Related Manuals for Exmark Frontrunner 720,000 & Higher Serial Nos.
Summary of Contents for Exmark Frontrunner 720,000 & Higher Serial Nos.
- Page 1 FRONTRUNNER AIR-COOLED MODELS For Serial Nos. 720,000 & Higher Part No. 4500-218 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 Weight Transfer Spring Adjustment ....33 Caster Pivot Bearings Pre-Load Adjustment ..........34 Introduction ............3 Cleaning ............34 Safety ..............5 Clean Engine Cooling System ......34 Safety Alert Symbol ......... 5 Remove Accumulated Debris from Safe Operating Practices ........5 Engine (Briggs &... -
Page 5: Safety
• Evaluate the terrain to determine what accessories ALERT! YOUR SAFETY IS INVOLVED! 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, Figure 2 substantial footwear, long trousers, and hearing 1. - Page 6 Safety DANGER DANGER In certain conditions gasoline is extremely In certain conditions during fueling, static flammable and vapors are explosive. electricity can be released causing a spark which can ignite gasoline vapors. A fire or A fire or explosion from gasoline can burn explosion from gasoline can burn you and you, others, and cause property damage.
- Page 7 Tip-over could cause serious injury or death. amputation or severe lacerations. When operating a FrontRunner tractor • Do Not operate the machine without without an approved Exmark front mount guards, shields, and safety devices in attachment, observe the following: place and working properly.
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Page 8: Slope Operation
Safety 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. -
Page 9: Maintenance And Storage
Safety negative terminal first and the positive last. WARNING Reconnect positive first and negative last. There is no rollover protection when the roll • Use care when checking blades. Wrap the blade(s) bar is down. Wheels dropping over edges, or wear gloves, and use caution when servicing ditches, steep banks, or water can cause them. -
Page 10: Safety And Instructional Decals
Exmark equipment dealer or labels. distributor or from Exmark Mfg. Co. Inc. • Replace all worn, damaged, or missing safety • Safety signs may be affixed by peeling off the signs. - Page 11 Safety 103-7218 107-2112 109-2355 109-2356 1. Fast 3. Neutral 2. Slow 4. Reverse 107-2102...
- Page 12 Safety 109-2396 109-2357 1. Fast 4. Reverse 2. Slow 5. Park Brake—Release 3. Neutral 6. Park Brake—Engage 109-3637 109-2358 109-2377...
- Page 13 Safety 109-7413 1. Cylinder—extend 4. Slow 2. Cylinder—retract 5. Choke—on 3. Fast 6. Choke—off 109-7949 109-2360...
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Page 14: Specifications
Specifications Specifications Model Numbers Serial Nos: 720,000 and Higher FR23KC; FR27KC; FR31BV Systems Safety Interlock System • PTO must be disengaged, brake engaged, and Engine motion control levers out (neutral lock) to start engine. (It is not necessary for the operator to be •... -
Page 15: Hydrostatic Ground Drive System
Specifications Tires & Wheels • Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other components. 27HP Kohler & 31HP Briggs & Stratton Units The seat is held in the tilted position with a linkage. Adjustable fore and aft seat track. Front Drive Rear Caster... -
Page 16: Dimensions
Specifications – 60 inch Deck: 20.50 inches (52.1 cm) 23HP Kohler 27HP Kohler & 31HP Briggs & – 72 inch Deck: 24.50 inches (62.2 cm) Stratton • Blade Spindles: Solid steel spindles with 1 3/4 60 inch Deck 112.4 inches 114.3 inches inch (4.45 cm) I.D. -
Page 17: Torque Requirements
Product Overview Torque Requirements Product Overview Bolt Location Torque Engine Mounting Bolts 30-35 ft-lb (41-47 N-m) Wheel Lug Nuts 90-95 ft-lb (122-129 N-m) Wheel Motor Mounting 72-77 ft-lb (98-104 N-m) Bolts Wheel Hub Lock Nut 210-250 ft-lb (285-339 N-m) Rollover Protection System 30-35 ft-lb (41-47 N-m) (Roll Bar) Mounting Bolts Clutch Retaining Bolt... -
Page 18: Operation
Operation Operation Push the lever forward and down to disengage the brake. Note: Determine the left and right sides of the The unit must be tied down and brake engaged when machine from the normal operating position. transporting. Controls Ignition Switch Located on right fuel tank console. -
Page 19: Pre-Start
Operation Drive Wheel Release Valves Make sure you understand the controls, their locations, their functions, and their safety Located on the top left front corner of hydrostatic requirements. pumps. Refer to the Maintenance section and perform all the Drive wheel release valves are used to release the necessary inspection and maintenance steps. -
Page 20: Starting The Engine
Operation Open the Fuel Shut-Off Valve DANGER The fuel shut-off valve is located on the right side of An uncovered discharge opening will allow unit in fuel line next to the fuel filter. Raise the rear objects to be thrown in an operator’s or hood to access fuel shut-off valve. -
Page 21: Driving The Machine
Operation Driving the Machine 3. To move forward in a straight line apply equal forward pressure to both levers. CAUTION To turn left or right, pull the motion control lever back toward neutral in the direction desired. Machine can spin very rapidly by positioning The machine will move faster the farther the one lever too much ahead of the other. -
Page 22: Transporting
Important: Do Not transport FrontRunner individual ramps to simulate a full width continuous tractor without an approved Exmark front mount ramp. attachment. Ramp should be long enough so that the angles... -
Page 23: Maintenance
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 The engine can become very hot. Touching made, someone could start the engine. a hot engine can cause severe burns. Accidental starting of the engine could Allow the engine to cool completely before seriously injure you or other bystanders. -
Page 24: Periodic Maintenance
Maintenance Maintenance Service Maintenance Procedure Interval • Check the battery charge. Monthly • Grease the fold lock pin. • Grease the rear caster pivot. • Grease the belt idlers. • Grease the motion control pivots. Yearly • Grease the transfer spring ends. •... -
Page 25: Check Safety Interlock System
Maintenance Run engine at one-third throttle, engage PTO Voltage Percent Maximum Charging and raise off of seat (but do not get off of Reading Charge Charger Interval machine) engine must initiate shutdown after Settings 1/2 second has elapsed. 12.6 or 100% 16 volts/7 Charging... -
Page 26: Check Rollover Protections Systems (Roll Bar) Pins
Maintenance Note: If machine does not pass any of these tests, B. Remove paper element. Check the Do Not operate. Contact your authorized EXMARK condition of the paper element. Replace if SERVICE DEALER. dirty, bent or damaged. C. Check the condition of the inner element. -
Page 27: Check Hydraulic Oil Level
Maintenance 5. Replace the oil filter every other oil change. Clean 3. Tilt the seat forward. around oil filter and unscrew filter to remove. 4. Locate the auxiliary hydraulic power unit reservoir Before reinstalling new filter, apply a thin coating (see Figure 9). -
Page 28: Check Condition Of Belts
Maintenance Check Condition Of Belts Service Interval: Every 40 hours 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Check pump and PTO drive belts. 3. Belts are spring tensioned and no adjustment is necessary. -
Page 29: Lubricate Brake Handle Pivot
7. Insert one bearing, one new seal into the wheel. Service Interval: Every 160 hours Note: Seals (Exmark P/N 103-0063) must be 1. Stop engine, wait for all moving parts to stop, and replaced. remove key. Engage parking brake. -
Page 30: Check Spark Plugs
Service Interval: After the first 100 hours Yearly thereafter Every 500 hours thereafter Note: Use only Exmark Part No. 103-2146. When tightening the lock nut on the wheel motor tapered shaft: 1. Stop engine, wait for all moving parts to stop, and remove key. -
Page 31: Dielectric Grease
Maintenance Adjustments • Pump drive sheave set screws. • Line shaft sheave setscrews. Note: Disengage PTO, shut off engine, wait for • Square head setscrews on Hydro pump control all moving parts to stop, engage parking brake, and arms. remove key before servicing, cleaning, or making any adjustments to the unit. -
Page 32: Motion Control Linkage Adjustment
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. -
Page 33: Weight Transfer Spring Adjustment
Maintenance Figure 14 Figure 15 1. Loosen jam nut 1. Motion control lever 3. Fender knob 2. Left fender 2. Pump control rod linkage 3. Use wrench to turn double nuts 3. Slide the fender forward and twist upward and outward to remove. -
Page 34: Caster Pivot Bearings Pre-Load Adjustment
Maintenance Cleaning Clean Engine Cooling System Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) CAUTION Figure 16 Excessive debris around the engine cooling Right-Hand Side of Unit Shown air intake and inside of the pump drive 1. -
Page 35: 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 36: Troubleshooting
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 37 Troubleshooting Problem Possible Cause Corrective Action Engine overheats 1. Engine load is excessive 1. Reduce the ground speed. 2. Oil level in the crankcase is low. 2. Add oil to the crankcase. 3. Cooling fins and air passages for the 3.
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Page 38: Schematics
Schematics Schematics Electrical Diagram —23HP & 27HP Kohler GREY BLACK BLACK BLACK GREY BLACK GREY GREEN GREEN ORANGE BLACK PINK ORANGE GREY GREY GREEN GREEN BLACK ORANGE BROWN WHITE GREEN BLACK YELLOW GREEN BROWN GREEN BLACK PINK BLUE BLUE BLUE BROWN GREEN GREEN... - Page 39 Schematics Electrical Diagram – 31HP Briggs & Stratton YELLOW/BLACK VIOLET BLACK BLACK GREY BLACK BLACK BLACK GREY BLACK GREY GREEN ORANGE GREEN BLACK PINK ORANGE GREY GREY GREEN GREEN BLACK ORANGE BROWN WHITE GREEN BLACK YELLOW GREEN GREEN BROWN BLACK PINK BLUE BLUE...
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Page 40: Hydraulic Diagram
Schematics Hydraulic Diagram BYPASS VALVE BYPASS VALVE HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE HIGH HIGH PRESSURE PRESSURE FORWARD REVERSE G007220 HIGH PRESSURE CHARGE PUMP CASE DRAIN... - Page 41 No Claim of breach of warranty shall be cause for cancellation included with the product. or rescission of the contract of sale of any Exmark mower. All warranty work must be performed by an authorized Some states do not allow exclusions of incidental or...
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Page 42: Service Record
Service Record Date: Description of Work Done: Service Done By:... - Page 44 SEE EXMARK’S COMPLETE LINE OF ACCESSORIES MID-MOUNT RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM ROLL OVER PROTECTION SYSTEM (ROPS) DECK LIFT ASSIST KIT SNOW BLADE HITCH KIT SUN SHADE LAZERLOCKER TRASH CONTAINER LIGHT KIT TURF STRIPER MICRO-MULCH SYSTEM ULTRA VAC COLLECTION SYSTEM...