Exmark Frontrunner Operating Manual Download

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Summary of Contents for Frontrunner

Page 1: ...itional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor If you need to order replacement parts from your dealer always give the model number and serial number of your mower as well as the part number description and quantity of the part needed The Serial No Plate on the right side of the unit under the fuel tank Fo...

Page 2: ...ing away from power driven parts Keep off mower unless seat platform is provided Keep others off mower WARNING POTENTIAL HAZARD Diesel fuel is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness HOW TO AVOID THE HAZARD Avoid prolonged breathing of vapors Keep face away from noz...

Page 3: ...bmitting 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 res...

Page 4: ...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 statio...

Page 5: ...stem 13 2 9 Tires 13 2 10 Mower Deck 13 2 11 Dimensions 13 2 12 Torque Requirements 14 3 OPERATION INSTRUCTIONS 3 1 Controls 14 17 3 2 Pre Start 17 3 3 Operating Instructions 17 18 3 4 Transporting 19 20 4 MAINTENANCE ADJUSTMENTS 4 1 Periodic Maintenance 21 32 4 2 Adjustments 32 38 5 WASTE DISPOSAL 5 1 Motor Oil Disposal 38 5 2 Battery Disposal 38 39 6 TROUBLESHOOTING 6 1 Mower Pulls Left or Right...

Page 6: ...rd the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit 1 2 2 Read the 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...

Page 7: ... 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 WARNING POTENTIAL HAZARD Engine exhaust contains carbon monoxide which is an odorless deadly poison W...

Page 8: ...dren Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot Never fill the fuel tank so that the fuel level rises above a level that is 1 2 below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage If fuel is spilled DO NOT attempt to start the engine Move away from the area of the spill...

Page 9: ...arts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts ca...

Page 10: ... on a flat level surface 9 Do not operate up or down a trailer ramp 9 Avoid sudden acceleration or deceleration 1 4 4 Use EXTREME caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes DANGER POTENTIAL HAZARD Mowing on wet grass or steep slopes can cause sliding and loss of control WHAT CAN HAPPEN Wheels...

Page 11: ...gle as rough terrain could overturn the machine Remove or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles Use extreme care with attachments These can change the stability of the machine and cause loss of control Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability 1 4 5 A Rollover Protection System roll ba...

Page 12: ...king a foreign object inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop the engine and wait for all moving parts to stop Engage parking brake Before refueling Before dumping the grass catcher 1 4 14 Before stopping the engine place the throttle control to the slow position Allow the engine to run a mi...

Page 13: ...ssive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire 1 5 5 Store fuel in a container specifically designed for this purpose in a cool dry place 1 5 6 Keep the mower and fuel container in locked storage to prevent children from playing or tampering with them 1 5 7 Diesel powered equipment or fuel containers should n...

Page 14: ...ep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system WARNING POTENTIAL HAZARD Fuel system components are under high pr...

Page 15: ...ur Exmark commercial mower PART NO 1 513746 LOCATION Outside of Rear Muffler Guard PART NO 1 513747 LOCATION LH Side of Battery Holder PART NO 1 523552 LOCATION Top Surface of Hydraulic Tank PART NO 1 643339 LOCATION On Top of Radiator PART NO 103 2076 LOCATION On Top of Radiator PART NO 103 7218 LOCATION On Seat Support Plate PART NO 103 0233 LOCATION On Front of the Fan Shroud PART NO 109 2358 L...

Page 16: ...l Crank PART NO 109 2357 LOCATION Top of Console LH Side PART NO 109 2360 LOCATION Front of Console PART NO 109 2377 LOCATION On Hydraulic Cylinder PART NO 109 2396 LOCATION Top of Seat Support Plate PART NO 109 3637 LOCATION Back of Seat PART NO 109 2698 LOCATION On Control Panel PART NO 107 2112 LOCATION Top of Floor Pan ...

Page 17: ...or engine will stop Engine will stop if the motion control levers are moved from neutral position while brake is engaged 2 5 COOLING SYSTEM 2 5 1 Fan Belt driven with continuous operation with engine running 2 5 2 Coolant Liquid 50 50 mix of DexCool extended life antifreeze and water 2 5 3 Coolant Capacity 4 quarts 2 6 OPERATOR CONTROLS 2 6 1 Steering and Motion Control Separate levers on each sid...

Page 18: ...il Wheel Pneumatic Air Filled Pneumatic Air Filled Semi Pneumatic Semi Pneumatic Quantity 2 2 2 2 Tread AT101 Turfmate Smooth Smooth Size 24 x 12 00 12 23 x 10 50 10 9 x 3 50 4 13 x 6 5 6 Ply Rating 4 4 Pressure 9 psi 62 kPa 13 psi 90 kPa 2 10 MOWER DECK Sold Separately 2 10 1 Models FR524 FR604 Discharge Side Discharge Side Discharge Cutting Width 52 in 132 cm 60 in 152 cm 2 11 DIMENSIONS 2 11 1 ...

Page 19: ...d in or the engine will kill When levers are centered in the T slot the drive system is in the neutral position With levers moved out in the T slot the drive system is in the neutral lock position See Figure 2 FIGURE 2 By moving both levers an equal amount forward or back from the neutral position the machine can be caused to move forward or backward in a straight line Movement of the left lever f...

Page 20: ...and moving throttle lever to the rear will decrease engine speed 3 1 5 Brake Lever Located on left side of unit between the seat and the dummy tank The brake lever engages a parking brake on the drive wheels Pull the lever up to engage the brake Push the lever down to disengage the brake The unit must be tied down and brake engaged when transporting 3 1 6 Ignition Switch Located on the right fuel ...

Page 21: ... sound See Section 3 1 13 3 1 13 Glow Plug Light Located on the right fuel tank console The glow plug light comes on when the glow plugs are preheating the combustion chamber This happens when the glow switch is depressed and while the engine is cranking 3 1 14 Warning Buzzer Located behind the seat under the engine cover on the right hand side of the engine fan shroud The buzzer is a warning sign...

Page 22: ...revent fuel spillage 3 2 2 Make sure you understand the controls their locations their functions and their safety requirements 3 2 3 Refer to Maintenance Section 4 and perform all the necessary inspection and maintenance steps 3 3 OPERATING INSTRUCTIONS 3 3 1 Raise roll bar Operate the unit with the roll bar in the raised and locked position and use seat belt There is no rollover protection when t...

Page 23: ...red unless there is a grass collection system or mulch kit in place and working properly The PTO push pull switch engages the cutting blades Be sure that all persons are clear of the mower deck and discharge area before engaging the PTO IMPORTANT Operator must be in seat before the PTO can be engaged Set throttle to midway position Pull the switch out to the ROTATE position Accelerate to full thro...

Page 24: ...equired by law Secure the trailer with a safety chain CAUTION POTENTIAL HAZARD This unit does not have proper turn signals lights reflective markings or a slow moving vehicle emblem These items are required to drive on a public street or roadway WHAT CAN HAPPEN Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on a street o...

Page 25: ...oading units on trailers or trucks One full width ramp is required If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves fr...

Page 26: ...e or making repairs around the engine area 4 1PERIODIC MAINTENANCE 4 1 1 Check engine oil level Service Interval Daily a Stop engine and wait for all moving parts to stop Make sure unit is on a level surface b Tilt seat forward and raise hood to gain access to access to engine area c Check with engine cold d Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick and push...

Page 27: ...zed liquid in the engine cooling system or touching a hot radiator may cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system CAUTION POTENTIAL HAZARD Engine coolant is toxic WHAT CAN HAPPEN Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow Keep out of reach of chil...

Page 28: ...and motion control levers moved out in the neutral lock position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO engaged and motion control levers in the neutral lock po...

Page 29: ... these tests do not operate Contact your authorized EXMARK SERVICE DEALER IMPORTANT It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing 4 1 6 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 ot...

Page 30: ...ine wait for all moving parts to stop and remove key Engage parking brake b Tilt seat up and tilt hood forward to gain access to the engine area c Drain oil while engine is warm from operation d Remove the oil drain plug Allow oil to drain then replace the drain plug e Replace the oil filter every other oil change f Clean around oil filter and unscrew filter to remove g Before reinstalling a new f...

Page 31: ...tely 1 2 1 27 cm for expansion Add 50 50 coolant mix to overflow bottle on the left side of the engine as required to bring the level up to the indicator line on the bottle WARNING POTENTIAL HAZARD Engine compartment contains open belt drives and fans Rotating components can cause injury WHAT CAN HAPPEN Fingers hands loose clothing or jewelry can get caught by the rotating fan and drive shaft HOW ...

Page 32: ...varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the CO...

Page 33: ...ubricate 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 LUBRICATION CHART Fitting Locations Initial Pumps No of Places Service Interval 1 Hitch and Cylinder Pivots 2 4 40 hrs 2 Fold Pivot Pin 2 2 100 hrs 3 Fold Lock Pin 2 2 yearly 4 Rear Caster Pivot 0 1 yearly 5 Belt Idlers 1 2 yearly 6 Motion Con...

Page 34: ... into the wheel l Apply a thread locking adhesive to the 2 nd spacer nut and thread onto the axle with the wrench flats facing outward m Torque the nut to 75 80 in lbs 8 9 N m loosen then re torque to 20 25 in lbs 2 3 N m Make sure axle does not extend beyond either nut n Re install the seal guards over the wheel hub and insert wheel into caster fork Re install caster bolt and tighten nut fully IM...

Page 35: ...rake b Tilt seat forward c Lubricate each end of both steering linkage rods with a spray lubricant or light oil 4 1 23 Drain water from fuel tank Service Interval 160 hrs a Park on level ground Stop engine wait for all moving parts to stop and remove key Engage parking brake b Place a drain pan under the fuel tank and loosen the drain cock approximately 1 turn c Drain out any water d When fuel beg...

Page 36: ...rubber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn d Fill reservoir as stated in Section 4 1 11 CAUTION POTENTIAL HAZARD Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fal...

Page 37: ...rol arms d Sheave retaining bolt in the end of engine crankshaft e Caster wheel spacer nuts f Fuel tank bulkhead fitting nuts g Motion control tab retaining bolt 4 1 30 Dielectric grease is used on blade type electrical connections to prevent corrosion and loss of contact 4 2 ADJUSTMENTS IMPORTANT Disengage PTO shut off engine wait for all moving parts to stop remove key and engage parking brake b...

Page 38: ...URE 9 c Disengage the park brake Measure the length of the park brake spring The spring should measure 2 5 6 4cm See Figure 10 FIGURE 10 d If necessary turn the thin nyloc nut to obtain the 2 5 6 4cm spring length e Engage the park brake Measure the gap between the thin nyloc nut and the park brake clevis The gap should measure 1 8 3 2mm FIGURE 11 f If necessary loosen the inner flanged nut and tu...

Page 39: ...e turning so motion control adjustment can be performed WHAT CAN HAPPEN Contact with moving parts or hot surfaces may cause personal injury HOW TO AVOID THE HAZARD Keep fingers hands and clothing clear of rotating components and hot surfaces CAUTION POTENTIAL HAZARD Raising the unit for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The me...

Page 40: ... loosen the jam nut next the ball joint at the upper end of the linkage rod assembly Then rotate the assembly using a wrench to turn the double nuts on the assembly See Figure 13 g Re tighten the jam nut against the ball joint on each side FIGURE 13 h Move the motion control levers to the reverse position Return the motion control levers to neutral The wheels must stop turning or slightly creep in...

Page 41: ...sfer spring adjustment Weight transfer springs are assembled from the factory to apply the maximum amount of weight onto the drive wheels This setting provides the greatest amount of traction Some conditions may require the rear wheel lift to be reduced This can be done by reducing the amount to weight transfer which will increase the amount of weight on the front and rear castors a To adjust the ...

Page 42: ...justments on the weight transfer springs See Deck Manual for Deck Raising instructions e Remove the retaining ring and washer at either end of the weight transfer spring that retains it to the transfer bellcrank pins and or weight transfer spring anchor pins See Figure 16 f Pull the spring off of front or rear pin and re install in the outer hole to reduce the spring force Re install the washer an...

Page 43: ...bled make sure the spring washers are reinstalled as shown in Figure 17 5 WASTE DISPOSAL 5 1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations 5 2 BATTERY DISPOSAL DANGER POTENTIAL HAZARD Battery electrolyte contains sulfuric acid which is poisonous and can caus...

Page 44: ...easurement should be consistent between all blade tips 6 3 ENGINE WILL NOT START a Make sure the battery has a full charge See section 4 1 3 for charging instructions b Be sure the throttle control is in the correct position See section 3 3 2 c Make sure there is fuel in the fuel tank d Make sure the parking brake is set and motion control levers in the neutral position e Check that the PTO is dis...

Page 45: ...erheating 6 4 5 Warning Buzzer Located behind the seat under the engine cover on the right hand side of the engine fan shroud The buzzer is a warning signal for the following circumstances a When the engine is running and the buzzer emits a continuous beep the buzzer is warning the user that the engine is overheating Perform the following steps 1 Disengage the mower blades and idle down the engine...

Page 46: ...41 7 ELECTRICAL DIAGRAM ...

Page 47: ...42 8 HYDRAULIC DIAGRAM ...

Page 48: ...sfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty ...

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Page 52: ...E SULKY SULKY HITCH KIT TURF STRIPER STANDON WARNING WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CALIFORNIA Proposition 65 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 2006 2007 PART NO 109...

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