Exmark Frontrunner 720,000 & Higher Serial Nos. User manual

FRONTRUNNERTM
AIR-COOLEDMODELS
ForSerialNos.
720,000&Higher
PartNo.4500-218Rev.A

WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,or
otherreproductiveharm.
Important:Whenthemowerisusedoroperated
onanyCaliforniaforest,brushorgrasscovered
land,aworkingsparkarrestermustbeattached
tothemufer.Ifnot,theoperatorisviolating
statelaw,Section4442PublicResourceCode.To
acquireasparkarresterforyourunit,seeyour
EngineServiceDealer.
ThissparkignitionsystemcomplieswithCanadian
ICES-002Cesystèmed’allumageparètincellede
vèhiculeestconformeàlanormeNMB-002du
Canada
TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.
KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2004–2008—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE683102
Contactusatwww.Exmark.com.
PrintedintheUSA.
AllRightsReserved

Introduction
CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.
Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
3

Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals.....................10
Specications.......................................................14
ModelNumbers............................................14
Systems.........................................................14
Dimensions...................................................16
TorqueRequirements....................................17
ProductOverview................................................17
Operation.............................................................18
Controls........................................................18
Pre-Start........................................................19
OperatingInstructions..................................19
Transporting.................................................22
Maintenance.........................................................23
RecommendedMaintenanceSchedule(s)...........23
PeriodicMaintenance.......................................24
CheckEngineOilLevel.................................24
CheckBatteryCharge....................................24
CheckSafetyInterlockSystem.......................25
CheckRolloverProtectionsSystems(Roll
Bar)Pins...................................................26
CheckSeatBelt..............................................26
CheckforLooseHardware............................26
ServiceAirCleaner........................................26
ChangeEngineOil........................................26
CheckHydraulicOilLevel.............................27
CheckTirePressures.....................................27
CheckConditionOfBelts..............................28
LubricateGreaseFittings...............................28
LubricateRearCasterWheelHub(s)...............28
LubricateBrakeHandlePivot........................29
LubricateBrakeRodBushings.......................29
LubricateMotionControlBronze
Bushings...................................................29
LubricateMotionControlShaft.....................29
LubricateSteeringLinkageRodEnds.............29
CheckSparkPlugs.........................................30
ChangeHydraulicSystemFilter.....................30
CheckWheelHubLocknuts..........................30
ThreadLockingAdhesives.............................30
DielectricGrease...........................................31
Adjustments.....................................................31
PumpDriveBeltTension...............................31
PumpDriveBeltReplacement.......................31
ParkBrakeAdjustment..................................31
MotionControlLinkageAdjustment.............32
WeightTransferSpringAdjustment...............33
CasterPivotBearingsPre-Load
Adjustment...............................................34
Cleaning...........................................................34
CleanEngineCoolingSystem........................34
RemoveAccumulatedDebrisfrom
Engine(Briggs&StrattonUnits
Only).........................................................34
RemoveEngineShroudsandCleanCooling
Fins...........................................................35
WasteDisposal..............................................35
Troubleshooting...................................................36
Schematics...........................................................38
4

Safety
Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
1.Safetyalertsymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.
CAUTION
Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.
Wearhearingprotectionwhenoperatingthis
machine.
•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
5

Safety
DANGER
Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.
Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.
•Fillthefueltankoutdoorsinanopen
area,whentheengineiscold.Wipeup
anygasolinethatspills.
•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.
•DoNotllthefueltankcompletely
full.Addgasolinetothefueltankuntil
thelevelis1/4to1/2inch(6–13mm)
belowthebottomofthellerneck.This
emptyspaceinthetankallowsgasoline
toexpand.
•Neversmokewhenhandlinggasoline,
andstayawayfromanopenameor
wheregasolinefumesmaybeignitedby
spark.
•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.
•Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.
•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
DANGER
Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.
•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.
•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.
•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.
•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.
•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.
WARNING
Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgas
tank/containeropening.
•Keepawayfromeyesandskin.
•Neversiphonbymouth.
•Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
6

Safety
Operation
WARNING
Operatingengineparts,especiallythe
mufer,becomeextremelyhot.Severeburns
canoccuroncontactanddebris,suchas
leaves,grass,brush,etc.cancatchre.
•Allowengineparts,especiallythemufer,
tocoolbeforetouching.
•Removeaccumulateddebrisfrommufer
andenginearea.
•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.
DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.
WARNING
OperatingaFrontRunnertractorwithoutan
approvedExmarkfrontmountattachment
increasesthepossibilityofforwardtipover.
Tip-overcouldcauseseriousinjuryordeath.
WhenoperatingaFrontRunnertractor
withoutanapprovedExmarkfrontmount
attachment,observethefollowing:
•Limitoperationtominimumrequiredto
installadifferentfrontmountattachment.
•Minimizespeedanduseextremecaution.
•Onlyoperateonaatlevelsurface.
•DoNotoperateupordownatrailerramp.
•Avoidsuddenaccelerationordeceleration.
•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.Useseatbelts.
•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly.
•DoNotchangetheenginegovernorsettingor
overspeedtheengine.
•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.
•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:
–Beforerefueling.
–Beforedumpingthegrasscatcher.
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.
•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
•NEVERcarrypassengers.DONOToperate
themowerwhenpeople,especiallychildren,or
petsareinthearea.
•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.
•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
7

Safety
transportingthemowertoandfromtheareato
bemowed.
•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.
•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.
DANGER
Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Wheels
droppingoveredges,ditches,steepbanks,or
watercancauserollovers,whichmayresult
inseriousinjury,deathordrowning.
•DoNotmowslopeswhengrassiswet.
•DoNotmowneardrop-offsornearwater.
•DoNotmowslopesgreaterthan15
degrees.
•Reducespeedanduseextremecaution
onslopes.
•Avoidsuddenturnsorrapidspeed
changes.
•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
•Useawalkbehindmowerand/orahandtrimmer
neardrop-offs,ditches,steepbanksorwater.
(Figure3).
Figure3
1.SafeZone-Usethemowerhereonslopeslessthan15
degrees
2.DangerZone-Useawalkbehindmowerand/orhand
trimmerneardrop-offsandwater.
3.Water
•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
•Avoidsuddenstopswhenmowingdownhill
becausethemowermaytipforwards.
•Beawarethatlossoftractionmayoccurgoing
uphill.Weighttransfertotherearwheelsmay
causedrivewheelstoslipandcauselossof
brakingandsteering.
•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.
UsingtheRolloverProtectionSystem
(ROPS)
ARolloverProtectionSystem(rollbar)isinstalled
ontheunit.
8

Safety
WARNING
Thereisnorolloverprotectionwhentheroll
barisdown.Wheelsdroppingoveredges,
ditches,steepbanks,orwatercancause
rollovers,whichmayresultinseriousinjury,
deathordrowning.
•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.
•Lowertherollbaronlywhenabsolutely
necessary.
•DoNotwearseatbeltwhentherollbar
isdown.
•Driveslowlyandcarefully.
•Raisetherollbarassoonasclearance
permits.
•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,andelectricalwires)before
drivingunderanyobjectsandDoNotcontactthem.
MaintenanceandStorage
•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.
•Keepengine,enginearea,andpumpdrivebelt
compartmentfreefromaccumulationofgrass,
leaves,excessivegreaseoroil,andotherdebris
whichcanaccumulateintheseareas.These
materialscanbecomecombustibleandmayresult
inare.
•LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.
•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.
•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplaceblades.Neverstraightenor
weldthem.
•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.
•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.
•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
•Checkallboltsfrequentlytomaintainproper
tightness.
•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.
•Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.
•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.
•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.
9

Safety
SafetyandInstructionalDecals
•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
•Replaceallworn,damaged,ormissingsafety
signs.
•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
103-2076
1-513747
1-523552
1-643339
98-4361
98-5954
103-3270
103-5881
10

Safety
103-7218
107-2102
107-2112
109-2355
109-2356
1.Fast3.Neutral
2.Slow4.Reverse
11

Safety
109-2357
1.Fast4.Reverse
2.Slow5.ParkBrake—Release
3.Neutral6.ParkBrake—Engage
109-2358
109-2377
109-2396
109-3637
12

Safety
109-7413
1.Cylinder—extend4.Slow
2.Cylinder—retract5.Choke—on
3.Fast6.Choke—off
109-7949
109-2360
13

Specications
Specications
ModelNumbers
SerialNos:720,000andHigher
FR23KC;FR27KC;FR31BV
Systems
Engine
•EngineSpecications:SeeyourEngineOwner’s
Manual
•RPM:FullSpeed:3750±50RPM(NoLoad)
Idle:1500RPM
FuelSystem
•Capacity:8.5gal.(32L)
•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher.
•FuelFilter:
–Kohler:
In-line15MicronKohlerP/N2405010.
–Briggs&Stratton:
In-line30MicronBriggsP/N695327.
•FuelShut-OffValve:1/4turnincrements(“ON”,
“OFF”).
•Fuelgaugeinrighthandfueltank.
ElectricalSystem
•ChargingSystem:FlywheelAlternator
•ChargingCapacity:
–Kohler:15amps
–Briggs&Stratton:20amps
•BatteryType:BCIGroupU1
•BatteryVoltage:12Volt
•Polarity:NegativeGround
•Fuses:
–Kohler:
One15ampandtwo20ampbladetype
–Briggs&Stratton:
One15amp,one20amp,andone30amp
bladetype
SafetyInterlockSystem
•PTOmustbedisengaged,brakeengaged,and
motioncontrolleversout(neutrallock)tostart
engine.(Itisnotnecessaryfortheoperatortobe
intheseattostarttheengine.)
•OperatormustbeinseatwhenPTOisengaged,
brakeisdisengaged,ormotioncontrolleversare
movedinorenginewillstop.
•Enginewillstopifthemotioncontrollevers
aremovedfromneutralpositionwhilebrakeis
engaged.
OperatorControls
•SteeringandMotionControl:
Note:Motioncontrolleversareadjustableto
threeheights.
–Separatelevers,oneachsideoftheconsole,
controlspeedanddirectionoftravelofthe
respectivedrivewheels.
–Steeringiscontrolledbyvaryingtheposition
oftheleversrelativetoeachother.
–Movingmotioncontrolleversoutward(in
slots)locksthedrivesysteminneutral.
•PTOEngagementLever:EngagesdrivetoPTO
(mowerdeck).
•ParkingBrakeLever:Engagesparkingbrakeby
pullingback.
Seat
•Type:Standardseatwithhighback,foampadded
(internalsuspension)andarmrestsandintegral
safetyswitch.
Optionalseataccessories:
–Customridesuspensionsystemtoenhance
StandardSeat.
–Deluxesuspensionseatwithhighback,low
prolefoam-in-placecushion(dampened,
adjustablespringsuspension)andarmrests.
14

Specications
•Mounting:Hingedtotiltupforaccessto
hydraulicpumps,batteryandothercomponents.
Theseatisheldinthetiltedpositionwitha
linkage.Adjustableforeandaftseattrack.
•Armrests:Standardseat:foampaddedip-up
armrests.Optionalsuspensionseat:molded
adjustableip-uparmrests.
•SeatSafetySwitch:Internaltothebottomseat
cushion,nonserviceable.Timedelaymodule
incorporatedintotheSafetyInterlockSystem
eliminatesroughgroundcut-outs.
HydrostaticGroundDriveSystem
•HydrostaticPumps:
–27HPKohler&31HPBriggs&Stratton
Units:TwoHydroGearPR16ccvariable
displacementpistonpumps.
–23HPKohlerUnits:TwoHydroGearPJ
12ccvariabledisplacementpistonpumps.
•WheelMotors:HydroGearplanetaryreduction
motors.
•HydraulicOilType:UseMobil115W-50
Syntheticmotoroil.
•HydraulicOilCapacity:
–27HPKohler&31HPBriggs&Stratton
Units:5.2qt.(4.9L)
–23HPKohlerUnits:4.0qt.(3.8L)
•HydraulicFilter:Replaceablecartridgetype.
P/N103-2146:25microns,Nobypass
•Speeds:
–27HPKohler&31HPBriggs&Stratton
Units:
0-10.5mph(16.9km/hr)forward
0-6.6mph(10.6km/hr)reverse
–23HPKohlerUnits:
0-8.7mph(14.0km/hr)forward
0-5.7mph(9.2km/hr)reverse
•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
Tires&Wheels
27HPKohler&31HPBriggs&StrattonUnits
DriveFront
Caster
RearCaster
(DualTail
Wheel)
Pneumatic
(Air-Filled)
Semi-
Pneumatic
Semi-
Pneumatic
Quantity222
TreadAT101SmoothSmooth
Size24x
12.00-12
9x3.50-413x6.5-6
PlyRating4
Pressure9psi
(62kPa)
23HPKohlerUnits
DriveFront
Caster
RearCaster
(SingleTail
Wheel)
Pneumatic
(Air-Filled)
Semi-
Pneumatic
Semi-
Pneumatic
Quantity221
TreadTurfmateSmoothSmooth
Size23x
10.50-10
9x3.50-413x6.5-6
PlyRating4
Pressure13psi
(90kPa)
CuttingDeck
(SoldSeparately)
•ModelNumbers:
–FR524
–FR604
–FR724
•CuttingWidth:
–52inch(132cm)
–60inch(152cm)
–72inch(183cm)
•Discharge:Side
•BladeSize:(3ea.)
–52inchDeck:18.00inches(45.7cm)
15

Specications
–60inchDeck:20.50inches(52.1cm)
–72inchDeck:24.50inches(62.2cm)
•BladeSpindles:Solidsteelspindleswith13/4
inch(4.45cm)I.D.bearings.
•DeckDrive:“B”-Sectionbeltfromjackshafton
decktobladespindles.
•Deck:Fulloatingdeckisattachedtoout-front
supportframe,removableforservice.Six
anti-scalprollersprovidemaximumturf
protection.Deckdesignallowsforbagging,
mulchingorsidedischarge.
•DeckDepth:
–52inchDeck:5.5inches(14.0cm)
–60inchDeck:5.5inches(14.0cm)
–72inchDeck:5.5inches(14.0cm)
•CuttingHeightAdjustment:Adjustsfrom11/2
inches(3.8cm)to5inches(12.7cm)innitely
variable.
•MulchingKit:Optional
•Bagger:Optional
Dimensions
OverallWidth:
52inch
Deck
60inch
Deck
72inch
Deck
Without
Deck
49.0inches
(124.5cm)
49.0inches
(124.5cm)
53.0inches
(135cm)
Deector
Up
53.3inches
(135.4cm)
61.4inches
(156cm)
73.4inches
(186cm)
Deector
Down
64.0inches
(163cm)
72.0inches
(183cm)
84.3inches
(214cm)
OverallLength:
23HPKohler27HPKohler&
31HPBriggs&
Stratton
Withoutdeck
andoorpan
folded
80.4inches
(204.2cm)
82.3inches
(209.0cm)
52inchDeck112.4inches
(285.5cm)
114.3inches
(290.3cm)
23HPKohler27HPKohler&
31HPBriggs&
Stratton
60inchDeck112.4inches
(285.5cm)
114.3inches
(290.3cm)
72inchDeck114.3inches
(290.3cm)
OverallHeight:
RollBar-UpRollBar-Down
69.2inches(175.8cm)50.7inches(128.8cm)
TreadWidth:(CentertoCenterof
Tires,Widthwise)
27HPKohler&31HPBriggs&StrattonUnits
52inchDeck60inchDeck72inchDeck
41.4inches
(105.2cm)
41.4inches
(105.2cm)
45.4inches
(115.3cm)
23HPKohlerUnits
52inchDeck60inchDeck72inchDeck
38.9inches
(98.8cm)
38.9inches
(98.8cm)
WheelBase:(CenterofCasterTireto
CenterofDriveTire)
•27HPKohler&31HPBriggs&StrattonUnits:
51.2inches(130.0cm)
•23HPKohlerUnits:54.1in(137.4cm)
MinimumTurningRadius
•27HPKohler&31HPBriggs&StrattonUnits:
55.25inches(140.3cm)
•23HPKohlerUnits:56.3in(143.0cm)
CurbWeight:
Withoutdeck911lb(413kg)
52inchDeck1303lb(591kg)
60inchDeck1348lb(611kg)
72inchDeck1397lb(634kg)
16

ProductOverview
TorqueRequirements
BoltLocationTorque
EngineMountingBolts30-35ft-lb(41-47N-m)
WheelLugNuts90-95ft-lb(122-129N-m)
WheelMotorMounting
Bolts
72-77ft-lb(98-104N-m)
WheelHubLockNut210-250ft-lb
(285-339N-m)
RolloverProtectionSystem
(RollBar)MountingBolts
30-35ft-lb(41-47N-m)
ClutchRetainingBolt
(securedwiththreadlocker)
55-60ft-lb(75-81N-m)
ProductOverview
Figure4
1.FuelCap4.SeatBelt
2.RollBar5.MotionControlLever
3.Controls6.ParkingBrakeLever
17

Operation
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
MotionControlLevers
Themotioncontrolleverslocatedoneachsideofthe
consolecontroltheforwardandreversemotionof
themachine.Theleverscontroltheowofhydraulic
oilfromthehydrostaticpumptothedrivewheel
motorforeachside.
Movingtheleversforwardorbackwardturnsthe
wheelonthesamesideforwardorinreverse.Wheel
speedisproportionaltotheamounttheleveris
moved.
Movingtheleversoutwardfromthecenterposition
intotheT-slotlocksthemintheneutralposition
(Figure6).
ChokeControl
Locatedonrightfueltankconsole.
Thechokeisusedtoaidinstartingacoldengine.
Movingthechokeleverforwardwillputthechokein
the“ON”positionandmovingthechokelevertothe
rear,tothedetent,willputthechokeinthe“OFF”
position.DoNotrunawarmenginewithchokein
the“ON”position.
ThrottleControl
Locatedonrightfueltankconsole.
Thethrottleisusedtocontrolenginespeed.Moving
thethrottleleverforwardwillincreaseenginespeed
andmovingthethrottlelevertotherearwilldecrease
enginespeed.Movingthethrottleforwardintothe
detentisfullthrottle.
ParkBrakeLever
Locatedonleftsideofunit,betweentheseatandthe
dummytank.
Thebrakeleverengagesaparkingbrakeonthedrive
wheels.
Pulltheleverupandrearwardtoengagethebrake.
Pushtheleverforwardanddowntodisengagethe
brake.
Theunitmustbetieddownandbrakeengagedwhen
transporting.
IgnitionSwitch
Locatedonrightfueltankconsole.
Theignitionswitchisusedtostartandstopthe
engine.Theswitchhasthreepositions“OFF”,“ON”
and“START”.Insertkeyintoswitchandrotate
clockwisetothe“ON”position.Rotateclockwiseto
thenextpositiontoengagethestarter(keymustbe
heldagainstspringpressureinthisposition).
Note:Brakemustbeengaged,motioncontrollevers
out(neutrallockposition),andPTOswitch“OFF”
tostartengine.(Itisnotnecessaryfortheoperator
tobeintheseattostarttheengine.)
HourMeter
Locatedontherightfueltankconsole.
Thehourmeterisconnectedtoapressureswitch
installedintheengineblockanditrecordsthe
numberofhoursthattheenginehasrun.Ifthe
ignitionswitchisleftonwithoutenginerunning,
hourmeterwillnotrun.
Note:Thisswitchisnotalowoilsensorandwillnot
alerttheoperatoriftheengineoilislow .
FuelShut-OffValve
Locatedinfuellinebyfueltankandfuellter.
Thefuelshut-offvalveisusedtoshutoffthefuel
whenthemachinewillnotbeusedforafewdays,
duringtransporttoandfromthejobsite,andwhen
parkedinsideabuilding.
Rotatethevalve1/4turnclockwisetoshutofffuel.
Rotatethevalve1/4turncounterclockwisetoturn
onfuel.
FuelGauge
Locatedattherearoftherightfueltank.
Thefuelgaugemonitorstheamountoffuelinthe
rightfueltankonly.Thelefttankdoesnotholdfuel.
18

Operation
DriveWheelReleaseValves
Locatedonthetopleftfrontcornerofhydrostatic
pumps.
Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
pushedwithouttheenginerunning.
Withawrench,turnbothvalvesoneturn
counterclockwisetoreleasedrivesystem.Turn
clockwisetoresetsystem.DoNotovertighten.Do
Nottowmachine.
•For27HPKohler&31HPBriggs&Stratton
Units:Usea5/8inchwrenchtoturnthevalves.
•For23HPKohlerUnits:Usea7/16inchwrench
toturnthevalves.
PTOEngagementSwitch
Locatedonrightfueltank.
Switchmustbepulledouttothe“ROTATE”
positiontoengagetheblades.Switchispushedinto
the“STOP”positiontostoptheblades.
HydraulicLiftSwitch
Locatedonrightfueltankconsole.
Thehydraulicliftswitchisusedtoraiseandlower
themowerdeck.
Pushthefrontportionofthehydraulicliftswitch
downtoraisethemowerdecktothedesiredheight.
Pushtherearportionofthehydraulicliftswitch
downtolowerthemowerdecktothedesiredheight.
Pre-Start
Fillfueltanks.Forbestresultsuseonlyclean,fresh
regulargradeunleadedgasolinewithanoctanerating
of87orhigher.Regulargradeleadedgasolinemay
alsobeused;however,combustionchamberand
cylinderheadwillrequiremorefrequentservice.See
EngineOwner’sManual.
DoNotaddoiltogasoline.
DoNotoverllfueltank.Neverllthefueltankso
thatthefuellevelrisesabovealevelthatis1/2inch
(13mm)belowthebottomofthellernecktoallow
forfuelexpansionandpreventfuelspillage.
Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.
RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.
OperatingInstructions
RaisetheRolloverProtectionSystem
(ROPS)
Important:Lowertherollbaronlywhen
absolutelynecessary.
1.Removethehairpincotterpinsandremovethe
tworollbarpins(Figure5).
2.Raisetherollbartotheuprightpositionand
installthetwopinsandsecurethemwiththe
hairpincotterpins(Figure5).
Important:Alwaysusetheseatbeltwiththe
rollbarintheraisedposition.Ensurethatthe
rearpartoftheseatissecuredwiththeseat
latch.
Figure5
1.Rollbar3.Pin
2.Raisedposition4.Hairpincotterpin
19

Operation
OpentheFuelShut-OffValve
Thefuelshut-offvalveislocatedontherightsideof
unitinfuellinenexttothefuellter.Raisetherear
hoodtoaccessfuelshut-offvalve.
StartingtheEngine
1.Movethemotioncontrolleversouttotheneutral
lockposition.
2.Pullupandbackontheparkingbrakeleverto
engagetheparkingbrake.
3.PushinonthePTOswitchtothe“STOP”
position.
Note:Itisnotnecessaryfortheoperatortobe
intheseattostarttheengine.
4.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.
5.Onacoldengine,pushthechokeleverforward
intothe“ON”position.
Onawarmengine,leavethechokeinthe“OFF”
position.
6.Turnignitionswitchtothe“START”position.
Releasetheswitchassoonastheenginestarts.
Important:DoNotcranktheengine
continuouslyformorethantensecondsata
time.Iftheenginedoesnotstart,allowa60
secondcool-downperiodbetweenstarting
attempts.Failuretofollowtheseguidelines
canburnoutthestartermotor.
7.Ifthechokeisinthe“ON”position,gradually
returnchoketothe“OFF”positionastheengine
warmsup.
EngagingthePTO
DANGER
Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.
DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.
DANGER
Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryordeath.
Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunless
thereisagrasscollectionsystemormulch
kitinplaceandworkingproperly.
ThePTOpush-pullswitchengagesthecuttingblades.
Besurethatallpersonsareclearofthemowerdeck
anddischargeareabeforeengagingPTO.
Important:Operatormustbeinseatbeforethe
PTOcanbeengaged.
1.Setthethrottletothe“MIDWAY”position.
2.PullthePTOswitchoutwardtothe“ROTATE”
position.
3.Placethethrottleinthe“FAST”positiontobegin
mowing.
DisengagingthePTO
1.Setthethrottletothe“MIDWAY”position.
2.PushthePTOswitchintothe“STOP”position
todisengagetheblades.
StoppingtheEngine
1.Bringtheunittoafullstop.
2.DisengagethePTO.
3.Movethemotioncontrolleversouttotheneutral
lockposition.
4.Engagetheparkingbrake.
5.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.
6.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.
7.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.
8.Closethefuelshut-offvalvewhenthemachine
willnotbeinuseforafewdays,when
transporting,orwhentheunitisparkedinside
abuilding.
20