Exmark FrontRunner Diesel Operator'S Manual Download

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FRONTRUNNER

DIESEL MODELS

For Serial Nos.
720,000 & Higher

Part No. 4500-227 Rev. A

Summary of Contents for FrontRunner Diesel

Page 1: ...FRONTRUNNERTM DIESEL MODELS For Serial Nos 720 000 Higher Part No 4500 227 Rev A ...

Page 2: ...lied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes or...

Page 3: ...tributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is...

Page 4: ...ine Oil 27 Check Hydraulic Oil Level 28 Check Tire Pressures 28 Check Condition Of Belts 28 Lubricate Grease Fittings 29 Lubricate Rear Caster Wheel Hub s 29 Lubricate Brake Handle Pivot 30 Lubricate Brake Rod Bushings 30 Lubricate Motion Control Bronze Bushings 30 Lubricate Motion Control Shaft 30 Lubricate Steering Linkage Rod Ends 31 Change Fuel Filter 31 Change Hydraulic System Filter 31 Check...

Page 5: ... mechanic s can not read English it is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate or service the equipment Local regulations may restrict the age of t...

Page 6: ...ve dissipated Do Not operate without entire exhaust system in place and in proper working condition WARNING Diesel fuel is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness Avoid prolonged breathing of vapors Keep face away from nozzle and diesel tank container opening Keep away from eyes an...

Page 7: ... abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage parking brake Before refueling Before dumping the grass catcher WARNING Hands feet hair clothing or accessories can become entangled in rotating parts Contact with the rotat...

Page 8: ...ownhill because the mower may tip forwards Be aware that loss of traction may occur going uphill Weight transfer to the rear wheels may cause drive wheels to slip and cause loss of braking and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights or counte...

Page 9: ... running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools Keep all guards shields and all safety devices in place and in safe working condition Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that co...

Page 10: ...s been installed make sure current safety signs are visible New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and instruction...

Page 11: ...Safety 103 1636 103 5881 103 7218 107 2102 107 2112 11 ...

Page 12: ...Safety 109 2355 109 2356 1 Fast 3 Neutral 2 Slow 4 Reverse 109 2357 1 Fast 4 Reverse 2 Slow 5 Park Brake Release 3 Neutral 6 Park Brake Engage 109 2358 109 2377 109 2396 12 ...

Page 13: ...Safety 109 2698 1 Cylinder extend 3 Fast 2 Cylinder retract 4 Slow 109 3637 109 7949 19426 87881 19426 87903 109 2360 13 ...

Page 14: ...gine will stop Engine will stop if the motion control levers are moved from neutral position while brake is engaged Cooling System Fan Belt driven with continuous operation with engine running Coolant Liquid 50 50 mix of DexCool extended life antifreeze and water Coolant Capacity 4 quarts Operator Controls Steering and Motion Control Note Motion control levers are adjustable to three heights Separ...

Page 15: ... Air Filled Standard Pneumatic Air Filled Optional Quantity 2 2 Tread AT101 TurfMate Size 24 x 12 00 12 23 x 10 50 10 Ply Rating 4 4 Pressure 9 psi 62 kPa 13 psi 90 kPa Caster Front Caster Rear Caster Dual Tail Wheel Semi Pneumatic Semi Pneumatic Quantity 2 2 Tread Smooth Smooth Size 9 x 3 50 4 13 x 6 5 6 Ply Rating Pressure Cutting Deck Sold Separately Model Numbers FR524 FR604 FR724 Cutting Widt...

Page 16: ...2 inches 175 8 cm 50 7 inches 128 8 cm Tread Width Center to Center of Tires Widthwise 52 inch Deck 60 inch Deck 72 inch Deck 41 4 inches 105 2 cm 41 4 inches 105 2 cm 45 4 inches 115 3 cm Wheel Base Center of Caster Tire to Center of Drive Tire 51 2 inches 130 0 cm Minimum Turning Radius 55 25 inches 140 3 cm Curb Weight Without deck 1163 lb 528 kg 52 inch Deck 1555 lb 705 kg 60 inch Deck 1600 lb...

Page 17: ... levers outward from the center position into the T slot locks them in the neutral position Figure 6 Throttle Control Located on right fuel tank console The throttle is used to control engine speed Moving the throttle lever forward will increase engine speed and moving the throttle lever to the rear will decrease engine speed Moving the throttle forward into the detent is full throttle Park Brake ...

Page 18: ...hed in to the STOP position to stop the blades Hydraulic Lift Switch Located on the right fuel tank console The hydraulic lift switch is used to raise and lower the mower deck Push the front portion of the hydraulic lift switch down to raise the mower deck to the desired height Push the rear portion of the hydraulic lift switch down to lower the mower deck to the desired height Coolant Temperature...

Page 19: ...e hairpin cotter pins and remove the two roll bar pins Figure 5 2 Raise the roll bar to the upright position and install the two pins and secure them with the hairpin cotter pins Figure 5 Important Always use the seat belt with the roll bar in the raised position Ensure that the rear part of the seat is secured with the seat latch Figure 5 1 Roll bar 3 Pin 2 Raised position 4 Hairpin cotter pin St...

Page 20: ...eflector raised removed or altered 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 PTO Important Operator must be in seat before the PTO can be engaged 1 Set the throttle to the MIDWAY position 2 Pull the PTO switch outward...

Page 21: ...neutral 4 To stop pull the motion control levers back to the neutral position Figure 7 1 Handles Out Neutral Lock 4 Forward 2 Handles In Neutral 5 Reverse 3 Front of Unit Driving in Reverse 1 Move the motion control levers inward to the center to the neutral unlocked position 2 To move rearward in a straight line applying equal pressure pull both motion control levers rearward To turn left or righ...

Page 22: ... exceed a 15 angle between ramp and ground or between ramp and trailer or truck Avoid sudden acceleration while driving unit on a ramp Loading a Unit Use extreme caution when loading 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 ...

Page 23: ...the wheel hub locknuts torque specification After the first 250 hours Change the hydraulic filter Before each use or daily Check the engine oil level Check the engine coolant level Check the safety interlock system Check the rollover protections systems roll bar pins Check the seat belt Check for loose hardware Clean the engine cooling system Every 40 hours Check the hydraulic oil level Check the ...

Page 24: ... overfill Important Do Not operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check Engine Coolant Level Service Interval Before each use or daily 1 Stop engine and wait for all moving parts to stop Make sure machine is on a level surface 2 Tilt seat up and tilt hood forward to gain access to the cooling area 3 Check with engine cold 4 View coolan...

Page 25: ...lothing or jewelry can get caught by the rotating fan and drive shaft Do Not operate machine without the covers in place Keep fingers hands and clothing clear of rotating components Shut off engine wait for moving parts to stop engage parking brake and remove key before performing maintenance 6 With the cap off the radiator tilt hood closed and put the seat down Start the engine as stated in the O...

Page 26: ...g 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 position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat ag...

Page 27: ...orrect the problem before operating Service Air Cleaner Service Interval Every 50 hours May need more often under severe conditions See the Engine Owner s Manual for additional information 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Tilt seat forward and raise hood to gain access to the air cleaner 3 Loosen retaining clips and remove air cleaner compartmen...

Page 28: ...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 COLD level Check Auxiliary Hydraulic Oil Level Service Interval As required Note Check the auxiliary hydraulic oil level if there is evidence of a leak or the hydraulic cylinder does not perform normally 1 Retract the hydraulic cylinder 2 Stop engine and wait for all moving par...

Page 29: ... 2 Yearly 7 Transfer Spring Ends 1 4 Yearly 8 Dual Tail Wheel Pivot 2 1 40 Hours See step 3 for special lubrication instructions on the rear caster pivots and the Lubricate Rear Caster Wheel Hub section for special lubrication instructions on the rear casters wheel hub 3 Lubricate front caster pivots once a year Remove hex plug and cap Thread grease zerk in hole and pump with grease until it oozes...

Page 30: ...Important To prevent seal and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Reapply thread locking adhesive Lubricate Brake Handle Pivot Service Interval Every 160 hours 1 Stop engine wait for all mo...

Page 31: ...r contaminants in fuel can severely damage fuel pump and or the other engine components 7 If any water was drained run engine for approximately two minutes to flush any remaining water out of the engine and fuel system Change Fuel Filter Service Interval Every 400 hours or as required A fuel filter is installed between the fuel tank and fuel pump and between the fuel pump and the engine Replace wh...

Page 32: ...urs thereafter When tightening the lock nut on the wheel motor tapered shaft Torque to 210 250 ft lb 285 339 N m Note Do Not use antiseize on wheel hub Fuel Tank Mounting Hardware Specifications Service Interval As required When installing the nuts on the fuel tank studs fully tighten the nyloc nut and back off 1 2 turn This allows for normal fuel tank expansion and contraction with changes in tem...

Page 33: ...m engine and re tighten hardware to secure in place 4 When properly tensioned the alternator belt will deflect 1 4 3 8 inches 7 9 mm while applying 22 pounds of force to the belt midway between alternator and crankshaft pulley Park Brake Adjustment Check to make sure brake is adjusted properly 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Tilt seat forward a...

Page 34: ... is obtained 11 Repeat procedure for other side Motion Control Linkage Adjustment WARNING Engine must be running and drive wheels must be turning so motion control adjustment can be performed Contact with moving parts or hot surfaces may cause personal injury Keep fingers hands and clothing clear of rotating components and hot surfaces 1 This adjustment must be made with the drive wheels turning F...

Page 35: ...lever is relative to notch in neutral plate should be centered allowing lever to pivot outward to the neutral lock position 5 If adjustment is needed loosen the nut against the yoke and while applying slight rearward pressure on the motion control lever turn the head of the adjustment bolt in the appropriate direction until lever is centered keeping rearward pressure on the lever will keep the pin...

Page 36: ...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 20 6 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 and retaining ring Figure 20 Right Hand Side of Unit Shown 1 Re install spring in outer holes to reduce spring t...

Page 37: ... and local regulations Battery Disposal DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte Federal law states that batteries should not be ...

Page 38: ...lay or switch is defective 7 Contact an Authorized Service Dealer 1 Fuel tank is empty 1 Fill the fuel tank 2 Fuel shutoff valve is closed 2 Open the fuel shutoff valve 3 Oil level in the crankcase is low 3 Add oil to the crankcase 4 The throttle and choke are not in the correct position 4 Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the ON positio...

Page 39: ...ump belt is worn loose or broken 2 Change the belt 3 Drive or pump belt is off a pulley 3 Change the belt 4 Broken or missing idler spring 4 Replace the spring Machine does not drive 5 Hydraulic fluid level is low or too hot 5 Add hydraulic fluid to reservoir or let it cool down 1 Engine mounting bolts are loose 1 Tighten the engine mounting bolts 2 Loose engine pulley idler pulley or blade pulley...

Page 40: ...CH HOUR METER RED RED ORANGE ORANGE ORANGE YELLOW TAN TAN ORANGE BLACK LT BLUE LT GREEN DK GREEN DK GREEN DK GREEN LT BLUE LT BLUE VIOLET BLACK BLACK BLACK BLACK RED RED ORANGE BLACK ORANGE BROWN BLACK YELLOW BLACK YELLOW BLACK YELLOW BLACK PINK BLACK SEAT DELAY MODULE DIODE GRAY BLACK WHITE BLACK BLUE BLACK YELLOW BLACK AUXILLARY HYDRAULICS RAISE LOWER OIL SWITCH OIL PRESSURE RELAY ALTERNATOR REL...

Page 41: ...Schematics Hydraulic Diagram CASE DRAIN CHARGE PUMP HIGH PRESSURE G007220 BYPASS VALVE BYPASS VALVE HIGH PRESSURE REVERSE HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE HIGH PRESSURE FORWARD 41 ...

Page 42: ...vice Dealer before obtaining any warranty service Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S Customers may also call 402 223 6375 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exm...

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Page 44: ...RONT RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS ROTARY BROOM SNOW BLADE SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Date Purchas...

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