FRONTRUNNERTM
AIR-COOLED MODELS
For Serial Nos.
720,000 & Higher
Part No. 4500-219 Rev. A
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READ OPERATOR’S MANUAL BEFORE
OPERATING OR SERVICING EXMARK EQUIPMENT.
TABLE OF CONTENTS
Description
Page
Auxiliary Hydraulic Group ................................................. 17
Decals .............................................................................. 23
Electrical Diagram 23HP & 27HP ..................................... 19
Electrical Diagram 31HP................................................... 20
Electrical Logic Schematic 23HP & 27HP......................... 21
Electrical Logic Schematic 31HP...................................... 22
Electrical Group................................................................ 18
Engine Group 23HP & 27HP ............................................ 13
Engine Group 31HP.......................................................... 14
Fuel Group........................................................................ 12
Hydraulic Group...........................................................15-16
Main Frame Group...........................................................3-6
Motion Control Group ....................................................... 11
Park Brake Group............................................................. 10
PTO Drive Group................................................................ 9
Rear Frame Group 23HP.................................................... 7
Rear Frame Group 27HP & 31HP ...................................... 8
2
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MAIN FRAME GROUP
Item
DESCRIPTION
Qty.
Item
DESCRIPTION
Qty.
Part No.
Part No.
1
2
3
1-323142
109-2365
109-3339
1-633008
109-3338
1-633859
1-803035
98-5975
Nut, Push 1/2.........................................2
Bumper..................................................4
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
38 109-3637
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) (27 & 31HP) .... 1
Wheel.................................................... 1
Tire, 24x12-12 4 Ply............................... 1
Asm, Wheel & Tire (RH) (27 & 31HP).... 1
Wheel.................................................... 1
Tire, 24x12-12 4 Ply............................... 1
Asm, Wheel & Tire (23HP).....................2
Tire, 23x10.5-12 4 Ply............................2
WheWel.................................................2
4
5
6
7
8
9
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
103-0291
103-0292
103-2882
10 103-3520
11Q 103-4553
12 1-543401
13 103-8383
14 103-5161
15ꢀ 103-6761
43 322-7
44 323-6
45 323-8
16 103-6765-03 Latch, Seat ............................................1
46 323-9
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
27 107-3155
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
Cotter, Hair Pin Double Loop .................2
47 3212-4
48 3296-29
49 3256-3
50 3256-4
51 3290-357
52 109-3479
109-3156
103-6771
53 109-3478
109-3156
103-6771
28 109-3633-03 Spacer, Seat Mount ...............................2
Exmark black touch up spray paint – Gloss black
Q
X
Includes ROPS fold pin plus hairpin, item #27.
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
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
32 109-1256-03 Arm, Pivot.............................................. 2
33 109-1257-03 Hook, Hood............................................ 2
34 109-2114
35 109-2857
36 109-2777
Decal, Frontrunner................................. 1
Asm, Hood............................................. 1
Asm, Hood Support W/Decals .............. 1
Asm, Hood Support W/Decals
(27 & 31 HP)
109-6070
1
37 109-2004
38 32128-20
39 109-2355
40 109-2356
41 109-2357
42 109-2396
43 302-19
44 322-3
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
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
31 109-0634
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
Wld, Spring Anchor................................4
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 23HP
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..................2
Cone, Bearing Tapered Roller................2
Seal, Grease..........................................1
Washer, Spring Disc..............................3
Bearing, Cone Tapered Roller................2
Latch......................................................2
Plug .......................................................1
Seal, Double Lip.....................................2
Guard, Seal............................................2
Spacer, Nut............................................2
Asm, Caster Wheel................................1
Rivet ......................................................4
Cap, Grease ..........................................1
Axle, Caster ...........................................1
Asm, Single Tailwheel............................1
18 103-9789-03 Guard, Hose .......................................... 1
19 103-9868-03 Wld, Caster Fork ................................... 1
20 105-7699
21 109-2769
Strip, Seal.............................................. 2
Kit, Rear Guard...................................... 1
22 109-0414-03 Cover, Muffler........................................ 1
23 322-3
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....................... 1
Screw, HH 1/2-13 x 1 1/4....................... 6
Washer, 5/16 SAE................................. 5
Washer, 3/8 Std..................................... 2
Nut, Whizlock 3/8-16 ............................. 4
Nut, Nyloc 1/2-13................................... 1
Nut, Nyloc 3/4-10................................... 1
Nut, Whizlock 5/16-18 ........................... 5
Nut, Whizlock 1/2-13 ............................. 6
24 323-6
25 325-39
26 325-5
10 103-2768
11 103-3051
12 103-3799
13 923786
27 3256-23
28 3256-4
29 3290-357
30 3296-23
31 3296-51
32 32128-20
33 32128-49
14 103-4882
15 103-5156
16 103-6704
17 103-6748-03 Wld, Rear Caster Hub............................1
Exmark black touch up spray paint – Gloss black
7
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REAR FRAME GROUP 27HP & 31HP
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
13 103-3799
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
8
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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
103-3330
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.
9
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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
10
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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
Wld, Control Shaft..................................2
Nut, Whizlock 3/8-16..............................8
23 3296-29
24 32128-20
25 106-5335
Nut, Nyloc 5/16-18................................. 4
Nut, Whizlock 5/16-18 ........................... 8
Washer, Wave....................................... 6
26 109-0558-03 Wld, Pump Ctrl (RH) (23HP).................. 1
103-8286-03 Wld, Pump Ctrl (RH) (27HP) ................. 1
27 109-0559-03 Wld, Pump Ctrl (LH) (23HP) .................. 1
103-8285-03 Wld, Pump Ctrl (LH) (27HP) .................. 1
28 109-1198
103-8300
Link, Tracking Rod (23HP)..................... 2
Link, Tracking Rod (27HP)..................... 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 (23HP).................... 2
Asm, Tracking Rod (27HP).................... 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
21 109-3618
22 3290-357
29 109-2339
30 322-12
31 322-6
32 323-4
33 323-6
34 3217-6
35 3219-2
36 3220-2
37 3256-2
38 3272-5
39 109-2583
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.
11
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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
5ꢀ Kohler
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.
12
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ENGINE GROUP 23HP & 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 (27HP) .................. 1
18 321-4
19 322-3
Screw, HH 1/4-20 x 3/4.......................... 1
Screw, HH 5/16-18 x 3/4 (27HP)............ 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 (27HP) ............... 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
8ꢀ 109-1012
98-5975
24V 3212-5
25 3253-6
26 3256-4
27 3290-357
28 32128-20
29 32128-33
30 33014-00
31 103-3535
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.
ꢀ
Use a Teflon Pipe Sealant or equivalent on threads.
V
X
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on screws, item #4, #20, #21 & #24
Includes item #3.
23HP Kohler Replacement Parts List
(Refer to Engine Owner’s Manual)
Description
27 HP Kohler Replacement Parts List
(Refer to Engine Owner’s Manual)
Description
Kohler Part No.
Kohler Part No.
Engine Oil Filter....................................5205002-S
Engine Air Filter....................................2408303-S
Safety Filter..........................................2508305-S
Engine Oil Filter ................................... 5205002-S
Engine Air Filter ................................... 2508301
Safety Filter.......................................... 2508304
13
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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
16ꢀ 109-1012
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
28ꢀ 109-4324
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
14
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HYDRAULIC GROUP
Item Part No.
Description
Qty.
Item Part No.
Description
Qty.
1
2
1-413088
1-603990
1-603992
1-603920
109-4076
1-805004
1-807272
103-2739
Spacer ...................................................1
Adapter, Straight (23HP)........................8
O-Ring (37° Flare #8).............................1
O-Ring (SAE #8)....................................1
Sheave, Idler..........................................1
Washer, Lock 1/4 Heavy........................2
Key, 5mm x 5mm x 25mm (23HP).........2
Key, 5mm x 5mm x 32mm (27 & 31HP).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
28 109-0816
29 109-0899
30 109-0900
31 109-0901
32 109-0902
33 109-1008
34 109-1009
35 109-1010
36O 109-1055
Belt........................................................ 1
Hose, Hydraulic ..................................... 1
Hose, Hydraulic ..................................... 1
Hose, Hydraulic ..................................... 1
Hose, Hydraulic ..................................... 1
Hose, Case Drain .................................. 2
Hose, Hydraulic ..................................... 1
Hose, Hydraulic ..................................... 1
Motor, Wheel (RH) (23HP)..................... 1
Motor, Wheel (RH) (27HP & 31HP) ....... 1
Motor, Wheel (LH) (23HP) ..................... 1
Motor, Wheel (LH) (27 & 31HP)............. 1
Adapter, 90° (23HP) .............................. 2
Adapter, 90° (27HP & 31HP) ................. 2
O-Ring (37° Flare #6) ............................ 1
O-Ring (SAE #8).................................... 1
Sheave (23HP)...................................... 2
Sheave (27HP & 31HP)......................... 2
Hose, Hydraulic (23HP) ......................... 1
Hose, Hydraulic (27HP & 31HP)............ 1
Hose, Hydraulic (23HP) ......................... 1
Hose, Hydraulic (27HP & 31HP)............ 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
3
4
5
6V 30-1710
7
8
98-5975
103-9519
37O 109-1056
103-9520
O
103-1828
1-603921
103-1947
O
9
38 109-1217
103-2153
W/Decal (23HP).....................................1
Asm, Hydraulic Reservoir
109-0582
103-1020
W/Decal (27 & 31HP).............................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 (23HP)........................3
O-Ring (37° Flare #6).............................1
O-Ring (SAE #6)....................................1
Adapter, Straight (27 & 31HP)................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) (23HP) ..........1
Pump, Hydro W/Fan (LH) (27 & 31HP)..1
Pump, Hydro W/Fan (RH) (23HP)..........1
Pump, Hydro W/Fan (RH) (27 & 31HP)..1
O-Ring ...................................................2
1-603920
10 103-7615
11 103-1949
12 103-1988
13 103-2146
14 103-2155
15 103-2156
103-1020
39 109-2201
109-2202
40 109-2655
109-4644
41 109-2656
109-4645
42 302-40
43 321-3
1-603921
1-603990
44 321-6
103-1020
45 323-16
46 323-7
1-603920
16 103-2259
17 103-2916
18 103-3330
19 103-3504
20 103-3506
21 103-6409
22 1-303287
23 103-8011
24Q 103-9196
47 325-10
48 3231-10
49 3231-6
50 3256-22
51 3256-26
52 3256-4
53 3290-357
54 32120-10
55 32128-33
56 32128-49
57 1-523552
58 32128-43
59 3256-24
As
Washer, 3/8 Std.....................................
Req’d.
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
Nut, Whizlock 3/8-16 ............................. 4
Washer.................................................. 1
103-8357
25Q 103-9197
103-8358
26 106-7159
ꢀ
ꢀ
27 109-5949-03 Arm, Idler...............................................1
Exmark black touch up spray paint – gloss black.
V
O
Use Prolock, Nut Type (P/N 1-840022, .5ml tube) on setscrews, items #6.
Wheel Motor Service Kits Wheel Motor Service Kits
O
Part No.
Description
Qty.
Part No.
Description
Qty.
103-9762
103-9763
103-9764
Kit, Seal .......................................................1
Handle, Actuating.........................................1
Clip, Retaining..............................................1
103-9765
103-4242
103-7447
Nut, Hex Toplock 1-20UNEF-2B .................. 1
Asm, Wheel Hub W/Studs........................... 1
Stud, Wheel 1/2-20 x 1/2 ............................. 4
Q
Hydro Pump Service Kits 23HP
ꢀ
Hydro Pump Service Kits 27HP & 31HP
Part No.
Description
Qty.
Part No.
Description
Qty.
103-7441
103-7443
103-8448
105-6184
103-7488
103-7489
Bearing, Input Shaft PJ................................1
Kit, Cylinder Block 12CC PJ.........................1
Bearing, Thrust PJ .......................................1
Kit, Overhaul Seal PJ...................................1
Fan, Pump Cooling ......................................1
Guard, Pump Fan ........................................1
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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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.
17
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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 (23HP & 27HP)............... 2
Fuse, 20 Amp (31HP)............................ 1
Fuse, 15 Amp........................................ 1
Fuse, 30 Amp (31HP)............................ 1
3■ 109-7608
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 (23HP & 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 (23HP & 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
45 1-816003
Exmark black touch up spray paint – gloss black.
Use dielectric grease on all wiring harness connectors.
Includes items 4 & 26.
X
■
18
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ELECTRICAL DIAGRAM – 23HP & 27HP
19
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ELECTRICAL DIAGRAM – 31HP
20
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ELECTRICAL LOGIC SCHEMATIC – 23HP & 27HP
21
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ELECTRICAL LOGIC SCHEMATIC – 31HP
22
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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
1-523552
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
109-3637
10 107-2102
11 109-2396
12 1-643339
23
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SERVICE RECORD
Description of Work Done
Service Done By
Date
24
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NOTES
25
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NOTES
26
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© 2005–2008 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
Part No. 4500-219 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed In USA.
All Rights Reserved
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