not measure 7 3 8 18 7 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 A WARNING A POTENTIAL HAZARD Engine must be running an
5. PART NO 1 523552 LOCATION On Top of Radiator LOCATION Top Surface of PART NO 103 0233 Hydraulic Tank LOCATION On Front of the Fan Shroud N START 0 DIESEL ONLY N 6 109 2358 5 PART 103 1636 LOCATION On of PART NO 109 2358 Fuel Tank LOCATION On Control Panel PART NO 109 2356 COWARNING RH Si ROTATING MECHANICAL DEVICES x ROTATING BLADES 5 Sef Can cause serious injury SO NOT operate without guards in place 71 4 Stop engine before removing guards 103 7218 CAN CAUSE SERIOUS INJURY DO NOT operate without guards in place Stop engine before opening cover M 103 5881 PART NO 103 5881 PART NO 103 7218 LOCATION On top of Radiator LOCATION On Seat Support Plate CAUTION A DANGER AWARNING E gt gt THIS UNIT WHEN COVER IS NOT IN PLACE SURFACE PART NO 98 5954 PART NO 93 4361 g LOCATION Top of Radiator LOCATION On LH and RH Side Near Back of Unit PART NO 103 2076 LOCATION On Top of Radiator 10 AWARNING dig TO AVOID INJURY OR DEATH FROM ROLLOVER Keep roll bar in the raised and locked position and use seat belt BAR IS DOWN 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 Read and
6. 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 17 3 3 3 3 3 4 3 3 5 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 Engaging PTO A DANGER A 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 A DANGER
7. X X xT x x x sossen x X X X X X X X X X X X X X X sew X X X X X x x X Wewecewewe xix 6 4 ENGINE WARNING SYSTEMS 6 4 1 6 4 2 6 4 3 6 4 4 6 4 5 Alternator Charging Light Located to the rear of the key switch Light will come on when the alternator is not charging 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 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 Coolant Temperature Light Located on the right fuel tank console The light will come on if the engine is overheating 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 an
8. 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 Change engine coolant Service Interval 4 years 4000 hours Dex CoolO extended life coolant orange color t 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 25 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 an
9. 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 16 3 1 15 3 1 16 3 1 17 Alternator Charging Light Located to the rear of the key switch Light will come on when the alternator is not charging 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 engin
10. 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 22 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 vollage x Charging Interval Reading Charge Charger Settings gng 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 7596 16 volts 7 amps 1 Hour 12 0 12 2 25 50 14 4 volts 4 amps 2 Hours 11 7 12 0 0 2596 14 4 volts 4 amps 3 Hours 11 7 or less 096 14 4 volts 2 amps 6 Hours or More 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 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 th
11. 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 43 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 se
12. 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 22 0 S Service Interval If there is evidence of a leak or the hydraulic cylinder does not perform normally Retract the hydraulic cylinder Stop engine and wait for all moving parts to stop Tilt the seat forward Locate the auxiliary hydraul
13. deck 49 0 in 124 5 49 0 in 124 cm deflector up 53 3 in 135 4 61 4 in 156 deflector down 64 0 in 163 cm 72 0 in 183 cm Overall Length without deck amp 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 Overall Height Curb Weight Roll Bar Up Roll Bar Down 69 2 in 175 8 cm 50 7 in 128 8 cm without Deck 1163 Ibs 528 kg w 52 Deck 1555 Ibs 705 kg w 60 Deck 1600 Ibs 726 kg 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 13 2 12 TORQUE REQUIREMENTS Bolt Location Torque Wheel Eug Nuts 90 95 ft lbs 122 129 N m Wheel Motor Mounting 72 77 ft lbs 98 104 N m Rollover Protection System Roll Bar Mounting Bolts 30 35 ft Ibs 41 47 N m Clutch Retaining Bolt secured with threadlocker 55 60 ft Ibs 75 81 N m Wheel Hub Slotted minimum 125 ft lbs 169 N m 3 OPERATION INSTRUCTIONS 3 1 CONTROLS 3 1 1 3 1 2 HANDLES OUT NEUTRAL LOCK Familiarize yourself with all controls before operating the mower Motion Control Levers Located on each side of the console The left lever controls the flow of hydraulic oi
14. follow slope operation instructions and warnings 107 2102 PART NO 107 2102 LOCATION Inside Surface of Upper Roll Bar b SERVICE AID PART NO 109 3637 WARNING Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning avoid loss of control and possibility of rollover NOT operate near drop offs or near water NOT operate on slopes greater than 15 Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes There is no roll over protection when the roll bar is down Always keep roll bar in the raised and locked position and use seat belt Read and follow rollover protection instructions and warning 107 2112 PART NO 107 2112 LOCATION Top of Floor Pan WARNING HIGH PRESSURE OIL Can cause serious injury or death Do NOT go near leaks Relieve hydraulic pressure before loosening fittings Read operator s manual for complete procedure PART NO 109 2377 LOCATION On Hydraulic Cylinder A WARNING SPRING LOADED MECHANISM Can cause serious injury See operator s manual for disassembly procedure PART NO 109 2355 LOCATION Outside of each Weight Transfer Bell Crank Every 8 hours 1 Check engine oil 2 Grease front caster wheel bearings Every 40 hours 3 C
15. is fuel in the fuel tank Make sure the parking brake is set and motion control levers in the neutral position Check that the PTO is disengaged Check for loose or faulty wiring connections 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 39 PROBLEM 2 TROUBLESHOOTING TABLE 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 rere ee Hardstarting
16. 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 31 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 are used on the following fasteners a Pump drive sheave set screws Line shaft sheave setscrews c Square head setscrews on Hydro pump control arms Sheave retaining bolt in the end of engine crankshaft 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
17. 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 e All Products except as noted below 2 years e All Attachments and Accessories 1 year e Metro 21 and Metro 26 Series 1 year e Belts and Tires 90 days 1 Year Prorated Warranty is covered by engine manufacturer e Battery e Engine 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 e Pickup and delivery charges to and from any authorized Exmark Service Dealer e Any damage or deterioration due to normal use wear and tear or exposure e Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments e 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 e 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
18. to pivot outward to the neutral lock position 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 MOTION CONTROL LEVER LEFT FENDER E FENDER KNOB 60591 FIGURE 15 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 36 A WARNING A POTENTIAL HAZARD Weight
19. 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 ex
20. 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 A s Pe E PN RIGHT SIDE RE INSTALL SPRING IN OF UNLDSHOWN OUTER HOLES TO REDUCE SPRING TENSION REMOVE E RING AND WASHER WEIGHT TRANSFER SPRING gt 60579 FIGURE 16 0 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 37 A CAUTION A 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 u
21. 2 223 6300 ark MFG CO INC
22. A POTENTIAL HAZARD Anuncovered 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 Stopping PTO Set throttle to the midway position Push the switch in to the STOP position to stop the PTO 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 18 3 4 TRANSPORTING IMPORTANT Do not transpor
23. AZARD 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 A WARNING A 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 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 be obtained from Exmark Mfg Co Inc 1 6 5 Safety signs may be affixed by peeling off the backin
24. For Serial Nos 670 000 amp Higher MFG INC DIESEL MODELS 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 Place Model No and Serial No Label Here Engine Model No and Spec No Code Included in Literature Pack or Fill in Below Engine Serial No E No Model No Date Purchased Serial No Part No 109 4334 Rev A 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
25. 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 8 mm from the outer surface of the spacer nut to the end of the axle inside the nut Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing 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 Insert the second bearing and new seal into the wheel Apply a thread locking adhesive to the 2 spacer nut and thread onto the axle with the wrench flats facing outward Torque the nut to 75 80 in Ibs 8 9 N m loosen then re torque to 20 25 in Ibs 2 3 N m Make sure axle does not extend beyond either nut 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 Stop engine wait for
26. Interval 250 hrs Normal Interval Yearly NOTE Use only Exmark Part No 103 2146 Stop engine wait for all moving parts to stop and remove key Engage parking brake Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system 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 Fill reservoir as stated in Section 4 1 11 A CAUTION A 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 hydraulic jacks for support Use adequate jack stands or equivalent support 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 Start engine and move throttle control ahead to full throttle position Move the motion control levers to the full soeed and run for several minutes Shut down machine and recheck oil level Do
27. TROL t de N R ENGAGE PART 109 2357 LOCATION Top of Console LH Side DRIVE WHEEL RELEASE One turn counterclockwise to release Do not over tighten 109 2396 PART NO 109 2396 LOCATION Top of Seat Support Plate HYDRAULIC LIFT eXmark AWARNING EXPOSED BLADES and TIPPING HAZARD Can cause serious injury Do NOT operate with deck in folded position PART NO 109 2698 LOCATION On Control Panel Look behind and to the side before changing directions Hearing protection is recommended Before leaving the operator s position Disengage PTO Move drive levers out to neutral lock position Engage park brake Stop engine 109 2360 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 x50 RPM 2 3 FUEL SYSTEM 2 3 1 Capacity 8 5 gal 32 L 2 3 2 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 is
28. all moving parts to stop and remove key Engage parking brake Tilt seat forward 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 Stop engine wait for all moving parts to stop and remove key Engage parking brake Tilt seat forward and raise hood 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 29 4 1 20 Lubricate the motion control bronze bushings 4 1 21 4 1 22 4 1 23 4 1 24 Service Interval 160 hrs Stop engine wait for all moving parts to stop and remove key Engage parking brake Tilt seat forward Lubricate bronze bushings on the flange bearings securing the motion control arm shafts with a light oil or a spray type lubricant Lubricate the motion control shaft Service Interval Yearly Stop engine wait for all moving parts to stop and remove key Engage parking brake Tilt seat forward Remove tab at rear of motion control shaft Pull motion control shaft out and lubricate with an NGLI grade 2 multi purpose gun grease Re install shaft and tab Lubricate steering linkage rod ends Service Interval 160 hrs Stop engine wait for all moving parts to stop and remove key Engage parking brake Tilt seat forward Lubricate each end of both steerin
29. 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 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 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 deale
30. 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 Route new belt onto sheaves as shown the decal located on the top of the radiator See Figure 8 PUMP BELT ROUTING 1 643339 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 32 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 PARK BRAKE ENGAGED YOKE THIN NYLOC NUT d 1 8 GAP BETWEEN NUT AND YOKE FIGURE 9 Disengage the park brake Measure the length of the park brake spring The spring should measure 2 5 6 4cm See Figure 10
31. ceeding 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 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 be
32. d 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 A CAUTION A 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 rely solely on mechanical hydraulic jacks for support Use adequate jack stands or equivalent 34 PUMP CONTROL ROD LINKAGE i Set neutral Remove the electrical connection from the seat safety switch located directly in front of the seat switch assembly 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 Start the engine Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic system oil up to operating temperature To obtain the neutral position adjust the left and right pump control rod linkages that connect the steering control to the
33. d 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 40 7 ELECTRICAL DIAGRAM NOLLISOd 4901 Q39voN3 WALAN NI SHBAST OHLNOO
34. d 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 DRAIN COCK 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 A WARNING A 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 26 f g 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 When the radiator is completely full and no additional
35. e drive wheels to slip and cause loss of braking and steering e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine e Remove or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles e Use extreme care with attachments These can change the stability of the machine and cause loss of control e Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability A Rollover Protection System roll bar is installed on the unit A DANGER A 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 1 4 6 1 4 7 1 4 8 1 4 9 1 4 10 1 4 11 1 4 12 1 4 13 1 4 14 1 4 15 1 4 16 1 4 17 1 4 18 1 4 19 certain that the seat belt can be released quickly if the machine is driven or rolls into ponds of water e Check carefully for overhead clearances i e branches doorways and elect
36. e 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 23 4 1 6 Repeat again moving the right lever in then moving both levers in engine m
37. e oil level is low 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 3 2 2 3 2 3 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 Make sure you understand the controls their locations their functions and their safety requirements Refer to Maintenance Section 4 and perform all the necessary inspection and maintenance steps 3 3 OPERATING INSTRUCTIONS 3 3 1 3 3 2 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
38. e the brake Pushthe lever down to disengage the brake The unit must be tied down and brake engaged when transporting 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 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 15 3 1 10 3 1 11 3 1 12 3 1 13 3 1 14 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 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 eng
39. ecommended 1 3 3 1 3 4 A CAUTION A 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 While mowing always wear substantial footwear and long trousers Do not operate equipment when barefoot or when wearing open sandals 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 A WARNING A POTENTIAL HAZARD Engine exhaust contains carbon monoxide which is an odorless deadly poison WHAT CAN HAPPEN Carbon monoxide 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 A DANGER A 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 c
40. er operation of retractor and buckle Replace before operating if damaged 24 4 1 9 4 1 10 4 1 11 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 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 0 Reinstall elements Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips 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
41. erate up or down a trailer ramp 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 A 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 15 wet Do 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 rapid speed changes 1 4 5 e See inside the back cover to determine the approximate slope angle of the area to be mowed e Usea walk behind mower and or a hand trimmer near drop offs ditches steep banks or water This area can be dangerous see Figure 1 Danger Zone G0544 FIGURE 1 Progressively greater care is needed as the slope increases e Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope e Avoid sudden stops when mowing downhill Tractor may tip forwards e Be aware that loss of traction may occur going uphill Weight transfer to the rear wheels may caus
42. fore leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance TABLE OF CONTENTS 1 SAFETY PAGE 1 1 Safety Alert Symbol ree REB 1 dele D re RO d RPE Md AP 1 1594 TPS PARTON ot elle el utu teste ttt a 1 3 1 4 ODSIAUOTE ui es ice Pub TES ces 4 7 1 5 Maintenance amp 8 9 T 9 11 2 SPECIFICATIONS 2 1 Model tee been Beat uis ues 12 227 ENGNG ated cute os chee 12 29 Fuel SVSIBITPs ceti qus 12 24 Electrical eee E E 12 257 S Es 12 2 6 6 DU 12 lt T E 12 13 2 8 Hydrostatic Ground Drive 13 c EE ERE 13 2 40 Mower Deck focii epo D o tdt 13 2 11 IS si eec oer ceri N 13 2 12 Torque Requiremehls e 14 3 OPERATION INSTRUCTIONS OA SOOM OSs ews sn inten can mee cain ened Gains nace rd 14 17 32
43. g linkage rods with a spray lubricant or light oil Drain water from fuel tank Service Interval 160 hrs Park on level ground Stop engine wait for all moving parts to stop and remove key Engage parking brake Place a drain pan under the fuel tank and loosen the drain cock approximately 1 turn Drain out any water When fuel begins to flow from the tank tighten the drain cock Prime the fuel system See Section 4 1 24 Start engine Check for leaks IMPORTANT Water or other contaminants in fuel can severely damage fuel pump and or the other engine components If any water was drained run engine for approximately 2 minutes to flush any remaining water out of the engine and fuel system Change fuel filter a Service Interval 400 hrs or as required 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 30 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
44. g 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 WARNING Na BATTERY CONTAINS SULFURIC ACID AVOID CONTACT OR USE BOOSTER CABLES OR ADJUST POST CONNECT AND ALWAYS SHIELD EYES FACE SKIN AND CLOTHING IONS WITHOUT PROPER TRAINING IN EVENT OF AN FROM BATTERY CIGARETTES FLAMES OR SPARKS ACCIDENT FLUSH WITH WATER AND CALL A PHYSICIAN COULD CAUSE BATTERY TO EXPLODE DO NOT CHARGE IMMEDIATELY KEEP OUT OF REACH OF CHILDREN ACAUTION MUFFLER AND SHIELDS MAY EXCEED 1506 PART NO 1 513746 PART NO 1 513747 LOCATION Outside of Rear LOCATION LH Side of Battery Holder Muffler Guard HYDRAULIC Olt USE ONLY PUMP BELT ROUTING Shell DEX COOL MOBIL 1 SAE 15W 50 Extended Life Antifreeze Coolant SYNTHETIC ENGINE OIL off only with Shell DEX COOL Extended Life Antifreeze Coolant FILL TOP BAFFLE Suggested change interval is at 57 jo 4 or 4 000 hours of service Do not mix with conventional coolants Shell DEX COOL Extended Life CAUTION GN WE 29 OT SURFACE N e 1 643339 Another Product Innovation From Antifreeze Coolant is available at your CX Manr PART NO 1 643339
45. heck hydraulic oil Use only Mobil 1 15W 50 Synthetic Motor oil Check tire sure Turf Mate Tires 13 psi 101 Tires 9 psi Grease deck drive PTO Grease deck pivots Grease hitch and cylinder pivots Check air cleaner Grease wheel pivot Dual tail wheel only Every 100 hours 10 Grease fold pivot pin 11 Check gearbox oil Use only Mobil 1 75W 90 gear oil 12 Check auxiliary hydraulic oil Use only Mobil 1 15W 50 Synthetic Motor oil Yearly 13 Grease fold lock pin 14 Grease front caster pivots 15 Grease rear caster pivot s 16 Grease deck idler 17 Grease belt idlers 18 Grease motion control pivots 19 Grease fold lock lever 20 Grease transfer spring end pivots both ends a See operator s manual for additional details LOCATION Back of Seat Do NOT operate under the influence of alcohol or drugs Do NOT operate without shields guards and safety devices in place and working Check the function of the operator presence controls OPC safety system daily Do NOT defeat the OPC system Stop engine and remove key before adjusting servicing or cleaning machine and attachments Do NOT carry passengers WARNING To avoid serious injury or death Read and understand the operator s manual before using this machine Do NOT operate unless trained to safely use this machine PART NO 109 2360 LOCATION Front of Console 11 RELEASE CON
46. hildren 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 operate without entire exhaust system in place and in proper working condition 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 A WARNING A 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 wo
47. htly 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 14 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 A CAUTION A 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 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 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 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 engag
48. ic power unit reservoir See Figure 5 AUXILIARY HYDRAULIC RESERVOIR PLUG FIGURE 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 4 1 14 Check tire pressures a b Service Interval 40 hrs Stop engine wait for all moving parts to stop and remove key Engage parking brake Check tire pressure in drive tires 27 4 1 15 4 1 16 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 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 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 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 Lubricate grease fittings Service Interval Refer to chart a Stop engine wait for all moving parts to stop and remove
49. ided 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 24 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 r
50. ine has run If the ignition switch is left on without engine running hour meter will not run 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 Jower the mower deck to the desired height 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 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 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 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 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
51. 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 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 N G0710 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 28 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 a SPACER NUT WITH Pry out seals and inspect bearings for come WRENCH FLATS wear or damage and replace if necessary FIGURE 7 Pack the bearings with a NGLI grade 1 multi purpose grease Insert 1 bearing 1 new seal into the wheel NOTE Seals Exmark PN 103 0063 must be replaced
52. l 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 HANDLES IN NEUTRAL f FRONT OF UNIT LEFTHAND SIDE SHOWN T LEVER 60552 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 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 slig
53. m mower during operation 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 DO NOT operate mower under the influence of alcohol or drugs Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision 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 1 5 MAINTENANCE AND STORAGE 1 5 1 1 5 2 1 5 3 1 5 4 1 5 5 1 5 6 1 5 7 1 5 8 1 5 9 1 5 10 1 5 11 1 5 12 For engine maintenance follow the engine manufacturer s recommendations precisely as stated in the engine manual Disconnect the battery cable from the negative battery post when the unit will be allowed to sit for more than 30 days without use 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
54. nit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanical 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 18 nyloc nut until washers are flat Back the nyloc off 1 4 of a turn to properly To es SS pre load on the bearings Note If disassembled make sure the spring washers are reinstalled as shown in Figure 17 60343 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 A DANGER A 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 38 If a battery is being replaced or if the unit containing the battery is no l
55. 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 DexCoolO 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 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 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 12 2 7 3 Seat Safety Switch Internal to the bottom seat cushion non serviceable Time delay module incorporated into the Safet
56. on switch and engage parking brake Disconnect the negative battery cable before you do any maintenance A WARNING A 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 Stop engine and wait for all moving parts to stop Make sure unit is on a level surface Tilt seat forward and raise hood to gain access to access to engine area Check with engine cold 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 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 21 4 1 2 4 1 3 Check engine coolant level Service Interval Daily Stop engine and wait for all moving parts to stop Make sure machine is on a level surface Tilt seat up and tilt hood forward to gain access to the cooling area Check with engine cold View coolant level in overflow b
57. onger 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 b Refer to Tracking Adjustment Section 4 2 5 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 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 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 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 Make sure the battery has a full charge See section 4 1 3 for charging instructions Be sure the throttle control is in the correct position See section 3 3 2 Make sure there
58. ottle on the left side of the engine Coolant level should be at the indicator line on the overflow bottle 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 A WARNING A 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 A CAUTION A 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 Check battery charge 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 Service Interval Monthly 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
59. p M EM 188 ten Ra 2 jn ju ILL vage vegg 55 Tze 8 a dWaL nnd O3139WVHO LY HOLMS HOLMS TINON 835970 Old Old vas Lvas Las HOLMS HIM L OL NI HOLIMS 038070 1 HOLMS 41 8 HYDRAULIC DIAGRAM 60561 1 m m 41001 dT BYPASS VALVE d BYPASS VALVE Ys m HIGH PRESSURE FORWRD i HIGH PRESSURE REVERSE HIGH PRESSURE HIGH PRESSURE FORWARD REVERSE HIGH PRESSURE CHARGE PUMP CASE DRAIN 42 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
60. prevent damage due to freezing battery should be fully charged before putting away for winter storage 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 Store fuel in a container specifically designed for this purpose in a cool dry place Keep the mower and fuel container in locked storage to prevent children from playing or tampering with them 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 Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly Check all bolts frequently to maintain proper tightness Keep all guards shields and all safety devices in place and in safe working condition 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 A WARNING A 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 H
61. pump control arms until the wheels stop or creep slightly in reverse 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 Re tighten the jam nut against the ball joint on each side LOOSEN JAM NUT USE WRENCH TO TURN DOUBLE NUTS FIGURE 13 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 Stop engine and wait for all moving parts to stop Remove jumper wire from wire harness connector and plug connector into seat switch Lower from jackstands 4 2 6 Reverse Indicator Adjustment a b Stop engine wait for all moving parts to stop and remove key Engage parking brake Tilt seat forward 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 35 END OF SLOT MOTION CONTROL YOKE Dur E 005 LOOSEN HERE X TURN BOLT HERE 4 id Ww p Ru T FIGURE 14 Check where lever is relative to notch neutral plate Should be centered allowing lever
62. quential 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 NOTES 44 NOTES 45 ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC ios Ub EH FOLD ALONG APPROPRIATE LINE 46 A WAR 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 Check us out on the Web www exmark com NING A A WARNING The engine exhaust from this product CALIFORNIA contains chemicals known to the State Proposition 65 of California to cause cancer birth Diesel engine exhaust and some of its constituents defects or other reproductive harm are known to the State of California to cause cancer birth defects and other reproductive harm 2006 2007 EXMARK MFG CO INC INDUSTRIAL PARK BOX 808 FAX 402 223 5489 BEATRICE NE 68310 ALL RIGHTS RESERVED PRINTED IN U S A PART NO 109 4334 Rev A 40
63. r 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 Distributor ships part s to dealer or customer as E M ARK A R T L U TS requested by dealer same day overnight UPS Distributor bills dealer for part and freight charges where applicable 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 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 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 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 Ifthe 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
64. rical wires before driving under any objects and do not contact them Use EXTREME caution when backing LOOK BEHIND YOU Stop the blades 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 DO NOT change the engine governor settings or overspeed the engine Operating an engine at excessive speed may increase the hazard of personal injury Disengage PTO before starting engine Start the engine carefully with feet well away from the blades Keep hands feet and clothing away from rotating parts while the mower is being operated Stop engine wait for all moving parts to stop and remove key Engage parking brake e Before checking cleaning or working on the mower e After striking a foreign object inspect the mower for damage and make repairs before restarting and operating the mower e Before clearing blockages e Whenever you leave the mower Stop the engine and wait for all moving parts to stop Engage parking brake e Before refueling e Before dumping the grass catcher 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 This mower was designed for one operator only Keep all others away fro
65. rking order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land A WARNING A 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 1 4 3 When feasible avoid operating the equipment wet grass A WARNING A 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 Limit operation to minimum required to install a different front mount attachment Minimize speed and use extreme caution Only operate on a flat level surface Do not op
66. se enough ramps to create an unbroken ramp surface wider than the unit DO NOT exceed 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 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 20 4 MAINTENANCE amp ADJUSTMENTS A WARNING A 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 igniti
67. t 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 A CAUTION A 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 street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on 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 19 3 4 2 A WARNING A 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 u
68. t 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 e Expenses related to gasoline oil or lubricants e 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 e Rental of like or similar replacement equipment during the period of any warranty repair or replacement work e Any telephone or telegram charges or travel charges e Loss or damage to person or property other than that covered by the terms of this warranty e Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty e 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 conse
69. ust 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 switch See Figure 3 LEFT SIDE INSIDE OF HITCH SHOWN PTO KILL SWITCH SWITCH ARM 1 LOWER DECK UNTIL ARM DOES NOT CONTACT SWITCH FIGURE 3 90572 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 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 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 Check seat belt Service Interval Daily a Visually inspect seat for wear cuts and prop
70. y 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 2 8 2 2 8 3 2 8 4 2 8 5 2 8 6 Hydrostatic Pumps Two Hydro Gear PR 16 cc variable displacement piston pumps Wheel Motors Hydro Gear planetary reduction motors Hydraulic Oil Type Use Mobil 1 15W 50 Synthetic Motor Oil Hydraulic Oil Capacity 5 2 qt 4 9 L 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 2 8 7 Drive wheel release valves allow machine to be moved when engine is not running 2 9 TIRES Rear Caster Drive Front 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 2 11 2 2 11 3 2 11 4 2 11 5 Tread Width Center to Center of Drive Wheels 41 4 in 105 2 cm Overall Width w 52 Deck w 60 Deck without

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