Page 2 - WARNING; CALIFORNIA
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects, orother reproductive harm. Important: When the mower is used or operated on any California forest, brush or grass coveredland, a working sp...
Page 3 - Introduction; CONGRATULATIONS; on the purchase of your
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefullydesigned and manufactured to give you a maximumamount of dependability and years of trouble-freeoperation. This manual contains operating, maintenance,adjustment, and safety instructions for your Exmark...
Page 4 - Contents; Remove Engine Shrouds and Clean Cooling
Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...
Page 5 - Safety; Safety Alert Symbol; Safe Operating Practices; Training; CAUTION
Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both inthis manual and on the machine to identify importantsafety messages which must be followed to avoidaccidents This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Figure 2 1. Safety alert symbol The s...
Page 6 - DANGER; Avoid prolonged breathing of vapors.
Safety DANGER In certain conditions gasoline is extremelyflammable and vapors are explosive. A fire or explosion from gasoline can burnyou, others, and cause property damage. • Fill the fuel tank outdoors in an openarea, when the engine is cold. Wipe upany gasoline that spills. • Never refill the fu...
Page 7 - Operation
Safety Operation WARNING Operating engine parts, especially themuffler, become extremely hot. Severe burnscan occur on contact and debris, such asleaves, grass, brush, etc. can catch fire. • Allow engine parts, especially the muffler,to cool before touching. • Remove accumulated debris from mufflera...
Page 8 - Slope Operation; Use; Extreme; caution when mowing and/or turning; Do Not mow slopes when grass is wet.
Safety transporting the mower to and from the area tobe mowed. • Be aware of the mower discharge path and directdischarge away from others. • Do Not operate the mower under the influenceof alcohol or drugs. • Use extreme care when loading or unloading themachine into a trailer or truck. • Use care w...
Page 9 - Drive slowly and carefully.; Maintenance and Storage
Safety WARNING There is no rollover protection when the rollbar is down. Wheels dropping over edges,ditches, steep banks, or water can causerollovers, which may result in serious injury,death or drowning. • Keep the roll bar in the raised and lockedposition and use seat belt. • Lower the roll bar on...
Page 10 - Safety and Instructional Decals
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease,dirt and debris from safety signs and instructionallabels. • Replace all worn, damaged, or missing safetysigns. • When replacement components are installed, besure that current safety signs are affixed to there...
Page 14 - Specifications; Model Numbers
Specifications Specifications Model Numbers Serial Nos: 720,000 and Higher FR23KC; FR27KC; FR31BV Systems Engine • Engine Specifications: See your Engine Owner’sManual • RPM: Full Speed: 3750 ±50 RPM (No Load)Idle: 1500 RPM Fuel System • Capacity: 8.5 gal. (32 L) • Type of Fuel: Regular unleaded gas...
Page 15 - Hydrostatic Ground Drive System; – 23HP Kohler Units: Two Hydro Gear PJ; Cutting Deck
Specifications • Mounting: Hinged to tilt up for access tohydraulic pumps, battery and other components.The seat is held in the tilted position with alinkage. Adjustable fore and aft seat track. • Armrests: Standard seat: foam padded flip-uparmrests. Optional suspension seat: moldedadjustable flip-u...
Page 16 - Mulching Kit: Optional; Dimensions; Minimum Turning Radius
Specifications – 60 inch Deck: 20.50 inches (52.1 cm) – 72 inch Deck: 24.50 inches (62.2 cm) • Blade Spindles: Solid steel spindles with 1 3/4inch (4.45 cm) I.D. bearings. • Deck Drive: “B”-Section belt from jackshaft ondeck to blade spindles. • Deck: Full floating deck is attached to out-frontsuppo...
Page 17 - Torque Requirements; Product Overview
Product Overview Torque Requirements Bolt Location Torque Engine Mounting Bolts 30-35 ft-lb (41-47 N-m) Wheel Lug Nuts 90-95 ft-lb (122-129 N-m) Wheel Motor MountingBolts 72-77 ft-lb (98-104 N-m) Wheel Hub Lock Nut 210-250 ft-lb(285-339 N-m) Rollover Protection System(Roll Bar) Mounting Bolts 30-35 ...
Page 18 - Controls
Operation Operation Note: Determine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control levers located on each side of theconsole control the forward and reverse motion ofthe machine. The levers control the flow of hydraulicoi...
Page 19 - Drive Wheel Release Valves; Located on right fuel tank.; Hydraulic Lift Switch; Located on right fuel tank console.; Operating Instructions; Remove the hairpin cotter pins and remove the
Operation Drive Wheel Release Valves Located on the top left front corner of hydrostaticpumps. Drive wheel release valves are used to release thehydrostatic drive system to allow the machine to bepushed without the engine running. With a wrench, turn both valves one turncounterclockwise to release d...
Page 20 - Open the Fuel Shut-Off Valve; Do Not crank the engine; Engaging the PTO; Operator must be in seat before the; Disengaging the PTO
Operation Open the Fuel Shut-Off Valve The fuel shut-off valve is located on the right side ofunit in fuel line next to the fuel filter. Raise the rearhood to access fuel shut-off valve. Starting the Engine 1. Move the motion control levers out to the neutral lock position. 2. Pull up and back on th...
Page 21 - Driving the Machine; Use caution when making turns.; Driving Forward; Driving in Reverse
Operation Driving the Machine CAUTION Machine can spin very rapidly by positioningone lever too much ahead of the other.Operator may lose control of the machine,which may cause damage to the machineor injury. • Use caution when making turns. • Slow the machine down before makingsharp turns. Importan...
Page 22 - Transporting; Transporting a Unit; Do Not transport FrontRunner; Loading a Unit; Do Not attempt to turn the unit; Avoid sudden acceleration when driving on a ramp.
Operation Transporting Transporting a Unit Important: Do Not transport FrontRunner tractor without an approved Exmark front mountattachment. Use a heavy-duty trailer or truck to transport themachine. Lock brake and block wheels. Securelyfasten the machine to the trailer or truck with straps,chains, ...
Page 23 - Maintenance
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING While maintenance or adjustments are beingmade, someone could start the engine.Accidental starting of the engine couldseriously injure you or other bystanders. Remove the key f...
Page 24 - Periodic Maintenance; Check Engine Oil Level; Service Interval: Before each use or daily; Check Battery Charge; Service Interval: Monthly
Maintenance Maintenance Service Interval Maintenance Procedure Monthly • Check the battery charge. Yearly • Grease the fold lock pin.• Grease the rear caster pivot.• Grease the belt idlers.• Grease the motion control pivots.• Grease the transfer spring ends.• Lubricate the caster wheel hub(s).• Lubr...
Page 26 - EXMARK; Check Seat Belt; Check for Loose Hardware; Service Air Cleaner; Do Not; Change Engine Oil; Service Interval: After the first 5 hours
Maintenance 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 properoperating condition prior to use for mowing. Check Rollover ProtectionsSystems (Roll Bar)...
Page 27 - Check Hydraulic Oil Level; Check Tire Pressures; Service Interval: Every 40 hours
Maintenance 5. Replace the oil filter every other oil change. Clean around oil filter and unscrew filter to remove.Before reinstalling new filter, apply a thin coatingof oil on the surface of the rubber seal. Turnfilter clockwise until rubber seal contacts the filteradapter then tighten filter an ad...
Page 28 - Check Condition Of Belts; Lubricate Grease Fittings; See chart for service intervals.; Lubricate Rear
Maintenance Check Condition Of Belts Service Interval: Every 40 hours 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Check pump and PTO drive belts. 3. Belts are spring tensioned and no adjustment is necessary. See Pump Drive Belt Tension and Replacement ...
Page 29 - To prevent seal and bearing damage,; Lubricate Brake Handle Pivot; Service Interval: Every 160 hours
Maintenance spacer nuts to the axle. Remove the axle (withthe other spacer nut still assembled to it) fromthe wheel assembly. 5. Pry out seals, and inspect bearings for wear or damage and replace if necessary. 6. Pack the bearings with a NGLI grade #1 multi-purpose grease. 7. Insert one bearing, one...
Page 30 - Check Spark Plugs; Before reinstalling new filter, fill
Maintenance 2. Tilt seat forward.3. Lubricate each end of both steering linkage rods with a spray lubricant or light oil Check Spark Plugs Service Interval: Every 160 hours Remove spark plugs, check condition and reset gaps,or replace with new plugs. See Engine Owner’sManual. Change Fuel Filter Serv...
Page 31 - Dielectric Grease; Adjustments; Pump Drive Belt Tension
Maintenance • Pump drive sheave set screws. • Line shaft sheave setscrews. • Square head setscrews on Hydro pump controlarms. • Sheave retaining bolt in the end of enginecrankshaft. • Caster wheel spacer nuts. • Fuel tank bulkhead fitting nuts. • Motion control tab retaining bolt. Adhesives such as ...
Page 32 - Temporarily
Maintenance Figure 12 1. Park brake engaged 3. Thin nyloc nut 2. Yoke 4. 1/8 inch (3 mm) gapbetween nut and yoke. 5. If park brake does not fully disengage when the lever is disengaged check the brake rod linkageassembly. The assembly should measure 7 3/8inch (18.7 cm) from the center of the ball jo...
Page 34 - Cleaning
Maintenance Figure 16 Right-Hand Side of Unit Shown 1. Re-install spring in outerholes to reduce springtension. 3. Remove e-ring andwasher. 2. Weight transfer spring. 7. Re-install the left fender 8. For additional weight transfer adjustment, repeat steps 4 through 7 on the right side of the unit. C...
Page 35 - Service Interval: Every 80 hours; Remove cooling shroud clean-out covers from; Waste Disposal; Motor Oil Disposal; Do Not swallow electrolyte.
Maintenance Remove Engine Shrouds andClean Cooling Fins Service Interval: Every 80 hours 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Remove cooling shroud clean-out covers from engine and clean cooling fins. Also clean dust,dirt, and oil from external ...
Page 36 - Troubleshooting; condition prior to mower use.
Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, Do Not overlook the simple causes. For example: starting problems could becaused by an empty fuel tank. The followi...
Page 38 - Schematics; Electrical Diagram —23HP & 27HP Kohler
Schematics Schematics Electrical Diagram —23HP & 27HP Kohler BA TT (POS) CIRCUIT BREAKER BA TT (NEG) BL ACK BL ACK ORANGE ORANGE M OT OR (FWD) M OT OR (REV) RED RED BLACK BLACK GREY / BLACK GREY L T BLUE YELL OW / BL ACK ORANGE ORANGE YELL OW / BL ACK ORANGE PINK / BLACK GREY GREY RED BL ACK DK ...
Page 39 - Electrical Diagram – 31HP Briggs & Stratton
Schematics Electrical Diagram – 31HP Briggs & Stratton 3 I A S B X Y SE AT DEL AY MODULE CONT ROL SE AT DEL AY MODULE INPUT SE AT SWITCH P TO CLUTCH P TO SWITCH G ROUND FUSE 20 AMP KILL REL AY ST A RT REL AY BRAKE SWITCH LH M O TION CONT RO L RH M O TION CONT ROL IGNITION SWITCH HOUR METER FUSE ...
Page 40 - Hydraulic Diagram
Schematics Hydraulic Diagram CASE DRAIN CHARGE PUMP HIGH PRESSURE G007220 BYPASS VALVE BYPASS VALVE HIGH PRESSUREREVERSE HIGH PRESSUREFORWARD HIGH PRESSUREREVERSE HIGH PRESSUREFORWARD 40
Page 42 - Service Record
Service Record Date: Description of Work Done: Service Done By: 42
Page 44 - M I D - M O U N T R I D I N G AC C E S S O R I E S; SEE EXMARK’S COMPLETE LINE OF ACCESSORIES; WALK-BEHIND ACCESSORIES
M I D - M O U N T R I D I N G AC C E S S O R I E S SEE EXMARK’S COMPLETE LINE OF ACCESSORIES WALK-BEHIND ACCESSORIES GRASS CATCHER LAZERLOCKER MICRO-MULCH SYSTEM TURF STRIPER STANDON CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LAZERLOCKER LIGHT KIT MICRO-MULCH SYSTEM OPERATOR C...
