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FRONTRUNNER TM
AIR-COOLED MODELS
For Serial Nos.
720,000 & Higher
Par t No. 4500-218 Rev . A
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W ARNING CALIFORNIA Pr oposition 65 W ar ning T he engine exhaust fr om this pr oduct contains chemicals kno wn to the State of Calif or nia to cause cancer , bir th defects, or other r epr oducti v e har m. Important: W hen the mo w er is used or operated on an y Calif or nia f or est, br ush or g rass co v er ed land, a w or king spar k ar r ester must be attached to the muf fler . If not, the operator is violating state la w , Section 4442 Public R esource Code. T o acquir e a spar k ar r est
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Introduction CONGRATULATIONS on the purc hase of y our Exmark Mo w er . T his product has been carefully designed and man ufactured to gi v e y ou a maxim um amount of de pendability and years of trouble-free operation. T his man ual contains operating, maintenance , adjustment, and safety instr uctions for y our Exmark mo w er . BEFORE OPERATING Y OUR MO WER, Figure 1 CAREFULL Y READ THIS MANU AL IN ITS ENTIRETY . 1. Model and serial number location By follo wing the operating, maintenance , an
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W eight T ransfer Spring Adjustment . . . . . . . . . . . . . . . 33 Contents Caster Pi v ot Bearings Pre-Load Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Safety . . . . . .
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Safety • Nev er let c hildren or untrained people operate Safety or ser vice the equipment. Local regulations ma y restrict the ag e of the operator . Safety Alert Symbol • T he o wner/user can prev ent and is responsible T his Safety Aler t Symbol ( Figure 2 ) is used both in for accidents or injuries occur ring to himself or this man ual and on the mac hine to identify impor tant herself , other people or proper ty . safety messag es whic h m ust be follo w ed to a v oid accidents Preparation
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Safety DANGER DANGER In cer tain conditions gasoline is extr emel y In cer tain conditions during fueling , static flamma ble and v apor s ar e explosi v e. electricity can be r eleased causing a spar k which can ignite gasoline v apor s. A fir e or A fir e or explosion fr om gasoline can bur n explosion fr om gasoline can bur n y ou and y ou, other s, and cause pr oper ty dama ge. other s and cause pr oper ty dama ge. • Fill the fuel tank outdoor s in an open • Al w ays place gasoline container
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Safety Operation • Be sure all dri v es are in neutral and parking brak e is eng ag ed before star ting engine . Use seat belts . • Nev er operate the mo w er with damag ed guards , W ARNING shields , or co v ers . Alw a ys ha v e safety shields , Operating engine par ts, especiall y the guards , switc hes and other devices in place and in muf fler , become extr emel y hot. Sev er e bur ns proper w orking condition. can occur on contact and de bris, such as • Nev er mo w with the disc harg e def
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Safety transpor ting the mo w er to and from the area to be mo w ed. • Be a w are of the mo w er disc harg e path and direct disc harg e a w a y from others . • Do Not operate the mo w er under the influence of alcohol or dr ugs . • Use extreme care when loading or unloading the mac hine into a trailer or tr uc k. • Use care when approac hing blind cor ners , shr ubs , trees , or other objects that ma y obscure vision. Slope Operation Figure 3 Use Extr eme caution when mo wing and/or tur ning 1.
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Safety neg ati v e ter minal first and the positi v e last. W ARNING R econnect positi v e first and neg ati v e last. T her e is no r ollo v er pr otection when the r oll • Use care when c hec king blades . W rap the blade(s) bar is do wn. W heels dr opping o v er edges, or w ear glo v es , and use caution when ser vicing ditches, steep banks, or w ater can cause them. Only re place blades . Nev er straighten or r ollo v er s, which may r esult in serious injur y , w eld them. death or dr o wni
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Safety Safety and Instructional Decals • K ee p all safety signs legible . R emo v e all g rease , • New safety signs ma y be obtained from dir t and debris from safety signs and instr uctional y our authorized Exmark equipment dealer or labels . distributor or from Exmark Mfg . Co . Inc . • R e place all w or n, damag ed, or missing safety • Safety signs ma y be affix ed b y peeling off the signs . bac king to expose the adhesi v e surface . Apply only to a clean, dr y surface . Smooth to remo
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Safety 103-7218 107-21 12 109-2355 109-2356 1. Fast 3. Neutral 2. Slow 4. Reverse 107-2102 1 1
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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 12
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Safety 109-7413 1. Cylinder—extend 4. Slow 2. Cylinder—retract 5. Choke—on 3. Fast 6. Choke—of f 109-7949 109-2360 13
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Specifications Specifications Model Numbers Serial Nos: 720,000 and Higher FR23K C; FR27K C; FR31BV Systems Safety Interlock System • PTO m ust be diseng ag ed, brak e eng ag ed, and Engine motion control lev ers out (neutral loc k) to star t engine . (It is not necessar y for the operator to be • Engine Specifications: See y our Engine Owner’ s in the seat to star t the engine .) Man ual • Operator m ust be in seat when PTO is eng ag ed, • RPM: Full Speed: 3750 ±50 RPM (No Load) brak e is disen
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Specifications • Mounting: Hing ed to tilt up for access to T ires & Wheels h y draulic pumps , batter y and other components . 27HP Kohler & 31HP Briggs & Stratton Units T he seat is held in the tilted position with a linkag e . Adjustable fore and aft seat trac k. Dri v e F r ont R ear Caster Caster (Dual T ail • Ar mrests: Standard seat: foam padded flip-up W heel) ar mrests . Optional suspension seat: molded adjustable flip-up ar mrests . Pneumatic Semi- Semi- (Air -Filled) Pneumatic Pneumat
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Specifications – 60 inc h Dec k: 20.50 inc hes (52.1 cm) 23HP K ohler 27HP K ohler & 31HP Brig gs & – 72 inc h Dec k: 24.50 inc hes (62.2 cm) Stratton • Blade Spindles: Solid steel spindles with 1 3/4 60 inc h Dec k 112.4 inc hes 114.3 inc hes inc h (4.45 cm) I.D . bearings . (285.5 cm) (290.3 cm) • Dec k Dri v e: “B”-Section belt from jac kshaft on 72 inc h Dec k 114.3 inc hes dec k to blade spindles . (290.3 cm) • Dec k: Full floating dec k is attac hed to out-front suppor t frame , remo v abl
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Product Overview T orque Requirements Product Overview Bolt Location T orque Engine Mounting Bolts 30-35 ft-lb (41-47 N-m) W heel Lug Nuts 90-95 ft-lb (122-129 N-m) W heel Motor Mounting 72-77 ft-lb (98-104 N-m) Bolts W heel Hub Loc k Nut 210-250 ft-lb (285-339 N-m) R ollo v er Protection System 30-35 ft-lb (41-47 N-m) (R oll Bar) Mounting Bolts Clutc h R etaining Bolt 55-60 ft-lb (75-81 N-m) (secured with threadloc k er) Figure 4 1. Fuel Cap 4. Seat Belt 2. Roll Bar 5. Motion Control Lever 6. P
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Operation Push the lev er forw ard and do wn to diseng ag e the Operation brak e . Note: Deter mine the left and right sides of the T he unit m ust be tied do wn and brak e eng ag ed when mac hine from the nor mal operating position. transpor ting . Controls Ignition Switch Located on right fuel tank console . Motion Control Levers T he ignition switc h is used to star t and stop the T he motion control lev ers located on eac h side of the engine . T he switc h has three positions “OFF”, “ON” co
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Operation Drive Wheel Release V alves Mak e sure y ou understand the controls , their locations , their functions , and their safety Located on the top left front cor ner of h y drostatic requirements . pumps . R efer to the Maintenance section and perfor m all the Dri v e wheel release v alv es are used to release the necessar y inspection and maintenance ste ps . h y drostatic dri v e system to allo w the mac hine to be pushed without the engine r unning . Operating Instructions With a wrenc h
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Operation Open the Fuel Shut-Off V alve DANGER T he fuel shut-off v alv e is located on the right side of An unco v er ed discharge opening will allo w unit in fuel line next to the fuel filter . Raise the rear objects to be thr o wn in an operator’ s or hood to access fuel shut-off v alv e . bystander’ s dir ection. Also, contact with the blade could occur . T hr o wn objects or blade Starting the Engine contact can cause serious injur y or death. 1. Mo v e the motion control lev ers out to the
