Exmark Frontrunner User Manual

For Serial Nos.

670,000 & Higher

CONGRA TULATIONS

a maximum amount of dependability and years of trouble-free operation. If additional 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. For ease of ordering and reference, we suggest that you record the information requested in the following identification table.

Place Model No. and Serial No. Label Here

(Included in Literature Pack)

on the purchase of your new Exmark mower. This product has been carefully designed and manufactured to give you

or Fill in Below

Engine Model No. and Spec. No. (Code)

Engine Serial No. (E/No)

Model No.

Date Purchased

Serial No.

Part No. 109-4334 Rev. A

WARNING

POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating pr actices can result in serious

operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass

discharge system) in place and in proper working condit ion. ♦ Stop engine, wait for all moving part s t o stop and engage parking

brake. Disconnect battery ground or r emove key before

adjusting, servicing, or performing maintenance. ♦ If mower deck becomes clogged, stop engine, wait for all moving

parts to stop and engage parking brake. Disconnect battery

ground or remove key before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts . ♦ Keep off mower unless seat platf o r m is pr ovided. ♦ 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 nozzle and fuel tank/container opening. ♦ Keep away from eyes and skin. ♦ Never siphon by mouth.

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the Cali f ornia Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner’s M anual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995 Program

If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

2. Distributor ships part(s) to dealer or customer, as

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by

5. The customer pays for the part

6. Who pays for the part A. Under any circumstance the customer does not pay. B. If the part does not arrive overnight due to:

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus

3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,

4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark

the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus

shipment of six (6) line items or less.

requested by dealer, same day, overnight UPS Distributor bills dealer for part and freight charges where applicable.

order, he contacts Exmark by 3:00 p.m.,

central time, with an Exmark Parts Plus

order of six (6) line items or less.

distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.

and freight if it is shipped under the Exmark Parts Plus® and if it arrives in

accordance to the program.

and freight if it fails to arrive overnight in accordance to the program?

1. The dealer not submitting the Exmark Parts Plus

order to his Exmark distributor by 1:00 p.m., the dealer

pays for the part and freight.

order

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

Exmark pays for the part and freight.

pays for the part.

The following restrictions apply

-- The Exmark Parts Plus® Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus

Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

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 oper at ion.

OPERATOR'S MANUAL

This manual contains operating, maintenance, adjustment, and safety instructions for your Exmark mower.

BEFORE OPERATING YOUR MOWER,

CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.

By following the oper ating, maintenance, and safet y instr uctions, you will prolong the life of your mower, mainta in it s m aximum 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 distribut or s are kept informed of the latest methods of servicing and are equipped t o pr ovide prom pt and efficient service in the field or at their service stations. T hey carr y ample stock of service parts or can secure them promptly for you fr om the factory.

All Exmark parts are thoroug hly test ed and inspect ed before leaving the factory, however, attention is required on your part if you are t o obt ain the fullest measure of satisfaction and performance.

iii

TABLE OF CONTENTS

1. SAFETY PAGE

1.1 Safety Alert Symbol....................................................................................... 1

1.2 Training.........................................................................................................1

1.3 Preparation.................................................................................................1-3

1.4 Operation...................................................................................................4-7

1.5 Maintenance & Storage.............................................................................. 8-9

1.6 Safety Signs............................................................................................. 9-11

2. SPECIFICATIONS

2.1 Model Number............................................................................................. 12

2.2 Engine......................................................................................................... 12

2.3 Fuel System................................................................................................ 12

2.4 Electrical System.........................................................................................12

2.5 Cooling System........................................................................................... 12

2.6 Operator Controls........................................................................................ 12

2.7 Seat........................................................................................................12-13

2.8 Hydrostatic Ground Drive System ............................................................... 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 ............................................................................ 39

6.2 Mower Cuts Unevenly..................................................................................39

6.3 Engine Will Not Start.............................................................................. 39-40

6.4 Engine Warning Systems............................................................................ 40

7. ELECTRICAL DIAGRAM ................................................................................... 41

8. HYDRAULIC DIAGRAM .................................................................................... 42

9. WARRANTY ........................................................................................................43

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is used both in this manual and on the machine to

identify important safety messages which must be followed to avoid accidents. This symbol means:

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

The safety alert symbol appears above information which alerts you to unsafe actions or

situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White lettering / Red background. Indicates an imminent ly hazardous situation

which, if not avoided, WILL result in death or serious injur y.

WARNING: Black lettering / Orange background. Indicates a potentially hazardous

situation which, if not avoided, COULD result in deat h or serious injury.

CAUTION: Black lett ering / Yellow background. Indicates a pot ent ially hazardous

situation which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

1.2.1 Regard 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. Familiar ize yourself with the cont r ols and t he proper use of the equipment. If the operator(s) or m echanic( s) can not read English, it is the owner’s responsibility to explain this mater ial t o t hem .

1.2.3 Do not allow operation of this machine by untrained personnel. Never allow children, teenagers, or people unfamiliar with these instructions to use the mower. Local regulations may restrict the age of the operator.

1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

1.3 PREPARATION

1.3.1 Evaluate the terrain to determine what accessories and attachment s ar e needed to properly and safely perform the job. Only use accessories and attachments approved by Exmark.

1.3.2 The use of personal protective equipment , such as (but not limited to) protect ion for the eyes, ears, feet , and head is r ecom m ended.

CAUTION

POTENTIAL HAZARD ♦ This machine produces sound levels in

excess of 85 dBA at the operator’s ear

when in operation. WHAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or

above for extended periods of time can

cause hearing loss. HOW TO AVOID THE HAZARD

♦ Wear hearing protection when operating

this machine.

1.3.3 While mowing, always wear substantial footwear and long trousers. Do not operate equipment when barefoot or when wearing open sandals.

1.3.4 Thoroughly inspect the area where the equipment is t o be used and r emove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operat or or bystander s.

WARNING

POTENTIAL HAZARD ♦ Engine exhaust contains carbon

monoxide, which is an odorless deadly

poison. WHAT CAN HAPPEN ♦ Carbon monoxide can kill you. HOW TO AVOID THE HAZARD

♦ Do not run engine indoors or in a small

confined area where dangerous carbon

monoxide fumes can collect.

DANGER

POTENTIAL HAZARD ♦ Diesel fuel is flammable. WHAT CAN HAPPEN ♦ A fire from diesel fuel can burn you,

others, and cause property damage. HOW TO AVOID THE HAZARD

♦ DO NOT smoke while refueling , and stay

away from an open flame or where fuel fumes may be ignited by spark.

♦ Refuel only outdoors. ♦ Store fuel in an approved container and

keep it out of the reach of children.

♦ Add fuel before start ing the engine.

Never remove the cap of the fuel t ank 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 and avoid creating any source of ignition until fuel vapors have dissipated.

♦ Do not operate without entire exhaust

system in place and in proper working

condition.

1.4 OPERATION

Although hazard control and accident prevention are partially dependent upon the

design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence, and proper training of t he personnel i nvolved in the operation, transport, maintenance, and st orage of t he equipment. It is essential that all Operator Safety Mechanisms be connect ed and i n operat i ng condition prior to use for mowing.

WARNING

POTENTIAL HAZARD ♦ Operating engine parts, especially the

muffler, become extremely hot. WHAT CAN HAPPEN

♦ Severe burns can occur on contact. ♦ Debris, such as leaves, grass, brush, etc.

can catch fire. HOW TO AVOID THE HAZARD

♦ Allow engine parts, especially the muff ler ,

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 br ush-

covered unimproved land.

WARNING

POTENTIAL HAZARD ♦ Hands, feet, hair, clothing, or accessories

can become entangled in rotating part s . WHAT CAN HAPPEN ♦ Contact with rotating parts can cause

traumatic amputation or severe

lacerations. HOW TO AVOID THE HAZARD

♦ Do not operate the machine without

guards, shields, and safety devices in place and working.

♦ Keep hands, feet, hair, j ewelry, or clot hing

away from rotating parts.

1.4.1 Give complete, undivided attention to the job at hand.

1.4.2 Mow only in daylight or good artificial light, keeping away from holes and hidden hazards. NEVER carry passengers. DO NOT operat e the mower when children or others are in the area.

1.4.3 When f easible, avoid operating the equipment in wet grass.

WARNING

POTENTIAL HAZARD ♦ Operating a FrontRunner tr act or without

an approved Exmark front mount attachment increases the possibility of

forward tip over. WHAT CAN HAPPEN ♦ Tip-over could cause serious injury or

death. HOW TO AVOID THE HAZARD

♦ When operating a FrontRunner tractor

without an approved Exmark front mount attachment, observe the following:

9 Limit operation to minimum required t o

install a different front mount attachment.

9 Minimize speed and use extreme

caution.

9 Only operate on a flat level surface.

9 Do not operat e up or down a trailer

ramp.

9 Avoid sudden acceleration or

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tr action and/or tip-over could occur. The operator is r esponsible for safe operation on slopes.

deceleration.

DANGER

POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can

cause sliding and loss of control. WHAT CAN HAPPEN ♦ Wheels dropping over edges, ditches,

steep banks, or water can cause

rollovers, which may result in serious

injury, death or drowning. HOW TO AVOID THE HAZARD

♦ Do not mow slopes when grass is wet. ♦ Do not mow near drop-offs or near water. ♦ Do not mow slopes greater than 15

degrees.

♦ Reduce speed and use extreme caution

on slopes.

♦ Avoid sudden turns or rapid speed

changes.

• See 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. This area can be dangerous, see Figure 1.

FIGURE 1

• Progressively greater care is needed as the slope increases.

• Always avoid sudden starting or stopping on a slope. If tires lose traction,

disengage the blades and proceed slowly off the slope.

• Avoid sudden stops when mowing downhill. Tractor 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.

• Watch for ditches, holes, rocks, dips, and r ises t hat change the operating angle, as rough terrain could overtur n the machine.

• Remove or mark obstacles such as rocks, t r ee lim bs, etc. from the mowing area. Tall grass can hide obstacles.

• Use extreme care with attachments. These can change t he st ability 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 bar) is installed on t he unit.

DANGER

POTENTIAL HAZARD ♦ There is no rollover protection when the

roll bar is down. WHAT CAN HAPPEN ♦ Wheels dropping over edges, ditches,

steep banks, or water can cause

rollovers, which may result in serious

injury, death or drowning. HOW TO AVOID THE HAZARD

♦ Keep the roll bar in the raised and locked

position and use seat belt.

♦ Lower the roll bar only when absolutely

necessary.

♦ Do not wear seat belt when the roll bar is

down.

♦ Drive slowly and carefully.

♦ Raise the roll bar as soon as clearance

permits.

• Be certain that the seat belt can be released q u ickly if the machine is driven or rolls into ponds of water.

• Check carefully for overhead clearances (i. e. branches, doorways, and electrical wires) before driving under any objects and do not contact them.

1.4.6 Use EXTREME caution when backing up. LOOK BEHI ND YOU!

1.4.7 Stop the blades when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed.

1.4.8 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.

1.4.9 DO NOT change the engine governor settings or overspeed the engine. Operating an engine at excessive speed may increase the hazard of personal injury.

1.4.10 Disengage PTO before starting engine.

1.4.11 Start

the engine carefully with feet well away from the blades.

1.4.12 Keep hands, feet, and clothing away from r otat ing par ts while the mower is being operated.

1.4.13 Stop engine, wait for all moving parts t o stop, and remove key. Eng age parking brake:

• Bef ore checking, cleaning or working on t he m o wer.

• Af ter striking a foreign object (inspect the mower for dam age and make

repairs before restart ing and operating the mower).

• Bef ore clearing blockages.

• Whenever you leave the mower.

Stop the engine and wait for all moving part s t o stop. Engage parking br ake:

• Before refueling.

• Bef or e dumping the grass catcher.

1.4.14 Before stopping the engine, place the throt t le cont rol to the “slow” position. Allow the engine to run a minimum of 15 seconds; t hen stop the engine.

1.4.15 This mower was designed fo r one oper at or only. Keep all others away from mower during operation.

1.4.16 DO NO T m ow with the discharge deflector raised, removed or altered unless there is a grass collection system or mulch k it in place and work ing properly.

1.4.17 DO NO T oper ate mower under the influence of alcohol or drug s.

1.4.18 Use extra care when approaching blind corners, shr ubs, trees, or other objects that may obscure vision.

1.4.19 If jump starting is required:

a) connect the positive (+) power cable from t he positive post on the booster

battery to the positive terminal post on the star ter solenoid switch (this post has the positive battery cable attached to it).

b) connect the negative or ground cable (-) from the negative post on the

booster battery to the engine block as far away from the battery as possible.

c) disconnect battery cables in the reverse order after starting.

1.5 MAINTENANCE AND STORAGE

1.5.1 For engine maintenance, follow the engine m anufacturer’s recommendations

precisely as stated in the engine manual.

1.5.2 Disconnect the battery cable from t he negative battery post when the unit will be

allowed to sit for more than 30 days without use.

1.5.3 Allowing batteries to stand for an extended period of time without recharging

them will result in reduced performance and ser vice life. To preserve optimum battery performance and lif e, recharge batteries in storage when the open circuit voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged before putting away for winter storag e.

1.5.4 Keep engine, engine area, and pump drive belt compar tment free fr om

accumulation of grass, leaves, excessive grease or oil, and ot her debris which can accumulate in these areas. These materials can become com bustible and may result in a fire.

1.5.5 Store fuel in a container specif ically desig ned 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 not be stored in a basement or

any enclosed area where open pilot lights or heat appliances are present.

1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly

maintained and operated correctly.

1.5.9 Check all bolts frequently to maintain proper tightness.

1.5.10 Keep all guards, shields, and all safety devices in place and in safe working condition.

1.5.11 Frequently check for worn or det er ior ating components that could create a hazard.

1.5.12 All replacement parts must be t he sam e as or equivalent to the parts supplied as

original equipment.

WARNING

POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure

can penetrate skin and cause injury. WHAT CAN HAPPEN ♦ Fluid accidentally injected into the skin

must be surgically removed within a few

hours by a doctor familiar with this for m of

injury or gangrene may result. HOW TO AVOID THE HAZARD

♦ Make sure all hydraulic fluid hoses and

lines are in good condition an all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

♦ The woven guards that protect the

hydraulic hoses may deteriorate and wear over time. Check the guards frequently and replace if necessary.

♦ 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 shutting off the

engine, before perf o r m ing any work on

the hydraulic system.

1.6 SAFETY SIGNS

1.6.1 Keep all safety signs legible. Remove all gr ease, dirt and debris from saf et y signs and instructional labels.

1.6.2 Safety signs must be replaced if they are missing or illegible.

WARNING

POTENTIAL HAZARD

Fuel system components are under high

♦

pressure.

WHAT CAN HAPPEN ♦

The use of improper components can result in system failure, fuel leakage and possible explosion.

HOW TO AVOID THE HAZARD

Use only approved fuel lines and clamps

♦

for high pressure systems.

1.6.3 When new components are installed, be sur e that current safety signs are

affixed to the replaced components.

1.6.4 New safety signs may be obtained from Exmark Mfg. Co. Inc.

1.6.5 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.

1.6.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They are critical to the safe operat ion of your Exmark commercial mower.

PART NO. 1-513746 LOCATION: Outside of Rear

Muffler Guard

PART NO. 1-523552 LOCATION: Top Surface of

Hydraulic Tank

PART NO. 103-1636 LOCATION: On Top of

Fuel Tank

PART NO. 103-5881 LOCATION: On top of Radiator

PART NO. 98-5954 LOCATION: Top of Radiator

PART NO. 1-513747 LOCATION: LH Side of Batter

PART NO. 1-643339 LOCATION: On Top of Radiator

PART NO. 109-2358 LOCATION: On Control

Panel

PART NO. 103-7218 LOCATION: On Seat Support Plate

PART NO. 93-4361 LOCATION: On LH and RH Side,

Near Back of Unit

Holder

PART NO. 103-0233 LOCATION: On Front of the

Fan Shroud

PART NO. 109-2356 LOCATION: Top of

Console, RH Side

PART NO. 103-2076 LOCATION: On Top of

Radiator

PART NO. 107-2102 LOCATION: Inside

Surface of Upper Roll Bar

PART NO. 109-3637 LOCATION: Back of Seat

PART NO. 107-2112 LOCATION: Top of Floor Pan

PART NO. 109-2377 LOCATION: On Hydraulic Cylinder

PART NO. 109-2355 LOCATION: Outside of each

Weight Transfer Bell Crank

PART NO. 109-2360 LOCATION: Front of Console

PART NO. 109-2357 LOCATION: Top of Console,

LH Side

PART NO. 109-2396 LOCATION: Top of Seat Support

Plate

PART NO. 109-2698 LOCATION: On Control Panel

+ 36 hidden pages

Exmark Frontrunner User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual