Exmark 720000 & Higher manual

FRONTRUNNER TM AIR-COOLED MODELS For Serial Nos. 720,000 & Higher Part No. 4500-218 Rev . A[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals known to the State of Califor nia to cause cancer , birth defects, or other reproductiv e har m. Important: When the mo wer is used or operated on any Califor nia forest, br ush or grass co vered land, a w orking spark arr ester must be attached to [...]

Introduction CONGRATULATIONS on the purchase of y our Exmark Mow er . T his product has been carefully designed and manufactured to giv e you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for your Exmark mow er . BEFORE OPERATING Y OUR MO WER,[...]

Contents Introduction .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 3 Safety .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . 5 Safety Alert Symbol . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 5[...]

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both in this man ual and on the mac hine to identify important safety messages which m ust be follow ed to av oid accidents This symbol means: ATTENTION! BECOME ALERT! Y OUR SAFETY IS INV OL VED! Figure 2 1. Safety alert symbol The safety alert symbol appears abo ve infor[...]

Safety DANGER In certain conditions gasoline is extremely ammable and v apors are explosi v e. A re or explosion from gasoline can bur n y ou, others, and cause proper ty damage. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any gasoline that spills. • Never rell the fuel tank or drain the machine indo[...]

Safety Operation W ARNING Operating engine parts, especially the mufer, become extremely hot. Sev ere bur ns can occur on contact and debris, such as leav es, grass, br ush, etc. can catch re. • Allow engine parts, especially the mufer, to cool before touching . • Remo ve accumulated de bris from mufer and engine area. • Install a[...]

Safety transporting the mow er to and from the area to be mow ed. • Be a ware of the mo wer discharge path and direct discharge a way from others . • Do Not operate the mow er under the inuence of alcohol or dr ugs . • Use extreme care when loading or unloading the machine into a trailer or tr uc k. • Use care when approac hing blind cor[...]

Safety W ARNING There is no rollov er protection when the roll bar is down. Wheels dropping o ver edges, ditches, steep banks, or w ater can cause rollov er s, which may result in serious injur y , death or drowning . • Keep the roll bar in the raised and lock ed position and use seat belt. • Lower the roll bar only when a bsolutely necessar y [...]

Safety Safety and Instructional Decals • Keep all safety signs legible . R emov e all grease, dirt and debris from safety signs and instructional labels . • R eplace all w or n, damaged, or missing safety signs . • When replacement components are installed, be sure that cur rent safety signs are afx ed to the replaced components . • If a[...]

Safety 103-7218 107-2102 107-21 12 109-2355 109-2356 1. Fast 3. Neutral 2. Slow 4. Reverse 1 1[...]

Safety 109-2357 1. Fast 4. Reverse 2. Slow 5. Park Brake—Release 3. Neutral 6. Park Brake—Engage 109-2358 109-2377 109-2396 109-3637 12[...]

Safety 109-7413 1. Cylinder—extend 4. Slow 2. Cylinder—retract 5. Choke—on 3. Fast 6. Choke—off 109-7949 109-2360 13[...]

Specications Specications Model Numbers Serial Nos: 720,000 and Higher FR23K C; FR27K C; FR31BV Systems Engine • Engine Specications: See y our Engine Owner’ s Manual • RPM: Full Speed: 3750 ±50 RPM (No Load) Idle: 1500 RPM Fuel System • Capacity: 8.5 gal. (32 L) • T ype of Fuel: R egular unleaded gasoline, 87 octane or higher .[...]

Specications • Mounting: Hing ed to tilt up for access to hy draulic pumps , battery and other components . The seat is held in the tilted position with a linkage. Adjustable fore and aft seat trac k. • Ar mrests: Standard seat: foam padded ip-up ar mrests . Optional suspension seat: molded adjustable ip-up ar mrests . • Seat Safety [...]

Specications – 60 inch Deck: 20.50 inc hes (52.1 cm) – 72 inch Deck: 24.50 inc hes (62.2 cm) • Blade Spindles: Solid steel spindles with 1 3/4 inch (4.45 cm) I.D . bearings . • Deck Dri ve: “B”-Section belt from jackshaft on deck to blade spindles . • Deck: Full oating deck is attac hed to out-front support frame, remo vable for[...]

Product Overview T orque Requirements Bolt Location T orque Engine Mounting Bolts 30-35 ft-lb (41-47 N-m) Wheel Lug Nuts 90-95 ft-lb (122-129 N-m) Wheel Motor Mounting Bolts 72-77 ft-lb (98-104 N-m) Wheel Hub Lock Nut 210-250 ft-lb (285-339 N-m) R ollover Protection System (R oll Bar) Mounting Bolts 30-35 ft-lb (41-47 N-m) Clutch R etaining Bolt (s[...]

Operation Operation Note: Deter mine the left and right sides of the machine from the nor mal operating position. Controls Motion Control Levers The motion control lev ers located on each side of the console control the forw ard and rev erse motion of the mac hine. The levers control the ow of hy draulic oil from the h ydrostatic pump to the dri[...]

Operation Drive Wheel Release V alves Located on the top left front corner of h ydrostatic pumps . Driv e wheel release v alves are used to release the hy drostatic driv e system to allow the machine to be pushed without the engine r unning . With a wrenc h, tur n both valv es one tur n counterclockwise to release driv e system. T urn clockwise to [...]

Operation Open the Fuel Shut-Off V alve The fuel shut-off valv e is located on the right side of unit in fuel line next to the fuel lter . Raise the rear hood to access fuel shut-off v alv e. Starting the Engine 1. Mov e the motion control lev ers out to the neutral lock position. 2. Pull up and bac k on the parking brake lev er to engag e the p[...]

Operation Driving the Machine CAUTION Machine can spin v er y rapidly by positioning one lev er too much ahead of the other . Operator may lose control of the machine, which may cause damage to the machine or injur y . • Use caution when making tur ns. • Slow the machine down before making shar p tur ns. Important: T o begin mov ement (forward [...]

Operation T ransporting T ransporting a Unit Important: Do Not transpor t FrontR unner tractor without an appro ved Exmark front mount attachment. Use a heavy-duty trailer or tr uc k to transport the machine . Loc k brake and bloc k wheels . Securely fasten the machine to the trailer or tr uc k with straps , chains , cable , or ropes . Be sure that[...]

Maintenance Maintenance Note: Deter mine the left and right sides of the mac hine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental star ting of the engine could seriously injure y ou or other bystanders. Remo ve the k ey from the ignition s witch, engage parki[...]

Maintenance Maintenance Ser vice Inter v al Maintenance Procedure Monthly • Check the battery c harge. Y early • Grease the fold lock pin. • Grease the rear caster pi vot. • Grease the belt idlers . • Grease the motion control piv ots . • Grease the transfer spring ends . • Lubricate the caster wheel hub(s). • Lubricate the motion c[...]

Maintenance V oltage Reading Percent Charge Maximum Charger Settings Charging Inter v al 12.6 or g reater 100% 16 v olts/7 amps No Charging R equired 12.4 – 12.6 75–100% 16 v olts/7 amps 30 Min utes 12.2 – 12.4 50–75% 16 v olts/7 amps 1 Hour 12.0–12.2 25–50% 14.4 volts/4 amps 2 Hours 11.7–12.0 0–25% 14.4 volts/4 amps 3 Hours 11.7 or[...]

Maintenance Note: If mac hine does not pass any of these tests , Do Not operate . Contact y our authorized EXMARK SER VICE DEALER. Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing . Check Rollover Protections Systems (Roll Bar) Pins Service Interval: Before each use or[...]

Maintenance 5. R eplace the oil lter ev er y other oil c hange. Clean around oil lter and unscrew lter to remov e . Before reinstalling new lter , apply a thin coating of oil on the surface of the rubber seal. T urn lter clockwise until rubber seal contacts the lter adapter then tighten lter an additional 2/3 to 3/4 tur n. 6. C[...]

Maintenance Check Condition Of Belts Service Interval: Every 40 hours 1. Stop engine, w ait for all moving parts to stop , and remov e key . Engag e parking brake . 2. Check pump and PTO driv e belts . 3. Belts are spring tensioned and no adjustment is necessar y . See Pump Dri ve Belt T ension and Replacement sections in Adjustments . Lubricate Gr[...]

Maintenance spacer n uts to the axle. Remo ve the axle (with the other spacer n ut still assembled to it) from the wheel assembly . 5. Pr y out seals , and inspect bearings for w ear or damage and replace if necessary . 6. P ack the bearings with a NGLI grade #1 multi-purpose grease. 7. Insert one bearing, one new seal into the wheel. Note: Seals ([...]

Maintenance 2. Tilt seat forw ard. 3. Lubricate eac h end of both steering linkage rods with a spray lubricant or light oil Check Spark Plugs Service Interval: Every 160 hours R emov e spark plugs , chec k condition and reset gaps, or replace with new plugs . See Engine Owner’ s Manual. Change Fuel Filter Service Interval: As required A fuel l[...]

Maintenance • Pump dri ve shea ve set screws . • Line shaft shea ve setscrews . • Square head setscrews on Hydro pump control ar ms . • Sheav e retaining bolt in the end of engine crankshaft. • Caster wheel spacer n uts . • Fuel tank bulkhead tting n uts . • Motion control tab retaining bolt. Adhesiv es such as “Loctite R C/609 o[...]

Maintenance Figure 12 1. Park brake engaged 3. Thin nyloc nut 2. Y oke 4. 1/8 inch (3 mm) gap between nut and yoke. 5. If park brak e does not fully disengage when the lever is disengag ed chec k the brake rod linkage assembly . The assembly should measure 7 3/8 inch (18.7 cm) from the center of the ball joint to the center of the lo wer end of the[...]

Maintenance Figure 14 1. Loosen jam nut 2. Pump control rod linkage 3. Use wrench to turn double nuts 9. Mov e the motion control lev ers to the rev erse position. R eturn the motion control lev ers to neutral. The wheels m ust stop turning (or slightly creep in reverse). 10. Stop engine and w ait for all mo ving parts to stop . R emov e jumper wir[...]

Maintenance Figure 16 Right-Hand Side of Unit Shown 1. Re-install spring in outer holes to reduce spring tension. 3. Remove e-ring and washer . 2. Weight transfer spring. 7. R e-install the left fender 8. F or additional w eight transfer adjustment, repeat steps 4 through 7 on the right side of the unit. Caster Pivot Bearings Pre-Load Adjustment R [...]

Maintenance Remove Engine Shrouds and Clean Cooling Fins Service Interval: Every 80 hours 1. Stop engine, w ait for all moving parts to stop , and remov e key . Engag e parking brake . 2. R emov e cooling shroud clean-out cov ers from engine and clean cooling ns . Also clean dust, dirt, and oil from external surfaces of engine , which can cause [...]

T roubleshooting T roubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mow er use. When a problem occurs , Do Not o verlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The follo wing table lists some of the common causes [...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e 1. R educe the ground speed. 2. Oil lev el in the crankcase is low . 2. Add oil to the crankcase . Engine ov erheats 3. Cooling ns and air passages for the engine are plug ged. 3. R emove the obstructions from the cooling ns and air passages . 1. T rac k[...]

Schematics Schematics Electrical Diagram —23HP & 27HP Kohler BA TT (POS) CIRCUIT BREAKER BA TT (NEG) BLACK BLACK ORANGE ORANGE MOT OR (FWD) MOT OR (REV) RED RED BLACK BLACK GREY / BLACK GREY L T BLUE YELLOW / BLA CK ORANGE ORANGE YELLOW / BLA CK ORANGE PINK / BLACK GREY GREY RED BLACK DK GREEN DK GREEN ORANGE / BLACK YELLOW T AN RED BRO WN BL[...]

Schematics Electrical Diagram – 31HP Briggs & Stratton 3 I A S B X Y SEA T DELA Y MODULE CONTROL SEA T DELA Y MODULE INPUT SEA T SWITCH PTO CLUTCH PTO SWITCH GROUND FUSE 20 AMP KILL RELA Y ST ART RELA Y BRAKE SWITCH LH MOTION CONTROL RH MOTION CONTROL IGNITION SWITCH HOUR METER FUSE 30 AMP ST ARTER; BA TTER Y (POS) RED YELLOW T AN T AN ORANGE[...]

Schematics Hydraulic Diagram CASE DRAIN CHARGE PUMP HIGH PRESSURE G007220 BYP ASS V AL VE BYP ASS V AL VE HIGH PRESSURE REVERSE HIGH PRESSURE FOR W ARD HIGH PRESSURE REVERSE HIGH PRESSURE FOR W ARD 40[...]

Conditions and Products Co vered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty 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 ex ercise of our reasonable discretion) to be defectiv e in fa[...]

Service Record Date: Description of Work Done: Service Done By: 42[...]

43[...]

MID-MOUNT RIDING A CCESSORIES SEE EXMARK’S COMPLETE LINE OF A CCESSORIES W ALK-BEHIND A CCESSORIES GRASS CA TCHER LAZERLOCKER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LAZERLOCKER LIGHT KIT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED DISCHARGE ROLL O VER PRO TECTION SYSTEM (ROPS) SNO[...]