Related Manuals for Exmark Frontrunner 4500-497
Summary of Contents for Exmark Frontrunner 4500-497
- Page 1 FRONTRUNNER AIR-COOLED MODELS For Serial Nos. 790,000 & Higher Part No. 4500-497 Rev. A...
- Page 2 Replacements may be ordered through the engine manufacturer. Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously.
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Page 3: Introduction
All Exmark parts are thoroughly tested and inspected before leaving the factory, however, attention is required on your part if you are to obtain the fullest measure of satisfaction and performance. -
Page 4: Table Of Contents
Contents Introduction ... 3 Safety ... 5 Safety Alert Symbol ... 5 Safe Operating Practices ... 5 Safety and Instructional Decals ... 11 Specifications ... 15 Model Numbers ... 15 Systems ... 15 Dimensions... 17 Torque Requirements ... 17 Product Overview ... 18 Operation ... -
Page 5: Safety
• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by Exmark. • Wear appropriate clothing including safety glasses, substantial footwear, long trousers, and hearing protection. - Page 6 Safety 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. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any gasoline that spills.
- Page 7 Tip-over could cause serious injury or death. When operating a FrontRunner tractor without an approved Exmark front mount attachment, observe the following: • Limit operation to minimum required to install a different front mount attachment.
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Page 8: Slope Operation
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. •... -
Page 9: Maintenance And Storage
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. • Keep the roll bar in the raised and locked position and use seat belt. - Page 10 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. •...
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Page 11: Safety And Instructional Decals
103-2076 • 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. - 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...
- Page 13 109-2358 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 Safety...
- Page 14 Safety 116-1003 109-2360...
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Page 15: Specifications
Specifications Model Numbers Serial Nos: 790,000 and Higher FR27KC; FR31BV Systems Engine • Engine Specifications: See your Engine Owner’s Manual • RPM: Full Speed: 3750 ±50 RPM (No Load) Idle: 1500 RPM Fuel System • Capacity: 8.5 gal. (32 L) •... -
Page 16: Hydrostatic Ground Drive System
• Hydrostatic Pumps: Two Hydro Gear PR 16 cc variable displacement piston pumps. • Wheel Motors: Hydro Gear planetary reduction motors. • Hydraulic Oil Type: Use Exmark Premium Hydro oil. • Hydraulic Oil Capacity: 5.2 qt. (4.9 L) • Hydraulic Filter: Replaceable cartridge type. -
Page 17: Dimensions
• Cutting Height Adjustment: Adjusts from 1 1/2 inches (3.8 cm) to 5 inches (12.7 cm) infinitely variable. • Mulching Kit: Optional • Bagger: Optional Dimensions Overall Width: 52 inch 60 inch Deck Deck Without 49.0 inches 49.0 inches Deck (124.5 cm) (124.5 cm) Deflector... -
Page 18: Product Overview
Operation Product Overview Figure 4 1. Fuel Cap 4. Seat Belt 2. Roll Bar 5. Motion Control Lever 3. Controls 6. Parking Brake Lever 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... -
Page 19: Pre-Start
Push the lever forward and down to disengage the brake. The unit must be tied down and brake engaged when transporting. Ignition Switch Located on right fuel tank console. The ignition switch is used to start and stop the engine. The switch has three positions “OFF”, “ON” and “START”. -
Page 20: Operating Instructions
Operation Refer to the Maintenance section and perform all the necessary inspection and maintenance steps. Operating Instructions Raise the Rollover Protection System (ROPS) Important: Lower the roll bar only when absolutely necessary. 1. Remove the hairpin cotter pins and remove the two roll bar pins (Figure 5). -
Page 21: Driving The Machine
DANGER 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. Never operate the mower with the discharge deflector raised, removed, or altered unless there is a grass collection system or mulch kit in place and working properly. -
Page 22: Transporting
Transporting Transporting a Unit Important: Do Not transport FrontRunner tractor without an approved Exmark front mount attachment. Use a heavy-duty trailer or truck to transport the machine. Lock brake and block wheels. Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. - Page 23 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.
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Page 24: Maintenance
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. 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. Remove the key from the ignition switch, engage parking brake, and pull the wire(s) off the spark plug(s) before you do any... -
Page 25: Periodic Maintenance
Maintenance Service Maintenance Procedure Interval • Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50) Every 500 hours • Check the wheel hub locknuts torque specification. Monthly • Check the battery charge. • Grease the fold lock pin. •... -
Page 26: Check Safety Interlock System
Maintenance Voltage Percent Maximum Reading Charge Charger Settings 12.6 or 100% 16 volts/7 greater amps 12.4 – 12.6 75–100% 16 volts/7 amps 12.2 – 12.4 50–75% 16 volts/7 amps 12.0–12.2 25–50% 14.4 volts/4 amps 11.7–12.0 0–25% 14.4 volts/4 amps 11.7 or less 14.4 volts/2 amps Check Safety Interlock... -
Page 27: Check Rollover Protections Systems (Roll Bar) Pins
Note: If machine does not pass any of these tests, Do Not operate. Contact your authorized EXMARK SERVICE DEALER. Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing. Check Rollover Protections... -
Page 28: Check Tire Pressures
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. -
Page 29: Lubricate Rear Caster Wheel Hub(S)
6. Pack the bearings with a NGLI grade #1 multi-purpose grease. 7. Insert one bearing, one new seal into the wheel. Note: Seals (Exmark P/N 103-0063) must be replaced. 8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward. -
Page 30: Lubricate Brake Handle Pivot
Maintenance 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. -
Page 31: Change Hydraulic System Filter
3. Unscrew filter to remove and allow oil to drain from reservoir. Important: Before reinstalling new filter, fill it with Exmark Premium Hydro oil and apply a thin coat of oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts the filter adapter, then tighten the filter an additional 2/3 to 3/4 turn. -
Page 32: Dielectric Grease
Maintenance • Pump drive sheave set screws. • Line shaft sheave setscrews. • Square head setscrews on Hydro pump control arms. • Sheave retaining bolt in the end of engine crankshaft. • Caster wheel spacer nuts. • Fuel tank bulkhead fitting nuts. •... -
Page 33: Motion Control Linkage Adjustment
Figure 12 1. Park brake engaged 3. Thin nyloc nut 2. Yoke 4. 1/8 inch (3 mm) gap between nut and yoke. 5. If park brake does not fully disengage when the lever is disengaged check the brake rod linkage assembly. -
Page 34: Weight Transfer Spring Adjustment
Maintenance Figure 14 1. Loosen jam nut 2. Pump control rod linkage 3. Use wrench to turn double nuts 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). -
Page 35: Caster Pivot Bearings Pre-Load Adjustment
Figure 16 Right-Hand Side of Unit Shown 1. Re-install spring in outer 3. Remove e-ring and holes to reduce spring washer. tension. 2. Weight transfer spring. 7. Re-install the left fender. 8. For additional weight transfer adjustment, repeat steps 4 through 7 on the right side of the unit. Caster Pivot Bearings Pre-Load Adjustment Remove dust cap from caster and tighten nyloc nut... - Page 36 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.
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Page 37: Cleaning
If the clutch does not disengage, reinstall the shim and reference the Troubleshooting section. 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. -
Page 38: Remove Engine Shrouds And Clean Cooling Fins
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. -
Page 39: 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. - Page 40 Troubleshooting Problem Engine overheats Mower pulls left or right (with levers fully forward) Machine does not drive Abnormal vibration Clutch will not engage. Possible Cause 1. Engine load is excessive 2. Oil level in the crankcase is low. 3. Cooling fins and air passages for the engine are plugged.
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Page 41: Schematics
Schematics Electrical Diagram —27HP Kohler BLACK BROWN BLACK BROWN BROWN BLUE BLUE ORANGE GREY GREY GREY ORANGE PINK ORANGE GREY GREY BLACK Schematics BLACK BLACK BLACK BLACK GREEN GREEN GREEN GREEN BLACK ORANGE WHITE GREEN YELLOW GREEN GREEN BLACK PINK BLUE BLUE BLUE... - Page 42 Schematics Electrical Diagram – 31HP Briggs & Stratton BLACK GREY GREY GREY ORANGE PINK ORANGE GREY GREY BROWN BLACK BROWN BROWN BLUE BLUE BLACK ORANGE YELLOW/BLACK VIOLET BLACK BLACK BLACK BLACK BLACK BLACK GREEN GREEN GREEN GREEN BLACK ORANGE WHITE GREEN YELLOW GREEN...
- Page 43 Electrical Logic Schematic – 27HP Kohler GREY GREY BLACK PINK GREY GREY ORANGE BROWN BLACK BROWN BROWN GREY BLACK BLUE BLUE ORANGE BLACK BLUE BLACK WHITE ORANGE Schematics GREEN GREEN BLACK BLACK WHITE GREEN WHITE BLACK BLACK GREEN GREEN WHITE GREEN BLACK ORANGE...
- Page 44 Schematics Electrical Logic Schematic – 31HP Briggs & Stratton GREY GREY BLACK PINK GREY GREY ORANGE BROWN BLACK BROWN BROWN GREY BLACK BLUE BLUE ORANGE BLACK BLUE BLACK WHITE ORANGE YELLOW/BLACK BLACK BLACK VIOLET GREEN GREEN BLACK BLACK WHITE GREEN WHITE BLACK BLACK...
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Page 45: Hydraulic Diagram
BYPASS VALVE HIGH PRESSURE FORWARD Hydraulic Diagram HIGH PRESSURE REVERSE HIGH PRESSURE FORWARD HIGH PRESSURE CHARGE PUMP CASE DRAIN Schematics BYPASS VALVE HIGH PRESSURE REVERSE G007220... - Page 46 • Attorney's fees. No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower. All implied warranties of merchantability (that the product is fit for ordinary use) and fitness for use (that the product is fit for a particular purpose) are limited to the duration of the express warranty.
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Page 49: Service Record
Service Record Date: Description of Work Done: Service Done By:... - Page 52 SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID-MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM FULL SUSPENSION SEAT DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT V POWER PORT MICRO-MULCH SYSTEM OUT-FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM...