Exmark FontRunner FR524 Programming manual

For Serial Nos.
600,000 & Higher
Part No. 109-4290 Rev. B

ii
EXMARK PARTS PLUS®PROGRAM
EFFECTIVE DATE: September 1, 1995
Program
If your Exmark dealer does not have the Exmark part in stock,
Exmark will get the parts to the dealer the next business day or
the part will be FREE* Guaranteed!!
How the Program Works
1. If dealer does not have part in stock for a "down" unit at
the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus®shipment of six (6) line items or less.
2. Distributor ships part(s) to dealer or customer, as
requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus®order, he contacts Exmark by 3:00 p.m.,
central time, with an Exmark Parts Plus®order of six (6) line items or less.
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by
distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.
5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus®and if it arrives in
accordance to the program.
6. Who pays for the part and freight if it fails to arrive overnight in accordance to the program?
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:
1. The dealer not submitting the Exmark Parts Plus®order to his Exmark distributor by 1:00 p.m., the dealer
pays for the part and freight.
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus®order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
Exmark pays for the part and freight.
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
pays for the part.
The following restrictions apply -- The Exmark Parts Plus®Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available
only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental
United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air
charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no
responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus®orders must be received by Exmark by
3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus®Program are:
Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and
5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United
Parcel Service size and weight restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day
or Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be
ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

iii
WARNING
POTENTIAL HAZARD
♦This product is a piece of power equipment.
WHAT CAN HAPPEN
♦Failure to follow safe operating practices can result in
serious operator injury or even death.
HOW TO AVOID THE HAZARD
♦Keep all shields, guards, and safety devices (especially
the grass discharge system) in place and in proper
working condition.
♦Stop engine and wait for all moving parts to stop and
engage parking brake. Remove spark plug wire(s) or
remove key before adjusting, servicing, or performing
maintenance.
♦If mower deck becomes clogged, stop engine and wait
for all moving parts to stop. Remove spark plug wire(s)
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.

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CONGRATULATIONS on the purchase of your Exmark FrontRunner Cutting Deck.
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 assembly, operating, maintenance, adjustment, and safety
instructions for your FrontRunner Cutting Deck.
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 equipment, maintain its maximum efficiency, and promote safe
operation.
If additional information is needed, or should you require trained mechanic
service, contact your authorized Exmark equipment dealer or distributor.
All Exmark equipment dealers and distributors are kept informed of the latest
methods of servicing and are equipped to provide prompt and efficient service in the
field or at their service stations. They carry ample stock of service parts or can
secure them promptly for you from the factory.
All Exmark parts are thoroughly tested and inspected before leaving the factory,
however, attention is required on your part if you are to obtain the fullest measure of
satisfaction and performance.

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TABLE OF CONTENTS
1.SAFETY PAGE
1.1 Safety Alert Symbol.......................................................................................1
1.2 Training......................................................................................................... 1
1.3 Preparation.................................................................................................1-2
1.4 Operation ...................................................................................................... 2
1.5 Maintenance & Storage.................................................................................2
1.6 Safety Signs...............................................................................................2-3
2. SPECIFICATIONS
2.1 Model Numbers.............................................................................................4
2.2 Dimensions....................................................................................................4
2.3 Torque Requirements....................................................................................4
3. ASSEMBLY INSTRUCTIONS
3.1 Assemble Deck to FrontRunner..................................................................4-6
3.2 Deck Removal............................................................................................6-7
4. MAINTENANCE & ADJUSTMENTS
4.1 Deck Raising and Lowering........................................................................7-9
4.2 Maintenance.............................................................................................9-12
4.3 Adjustments ...........................................................................................12-14
5. PARTS LIST
5.1 FR524 Deck Group ................................................................................15-16
5.2 FR604 Deck Group ................................................................................17-18
5.3 Front Frame Group.................................................................................19-20
5.4 Decal Group ............................................................................................... 21
6. WARRANTY.......................................................................................................... 22

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1. SAFETY
1.1 SAFETY ALERT SYMBOL
This SAFETY ALERT SYMBOL is used both in this manual and on the unit to identify
important safety messages which must be followed to avoid accidents. This symbol means:
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
The safety alert symbol appears above information which alerts you to unsafe actions or
situations and will be followed by the word DANGER, WARNING, or CAUTION.
DANGER: White lettering / Red background. Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
WARNING: Black lettering / Orange background. Indicates a potentially hazardous situation
which, if not avoided, COULD result in death or serious injury.
CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or moderate injury.
1.2 TRAINING
1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to all
who operate this unit.
1.2.2 Before operating your mower, read the FrontRunner tractor and cutting deck manual
instructions carefully. Familiarize yourself with the controls and the proper use of the
equipment. If the operator(s) or mechanic(s) can not read English, it is the owner’s
responsibility to explain this material to them.
1.2.3 Do not allow operation of this machine by untrained personnel. Never allow children,
teenagers, or people unfamiliar with these instructions to use the mower. Local
regulations may restrict the age of the operator.
1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind that
the operator or user is responsible for accidents or hazards occurring to other people or
their property.
1.3PREPARATION
1.3.1 Do not modify the FrontRunner cutting deck and only use on approved Exmark
machines.
1.3.2 The use of personal protective equipment, such as (but not limited to) protection for the
eyes, ears, feet, and head is recommended.
CAUTION
POTENTIAL HAZARD
♦This machine produces sound levels in excess of 85
dBA at the operator’s ear when in operation.
WHAT CAN HAPPEN
♦Exposure to sound levels of 85 dBA or above for
extended periods of time can cause hearing loss.
HOW TO AVOID THE HAZARD
♦Wear hearing protection when operating this machine.

2
1.3.3 While mowing, always wear substantial footwear and long trousers. Do not operate
equipment when barefoot or when wearing open sandals.
1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones,
sticks, wires, bones, and other foreign objects which may damage the equipment or
cause personal injury to the operator or bystanders.
1.4 OPERATION
Although hazard control and accident prevention are partially dependent upon the
design and configuration of the equipment, these factors are also dependent upon the
awareness, concern, prudence, and proper training of the personnel involved in the
operation, transport, maintenance, and storage of the equipment. It is essential that all
Operator Safety Mechanisms be connected and in operating condition prior to use for
mowing.
WARNING
POTENTIAL HAZARD
♦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.
1.4.3 Use EXTREME caution when backing up. LOOK BEHIND YOU!
1.4.4 Stop the blades when crossing surfaces other than grass and when transporting the
mower to and from the area to be mowed.
1.4.5 Never operate the mower with damaged guards, shields, or covers. Always have safety
shields, guards, switches, and other devices in place and in proper working condition.
1.5 MAINTENANCE AND STORAGE
1.5.1 Check all bolts frequently to maintain proper tightness.
1.5.2 Keep all guards, shields, and all safety devices in place and in safe working condition.
1.5.3 Frequently check for worn or deteriorating components that could create a hazard.
1.5.4 All replacement parts must be the same as or equivalent to the parts supplied as original
equipment.
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.

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1.6.4 New safety signs may be obtained from Exmark Mfg. Co. Inc.
1.6.5 Safety signs may be affixed by peeling off the backing to expose the adhesive surface.
Apply only to a clean, dry surface. Smooth to remove any air bubbles.
1.6.6 Familiarize yourself with the following safety signs and instruction labels. They are
critical to the safe operation of your Exmark commercial mower.
PART NO. 1-303508
LOCATION: On RH Side of Deck
by Discharge
PART NO. 1-643222
LOCATION: On Top of Deck
Between Sheaves
PART NO. 109-3148
LOCATION: On LH Front Side
of Deck by Chain
Mount
PART NO. 1-403005
LOCATION: On Top Front
Corners of Deck
PART NO. 98-5954
LOCATION: On Top of Deck,
Under Belt Covers
PART NO. 109-2993
LOCATION: On Front Frame
PART NO. 103-8425
LOCATION: 1) On Driveshaft
2) On LH side of Deck by
Gearbox Sheave
PART NO. 109-2354
LOCATION: On Top of LH & RH Belt Covers
PART NO. 1-633922
LOCATION: On Top Front
Center of Deck
PART NO. 109-2359
LOCATION: Top LH Rear Corner of Deck PART NO. 109-2376
LOCATION: Top RH Rear Corner of Deck

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2. SPECIFICATIONS
2.1 MODEL NUMBERS: FR524; FR604
2.2 DIMENSIONS
52” Deck 60” Deck
Overall Width (chute down)
Overall Width (chute up) 64.6” (164.1 cm) 53.9” (136.9 cm) 72.7” (184.7 cm) 61.4” (156.0 cm)
Overall Height 18.0” (45.7 cm) 18.0” (45.7 cm)
Overall Length 42.5” (108.0cm) 42.3” (107.4 cm)
Weight 393 lbs. (178 kg) 434 lbs. (197 kg)
2.3 TORQUE REQUIREMENTS
Bolt Location Torque
Blade Mounting Bolt...............................................................55-60 ft-lbs. (75-81 N-m)
Gearbox Mounting Bolts ........................................................16-18 ft-lbs. (22-24 N-m)
Drive Shaft Set Screw......................................................................18 ft-lbs. (24 N-m)
Drive Shaft Pinch Bolt...................................................................... 44 ft-lbs. (60 N-m)
Cutter Housing spindle Nut (secured with threadlocker) 140-145 ft-lbs. (190-197 N-m)
Anti-Scalp Roller – Whizlock Nut...........................................40-45 ft-lbs. (54-61 N-m)
3. ASSEMBLY INSTRUCTIONS
WARNING
POTENTIAL HAZARD
♦Operating a FrontRunner tractor without
an approved Exmark front mount
attachment increases the possibility of
forward tip over.
WHAT CAN HAPPEN
♦Tip-over could cause serious injury or
death.
HOW TO AVOID THE HAZARD
♦When operating a FrontRunner tractor
without an approved Exmark front mount
attachment, observe the following:
9Limit operation to minimum required to
install a different front mount
attachment.
9Minimize speed and use extreme
caution.
9Only operate on a flat level surface.
9Do not operate up or down a trailer
ramp.
9Avoid sudden acceleration or
deceleration.

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3.1 ASSEMBLE DECK TO FRONTRUNNER
IMPORTANT: Do not transport FrontRunner tractor without an approved Exmark front mount
attachment.
3.1.1 Stop engine, wait for all moving parts to stop and remove key. Engage parking brake.
3.1.2 Rotate the fold lock lever, located on the front frame, in the unlocked position. (See
Figure 1).
3.1.3 On the tractor, release the two retaining pins on the hitch latches so the latches can
actuate freely. Raise the floor pan and lock in upright position. (See Figure 2).
3.1.4 Align the front frame of the mower deck to the FrontRunner tractor lift cylinder section.
3.1.5 Manually lift up on the hitch to get the front frame started.
3.1.6 Push the front frame towards the tractor until the two hitch latches seat into the
“secure” position.
3.1.7 Insert the hitch latch retaining pins into the hitch pin lock. The deck is now locked onto
the tractor.
3.1.8 Reinstall key and turn switch to the “run” position. Do not start the engine.
3.1.9 Align the cylinder rod end to the top hole of the float link bracket and insert pin as
shown in Figure 3. Insert cotter hairpin to lock cylinder pin into place.
3.1.10 Retract the cylinder to fold the deck upward. Reattach weight transfer chains. It is
very important not to twist the chains. Lock the chains onto the pin by inserting the
cotter hairpin. (See Figure 4)
FIGURE 1 FIGURE 2
FIGURE 3 FIGURE 4

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3.1.11 Extend the cylinder fully until the caster wheels contact the ground and deck is in the
fully raised position. The fold lock levers should have reset and snapped into the
“locked” position. Lower the floor pan.
3.1.12 Connect the drive shaft by pushing back the spring loaded collar. Align and couple
drive shaft to splined drive shaft and release collar. (See Figure 5)
3.2 DECK REMOVAL
3.2.1 Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.
3.2.2 Disconnect the drive shaft by pulling back on the spring loaded collar and pulling away
from the splined shaft (See Figure 5). Lay the drive shaft on the ground.
3.2.3 Insert key and turn to the “run” position. Do not start the engine.
3.2.4 Extend the cylinder until the fold lock latches are unloaded, and then rotate them
toward the tractor.
3.2.5 Retract the cylinder and partially fold the deck just to the point where the weight
transfer chains go slack.
3.2.6 Pull out the hairpins and chain pins from the clevis bracket. Place the pin and cotter
hairpin on the chain and set aside.
3.2.7 Lower the deck by extending the cylinder until the deck folds down. The caster tires
should touch the ground.
3.2.8 The float link brackets will start to rotate forward and at this point, the cylinder can be
detached at the rod end by pulling the pin out of the bracket. Lift the cylinder out of the
way and position the rod end so that it rests on the buckle of the height indicator
bracket.
3.2.9 Remove the hitch latch pins from the hitch brackets. Raise the hitch latch above the
hole and insert pin. The top of the hitch latch should rest under the pin. (See Figure 7)
FIGURE 5 FIGURE 6
FIGURE 7

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3.2.10 Stand in front of the deck and pull the unit away from the tractor or back the tractor
away from the deck.
IMPORTANT: Do not transport FrontRunner tractor without an approved Exmark front mount
attachment.
4. MAINTENANCE & ADJUSTMENTS
WARNING
POTENTIAL HAZARD
♦While maintenance or adjustments are being made,
someone could start the engine.
WHAT CAN HAPPEN
♦Accidental starting of the engine could seriously injure
you or other bystanders.
HOW TO AVOID THE HAZARD
♦Remove the key from the ignition switch and pull the
wire(s) off the spark plug(s) before you do any
maintenance. Also push the wire(s) aside so it does not
accidentally contact the spark plug(s).
4.1 DECK RAISING AND LOWERING
4.1.1 Raising the Mower Deck into Service Position:
a) Stop engine, wait for all moving parts to stop, engage parking brake, and turn key
to “run” position. Do not start the engine.
WARNING
POTENTIAL HAZARD
♦Incorrectly raising or lowering a mower deck can be
dangerous.
WHAT CAN HAPPEN
♦A dropped mower deck can result in a serious injury or
property damage.
HOW TO AVOID THE HAZARD
♦Always raise and lower deck on flat, dry ground, free of
any obstructions.
♦Always make sure the deck is securely latched in the
“up” or “down” position.
b) Fully extend the cylinder to unload the fold lock levers.
c) Rotate the fold lock levers, located on each side of the deck, to the unlocked position.
(See Figure 1)
d) Retract the cylinder and the deck will fold to approximately 50 degrees.

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WARNING
POTENTIAL HAZARD
♦Operating the mower in the raised service position can
be dangerous.
WHAT CAN HAPPEN
♦Engaging the PTO with a deck in the raised position can
result in a serious injury or property damage.
HOW TO AVOID THE HAZARD
♦Always lower and lock mower deck in the operation
position before engaging the PTO.
4.1.2 Raising the Mower Deck into Storage Position:
a) Stop engine, wait for all moving parts to stop, engage parking brake, and turn key to
“run” position. Do not start the engine.
b) Flip up the floor pan and remove full fold pin. Retract the cylinder to align holes in
float link bracket with holes in front frame. (Deck will be at or near lowest height.)
Insert into the bottom hole of the float link bracket (see Figure 8). Lower the floor pan.
FIGURE 8
WARNING
POTENTIAL HAZARD
♦Folding the mower deck with the floor pan in locked
position may be dangerous.
WHAT CAN HAPPEN
♦Hooks will not automatically drop in the slots on the
front cover.
HOW TO AVOID THE HAZARD
♦Make sure the floor pan is not locked in the upright
position.
c) Fully retract cylinder. The deck will fold to an approximate 70 degree angle.

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WARNING
POTENTIAL HAZARD
♦Driving the mower deck in the folded service position
can be dangerous.
WHAT CAN HAPPEN
♦The mower can tip forward.
HOW TO AVOID THE HAZARD
♦Always lower and lock mower deck in the operation
position before driving.
4.1.3 Lowering the Mower Deck to the Operation Position:
a) Make certain that you and any observers are clear of the deck.
b) Raise the floor pan to the locked position as shown in Figure 8.
c) Extend the cylinder until the front caster wheels just touch the ground.
d) If the full fold pin was used when the deck was folded, remove it from the float link
and place it in the storage location under the floor pan.
e) Fully extend the cylinder until it stops. Confirm that the latches are in the locked
position.
f) Retract the cylinder until the deck lowers to the desired cut height reading shown on
the height indicator bar.
WARNING
POTENTIAL HAZARD
♦Operating mower without locking latches securely
latched can result in the mower deck folding up
unexpectedly.
WHAT CAN HAPPEN
♦The mower deck folding up unexpectedly can cause
serious injury.
HOW TO AVOID THE HAZARD
♦Always operate mower with locking latches securely
latched.
4.1.4 Cutting Height Adjustment:
a) Stop engine, wait for all moving parts to stop, engage parking brake, and turn key to
“run” position. Do not start the engine.
b) Adjust cylinder for height of cut desired.
4.2 PERIODIC MAINTENANCE
4.2.1 Clean grass build-up under deck.
Service Interval: Daily
a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking
brake.
b) Fold mower deck and secure in latched position. See section 4.1.1, Raising the
Mower Deck to the Service Position.
c) Clean out any grass build-up from underside of deck and in discharge chute.

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d) Lower deck to cutting position and lock deck locking pins. See section 4.1.3,
Lowering the Mower Deck to the Operation Position.
4.2.2 Check mower blades.
Service Interval: Daily
a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking
brake.
b) Fold deck and secure in raised position as stated in Section 4.1.1, Raising the Mower
Deck to the Service Position.
c) Inspect blades and sharpen or replace as required.
d) Reinstall the blades (if they were removed) in the following order (See Figure 9):
FIGURE 9
d) Install bushing through blade with bushing flange on bottom (grass) side of
blade.
e) Install bushing/blade combo into spindle.
f) Install blade bolt and spring disc washer. Be sure the spring disc washer cone is
installed towards the bolt head. Place a block of wood between front or rear
baffles and the blade then torque the blade bolts to 55-60 ft-lbs. (75-81 N-m).
g) Lower the mower deck to the operation position. See section 4.1.3, Lowering the
Mower Deck to the Operation Position.
IMPORTANT: DO NOT use components other than the original blade, blade bushing,
spring disc washer, and blade bolt supplied with the unit. Failure to use all original
components and assembled as shown will increase the risk of a blade bolt becoming
loose or weak after striking a foreign object.
CAUTION
POTENTIAL HAZARD
♦Operating a mower deck with loose or weakened blade
bolts can be dangerous.
WHAT CAN HAPPEN
♦A loose or weakened blade bolt could allow a blade
rotating at a high speed to come out from under the
deck, causing serious injury or property damage.
HOW TO AVOID THE HAZARD
♦Always reinstall original Exmark blades, blade
bushings, spring disc washers, and blade bolts in the
correct positions as shown.

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4.2.3 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 the unit.
4.2.4 Check tire pressures:
The front caster tires are semi-pneumatic and do not need to be inflated.
NOTE: Do not add any type of tire liner or foam fill material to the tires.
Excessive loads created by foam filled tires may cause failures to the hydro drive
system, frame, and other components. Foam filling tires will void the warranty.
4.2.5 Lubricate grease fittings:
Service Interval: Refer to chart.
a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking
brake.
b) Lubricate fittings with one to two pumps of NGLI grade #2 multi-purpose gun
grease.
Refer to the following chart for fitting locations and lubrication schedule.
GREASE FITTING LUBRICATION CHART
FITTING
LOCATIONS INITIAL PUMPS NO. of PLACES SERVICE INTERVAL
1. Drive Shaft 1 3 40 hours
2. Deck Flip-Up 1 2 100 hours
3. Front Caster Wheel Hub 1 2 8 hours
4. Caster Pivots *0 2 *Yearly
5. Height Adj. Shaft Bearings 1 4 40 hours
6. Deck Drive Belt Idler Arm 1 1 Yearly
*See 4.2.5 Section c) for special lubrication instructions on
the front caster pivots.
c) Lubricate front 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.
4.2.6 Change gearbox oil:
Change oil in gearbox housing after first 50 hrs of operation. Check every 100
hours thereafter. Add oil as needed until level with oil drain plug.
a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking
brake.
b) Place unit on a level surface.
FIGURE 10

12
c) Remove the gearbox and drive shaft assembly from the mower deck. Retain
hardware for re-use.
d) Remove the oil drain plug on the side of the gearbox section and drain oil. (See
Figure 11)
FIGURE 11
e) Reinstall the gearbox and drive shaft assembly to the mower deck.
f) Fill gearbox with Mobil SHC (synthetic) 75W-90 gear lube oil until level with oil
drain/fill plug. NOTE: Mower deck should remain level to the ground when filling
gearbox with oil. Do not fill gearbox with deck raised in the service position.
g) Apply a Teflon pipe sealant to the oil plug and re-install into the gearbox.
4.3 ADJUSTMENTS
IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop, and
remove key before servicing, cleaning, or making any adjustments to the unit.
4.3.1 Anti-Scalp Roller Adjustment:
a) Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of
the positions shown in Figure 12. Rollers will maintain 3/4 in. (19 mm) clearance
to the ground to minimize gouging and roller wear or damage.
For Maximum Deck Flotation, place rollers one hole position lower. Rollers
should maintain 1/4 in. (6.4 mm) clearance to ground. DO NOT adjust rollers to
support the deck. Be sure roller bolts and nuts are installed with the spring disc
washer between head of the bolt and mounting bracket. Torque the 3/8
whizlock nut to 40-45 ft-lbs. (54-61 N-m)
FIGURE12
b) When operating in extremely rough conditions it may be necessary to position
the anti-scalp rollers one or two holes higher than described in a) to prevent
damage to the rollers and/or belt failure.

13
NOTE: When anti-scalp rollers are placed in these positions, reduced deck
floatation will result.
4.3.2 Deck Leveling:
a) Position mower on a flat surface.
b) Stop engine, wait for all moving parts to stop. Engage parking brake.
c) Check tire pressure in drive tires.
For Units Equipped With Turf Tires: The drive tires should be inflated to
13 psi (90 kpa).
For Units Equipped With Bar-Lug Tires: The drive tires should be inflated to
9 psi (62 kpa).
d) Fully extend the cylinder to raise the deck as high as it will go (this is also the
transport position). Note the position of the cut height indicator. Adjust the
indicator if necessary so that the indicator is pointing to the 5" cut height mark.
See Figure 13.
FIGURE 13
e) Lower the deck to the 4" cut height position and remove ignition key. Orient the
blades longitudinally with respect to the machine. Stand a wooden block
approximately 5” long next to the front blade tip of the center blade; mark the
location of the blade tip on the block. Remove the block and measure height on
the block, it should be 4”. Repeat this process for the rear blade tip of both the
left and right blades, those should measure 4-1/4” to give the recommended 1/4”
positive rake. See Figure 14.
FIGURE 14
f) If adjustments are necessary, four socket head 5/16-18 x 1-1/4 screws have
been provided in the literature bag. Install these screws into the deck lift arms
until they touch the hex head deck chain screws. Loosen the top chain screws in
slots in the deck lift arms (See Figure 15). Turn the socket head screws to move

14
the deck chain screws up and down to correct the cut heights measured above.
Tighten the chain bolts in the deck lift arms making sure they don’t move while
tightening.
g) Recheck the cut heights and that the tension on all the chains is approximately
equal. Make sure all chain attachment bolts are tight. Remove the 4 socket
head screws and return back to the literature bag.
\
FIGURE 15
4.3.3 Caster pivot bearings pre-load adjustment:
a) Remove dust cap from caster and tighten nyloc
nut until washers are flat. Back the nyloc off 1/4
of a turn to properly set the pre-load on the
bearings.
Note: If disassembled, make sure the spring
washers are reinstalled as shown in Figure 16.
FIGURE 16

15
5. PARTS LIST
5.1 FR524 DECK GROUP
Item Part No. Description Qty.
1 1-303334 Washer, Spring Disk 5/16 ......................1
2 1-303508 Decal, Discharge Warning .....................1
3 1-322110 Wld, Belt Guide......................................1
4 1-323385 Knob, 3 Prong........................................4
5 1-373034 Washer..................................................2
6 1-403005 Decal, Danger........................................2
7 32128-20 Nut, Whizlock 5/16-18............................6
8 1-602913-01 Wld, Baffle Discharge............................1
9 1-603805 Sheave, Idler..........................................1
10 1-633109 Sheave, Flat Idler...................................2
11 1-633366 Belt ........................................................1
12 1-633456 Bushing, Idler.........................................2
13 1-633922 Decal, Anti-Scalp ...................................1
14 1-643222 Decal, Belt Routing................................1
15 63-8410 Washer..................................................4
16 98-5954 Decal, Danger........................................3
17 98-5961 Screw, HH 3/8-16 X 4 Gr8......................1
18 98-5975 Washer, Spring Disk 3/8........................3
19 103-1145 Decal, Ultracut 52..................................1
20 32120-10 Ring, Retaining......................................2
21 103-2916 Guard, Top.............................................1
22 103-3330 Spring, Extension...................................1
23 103-3504 Bearing, Spherical..................................2
24 103-3505 Seal, Double Lip.....................................1
Item Part No. Description Qty.
25 103-3506 Seal, Single Lip......................................1
26 103-3900 Spacer, Strut .........................................4
27 103-5677 Spacer...................................................1
28103-5693 Asm, Deck Idler.....................................1
29 3296-39 Nut, Nyloc 3/8-16...................................3
30 109-3148 Decal, Bolt Torque.................................1
31 103-8425 Decal, Driveline .....................................1
32 106-7159 O-Ring...................................................2
33 109-4383 Asm, Fmz524 Deck W/Decals...............1
34 109-2393 Asm, Belt Shield W/Decal......................2
35 109-2354 Decal, Crushing Hazard.........................2
36 109-2359 Decal, Deck Warning.............................1
37 109-2376 Decal, Crushing Hazard.........................1
38 109-2985 Strip, Seal, 2".........................................4
39 302-40 Zerk, 90° 1/4-28.....................................1
40 322-2 Screw, HH 5/16-18 x 5/8........................5
41 322-5 Screw, HH 5/16-18 x 1...........................1
42 323-12 Screw, HH 3/8-16 x 2 1/2.......................2
43 323-20 Screw, HH 3/8-16 x 3-1/4.......................2
44 3234-11 Screw, HH FLG 3/8-16 x 1.....................1
45 3256-24 Washer, 3/8 SAE...................................3
46 3256-4 Washer, 3/8 Std.....................................2
47 3290-357 Nut, Whizlock 3/8-16 .............................2
48X109-4382 Asm, Deck Complete.............................1
Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).
Kit also includes items #18 & #29.
XComplete deck assembly includes all items from pages 15 & 16 except drive shaft assembly, drive shaft
assembly hardware, deck chain, and deck chain hardware on page 16.