Exmark Lawn Mower 4500 341 User Manual

FRONTRUNNERTM  
AIR-COOLED MODELS  
For Serial Nos.  
790,000 & Higher  
Part No. 4500-341 Rev. A  
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READ OPERATOR’S MANUAL BEFORE  
OPERATING OR SERVICING EXMARK EQUIPMENT.  
TABLE OF CONTENTS  
Description  
Page  
Auxiliary Hydraulic Group ................................................. 14  
Decals .............................................................................. 22  
Electrical Diagram 27HP................................................... 18  
Electrical Diagram 31HP................................................... 19  
Electrical Logic Schematic 27HP...................................... 20  
Electrical Logic Schematic 31HP...................................... 21  
Electrical Group................................................................ 17  
Engine Group 27HP ......................................................... 12  
Engine Group 31HP.......................................................... 13  
Fuel Group........................................................................ 11  
Hydraulic Group...........................................................15-16  
Main Frame Group...........................................................3-6  
Motion Control Group ....................................................... 10  
Park Brake Group............................................................... 9  
PTO Drive Group................................................................ 8  
Rear Frame Group.............................................................. 7  
2
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MAIN FRAME GROUP  
Item  
DESCRIPTION  
Qty.  
Item  
27 107-3155  
28 109-3633-03 Spacer, Seat Mount............................... 2  
DESCRIPTION  
Qty.  
Part No.  
Part No.  
1
2
3
1-323142  
109-2365  
109-3478  
109-3156  
103-6771  
1-633859  
1-803035  
98-5975  
Nut, Push 1/2.........................................2  
Bumper..................................................4  
Asm, Wheel & Tire (RH) ........................1  
Wheel ....................................................1  
Tire, 24x12-12 4 Ply...............................1  
Frame, Seat...........................................1  
Rivet 3/16 x 1/4......................................9  
Washer, Spring Disc 3/8 ........................8  
Cushion, Armrest LH..............................1  
Cushion, Armrest RH.............................1  
Decal, Exmark Logo...............................2  
Seat, Back .............................................1  
Asm, ROPS Fold Pin .............................2  
Spacer, Seat Track ................................2  
Screw, HWH 1/4-20 x 3/4 Taptite...........11  
Link, Seat Stop ......................................2  
Asm, Seat Frame...................................1  
Cotter, Hair Pin Double Loop................. 2  
29 3296-7  
30 109-0768  
31 109-3547  
32 109-2008  
33 109-2009  
34O 109-2005  
35 109-2360  
36 3256-14  
37 3296-39  
38 116-1003  
39 110-0883  
40 242-50  
41 283-69  
42 322-5  
Nut, Nyloc 7/16-20................................. 2  
Skirt, Rubber.......................................... 1  
Asm, Front Console W/Decal ................ 1  
Cushion, Seat Bottom/W Switch............ 1  
Grp, Seat Track ..................................... 1  
Asm, Seat W/Decal ............................... 1  
Decal, Top Console ............................... 1  
Washer, #10 Std.................................... 9  
Nut, Nyloc 3/8-16................................... 4  
Decal, Service Aid ................................. 1  
Kit, Seatbelt........................................... 1  
Nut, Lug 1/2-20...................................... 8  
Pin, Clevis 1/2 x 3 1/2............................ 2  
Screw, HH 5/16-18 x 1........................... 8  
Screw, HH 5/16-18 x 1 1/2..................... 2  
Screw, HH 3/8-16 x 1............................. 2  
Screw, HH 3/8-16 x 1 1/2....................... 8  
Screw, HH 3/8-16 x 1 3/4....................... 2  
Screw, HH 7/16-20 x 1........................... 2  
Nut, Nyloc 5/16-18................................. 4  
Washer, 5/16 Std................................... 6  
Washer, 3/8 Std..................................... 1  
Nut, Whizlock 3/8-16 ............................. 8  
Asm, Wheel & Tire (LH)......................... 1  
Wheel.................................................... 1  
Tire, 24x12-12 4 Ply............................... 1  
4
5
6
7
8
9
103-0291  
103-0292  
103-2882  
10 103-3520  
11Q 103-4553  
12 1-543401  
13 103-8383  
14 103-5161  
15103-6761  
43 322-7  
16 103-6765-03 Latch, Seat ............................................1  
44 323-6  
17 32128-33  
18 9264964  
19 32128-20  
20 3296-73  
21 103-8316  
22 103-8826  
23 103-6761  
24 1-633080  
25X 109-2817  
26 107-2102  
Nut, Whizlock 1/4-20..............................2  
Bolt, HWH 5/16-18 x 3/4 Tap .................4  
Nut, Whizlock 5/16-18............................16  
Nut, Nyloc 1/4-20 ...................................2  
Spring ....................................................1  
Link, Lower Seat Stop............................2  
Plate, Seat Mount ..................................1  
Bushing..................................................2  
Kit, ROPS ..............................................1  
Decals, Warning ....................................1  
45 323-8  
46 323-9  
47 3212-4  
48 3296-29  
49 3256-3  
50 3256-4  
51 3290-357  
52 109-3479  
109-3156  
103-6771  
Exmark black touch up spray paint – Gloss black  
Q
Includes ROPS fold pin plus hairpin, item #27.  
X
Rollover protection frame is serviced as a complete assembly only. Includes complete ROPS frame, mounting  
hardware, fold pivot and locking hardware, seat frame assembly item #15 and seat belt assembly item #39.  
Includes armrests and seat back decal. Does not include seat belt or tracks.  
Does not include item #19 or #48.  
O
3
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MAIN FRAME GROUP  
4
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MAIN FRAME GROUP (cont.)  
Item  
DESCRIPTION  
Qty.  
Item  
31 109-0634  
DESCRIPTION  
Qty.  
Part No.  
Part No.  
1
2
3
4
5
6
7
8
9
1-513747  
1-523157  
1-643189  
1-643339  
1-806003  
1-806005  
1-808285  
5-0652  
Decal, Battery ........................................1  
Washer..................................................4  
Keeper, Rubber Latch............................2  
Belt Routing, Decal ................................1  
Hairpin, Cotter........................................2  
Hairpin, Cotter........................................1  
Pin, Clevis 3/8 x 1 1/8 ............................2  
Spacer ...................................................4  
Pin .........................................................2  
Decal, Warning ......................................2  
Decal, Danger........................................1  
Pin .........................................................2  
Tube, Pump Link Spacer .......................2  
Ring, Retaining ......................................4  
Decal, 3750 RPM...................................1  
Decal, Guard..........................................2  
Decal, Pump Fan Warning.....................1  
Asm, Frame W/Decals...........................1  
Latch, Hitch............................................2  
Decal, Danger........................................1  
Bumper, Rubber.....................................2  
Asm, Hitch .............................................1  
Wld, Spring Anchor................................ 4  
32 109-1256-03 Arm, Pivot.............................................. 2  
33 109-1257-03 Hook, Hood............................................ 2  
34 109-3197  
35 109-2857  
36 109-6070  
37 109-2004  
38 32128-20  
39 109-2355  
40 109-2356  
41 109-2357  
42 109-2396  
43 302-19  
Hood, W/Decal ...................................... 1  
Asm, Hood............................................. 1  
Asm, Hood Support W/Decals .............. 1  
Roller, Lock Lever.................................. 2  
Nut, Whizlock 5/16-18 ........................... 4  
Decal, Spring Loaded ............................ 2  
Decal, Motion Control ............................ 1  
Decal, Motion Cntl/Park Brake............... 1  
Decal, Pump Drive Release................... 1  
Zerk, 1/4-28 Str...................................... 2  
Screw, HH 5/16-18 x 3/4........................ 4  
Screw, HH 5/16-18 x 7/8........................ 8  
Screw, HH 3/8-16 x 2 1/4....................... 2  
Screw, HH 3/8-16 x 1 1/2....................... 2  
Screw, HH 1/2-13 x 4 1/2....................... 2  
Ring, Retaining...................................... 4  
Washer, 5/16 SAE................................. 20  
Washer, 3/8 SAE................................... 4  
Washer, 1/2 SAE................................... 8  
Washer, 5/8 SAE................................... 2  
Rivet ...................................................... 4  
Nut, Nyloc 1/2-13................................... 2  
Nut, Nyloc 5/16-18................................. 8  
Nut, Nyloc 3/8-16................................... 4  
E-Ring ................................................... 2  
Decal, FrontRunner ............................... 1  
93-2699  
10 98-4361  
11 98-5954  
12 100-1663  
13 103-1166  
14 32151-36  
15 103-3270  
16 103-5881  
17 103-7218  
18 109-6069  
19 103-9727  
20 107-2112  
21 107-8042  
22 109-0075  
44 322-3  
45 322-4  
46 323-11  
47 323-8  
48 325-18  
49 32120-47  
50 3256-23  
51 3256-24  
52 3256-26  
53 3256-27  
54 3269-24  
55 3296-23  
56 3296-29  
57 3296-39  
58 32120-19  
59 109-2114  
23 109-0080-03 Wld, Hitch..............................................1  
24 109-0325  
25 109-0411  
26 109-0435  
27 109-0450  
28 109-2772  
29 109-2773  
30 109-2774  
Pin, Full Fold..........................................1  
Spring ....................................................2  
Bushing..................................................4  
Asm, Spring...........................................2  
Asm, Floorpan W/Decal.........................1  
Asm, Spring Bellcrank W/Decal (RH).....1  
Asm, Spring Bellcrank W/Decal (LH) .....1  
Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).  
Exmark black touch up spray paint – Gloss black  
5
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MAIN FRAME GROUP (cont.)  
6
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REAR FRAME GROUP  
Item  
Description  
Qty.  
Item  
Description  
Qty.  
Part No.  
Part No.  
1
2
3
4
5
6
7
8
9
1-513746  
1-543508  
1-543509  
1-543511  
1-633508  
1-633585  
1-643188  
1-811010  
103-0063  
Decal, Muffler.........................................2  
Cup, Bearing Tapered Roller..................4  
Cone, Bearing Tapered Roller................4  
Seal, Grease..........................................2  
Washer, Spring Disc..............................6  
Bearing, Cone Tapered Roller................4  
Latch......................................................2  
Plug .......................................................2  
Seal, Double Lip.....................................4  
Guard, Seal............................................4  
Spacer, Nut............................................4  
Rivet ......................................................4  
Asm, Caster Wheel................................2  
Cap, Grease ..........................................2  
Axle, Caster ...........................................2  
Bearing, Sleeve......................................2  
22 103-9868-03 Wld, Caster Fork ................................... 2  
23 103-9974  
24 105-7699  
25 109-2769  
109-6071  
Washer.................................................. 1  
Strip, Seal.............................................. 2  
Asm, Rear Guard W/Decals (27 HP) ..... 1  
Asm, Rear Guard W/Decals (31 HP) ..... 1  
26 109-0414-03 Cover, Muffler (27 HP)........................... 1  
109-5580-03 Cover, Muffler (31 HP)........................... 1  
27 302-19  
28 322-3  
Zerk, 1/4-28 Str...................................... 1  
Screw, HH 5/16-18 x 3/4........................ 5  
Screw, HH 3/8-16 x 1............................. 4  
Screw, HH 1/2-13 x 9 1/2....................... 2  
Screw, HH 1/2-13 x 1 1/4....................... 6  
Screw, HH 5/8-11 x 5 3/4....................... 1  
Washer, 5/16 SAE................................. 5  
Washer, 3/8 Std..................................... 2  
Nut, Whizlock 3/8-16 ............................. 4  
Nut, Nyloc 1/2-13................................... 2  
Nut, Nyloc 3/4-10................................... 2  
Nut, Nyloc 5/8-11................................... 1  
Nut, Whizlock 5/16-18 ........................... 5  
Nut, Whizlock 1/2-13 ............................. 6  
10 103-2768  
11 103-3051  
12 923786  
29 323-6  
30 325-39  
31 325-5  
13 109-9127  
14 103-4882  
15 103-5156  
16 103-6825  
32 327-24  
33 3256-23  
34 3256-4  
35 3290-357  
36 3296-23  
37 3296-51  
38 3296-53  
39 32128-20  
40 32128-49  
17 103-7957-03 Wld, Dual Caster Tube...........................1  
18 103-8347 Asm, Dual Rear Wheels.........................1  
19 103-9045-03 Wld, Rear Frame Dual Wheel................1  
20 103-9051 Bearing, Thrust ......................................2  
21 103-9789-03 Guard, Hose ..........................................1  
Exmark black touch up spray paint – Gloss black  
7
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PTO DRIVE GROUP  
Item Part No.  
1-413088  
2V 1-803050  
DESCRIPTION  
Qty.  
Item Part No.  
18 103-8073  
DESCRIPTION  
Qty.  
1
Spacer ...................................................1  
Setscrew, 5/16-18 x 3/4 .........................2  
Bolt, Carriage 3/8-16 x 2 3/4 ..................1  
Key, Machine 1/4 x 1/4 x 2.....................1  
Bearing, Flanged....................................2  
Washer, Spring Disc 3/8 ........................5  
Guard, Top.............................................2  
Spring, Extension...................................1  
Bearing, Spherical..................................2  
Seal, Single Lip......................................2  
Ring, Retaining ......................................2  
Asm, Pump Idler....................................1  
Asm, Linedrive Idler............................... 1  
19 103-8366-03 Guard, Linedrive .................................... 1  
3
4
5
6
7
8
9
1-807525  
5-1336  
20 109-7588  
21 106-7159  
Belts, Matched Pair ............................... 1  
O-Ring................................................... 2  
92-8799  
98-5975  
103-2916  
116-0133  
103-3504  
22 109-0431-03 Arm, Idler............................................... 1  
23 251-347  
24 302-40  
25 323-10  
26 323-16  
27 323-6  
Bearing, Ball Deep Groove .................... 1  
Zerk, 90° 1/4-28..................................... 1  
Screw, HH 3/8-16 x 2............................. 1  
Screw, HH 3/8-16 x 4............................. 1  
Screw, HH 3/8-16 x 1............................. 4  
Screw, HH 3/8-16 x 1 1/4....................... 3  
Screw, HH 3/8-16 x 1 1/2....................... 1  
Screw, HH 3/8-16 x 1 3/4....................... 4  
Nut, Jam 3/8-16..................................... 1  
Washer, 3/8 Std..................................... 1  
Nut, Whizlock 3/8-16 ............................. 15  
Ring, Retaining...................................... 2  
10 103-3506  
11 32151-13  
12 103-6409  
28 323-7  
29 323-8  
13 103-6779-03 Shaft, Line .............................................1  
30 323-9  
14 103-6813  
15 103-6814  
16 103-6836  
17 103-8012  
Pulley, Idler............................................1  
Sheave ..................................................1  
Spacer ...................................................1  
Spacer, Spring.......................................1  
31 3218-3  
32 3256-4  
33 3290-357  
34 32120-10  
Exmark black touch up spray paint – Gloss black  
V
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on setscrew, item #2.  
8
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PARK BRAKE GROUP  
Item Part No.  
DESCRIPTION  
Qty.  
Item Part No.  
DESCRIPTION  
Qty.  
1
2
3
4
5
6
7
8
9
1-633102  
323-4  
Bearing, Flanged....................................2  
Screw, HH 3/8-16 x 3/4..........................4  
Nut, Whizlock 3/8-16..............................9  
Spacer ...................................................2  
Washer, 3/8 Std.....................................6  
Grommet................................................4  
Screw, HH 5/16-18 x 1 3/4 .....................2  
Nut, Nyloc 5/16-18 .................................4  
Screw, HH 5/16-18 x 1 1/4 .....................2  
Bushing..................................................2  
Washer, 5/16 Std...................................2  
Asm, Brake Linkage...............................2  
15 1-513140  
16 103-0608  
17 103-4399  
18 3219-3  
Bearing.................................................. 2  
Balljoint.................................................. 1  
Rod, Linkage Brake ............................... 1  
Nut, Hex 3/8-24...................................... 1  
Washer, 3/8 SAE................................... 1  
Pin, Cotter 1/8 x 3/4............................... 1  
Screw, HH 3/8-16 x 1 1/4....................... 1  
Ring, Retaining...................................... 1  
Grip, Brake Lever................................... 1  
Spring.................................................... 2  
Link, Brake ............................................ 2  
Clevis, Brake ......................................... 2  
Asm, Brake Lever W/Grip & Bearings.... 1  
Screw, HH 3/8-16 x 5............................. 2  
3290-357  
109-0262  
3256-4  
19 3256-24  
20 3272-10  
21 323-7  
1-633630  
322-9  
3296-29  
322-6  
22 32120-47  
23 1-633268  
24 103-4388  
25 109-0130  
26 109-0131  
27 109-1192  
28 323-39  
10 103-0126  
11 3256-3  
12 109-0132  
13 103-8625-03 Wld, Brake Cross Shaft .........................1  
14 3296-59 Nut, Nyloc 3/8-16 Thin ...........................2  
Exmark black touch up spray paint – Gloss black  
9
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MOTION CONTROL GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
1-303105  
1-323245  
1-403180  
1-543017  
1-603735  
1-603737  
1-603807  
1-633102  
1-633152  
Yoke, Adjustable....................................2  
Spring, Compression .............................2  
Screw, HH 5/16-18 X 1 1/4 Sp ...............4  
Balljoint..................................................2  
Bushing, Flanged...................................2  
Bolt, Neutral Return ...............................2  
Spring ....................................................2  
Bearing, Flanged....................................4  
Balljoint, (LH) .........................................2  
Setscrew, 5/16-18 X 5/8.........................2  
Nut, Hex 5/16-24 (LH)............................4  
Pin, Clevis 5/16 X 1................................2  
Washer, Spring Disc 3/8 ........................6  
Spacer ...................................................2  
Asm, Handle W/Grip (LH) ......................1  
Asm, Handle W/Grip (RH)......................1  
Grip, Control Lever.................................2  
Wld, Lever Control (LH) .........................1  
Wld, Lever Control (RH).........................1  
Tab, Motion Cntrl ...................................2  
21 109-3618  
22 3290-357  
23 3296-29  
24 32128-20  
25 106-5335  
Wld, Control Shaft ................................. 2  
Nut, Whizlock 3/8-16 ............................. 8  
Nut, Nyloc 5/16-18................................. 4  
Nut, Whizlock 5/16-18 ........................... 8  
Washer, Wave....................................... 6  
26 103-8286-03 Wld, Pump Ctrl (RH) ............................. 1  
27 103-8285-03 Wld, Pump Ctrl (LH) .............................. 1  
28 103-8300  
29 109-2339  
30 322-12  
31 322-6  
Link, Tracking Rod................................. 2  
Damper, Motion Control......................... 2  
Screw, HH 5/16-18 X 2 1/2 .................... 2  
Screw, HH 5/16-18 X 1 1/4 .................... 2  
Screw, HH 3/8-16 X 3/4 ......................... 10  
Screw, HH 3/8-16 X 1 ............................ 4  
Nut, Hex 5/16-18.................................... 4  
Nut, Hex 5/16-24.................................... 6  
Nut, Jam 5/16-24................................... 6  
Washer, 1/4 Std..................................... 2  
Pin, Cotter 3/32 X 1/2 ............................ 2  
Asm, Tracking Rod................................ 2  
10V 1-803022  
11 1-804524  
12 1-808280  
13 98-5975  
14 103-1361  
15 103-3457  
16 103-3458  
17 103-3456  
18 109-3623  
19 109-3622  
20 103-8262  
32 323-4  
33 323-6  
34 3217-6  
35 3219-2  
36 3220-2  
37 3256-2  
38 3272-5  
39 109-2582  
Exmark black touch up spray paint – Gloss black.  
V
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on screw, item #10 & screw, item #32 going into control shaft  
weldment item #21.  
10  
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FUEL GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
1-303077  
1-303334  
1-323385  
109-7416  
Clamp, Fuel Line....................................4  
Washer, Spring Disc 5/16 ......................2  
Knob, 3 Prong........................................1  
Control, Choke.......................................1  
Part No. 2405010 Fuel Filter..................1  
Part No. 695327 Fuel Filter....................1  
Valve, Fuel.............................................1  
Stud, Fuel Tank .....................................4  
Spring, Compression .............................4  
Washer, Lock 5/16 Heavy......................2  
Bolt, Carriage #10-24 x 1/2 ....................4  
Grommet................................................1  
Fitting, Fuel Bulkhead W/Strainer ..........1  
O-Ring ...................................................1  
Decal, Console ......................................1  
Control, Throttle.....................................2  
15 109-0303  
16 109-0346  
17 109-4714  
18 3296-2  
Hose, Fuel Line 7" ................................. 2  
Cap, Fuel (Gas)..................................... 1  
Console ................................................. 1  
Nut, Nyloc #10-24.................................. 4  
Nut, Nyloc 5/16-18 Thin......................... 6  
Hook, Fender......................................... 1  
Gauge, Fuel........................................... 1  
Asm, Fender.......................................... 1  
Asm, Fuel Tank ..................................... 1  
Bracket, Fender..................................... 1  
Bolt, Fender........................................... 1  
Screw, PPH #10-24 x 1/2....................... 4  
Screw, HH 5/16-18 x 3/4........................ 4  
Decal, Ignition........................................ 1  
Washer, 5/16 SAE................................. 11  
5Kohler  
19 3296-47  
20 109-1202  
21 109-1213  
22 109-1226  
23 109-3627  
24 109-2572  
25 109-2652  
26X 109-2661  
27 322-3  
Briggs  
6
1-603770  
7Q 1-633023  
8
9
1-633349  
1-805005  
10 1-807513  
11 95-8972  
12V 103-2605  
103-2784  
28 109-2358  
29 3256-23  
13 109-7413  
14 109-7415  
Exmark black touch up spray paint – Gloss black  
Q
V
X
Use Pro-Lock, Retaining Type (P/N 1-840023, .5ml tube) on stud threads, item #7 going into the tank.  
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on fuel fitting, item #11.  
Refer to Engine Owner’s Manual (Fuel Filter Must be 15 Micron or smaller).  
Snug fit only on slotted holes, Do Not Overtighten, tank must be able to expand.  
11  
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ENGINE GROUP 27HP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
1-603610  
1-633179  
1-653291  
Washer, Spring Disc 7/16 ......................2  
Spacer ...................................................1  
Gasket, Exhaust Manifold ......................2  
Setscrew, 5/16-18 x 3/4 .........................2  
Washer, Lock 5/16 Heavy......................4  
Key, Machine 1/4 x 1/4 x 1 1/4...............1  
Rod, Belt................................................1  
Plug, Oil Drain........................................1  
Washer, Spring Disc 3/8 ........................5  
Keeper, Clutch.......................................1  
Kit, Cable Heat Shield............................1  
Kit, Clutch ..............................................1  
Sheave ..................................................1  
Kit, Muffler .............................................1  
Hub, Adapter..........................................1  
Asm, Hose Oil Drain W/Plug..................1  
17 109-1830-03 Bracket, Air Cleaner............................... 1  
18 321-4  
19 322-3  
Screw, HH 1/4-20 x 3/4.......................... 1  
Screw, HH 5/16-18 x 3/4........................ 2  
Screw, HH 5/16-18 x 1........................... 3  
Screw, HH 3/8-16 x 2............................. 4  
Screw, HH 3/8-16 x 1............................. 1  
Screw, HH 7/16-14 x 3/4........................ 2  
Screw, HH 7/16-20 x 1 1/4..................... 1  
Washer, Lock 7/16................................. 2  
Washer, 3/8 Std..................................... 1  
Nut, Whizlock 3/8-16 ............................. 4  
Nut, Whizlock 5/16-18 ........................... 2  
Nut, Whizlock 1/4-20 ............................. 1  
Nut, Hex M8-1.25................................... 4  
Kit, Cable Heat Shield............................ 1  
4V 1-803050  
20V 322-5  
21V 323-10  
22 323-6  
5
6
7
1-805005  
13-2840  
52-4780  
23 324-2  
8109-1012  
98-5975  
24V 3212-5  
25 3253-6  
26 3256-4  
27 3290-357  
28 32128-20  
29 32128-33  
30 33014-00  
31O 103-3535  
9
10 103-0152  
11 103-3535  
12 109-6627  
13 103-6774  
14X 103-7480  
15 103-8813  
16 109-2987  
Exmark black touch up spray paint – gloss black.  
V
X
O
Use a Teflon Pipe Sealant or equivalent on threads.  
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on screws, item #4, #20, #21 & #24  
Includes item #3.  
Includes item 29  
Replacement Parts List  
(Refer to Engine Owner’s Manual)  
Description  
Kohler Part No.  
Engine Oil Filter....................................5205002-S  
Engine Air Filter....................................2508301  
Safety Filter..........................................2508304  
12  
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ENGINE GROUP 31HP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
1-603610  
109-6874  
3256-23  
Washer, Spring Disc 7/16 ......................2  
Spacer, XP A/C Clutch Inner..................1  
Washer, 5/16 SAE .................................2  
Setscrew, 5/16-18 x 3/4 .........................2  
Asm, Hood Air Intake W/Clamp .............1  
Key, Machine 1/4 x 1/4 x 1 1/4...............1  
Anchor, Clutch .......................................1  
Filter, Air ................................................1  
Washer, Spring Disc 5/16 ......................4  
Keeper, Clutch.......................................1  
Filter, Safety Air .....................................1  
Kit, Clutch ..............................................1  
Sheave ..................................................1  
Bracket, Air Filter ...................................1  
Hub, Adapter..........................................1  
16109-1012  
Plug, Oil Drain ....................................... 1  
17 109-5583-03 Bracket, Air Cleaner............................... 1  
18 103-5178  
19 2412-42  
20V 322-5  
Asm, Canister Air Filter W/Hood............ 1  
Clamp, Hose.......................................... 2  
Screw, HH 5/16-18 x 1........................... 5  
Screw, HH 5/16-18 x 2 1/4..................... 1  
Screw, HH 7/16-20 x 1 1/4..................... 1  
Screw, HH M8-1.25 x 20mm.................. 2  
Screw, Button Head 7/16-14 x 1 ............ 1  
Washer, Spring Disc 3/8........................ 2  
Screw, HH 5/16-18 x 2........................... 3  
Nut, Whizlock 5/16-18 ........................... 6  
Asm, Hose Oil Drain.............................. 1  
Hose, Air Intake..................................... 1  
4V 1-803050  
5
6
7
8
9
100-2436  
13-2840  
21 322-11  
109-5584  
103-1327  
1-303334  
22V 3212-5  
23 48-7710  
24V 3274-105  
25 98-5975  
26 322-10  
10 103-0152  
11 103-1326  
12 109-6627  
13 103-6774  
14 103-1058  
15 109-5823  
27 32128-20  
28109-4324  
29 109-5585  
Exmark black touch up spray paint – gloss black.  
Use a Teflon Pipe Sealant or equivalent on threads.  
V
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on screws, item #4, #20, #22 & #24  
31HP Briggs & Stratton Replacement Parts List  
(Refer to Engine Owner’s Manual)  
Description  
Briggs Part No.  
Engine Oil Filter....................................492932  
13  
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AUXILIARY HYDRAULIC GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1V 109-2853  
Asm, Hydraulic Power Unit ....................1  
Hose, Hydraulic......................................1  
Hose, Hydraulic......................................1  
Adapter, 90°...........................................2  
O-Ring (37° Flare #4).............................1  
O-Ring (SAE #4)....................................1  
Screw, HH 3/8-16 x 5/8..........................2  
Washer, Spring Disc 3/8 ........................2  
Asm, Cylinder W/Decal..........................1  
Kit, Hyd Cylinder Seal ............................1  
8
9
109-2663  
109-1180  
Terminal, Ring 5/16 ............................... 2  
Pin, Cylinder Mount ............................... 1  
Decal, High Pressure Oil ....................... 1  
Hairpin, Cotter ....................................... 1  
Screw, HH 1/4-20 x 3/4.......................... 1  
Nut, Nyloc 1/4-20................................... 1  
Clip, Loom ............................................. 2  
Adapter, Straight ................................... 2  
O-Ring (37° Flare #4) ............................ 1  
O-Ring (SAE #4).................................... 1  
2
3
4
109-2015  
109-2016  
109-0760  
109-1284  
1-603923  
323-4  
10 109-2377  
11 1-806005  
12 321-4  
13 3296-42  
14 103-1193  
15 109-2017  
109-1284  
5
6
7
98-5975  
109-2812  
109-2856  
1-603923  
V
Includes item #8.  
14  
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HYDRAULIC GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
1-413088  
32128-43  
109-4076  
1-805004  
103-2739  
Spacer ...................................................1  
Nut, Whizlock 3/8-16..............................4  
Sheave, Idler..........................................1  
Washer, Lock 1/4 Heavy........................2  
Key, 5mm x 5mm x 32mm .....................2  
Setscrew, 5/16-18 x 1 ............................4  
Washer, Spring Disc 3/8 ........................1  
Adapter, Running Tee............................3  
O-Ring (SAE #6)....................................1  
Asm, Hydraulic Reservoir W/Decal ........1  
Asm, Cap W/Gasket ..............................1  
Gasket, Reservoir Cap...........................1  
Clamp, Hose 11/16 ................................6  
Element Hydraulic Oil Filter....................1  
Adapter, 90°...........................................2  
Adapter, Straight....................................3  
O-Ring (37° Flare #6).............................1  
O-Ring (SAE #8)....................................1  
Head, Filter ............................................1  
Guard, Top.............................................2  
Spring, Extension...................................1  
Bearing, Spherical..................................2  
Seal, Single Lip......................................2  
Kit, Pump Idler.......................................1  
Tie, Cable 5 1/2 (Small) .........................1  
Spacer, Spring.......................................1  
Pump, Hydro W/Fan (LH) ......................1  
Pump, Hydro W/Fan (RH)......................1  
O-Ring ...................................................2  
30 109-0900  
31 109-0901  
32 109-0902  
33 109-1008  
34 109-1009  
35 109-1010  
36O 103-9519  
37O 103-9520  
38 103-2153  
103-1020  
Hose, Hydraulic ..................................... 1  
Hose, Hydraulic ..................................... 1  
Hose, Hydraulic ..................................... 1  
Hose, Case Drain .................................. 2  
Hose, Hydraulic ..................................... 1  
Hose, Hydraulic ..................................... 1  
Motor, Wheel (RH)................................. 1  
Motor, Wheel (LH) ................................. 1  
Adapter, 90° .......................................... 2  
O-Ring (37° Flare #6) ............................ 1  
O-Ring (SAE #8).................................... 1  
Sheave .................................................. 2  
Hose, Hydraulic ..................................... 1  
Hose, Hydraulic ..................................... 1  
Zerk, 90° 1/4-28..................................... 1  
Screw, HH 1/4-20 x 5/8.......................... 2  
Screw, HH 1/4-20 x 1............................. 2  
Screw, HH 3/8-16 x 4............................. 1  
Screw, HH 3/8-16 x 1 1/4....................... 7  
Screw, HH 1/2-13 x 2 1/2....................... 8  
Bolt, Carriage 3/8-16 x 3........................ 1  
Bolt, Carriage 3/8-16 x 2........................ 1  
Washer, 1/4 SAE................................... 2  
Washer, 1/2 SAE................................... 8  
6V 30-1710  
7
8
98-5975  
103-1828  
1-603921  
109-0582  
9
10 103-7615  
11 103-1949  
12 103-1988  
13 103-2146  
14 103-2155  
15 1-603990  
103-1020  
1-603920  
39 109-2202  
40 109-4644  
41 109-4645  
42 302-40  
43 321-3  
44 321-6  
1-603920  
45 323-16  
16 103-2259  
17 103-2916  
18 116-0133  
19 103-3504  
20 103-3506  
21 103-6409  
22 1-303287  
23 103-8011  
24103-8357  
25103-8358  
26 106-7159  
46 323-7  
47 325-10  
48 3231-10  
49 3231-6  
50 3256-22  
51 3256-26  
52 3256-4  
As  
Washer, 3/8 Std.....................................  
Req’d.  
53 3290-357  
54 32120-10  
55 32128-33  
56 32128-49  
57 116-0404  
58 3256-24  
Nut, Whizlock 3/8-16 ............................. 6  
Ring, Retaining...................................... 2  
Nut, Whizlock 1/4-20 ............................. 2  
Nut, Whizlock 1/2-13 ............................. 8  
Decal, Hydraulic Tank............................ 1  
Washer.................................................. 1  
27 109-5949-03 Arm, Idler...............................................1  
28 109-0816  
29 109-0899  
Belt ........................................................1  
Hose, Hydraulic......................................1  
Exmark black touch up spray paint – gloss black.  
V
Use Prolock, Nut Type (P/N 1-840022, .5ml tube) on setscrews, items #6.  
Wheel Motor Service Kits Hydro Pump Service Kits  
O
Part No.  
Description  
Qty.  
Part No.  
Description  
Qty.  
103-9762  
103-9763  
103-9764  
103-9765  
103-4242  
103-7447  
Kit, Seal .......................................................1  
Handle, Actuating.........................................1  
Clip, Retaining..............................................1  
Nut, Hex Toplock 1-20UNEF-2B ..................1  
Asm, Wheel Hub W/Studs ...........................1  
Stud, Wheel 1/2-20 x 1/2..............................4  
109-2863  
109-2864  
109-2865  
109-2866  
109-2867  
103-7488  
103-7489  
Bearing, Input Shaft PR ............................... 1  
Kit, Cylinder Block 16CC PR........................ 1  
Bearing, Thrust PR ...................................... 1  
Kit, Overhaul Seal PR.................................. 1  
Plate, Valve PR............................................ 1  
Fan, Pump Cooling...................................... 1  
Guard, Pump Fan ........................................ 1  
15  
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HYDRAULIC GROUP  
16  
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ELECTRICAL GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
1-303335  
1-513374  
Tie, Cable 7 5/16 (Large) .......................14  
Meter, Engine Hours ..............................1  
Cable, Battery (+)...................................1  
Insulator, Solenoid .................................2  
Wingnut, Nyloc 1/4-20............................2  
Clip, Loom .............................................2  
Switch....................................................1  
Switch....................................................1  
Plate, Tapped ........................................2  
Cable, Ground (-)...................................1  
Bolt Battery Hold Down..........................2  
24 109-0742  
25 109-2398  
26 109-2407  
27 109-2571  
28 240-3  
Contactor, Reversing Polarity ................ 1  
Breaker, Circuit 40A............................... 1  
Insulator, Battery (+).............................. 1  
Cover, Circuit Breaker ........................... 1  
Grommet ............................................... 1  
Screw, HH 1/4-20 x 3/4.......................... 2  
Screw, HH 5/16-18 x 1........................... 2  
Nut, Hex 5/16-24.................................... 4  
Bolt, Carriage 1/4-20 x 1........................ 2  
Screw, PPH #10-24 x 7/8....................... 2  
Washer, 1/4 SAE................................... 4  
Washer, 5/16 SAE................................. 2  
Screw, PPH #10-24 x 5/8....................... 6  
Nut, Nyloc #10-24.................................. 6  
Nut, Nyloc 5/16-18................................. 2  
Nut, Nyloc 1/4-20................................... 2  
Nut, Whizlock 1/4-20 ............................. 2  
Nut, Keps 10-32 UNF YZ....................... 2  
Key, Exmark Logo ................................. 1  
Fuse, 20 Amp (27HP)............................ 2  
Fuse, 20 Amp (31HP)............................ 1  
Fuse, 15 Amp........................................ 1  
Fuse, 30 Amp (31HP)............................ 1  
3109-7608  
4
5
6
7
8
9
1-543393  
1-543792  
1-603727  
1-633110  
1-633111  
1-633181  
29 321-4  
30 322-5  
31 3219-2  
32 3229-2  
33 3250-27  
34 3256-22  
35 3256-23  
36 3290-500  
37 3296-2  
38 3296-29  
39 3296-42  
40 32128-33  
41 32149-8  
42 103-2106  
43 1-816001  
1-816001  
10 1-633307  
11 1-633651  
12 107-9277-03 Strap, Battery Hold Down.......................1  
13 1-643275  
1-643275  
Relay, 12VDC 40 Amp (27HP)...............2  
Relay, 12VDC 40 Amp (31HP)...............3  
Harness, Auxiliary Hydraulics.................1  
Washer, Lock 5/16 Heavy......................4  
Bolt, Carriage #10-24 x 1/2 ....................2  
Switch....................................................2  
Switch....................................................1  
Asm, Switch W/Nut................................1  
Nut, Ignition............................................1  
Module, Seat Delay................................1  
Switch, PTO...........................................1  
Harness, Wiring (27HP).........................1  
Harness Wiring (31HP)..........................1  
14 109-2589  
15 1-805005  
16 1-807513  
17 82-2190  
18 109-4813  
19 109-4736  
20 103-0498  
21 103-5218  
22 103-5221  
23X 103-9268  
109-5593  
44 109355  
451-816003  
Exmark black touch up spray paint – gloss black.  
Use dielectric grease on all wiring harness connectors.  
Includes items 4 & 26.  
X
Not shown.  
17  
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ELECTRICAL DIAGRAM – 27HP KOHLER  
18  
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ELECTRICAL DIAGRAM – 31HP  
19  
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ELECTRICAL LOGIC SCHEMATIC – 27HP  
20  
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ELECTRICAL LOGIC SCHEMATIC – 31HP  
21  
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DECALS GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
116-0404  
103-5881  
103-7218  
109-2355  
103-3270  
98-5954  
Decal, Hydraulic Tank............................1  
Decal, Rotating Devices.........................2  
Decal, Pump Fan Warning.....................1  
Decal, Spring Loaded ............................2  
Decal, 3750 Rpm...................................1  
Decal, Missing Cover.............................1  
Decal, High Pressure Oil........................1  
Decal, Top Console ...............................1  
Decal, Service Aid .................................1  
Decal, Folding Rops Warning ................1  
Decal, Pump Drive Release...................1  
Decal, Routing Belt................................1  
13 109-7413  
14 103-2882  
15 1-513747  
16 103-2076  
17 107-2112  
18 109-2356  
19 109-2357  
20 109-2358  
21 98-4361  
22 109-2114  
109-2851  
Decal, Console ...................................... 1  
Decal, Exmark Logo .............................. 2  
Decal, Battery........................................ 1  
Decal, Caution Hot Surface ................... 2  
Decal, Warning...................................... 1  
Decal, Motion Control ............................ 1  
Decal, Motion Cntl/Park Brk................... 1  
Decal, Ignition........................................ 1  
Decal, Warning...................................... 2  
Decal, Frontrunner................................. 2  
Kit, Decal  
109-2377  
109-2360  
116-1003  
10 107-2102  
11 109-2396  
12 1-643339  
22  
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NOTES  
23  
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NOTES  
24  
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SERVICE RECORD  
Description of Work Done  
Service Done By  
Date  
25  
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-26-  
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© 2008 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-341 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed In USA  
All Rights Reserved  
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