Exmark Frontrunner 4500-497 manual

FRONTRUNNER TM AIR-COOLED MODELS For Serial Nos. 790,000 & Higher Part No. 4500-497 Rev . A[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals known to the State of Califor nia to cause cancer, bir th defects, or other reproductiv e har m. Important: When the mower is used or operated on any Califor nia forest, br ush or grass co vered land, a w orking spark arr ester must be attached to t[...]

Introduction CONGRATULATIONS on the purchase of y our Exmark Mow er . T his product has been carefully designed and manufactured to giv e you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for y our Exmark mow er . BEFORE OPERATING Y OUR MO WER[...]

Contents Introduction .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 3 Safety .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . 5 Safety Alert Symbol . . . . . . . .. . . . . . . . . . . . . . . . .[...]

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both in this man ual and on the machine to identify important safety messages which m ust be follow ed to av oid accidents This symbol means: ATTENTION! BECOME ALERT! Y OUR SAFETY IS INV OL VED! Figure 2 1. Safety alert symbol The safety alert symbol appears abo ve inform[...]

Safety DANGER In certain conditions gasoline is extremely ammable and v apors are explosi ve. A re or explosion from gasoline can bur n y ou, others, and cause proper ty damage. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any gasoline that spills. • Never rell the fuel tank or drain the machine indoo[...]

Safety Operation W ARNING Operating engine parts, especially the mufer, become extremely hot. Severe bur ns can occur on contact and debris, such as leav es, grass, br ush, etc. can catch re. • Allow engine parts, especially the mufer , to cool before touching . • Remo ve accumulated debris from mufer and engine area. • Install an[...]

Safety • Stop the blades , slo w do wn, and use caution when crossing surfaces other than grass and when transporting the mow er to and from the area to be mow ed. • Be a ware of the mo wer discharge path and direct discharge a way from others . • Do Not operate the mow er under the inuence of alcohol or dr ugs . • Use extreme care when [...]

Safety W ARNING There is no rollov er protection when the roll bar is down. Wheels dropping o ver edges, ditches, steep banks, or w ater can cause rollov er s, which may result in serious injur y , death or drowning . • Keep the roll bar in the raised and locked position and use seat belt. • Lower the roll bar only when a bsolutely necessar y .[...]

Safety W ARNING Hydraulic uid escaping under pressure can penetrate skin and cause injur y . F luid accidentally injected into the skin must be surgically remov ed within a few hours by a doctor familiar with this for m of injur y or gangr ene may result. • Make sure all h ydraulic uid hoses and lines are in good condition and all h y draul[...]

Safety Safety and Instructional Decals • Keep all safety signs legible . Remo ve all grease, dirt and debris from safety signs and instr uctional labels . • R eplace all w or n, damaged, or missing safety signs . • When replacement components are installed, be sure that cur rent safety signs are afx ed to the replaced components . • If a[...]

Safety 107-2102 107-21 12 109-2355 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 12[...]

Safety 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 1 16-0404 13[...]

Safety 1 16-1003 109-2360 14[...]

Specications Specications Model Numbers Serial Nos: 790,000 and Higher FR27K C; FR31BV Systems Engine • Engine Specications: See y our Engine Owner’ s Manual • RPM: Full Speed: 3750 ±50 RPM (No Load) Idle: 1500 RPM Fuel System • Capacity: 8.5 gal. (32 L) • T ype of Fuel: R egular unleaded gasoline, 87 octane or higher . • Fuel[...]

Specications • Mounting: Hing ed to tilt up for access to hy draulic pumps , battery and other components . The seat is held in the tilted position with a linkage. Adjustable fore and aft seat trac k. • Ar mrests: Standard seat: foam padded ip-up ar mrests . Optional suspension seat: molded adjustable ip-up ar mrests . • Seat Safety [...]

Specications • Cutting Height Adjustment: Adjusts from 1 1/2 inches (3.8 cm) to 5 inc hes (12.7 cm) innitely variable . • Mulching Kit: Optional • Bag g er: Optional Dimensions Overall W idth: 52 inch Deck 60 inch Deck 72 inch Deck Without Deck 49.0 inc hes (124.5 cm) 49.0 inc hes (124.5 cm) 53.0 inc hes (135 cm) Deector Up 53.3 inc [...]

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: Deter mine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control lev ers located on eac h side of the console control the forw ard[...]

Operation Push the lev er forw ard and down to disengag e the brake . The unit m ust be tied down and brake engag ed when transporting . Ignition Switch Located on right fuel tank console. The ignition switch is used to start and stop the engine. The switc h has three positions “OFF”, “ON” and “ST ART”. Insert k ey into switch and rotat[...]

Operation R efer to the Maintenance section and perfor m all the necessar y inspection and maintenance steps . Operating Instructions Raise the Rollover Protection System (ROPS) Important: Low er the roll bar only when absolutely necessar y . 1. R emov e the hairpin cotter pins and remo ve the tw o roll bar pins (Figure 5). 2. Raise the roll bar to[...]

Operation DANGER An unco v ered discharge opening will allo w 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 injur y or death. Never operate the mower with the discharge deector raised, remov ed, or altered unless there is a grass co[...]

Operation 3. T o mo ve forw ard in a straight line apply equal forward pressure to both lev ers . T o turn left or right, pull the motion control lev er back tow ard neutral in the direction desired. The mac hine will mo ve faster the farther the motion control lev ers are mov ed a wa y from neutral. 4. T o stop , pull the motion control lev ers ba[...]

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 [...]

Maintenance Maintenance Note: Deter mine the left and right sides of the machine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental star ting of the engine could seriously injure y ou or other bystanders. Remo ve the k ey from the ignition s witch, engage parkin[...]

Maintenance Maintenance Ser vice Inter val Maintenance Procedure Every 500 hours • Change the h ydraulic lter (Ev er y 250 hours/yearly if using Mobil 1 15W50) • Check the wheel hub loc knuts tor que specication. Monthly • Check the battery c harge. Y early • Grease the fold loc k pin. • Grease the rear caster piv ot. • Grease the[...]

Maintenance V oltage Reading Percent Charge Maximum Charger Settings Charging Inter val 12.6 or g reater 100% 16 v olts/7 amps No Charging R equired 12.4 – 12.6 75–100% 16 v olts/7 amps 30 Minutes 12.2 – 12.4 50–75% 16 v olts/7 amps 1 Hour 12.0–12.2 25–50% 14.4 volts/4 amps 2 Hours 11.7–12.0 0–25% 14.4 volts/4 amps 3 Hours 11.7 or l[...]

Maintenance Note: If mac hine does not pass any of these tests , Do Not operate. Contact your authorized EXMARK SER VICE DEALER. Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing . Check Rollover Protections Systems (Roll Bar) Pins Service Interval: Before each use or d[...]

Maintenance 2. Tilt seat up . 3. Clean area around hy draulic reser voir cap and remov e cap . Oil lev el should be to the top of the bafe inside the tank. If not, add oil. Use Exmark Premium Hydro oil. R eplace h ydraulic reser v oir cap and tighten until sn ug . Do Not ov ertighten. Note: The bafe is labeled “HOT” and “COLD”. T he o[...]

Maintenance Lubrication Chart Fitting Locations Initial Pumps Number of Places Ser vice Inter val 1. Hitch and Cylinder Piv ots 2 4 40 Hours 2. Fold Piv ot Pin 2 2 100 Hours 3. Fold Lock Pin 2 2 Y early 4. R ear Caster Pi vot *0 1 *Y early 5. Belt Idlers 1 2 Y early 6. Motion Control Piv ots 1 2 Y early 7. T ransfer Spring Ends 1 4 Y early 8. Dual [...]

Maintenance 10. With the open end of the wheel facing up , ll the area inside the wheel around the axle full of NGLI grade #1 m ulti-purpose grease. 11. Insert the second bearing and new seal into the wheel. 12. Apply a thread loc king adhesi ve to the 2nd spacer nut and thread onto the axle with the wrench ats facing outward. 13. T orque the[...]

Maintenance Replacement Filters Kohler Kohler P/N 2405010–15 Micron Brig gs & Stratton Briggs & Stratton P/N 695327– 30 Micron Change Hydraulic System Filter Service Interval: After the rst 250 hours Every 500 hours/Y early (whichever comes rst) thereafter (Every 250 hours/Y early if using Mobil 1 15W50) Note: Use only Exmark P ar[...]

Maintenance • Pump dri ve shea ve set screws . • Line shaft shea ve setscrews . • Square head setscrews on Hydro pump control ar ms . • Sheav e retaining bolt in the end of engine crankshaft. • Caster wheel spacer n uts . • Fuel tank bulkhead tting n uts . • Motion control tab retaining bolt. Adhesiv es such as “Loctite R C/609 o[...]

Maintenance Figure 12 1. Park brake engaged 3. Thin nyloc nut 2. Y oke 4. 1/8 inch (3 mm) gap between nut and yoke. 5. If park brak e does not fully disengage when the lever is disengag ed c heck the brak e rod linkage assembly . The assembly should measure 7 3/8 inch (18.7 cm) from the center of the ball joint to the center of the low er end of th[...]

Maintenance Figure 14 1. Loosen jam nut 2. Pump control rod linkage 3. Use wrench to turn double nuts 9. Mov e the motion control lev ers to the rev erse position. R eturn the motion control lev ers to neutral. The wheels m ust stop turning (or slightly creep in reverse). 10. Stop engine and wait for all mo ving parts to stop . R emov e jumper wire[...]

Maintenance Figure 16 Right-Hand Side of Unit Shown 1. Re-install spring in outer holes to reduce spring tension. 3. Remove e-ring and washer . 2. Weight transfer spring. 7. R e-install the left fender . 8. F or additional weight transfer adjustment, repeat steps 4 through 7 on the right side of the unit. Caster Pivot Bearings Pre-Load Adjustment R[...]

Maintenance 3. Check the condition of the wire harness leads , connectors , and ter minals . Clean or repair as necessar y . 4. V erify that 12V is present at the clutch connector when the PTO switch is engaged. 5. Measure the gap betw een the rotor and ar mature . If the gap is greater than .04 inch (1 mm), proceed with the following steps: A. Loo[...]

Maintenance If the clutch does not disengag e, reinstall the shim and reference the T roubleshooting section. c . Eng age and disengag e the PTO switch ten consecuti ve times to ensure the clutch is functioning properly . If the clutch does not engage properly , reference the T roubleshooting section. Cleaning Clean Engine Cooling System Service In[...]

Maintenance Remove Engine Shrouds and Clean Cooling Fins Service Interval: Every 80 hours 1. Stop engine, w ait for all mo ving par ts to stop , and remov e key . Engag e parking brake . 2. R emov e cooling shroud clean-out cov ers from engine and clean cooling ns . Also clean dust, dirt, and oil from external surfaces of engine , which can caus[...]

T roubleshooting T roubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mow er use. When a problem occurs , Do Not o verlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The follo wing table lists some of the common causes [...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e 1. R educe the ground speed. 2. Oil lev el in the crankcase is low . 2. Add oil to the crankcase . Engine ov erheats 3. Cooling ns and air passages for the engine are plug ged. 3. R emov e the obstr uctions from the cooling ns and air passages . 1. T rac[...]

Schematics Schematics Electrical Diagram —27HP Kohler BA TT (POS) CIRCUIT BREAKER BA TT (NEG) BLACK BLACK ORANGE ORANGE MOT OR (FWD) MOT OR (REV) RED RED BLACK BLACK GREY / BLACK GREY L T BLUE YELLOW / BLA CK ORANGE ORANGE YELLOW / BLA CK ORANGE PINK / BLACK GREY GREY RED BLACK DK GREEN DK GREEN ORANGE / BLACK YELLOW T AN RED BRO WN BLACK BRO WN [...]

Schematics Electrical Diagram – 31HP Briggs & Stratton 3 I A S B X Y SEA T DELA Y MODULE CONTROL SEA T DELA Y MODULE INPUT SEA T SWITCH PTO CLUTCH PTO SWITCH GROUND FUSE 20 AMP KILL RELA Y ST ART RELA Y BRAKE SWITCH LH MOTION CONTROL RH MOTION CONTROL IGNITION SWITCH HOUR METER FUSE 30 AMP ST ARTER; BA TTER Y (POS) RED YELLOW T AN T AN ORANGE[...]

Schematics Electrical Logic Schematic – 27HP Kohler DK. GREEN FUEL SOLENOID REGULA TOR ENGINE KILL OIL PRESSURE ST ARTER SOLENOID DK. GREEN DK. GREEN T AN BLACK BLACK WHITE DK. GREEN / WHITE BLACK BLACK DK. GREEN / WHITE ORANGE / BLACK YELLOW PINK / BLACK DK. GREEN DK. GREEN DK. GREEN DK. GREEN L T. GREEN L T. GREEN L T. BLUE L T. BLUE BLACK BLAC[...]

Schematics Electrical Logic Schematic – 31HP Briggs & Stratton ST ART SOLENOID 5 1 2 4 3 RED ORANGE RED 40 AMP CIRCUIT BREAKER BLACK YELLOW / BLA CK BLACK A UX 15A - 12V OUTLET ACCY PLUG (HEADLIGHT) BLUE / BLACK WHITE / BLACK BLACK ORANGE / BLACK DK GREEN T AN WHITE DK BLUE GREY GREY PINK / BLACK GREY GREY ORANGE AUXILAR Y HYDRAULIC PUMP WHIT[...]

Schematics Hydraulic Diagram CASE DRAIN CHARGE PUMP HIGH PRESSURE G007220 BYP ASS V AL VE BYP ASS V AL VE HIGH PRESSURE REVERSE HIGH PRESSURE FOR W ARD HIGH PRESSURE REVERSE HIGH PRESSURE FOR W ARD 45[...]

Conditions and Products Co vered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty Company , pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair , replace or adjust any part on these products and found by us (in the ex ercise of our reasonable discretion) to be defective in factory [...]

Notes: 47[...]

Notes: 48[...]

Service Record Date: Description of Work Done: Service Done By: 49[...]

50[...]

51[...]

MID-MOUNT RIDING A CCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF A CCESSORIES AND OPTIONS W ALK-BEHIND A CCESSORIES AND OPTIONS GRASS CA TCHER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM FULL SUSPENSION SEA T DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V PO WER PORT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED[...]