Exmark Frontrunner 4500-341 User Manual
FRONTRUNNERTM
AIR-COOLED MODELS
For Serial Nos.
790,000 & Higher
Part No. 4500-341 Rev. A
1
READ OPERATOR’S MANUAL BEFORE
OPERATING OR SERVICING EXMARK EQUIPMENT.
TABLE OF CONTENTS
Description Page
Auxiliary Hydraulic Group ................................................. 14
Decals .............................................................................. 22
Electrical Diagram 27HP................................................... 18
Electrical Diagram 31HP................................................... 19
Electrical Logic Schematic 27HP...................................... 20
Electrical Logic Schematic 31HP...................................... 21
Electrical Group ................................................................ 17
Engine Group 27HP ......................................................... 12
Engine Group 31HP.......................................................... 13
Fuel Group........................................................................ 11
Hydraulic Group........................................................... 15-16
Main Frame Group...........................................................3-6
Motion Control Group ....................................................... 10
Park Brake Group............................................................... 9
PTO Drive Group................................................................ 8
Rear Frame Group.............................................................. 7
2
MAIN FRAME GROUP
Item
Part No.
1 1-323142 Nut, Push 1/2 .........................................2
2 109-2365 Bumper .................................................. 4
3 109-3478 Asm, Wheel & Tire (RH) ........................ 1
109-3156 Wheel ....................................................1
103-6771 Tire, 24x12-12 4 Ply ............................... 1
4 1-633859 Frame, Seat ........................................... 1
5 1-803035 Rivet 3/16 x 1/4 ......................................9
6 98-5975 Washer, Spring Disc 3/8 ........................ 8
7 103-0291 Cushion, Armrest LH.............................. 1
8 103-0292 Cushion, Armrest RH ............................. 1
9 103-2882 Decal, Exmark Logo............................... 2
10 103-3520 Seat, Back ............................................. 1
11Q 103-4553 Asm, ROPS Fold Pin ............................. 2
12 1-543401 Spacer, Seat Track ................................ 2
13 103-8383 Screw, HW H 1/4-20 x 3/4 Taptite ........... 11
14 103-5161 Link, Seat Stop ......................................2
15 103-6761 Asm, Seat Frame................................... 1
16 103-6765-03 Latch, Seat ............................................ 1
17 32128-33 Nut, W hizlock 1/4-20 .............................. 2
18 9264964 Bolt, HWH 5/16-18 x 3/4 Tap .................4
19 32128-20 Nut, W hizlock 5/16-18 ............................ 16
20 3296-73 Nut, Nyloc 1/4-20 ...................................2
21 103-8316 Spring .................................................... 1
22 103-8826 Link, Lower Seat Stop ............................ 2
23 103-6761 Plate, Seat Mount .................................. 1
24 1-633080 Bushing.................................................. 2
25X 109-2817 Kit, ROPS .............................................. 1
26 107-2102 Decals, Warning .................................... 1
DESCRIPTION
Qty.
Exmark black touch up spray paint – Gloss black
Q Includes ROPS fold pin plus hairpin, item #27.
X Rollover protection frame is serviced as a complete assembly only. Includes complete ROPS frame, mounting
hardware, fold pivot and locking hardware, seat frame assembly item #15 and seat belt assembly item #39.
O Includes armrests and seat back decal. Does not include seat belt or tracks.
Does not include item #19 or #48.
Item
Part No.
27 107-3155 Cotter, Hair Pin Double Loop ................. 2
28 109-3633-03 Spacer, Seat Mount............................... 2
29 3296-7 Nut, Nyloc 7/16-20................................. 2
30 109-0768 Skirt, Rubber.......................................... 1
31 109-3547 Asm, Front Console W/Decal ................ 1
32 109-2008 Cushion, Seat Bottom/W Switch............ 1
33 109-2009 Grp, Seat Track ..................................... 1
34O 109-2005 Asm, Seat W/Decal ............................... 1
35 109-2360 Decal, Top Console ............................... 1
36 3256-14 Washer, #10 Std.................................... 9
37 3296-39 Nut, Nyloc 3/8-16 ................................... 4
38 116-1003 Decal, Service Aid ................................. 1
39 110-0883 Kit, Seatbelt........................................... 1
40 242-50 Nut, Lug 1/2-20...................................... 8
41 283-69 Pin, Clevis 1/2 x 3 1/2............................ 2
42 322-5 Screw, HH 5/16-18 x 1........................... 8
43 322-7 Screw, HH 5/16-18 x 1 1/2..................... 2
44 323-6 Screw, HH 3/8-16 x 1............................. 2
45 323-8 Screw, HH 3/8-16 x 1 1/2....................... 8
46 323-9 Screw, HH 3/8-16 x 1 3/4....................... 2
47 3212-4 Screw, HH 7/16-20 x 1........................... 2
48 3296-29 Nut, Nyloc 5/16-18 ................................. 4
49 3256-3 Washer, 5/16 Std................................... 6
50 3256-4 Washer, 3/8 Std..................................... 1
51 3290-357 Nut, Whizlock 3/8-16 ............................. 8
52 109-3479 Asm, Wheel & Tire (LH)......................... 1
109-3156 Wheel .................................................... 1
103-6771 Tire, 24x12-12 4 Ply............................... 1
DESCRIPTION
Qty.
3
MAIN FRAME GROUP
4
MAIN FRAME GROUP (cont.)
Item
Part No.
1 1-513747 Decal, Battery ........................................ 1
2 1-523157 Washer .................................................. 4
3 1-643189 Keeper, Rubber Latch ............................ 2
4 1-643339 Belt Routing, Decal ................................1
5 1-806003 Hairpin, Cotter........................................ 2
6 1-806005 Hairpin, Cotter........................................ 1
7 1-808285 Pin, Clevis 3/8 x 1 1/8 ............................ 2
8 5-0652 Spacer ................................................... 4
9 93-2699 Pin .........................................................2
10 98-4361 Decal, Warning ...................................... 2
11 98-5954 Decal, Danger ........................................ 1
12 100-1663 Pin ......................................................... 2
13 103-1166 Tube, Pump Link Spacer ....................... 2
14 32151-36 Ring, Retaining ......................................4
15 103-3270 Decal, 3750 RPM...................................1
16 103-5881 Decal, Guard..........................................2
17 103-7218 Decal, Pump Fan Warning ..................... 1
18 109-6069 Asm, Frame W/Decals........................... 1
19 103-9727 Latch, Hitch............................................ 2
20 107-2112 Decal, Danger........................................ 1
21 107-8042 Bumper, Rubber..................................... 2
22 109-0075 Asm, Hitch .............................................1
23 109-0080-03 Wld, Hitch .............................................. 1
24 109-0325 Pin, Full Fold.......................................... 1
25 109-0411 Spring .................................................... 2
26 109-0435 Bushing.................................................. 4
27 109-0450 Asm, Spring ...........................................2
28 109-2772 Asm, Floorpan W/Decal .........................1
29 109-2773 Asm, Spring Bellcrank W/Decal (RH) ..... 1
30 109-2774 Asm, Spring Bellcrank W/Decal (LH) ..... 1
DESCRIPTION
Qty.
Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).
Exmark black touch up spray paint – Gloss black
Item
Part No.
31 109-0634 Wld, Spring Anchor................................ 4
32 109-1256-03 Arm, Pivot.............................................. 2
33 109-1257-03 Hook, Hood............................................ 2
34 109-3197 Hood, W/Decal ...................................... 1
35 109-2857 Asm, Hood............................................. 1
36 109-6070 Asm, Hood Support W/Decals .............. 1
37 109-2004 Roller, Lock Lever.................................. 2
38 32128-20 Nut, Whizlock 5/16-18 ........................... 4
39 109-2355 Decal, Spring Loaded ............................ 2
40 109-2356 Decal, Motion Control ............................ 1
41 109-2357 Decal, Motion Cntl/Park Brake............... 1
42 109-2396 Decal, Pump Drive Release................... 1
43 302-19 Zerk, 1/4-28 Str...................................... 2
44 322-3 Screw, HH 5/16-18 x 3/4........................ 4
45 322-4 Screw, HH 5/16-18 x 7/8........................ 8
46 323-11 Screw, HH 3/8-16 x 2 1/4....................... 2
47 323-8 Screw, HH 3/8-16 x 1 1/2....................... 2
48 325-18 Screw, HH 1/2-13 x 4 1/2....................... 2
49 32120-47 Ring, Retaining ......................................4
50 3256-23 Washer, 5/16 SAE ................................. 20
51 3256-24 Washer, 3/8 SAE ................................... 4
52 3256-26 Washer, 1/2 SAE ................................... 8
53 3256-27 Washer, 5/8 SAE ................................... 2
54 3269-24 Rivet...................................................... 4
55 3296-23 Nut, Nyloc 1/2-13 ................................... 2
56 3296-29 Nut, Nyloc 5/16-18 ................................. 8
57 3296-39 Nut, Nyloc 3/8-16 ................................... 4
58 32120-19 E-Ring ................................................... 2
59 109-2114 Decal, FrontRunner ............................... 1
DESCRIPTION
Qty.
5
MAIN FRAME GROUP (cont.)
6
REAR FRAME GROUP
Item
Part No.
1 1-513746 Decal, Muffler......................................... 2
2 1-543508 Cup, Bearing Tapered Roller.................. 4
3 1-543509 Cone, Bearing Tapered Roller................ 4
4 1-543511 Seal, Grease.......................................... 2
5 1-633508 Washer, Spring Disc ..............................6
6 1-633585 Bearing, Cone Tapered Roller................ 4
7 1-643188 Latch...................................................... 2
8 1-811010 Plug ....................................................... 2
9 103-0063 Seal, Double Lip..................................... 4
10 103-2768 Guard, Seal............................................4
11 103-3051 Spacer, Nut............................................ 4
12 923786 Rivet ...................................................... 4
13 109-9127 Asm, Caster Wheel................................ 2
14 103-4882 Cap, Grease .......................................... 2
15 103-5156 Axle, Caster ........................................... 2
16 103-6825 Bearing, Sleeve...................................... 2
17 103-7957-03 Wld, Dual Caster Tube........................... 1
18 103-8347 Asm, Dual Rear Wheels......................... 1
19 103-9045-03 Wld, Rear Frame Dual Wheel ................ 1
20 103-9051 Bearing, Thrust ...................................... 2
21 103-9789-03 Guard, Hose .......................................... 1
Exmark black touch up spray paint – Gloss black
Description
Qty.
Item
Part No.
22 103-9868-03 Wld, Caster Fork ................................... 2
23 103-9974 Washer .................................................. 1
24 105-7699 Strip, Seal .............................................. 2
25 109-2769 Asm, Rear Guard W/Decals (27 HP) ..... 1
109-6071 Asm, Rear Guard W/Decals (31 HP) ..... 1
26 109-0414-03 Cover, Muffler (27 HP) ........................... 1
109-5580-03 Cover, Muffler (31 HP)........................... 1
27 302-19 Zerk, 1/4-28 Str...................................... 1
28 322-3 Screw, HH 5/16-18 x 3/4........................ 5
29 323-6 Screw, HH 3/8-16 x 1............................. 4
30 325-39 Screw, HH 1/2-13 x 9 1/2....................... 2
31 325-5 Screw, HH 1/2-13 x 1 1/4....................... 6
32 327-24 Screw, HH 5/8-11 x 5 3/4....................... 1
33 3256-23 Washer, 5/16 SAE ................................. 5
34 3256-4 Washer, 3/8 Std..................................... 2
35 3290-357 Nut, Whizlock 3/8-16 ............................. 4
36 3296-23 Nut, Nyloc 1/2-13 ................................... 2
37 3296-51 Nut, Nyloc 3/4-10 ................................... 2
38 3296-53 Nut, Nyloc 5/8-11 ................................... 1
39 32128-20 Nut, Whizlock 5/16-18 ........................... 5
40 32128-49 Nut, Whizlock 1/2-13 ............................. 6
Description
7
Qty.
PTO DRIVE GROUP
Item Part No.
1 1-413088 Spacer ................................................... 1
2V 1-803050 Setscrew, 5/16-18 x 3/4 ......................... 2
3 1-807525 Bolt, Carriage 3/8-16 x 2 3/4 .................. 1
4 5-1336 Key, Machine 1/4 x 1/4 x 2..................... 1
5 92-8799 Bearing, Flanged.................................... 2
6 98-5975 Washer, Spring Disc 3/8 ........................ 5
7 103-2916 Guard, Top............................................. 2
8 116-0133 Spring, Extension...................................1
9 103-3504 Bearing, Spherical.................................. 2
10 103-3506 Seal, Single Lip...................................... 2
11 32151-13 Ring, Retaining ......................................2
12 103-6409 Asm, Pump Idler .................................... 1
13 103-6779-03 Shaft, Line ............................................. 1
14 103-6813 Pulley, Idler ............................................ 1
15 103-6814 Sheave ..................................................1
16 103-6836 Spacer ................................................... 1
17 103-8012 Spacer, Spring ....................................... 1
DESCRIPTION
Qty.
Exmark black touch up spray paint – Gloss black
V Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on setscrew, item #2.
Item Part No.
18 103-8073 Asm, Linedrive Idler............................... 1
19 103-8366-03 Guard, Linedrive .................................... 1
20 109-7588 Belts, Matched Pair ............................... 1
21 106-7159 O-Ring ................................................... 2
22 109-0431-03 Arm, Idler............................................... 1
23 251-347 Bearing, Ball Deep Groove .................... 1
24 302-40 Zerk, 90° 1/4-28..................................... 1
25 323-10 Screw, HH 3/8-16 x 2............................. 1
26 323-16 Screw, HH 3/8-16 x 4............................. 1
27 323-6 Screw, HH 3/8-16 x 1............................. 4
28 323-7 Screw, HH 3/8-16 x 1 1/4....................... 3
29 323-8 Screw, HH 3/8-16 x 1 1/2....................... 1
30 323-9 Screw, HH 3/8-16 x 1 3/4....................... 4
31 3218-3 Nut, Jam 3/8-16 ..................................... 1
32 3256-4 Washer, 3/8 Std..................................... 1
33 3290-357 Nut, Whizlock 3/8-16 ............................. 15
34 32120-10 Ring, Retaining ......................................2
DESCRIPTION
Qty.
8
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