Exmark Frontrunner Operator'S Manual Download

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FRONTRUNNER

AIR-COOLED MODELS

For Serial Nos.
790,000 & Higher

Part No. 4500-497 Rev. A

Summary of Contents for Frontrunner

Page 1: ...FRONTRUNNERTM AIR COOLED MODELS For Serial Nos 790 000 Higher Part No 4500 497 Rev A ...

Page 2: ...pplied 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 ...

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: ... 28 Check Condition Of Belts 28 Lubricate Grease Fittings 28 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 30 Check Spark Plugs 30 Change Hydraulic System Filter 31 Check Wheel Hub Locknuts 31 Thread Locking Adhesives 31 Dielectric...

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: ...during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners m...

Page 7: ...al and parking brake is engaged before starting engine Use seat belts with the roll bar in the raised and locked position Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulc...

Page 8: ...inside the back cover to determine the approximate slope angle of the area to be mowed Use a walk behind mower and or a hand trimmer near drop offs ditches steep banks or water Figure 3 Figure 3 1 Safe Zone Use the mower here on slopes less than 15 degrees 2 Danger Zone Use a walk behind mower and or hand trimmer on slopes greater than 15 degrees near drop offs and water 3 Water Remove or mark obs...

Page 9: ...e storing and Do Not store near flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy D...

Page 10: ...d hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep 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 ...

Page 11: ...en 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 lab...

Page 12: ...Safety 107 2102 107 2112 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 12 ...

Page 13: ...Safety 109 2358 109 2377 109 2396 109 7413 1 Cylinder extend 4 Slow 2 Cylinder retract 5 Choke on 3 Fast 6 Choke off 109 7949 116 0404 13 ...

Page 14: ...Safety 116 1003 109 2360 14 ...

Page 15: ...It is not necessary for the operator to be in the seat to start the engine Operator must be in seat when PTO is engaged brake is disengaged or motion control levers are moved in or engine will stop Engine will stop if the motion control levers are moved from neutral position while brake is engaged Operator Controls Steering and Motion Control Note Motion control levers are adjustable to three heig...

Page 16: ...6 6mph 10 6 km hr reverse Drive wheel release valves allow machine to be moved when engine is not running Tires Wheels Drive Front Caster Rear Caster Dual Tail Wheel Pneumatic Air Filled Semi Pneumatic Semi Pneumatic Quantity 2 2 2 Tread AT101 Smooth Smooth Size 24 x 12 00 12 9 x 3 50 4 13 x 6 5 6 Ply Rating 4 Pressure 9 psi 62 kPa Cutting Deck Sold Separately Model Numbers FR524 FR604 FR724 Cutti...

Page 17: ...Overall Height Roll Bar Up Roll Bar Down 69 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 911 lb 413 kg 52 in...

Page 18: ...enter position into the T slot locks them in the neutral position Figure 6 Choke Control Located on right fuel tank console The choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the ON position and moving the choke lever to the rear to the detent will put the choke in the OFF position Do Not run a warm engine with choke in the ON position Throttle ...

Page 19: ...l tank The fuel gauge monitors the amount of fuel in the right fuel tank only The left tank does not hold fuel Drive Wheel Release Valves Located on the top left front corner of hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running With a 5 8 inch wrench turn both valves one turn counterclockwise t...

Page 20: ...out to the neutral lock position 2 Pull up and back on the parking brake lever to engage the parking brake 3 Push in on the PTO switch to the STOP position Note It is not necessary for the operator to be in the seat to start the engine 4 Place the throttle midway between the SLOW and FAST positions 5 On a cold engine push the choke lever forward into the ON position On a warm engine leave the chok...

Page 21: ...e SLOW and FAST positions 6 Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 7 Remove the key to prevent children or other unauthorized persons from starting engine 8 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machi...

Page 22: ...achine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure a trailer with a safety chain CAUTION This unit does not have proper turn signals lights reflective markings or a slow moving vehicle emblem Driving on a street or roadway without ...

Page 23: ...ck do not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip If loading on or near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible Impor...

Page 24: ... 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 safety interlock system Check the rollover protections systems roll bar pins Check the seat belt Check for loose hardware Clean the engine cooling system Remove accumulated debris from engine Every 40 hours Check the hydraulic oil level Check ...

Page 25: ...ual Do Not 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 Battery Charge Service Interval Monthly WARNING CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands a...

Page 26: ...ter must not crank 2 Check the kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must initiate shutdown after approximately 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise off of seat but do not get off of machine engine m...

Page 27: ...ever it appears dirty typically every other time the paper element is replaced Clean the base around the inner element before removing so dirt does not get into the engine 6 Do Not wash or use pressurized air to clean paper element or inner element 7 Reinstall elements Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips Change Engine Oil Service ...

Page 28: ...lug and remove Oil level should be up to the reservoir plug hole If not add oil Use only Exmark Premium Hydro oil Replace reservoir plug and tighten until snug Do Not overtighten Check Tire Pressures Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Check tire pressure in drive tires Bar lug drive tires should be inflated to 9 psi...

Page 29: ...brake Figure 10 1 Seal guard 2 Spacer nut with wrench flats 2 Remove caster wheel from caster forks 3 Remove seal guards from the wheel hub 4 Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has been applied to lock the spacer nuts to the axle Remove the axle with the other spacer nut still assembled to it from the wheel assembly 5 Pry out ...

Page 30: ...parts to stop and remove key Engage parking brake 2 Tilt seat forward and raise hood 3 Lubricate bronze bushings on each end of the brake rod shaft with a spray type lubricant or light oil bushings are located to the inside of the flange bearings Lubricate Motion Control Bronze Bushings Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking b...

Page 31: ...Raising the mower for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support 6 Start engine and move throttle control ahead ...

Page 32: ... remove key before servicing cleaning or making any adjustments to the unit Pump Drive Belt Tension Self tensioning No adjustment necessary Pump Drive Belt Replacement 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove pump drive belt 3 Route new belt onto sheaves as shown in the decal located on the right hand side of the left hood support see Figure 11 F...

Page 33: ...g 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 First raise the frame and block up so that drive wheels can rotate freely 2 Remove the electrical connection from the seat safety switch located directly in front of the seat switch assembly 3 Temporarily instal...

Page 34: ...sition 2 Locate and loosen the knob under the rear of the left fender see Figure 15 Figure 15 1 Motion control lever 3 Fender knob 2 Left fender 3 Slide the fender forward and twist upward and outward to remove 4 To adjust the weight transfer springs fold the mower deck and front frame and lock in service position See Deck Manual for complete instructions WARNING Weight transfer springs may have s...

Page 35: ...g disc washers are reinstalled as shown in Figure 17 Figure 17 1 Spring disc washers Clutch Shim Some later model year units have been built with clutches that contain a brake shim When the clutch brake has worn to the point where the clutch no longer engages consistently the shim can be removed to extend the clutch life Figure 18 1 Armature 5 Brake spacer 2 Field shell 6 Re gap shim 3 Rotor 7 Bra...

Page 36: ...him Do Not discard the shim until proper clutch function has been confirmed Figure 21 1 Shim C Using a pneumatic line blow out any debris from under the brake pole and around the brake spacers D Re torque each bolt M6 x 1 to 10 ft lb 13 N m 0 5 ft lb 0 7 N m E Using a 0 010 inch thick feeler gauge verify that a gap is present between the rotor and armature face on both sides of the brake pole as s...

Page 37: ...te a fire hazard Clean all debris from inside of pump drive belt compartment daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all debris from rotating engine air intake screen and from around engine shrouding 3 Clean all debris from around the engine and drive belts Remove Accumulated Debris from Engine Briggs Stratton Units Only Service Interval Be...

Page 38: ...oil at a certified recycling center or according to your state 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 swallo...

Page 39: ...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 position for a cold engine or the OFF position for a warm engine 5 Dirt in fuel filter 5 Replace the fuel filter 6 Dirt water or stale f...

Page 40: ...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 2 Tighten the appropriate pulley Abnormal vibration 3 Engine ...

Page 41: ...DK GREEN ENGINE FUSE 15 AMP HEADLIGHT HARNESS YELLOW BLACK YELLOW BLACK DK BLUE WHITE ORANGE DK GREEN WHITE YELLOW BLACK YELLOW BLACK BLACK BLACK BLACK PINK BLACK LT BLUE DK GREEN DK GREEN ORANGE BLACK TAN TAN YELLOW RED RED STARTER BATTERY POS FUSE 20 AMP HOUR METER IGNITION SWITCH RH MOTION CONTROL LH MOTION CONTROL BRAKE SWITCH START RELAY KILL RELAY STARTER SOLENOID SIGNAL FUSE 20 AMP GROUND P...

Page 42: ...EN WHITE LT GREEN LT GREEN LT BLUE GREY BROWN TAN LT BLUE LT BLUE VIOLET ORANGE ORANGE ORANGE DK BLUE WHITE DK GREEN TAN LT BLUE ORANGE GREY GREY BROWN BROWN BLACK BROWN RED TAN YELLOW ORANGE BLACK DK GREEN DK GREEN BLACK RED GREY GREY PINK BLACK ORANGE YELLOW BLACK ORANGE ORANGE YELLOW BLACK LT BLUE GREY GREY BLACK BLACK BLACK VIOLET RED MOTOR REV MOTOR FWD ORANGE ORANGE BLACK BLACK BATT NEG CIRC...

Page 43: ...SSING NOT CONNECTED WIRES CONNECTED Y X S I B A START RUN OFF GREY GREY GREY GREY GREY BLACK GREY BLACK BROWN DECK TILT SAFETY SWITCH DK BLUE ORANGE ORANGE AUX HYDRAULIC RAISE LOWER RED RED RED YELLOW BLACK YELLOW BLACK YELLOW BLACK YELLOW BLACK 15 AMP FUSE ORANGE ORANGE TAN YELLOW ORANGE ORANGE RED YELLOW BLACK YELLOW BLACK ORANGE BLUE BLACK WHITE BLACK AUXILARY HYDRAULIC PUMP ORANGE GREY GREY PI...

Page 44: ...I A NONE X Y CIRCUIT MAKE B I S 2 RUN 1 OFF POSITION 3 START KILL RELAY PTO SWITCH HOUR METER IGNITION SWITCH START RELAY BRAKE LH MOTION CONTROL RH MOTION CONTROL 30 AMP FUSE 20 AMP FUSE GROUND ELECTRIC CLUTCH PTO SEAT SWITCH SEAT DELAY MODULE TAN LT BLUE LT BLUE BLACK BROWN BROWN TAN BLACK BROWN BLACK BLACK LT BLUE LT BLUE LT GREEN LT GREEN DK GREEN DK GREEN DK GREEN DK GREEN PINK BLACK YELLOW O...

Page 45: ...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 45 ...

Page 46: ...r Canada 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 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 t...

Page 47: ...Notes 47 ...

Page 48: ...Notes 48 ...

Page 49: ...Service Record Date Description of Work Done Service Done By 49 ...

Page 50: ...50 ...

Page 51: ...51 ...

Page 52: ...DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS 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 i...

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