FRONTRUNNER TM AIR-COOLED MODELS For Serial Nos. 790,000 & Higher Part No. 4500-497 Rev.
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: When the mower is used or operated on any California forest, brush or grass covered land, a working spark arrester must be attached to the muffler. If not, the operator is violating state law, Section 4442 Public Resource Code. To acquire a spark arrester for your unit, see your Engine Service Dealer.
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY. Figure 1 1.
Contents Weight Transfer Spring Adjustment ............... 34 Caster Pivot Bearings Pre-Load Adjustment ............................................... 35 Clutch Shim .................................................. 35 Cleaning ........................................................... 37 Clean Engine Cooling System ........................ 37 Remove Accumulated Debris from Engine (Briggs & Stratton Units Only).........................................................
Safety Safety • Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. Safety Alert Symbol • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property.
Safety DANGER DANGER In certain conditions gasoline is extremely flammable and vapors are explosive. A fire or explosion from gasoline can burn you, others, and cause property damage. In certain conditions 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. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any gasoline that spills.
Safety Operation • Be sure all drives are in neutral 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 mulch kit in place and working properly.
Safety • Stop the blades, slow down, and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed. • Be aware of the mower discharge path and direct discharge away from others. • Do Not operate the mower under the influence of alcohol or drugs. • Use extreme care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.
Safety • Carefully release pressure from components with stored energy. WARNING There is no rollover protection when the roll bar is down. Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Use care when checking blades.
Safety WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels. • Replace all worn, damaged, or missing safety signs. • When replacement components are installed, be sure that current safety signs are affixed to the replaced components. • If an attachment or accessory has been installed, make sure current safety signs are visible.
Safety 109-2355 109-2356 1. Fast 2. Slow 3. Neutral 4. Reverse 107-2102 109-2357 1. Fast 2. Slow 3. Neutral 107-2112 12 4. Reverse 5. Park Brake—Release 6.
Safety 109-2358 109-2377 109-7413 1. Cylinder—extend 2. Cylinder—retract 3. Fast 4. Slow 5. Choke—on 6.
Safety 116-1003 109-2360 14
Specifications Specifications Model Numbers Serial Nos: 790,000 and Higher FR27KC; FR31BV Systems Safety Interlock System • PTO must be disengaged, brake engaged, and motion control levers out (neutral lock) to start engine. (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.
Specifications Tires & Wheels • Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other components. The seat is held in the tilted position with a linkage. Adjustable fore and aft seat track. • Armrests: Standard seat: foam padded flip-up armrests. Optional suspension seat: molded adjustable flip-up armrests.
Specifications • Cutting Height Adjustment: Adjusts from 1 1/2 inches (3.8 cm) to 5 inches (12.7 cm) infinitely variable. Minimum Turning Radius • Mulching Kit: Optional Curb Weight: 55.25 inches (140.3 cm) • Bagger: Optional Without deck 911 lb (413 kg) Dimensions 52 inch Deck 1303 lb (591 kg) 60 inch Deck 1348 lb (611 kg) Overall Width: 72 inch Deck 1397 lb (634 kg) 52 inch Deck 60 inch Deck 72 inch Deck Without Deck 49.0 inches (124.5 cm) 49.0 inches (124.5 cm) 53.
Operation Product Overview Operation Note: Determine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control levers located on each side of the console control the forward and reverse motion of the machine. The levers control the flow of hydraulic oil from the hydrostatic pump to the drive wheel motor for each side. Moving the levers forward or backward turns the wheel on the same side forward or in reverse.
Operation Drive Wheel Release Valves Push the lever forward and down to disengage the brake. Located on the top left front corner of hydrostatic pumps. The unit must be tied down and brake engaged when transporting. Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running. Ignition Switch Located on right fuel tank console. With a 5/8 inch wrench, turn both valves one turn counterclockwise to release drive system.
Operation Starting the Engine Refer to the Maintenance section and perform all the necessary inspection and maintenance steps. 1. Move the motion control levers out to the neutral lock position. Operating Instructions 2. Pull up and back on the parking brake lever to engage the parking brake. Raise the Rollover Protection System (ROPS) 3. Push in on the PTO switch to the “STOP” position. Important: Lower the roll bar only when absolutely necessary. 1.
Operation Driving the Machine DANGER CAUTION An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also, contact with the blade could occur. Thrown objects or blade contact can cause serious injury or death. Machine can spin very rapidly by positioning one lever too much ahead of the other. Operator may lose control of the machine, which may cause damage to the machine or injury.
Operation Transporting 3. To move forward in a straight line apply equal forward pressure to both levers. Transporting a Unit To turn left or right, pull the motion control lever back toward neutral in the direction desired. Important: Do Not transport FrontRunner tractor without an approved Exmark front mount attachment. The machine will move faster the farther the motion control levers are moved away from neutral. Use a heavy-duty trailer or truck to transport the machine.
Operation 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 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 from ramp to trailer or truck.
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING WARNING While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders. The engine can become very hot. Touching a hot engine can cause severe burns. Allow the engine to cool completely before service or making repairs around the engine area.
Maintenance Maintenance Service Interval Every 500 hours Monthly Yearly Maintenance Procedure • Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50) • Check the wheel hub locknuts torque specification. • Check the battery charge. • • • • • • • Grease the fold lock pin. Grease the rear caster pivot. Grease the belt idlers. Grease the motion control pivots. Grease the transfer spring ends. Lubricate the caster wheel hub(s). Lubricate the motion control shaft.
Maintenance Voltage Reading Percent Charge Maximum Charger Settings Charging Interval 12.6 or greater 100% 16 volts/7 amps No Charging Required 12.4 – 12.6 75–100% 16 volts/7 amps 30 Minutes 12.2 – 12.4 50–75% 16 volts/7 amps 1 Hour 12.0–12.2 25–50% 14.4 volts/4 2 Hours amps 11.7–12.0 0–25% 14.4 volts/4 3 Hours amps 11.7 or less 0% 14.
Maintenance Note: If machine does not pass any of these tests, Do Not operate. Contact your authorized EXMARK SERVICE DEALER. 5. Check the condition of the inner element. Replace whenever 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. Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing. 6.
Maintenance If not, add oil. Use only Exmark Premium Hydro oil. Replace reservoir plug and tighten until snug. Do Not overtighten. 2. Tilt seat up. 3. Clean area around hydraulic reservoir cap and remove cap. Oil level should be to the top of the baffle inside the tank. If not, add oil. Use Exmark Premium Hydro oil. Replace hydraulic reservoir cap and tighten until snug. Do Not overtighten. Check Tire Pressures Service Interval: Every 40 hours Note: The baffle is labeled “HOT” and “COLD”.
Maintenance Lubricate Rear Caster Wheel Hub(s) Lubrication Chart Fitting Locations Initial Pumps Number of Places Service Interval 1. Hitch and Cylinder Pivots 2 4 40 Hours 2. Fold Pivot Pin 2 2 100 Hours 3. Fold Lock Pin 2 2 Yearly 4. Rear Caster Pivot *0 1 *Yearly 5. Belt Idlers 1 2 Yearly 6. Motion Control Pivots 1 2 Yearly 7. Transfer Spring Ends 1 4 Yearly 8. Dual Tail Wheel Pivot 2 1 40 Hours Service Interval: Yearly 1.
Maintenance 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 10. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of NGLI grade #1 multi-purpose grease. 11. Insert the second bearing and new seal into the wheel. 12. Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward. 13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-torque to 20-25 in-lb (2-3 N-m).
Maintenance Replacement Filters Kohler CAUTION Kohler P/N 2405010–15 Micron Briggs & Stratton 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. Briggs & Stratton P/N 695327– 30 Micron Change Hydraulic System Filter Do Not rely solely on mechanical or hydraulic jacks for support.
Maintenance Adjustments • Pump drive sheave set screws. • Line shaft sheave setscrews. Note: Disengage PTO, shut off engine, wait for all moving parts to stop, engage parking brake, and remove key before servicing, cleaning, or making any adjustments to the unit. • Square head setscrews on Hydro pump control arms. • Sheave retaining bolt in the end of engine crankshaft. • Caster wheel spacer nuts. Pump Drive Belt Tension • Fuel tank bulkhead fitting nuts. Self-tensioning - No adjustment necessary.
Maintenance remove the bolt that secures the ball joint to the brake lever and loosen the jam nut next to the ball joint. Rotate the ball joint in half-turns counterclockwise until desired disengagement is obtained. 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 Figure 12 1. Park brake engaged 2.
Maintenance Figure 14 Figure 15 1. Loosen jam nut 2. Pump control rod linkage 3. Use wrench to turn double nuts 1. Motion control lever 2. Left fender 3. Fender knob 3. Slide the fender forward and twist upward and outward to remove. 9. 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 reverse). 4.
Maintenance 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 16 Right-Hand Side of Unit Shown 1. Re-install spring in outer holes to reduce spring tension. 2. Weight transfer spring. 3. Remove e-ring and washer. 7. Re-install the left fender. Figure 18 8.
Maintenance 3. Check the condition of the wire harness leads, connectors, and terminals. Clean or repair as necessary. 4. Verify that 12V is present at the clutch connector when the PTO switch is engaged. 5. Measure the gap between the rotor and armature. If the gap is greater than .04 inch (1 mm), proceed with the following steps: A. Loosen both brake mounting bolts one-half to one full turn as shown below. C.
Maintenance Cleaning If the clutch does not disengage, reinstall the shim and reference the Troubleshooting section. Clean Engine Cooling System c. Engage and disengage the PTO switch ten consecutive times to ensure the clutch is functioning properly. If the clutch does not engage properly, reference the Troubleshooting section. Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.
Maintenance Remove Engine Shrouds and Clean Cooling Fins Service Interval: Every 80 hours 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Remove cooling shroud clean-out covers from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine, which can cause improper cooling. 3. Make sure cooling shroud clean-out covers are reinstalled.
Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, Do Not overlook the simple causes. For example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of trouble. Do Not attempt to service or replace major items or any items that call for special timing of adjustment procedures (such as valves, governor, etc.).
Troubleshooting Problem Engine overheats Possible Cause Corrective Action 1. Engine load is excessive 1. Reduce the ground speed. 2. Oil level in the crankcase is low. 3. Cooling fins and air passages for the engine are plugged. 2. Add oil to the crankcase. 3. Remove the obstructions from the cooling fins and air passages. Mower pulls left or right (with levers fully forward) 1. Tracking needs adjustment 1. Adjust the tracking. 2. Tire pressure in drive tires not correct. 3.
HOUR METER, AUX HYD, PTO SWITCH TERMINAL Y 3. START 2. RUN 1.
START RELAY SEAT DELAY HOUR METER, AUX HYD, PTO SWITCH TERMINAL S TERMINAL X TERMINAL Y 3. START 2. RUN 1.
G009845 TERMINAL X TERMINAL I 3. START 2. RUN 1.
TERMINAL X NONE IGNITION SWITCH TERMINAL Y TERMINAL A TERMINAL B TERMINAL S B+I+S X +Y CIRCUIT "MAKE" B+I+A G009846 TERMINAL I 3. START 2. RUN 1.
Schematics Hydraulic Diagram BYPASS VALVE BYPASS VALVE HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE G007220 HIGH PRESSURE CHARGE PUMP CASE DRAIN 45
Exmark Commercial Turf Equipment 2 Year Limited Warranty 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 Conditions and Products Covered Exmark Mfg. Co. Inc.
Notes: 47
Notes: 48
Service Record Date: Description of Work Done: 49 Service Done By:
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID-MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM (ROPS) DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO-MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM OUT-FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL-TAIL WHEEL SN
