Exmark Frontrunner 4500-497 User Manual

FRONTRUNNERTMAIR-COOLEDMODELSForSerialNos.790,000&HigherPartNo.4500-497Rev.A

SafetyWARNINGHydraulicuidescapingunderpressurecanpenetrateskinandcauseinjury.Fluidaccidentallyinjectedintotheskinmustbesurgicallyremovedwithinafewhou

SafetySafetyandInstructionalDecals•Keepallsafetysignslegible.Removeallgrease,dirtanddebrisfromsafetysignsandinstructionallabels.•Replaceallworn,damage

Safety107-2102107-2112109-2355109-23561.Fast3.Neutral2.Slow4.Reverse109-23571.Fast4.Reverse2.Slow5.ParkBrake—Release3.Neutral6.ParkBrake—Engage12

Safety109-2358109-2377109-2396109-74131.Cylinder—extend4.Slow2.Cylinder—retract5.Choke—on3.Fast6.Choke—off109-7949116-040413

Safety116-1003109-236014

SpecicationsSpecicationsModelNumbersSerialNos:790,000andHigherFR27KC;FR31BVSystemsEngine•EngineSpecications:SeeyourEngineOwner’sManual•RPM:FullSpee

Specications•Mounting:Hingedtotiltupforaccesstohydraulicpumps,batteryandothercomponents.Theseatisheldinthetiltedpositionwithalinkage.Adjustableforean

Specications•CuttingHeightAdjustment:Adjustsfrom11/2inches(3.8cm)to5inches(12.7cm)innitelyvariable.•MulchingKit:Optional•Bagger:OptionalDimensionsOv

OperationProductOverviewFigure41.FuelCap4.SeatBelt2.RollBar5.MotionControlLever3.Controls6.ParkingBrakeLeverOperationNote:Determinetheleftandrightside

OperationPushtheleverforwardanddowntodisengagethebrake.Theunitmustbetieddownandbrakeengagedwhentransporting.IgnitionSwitchLocatedonrightfueltankconsol

WARNINGCALIFORNIAProposition65WarningTheengineexhaustfromthisproductcontainschemicalsknowntotheStateofCaliforniatocausecancer,birthdefects,orotherrepr

OperationRefertotheMaintenancesectionandperformallthenecessaryinspectionandmaintenancesteps.OperatingInstructionsRaisetheRolloverProtectionSystem(ROPS

OperationDANGERAnuncovereddischargeopeningwillallowobjectstobethrowninanoperator’sorbystander’sdirection.Also,contactwiththebladecouldoccur.Thrownobje

Operation3.Tomoveforwardinastraightlineapplyequalforwardpressuretobothlevers.Toturnleftorright,pullthemotioncontrolleverbacktowardneutralinthedirectio

OperationLoadingaUnitUseextremecautionwhenloadingunitsontrailersortrucks.Onefullwidthrampisrequired.Ifitisnotpossibletouseonefullwidthramp,useenoughin

MaintenanceMaintenanceNote:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.WARNINGWhilemaintenanceoradjustmentsarebeingmade,so

MaintenanceMaintenanceServiceIntervalMaintenanceProcedureEvery500hours•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)•Checkthewheelhu

MaintenanceVoltageReadingPercentChargeMaximumChargerSettingsChargingInterval12.6orgreater100%16volts/7ampsNoChargingRequired12.4–12.675–100%16volts/7a

MaintenanceNote:Ifmachinedoesnotpassanyofthesetests,DoNotoperate.ContactyourauthorizedEXMARKSERVICEDEALER.Important:Itisessentialthatoperatorsafetymec

Maintenance2.Tiltseatup.3.Cleanareaaroundhydraulicreservoircapandremovecap.Oillevelshouldbetothetopofthebafeinsidethetank.Ifnot,addoil.UseExmarkPremi

MaintenanceLubricationChartFittingLocationsInitialPumpsNumberofPlacesServiceInterval1.HitchandCylinderPivots2440Hours2.FoldPivotPin22100Hours3.FoldLoc

IntroductionCONGRATULATIONSonthepurchaseofyourExmarkMower.Thisproducthasbeencarefullydesignedandmanufacturedtogiveyouamaximumamountofdependabilityandy

Maintenance10.Withtheopenendofthewheelfacingup,lltheareainsidethewheelaroundtheaxlefullofNGLIgrade#1multi-purposegrease.11.Insertthesecondbearingandn

MaintenanceReplacementFiltersKohlerKohlerP/N2405010–15MicronBriggs&StrattonBriggs&StrattonP/N695327–30MicronChangeHydraulicSystemFilterService

Maintenance•Pumpdrivesheavesetscrews.•Lineshaftsheavesetscrews.•SquareheadsetscrewsonHydropumpcontrolarms.•Sheaveretainingboltintheendofenginecranksha

MaintenanceFigure121.Parkbrakeengaged3.Thinnylocnut2.Yoke4.1/8inch(3mm)gapbetweennutandyoke.5.Ifparkbrakedoesnotfullydisengagewhentheleverisdisengaged

MaintenanceFigure141.Loosenjamnut2.Pumpcontrolrodlinkage3.Usewrenchtoturndoublenuts9.Movethemotioncontrolleverstothereverseposition.Returnthemotioncon

MaintenanceFigure16Right-HandSideofUnitShown1.Re-installspringinouterholestoreducespringtension.3.Removee-ringandwasher.2.Weighttransferspring.7.Re-in

Maintenance3.Checktheconditionofthewireharnessleads,connectors,andterminals.Cleanorrepairasnecessary.4.Verifythat12Vispresentattheclutchconnectorwhent

MaintenanceIftheclutchdoesnotdisengage,reinstalltheshimandreferencetheTroubleshootingsection.c.EngageanddisengagethePTOswitchtenconsecutivetimestoensu

MaintenanceRemoveEngineShroudsandCleanCoolingFinsServiceInterval:Every80hours1.Stopengine,waitforallmovingpartstostop,andremovekey.Engageparkingbrake.

TroubleshootingTroubleshootingImportant:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperatingconditionpriortomoweruse.Whenaprobl

ContentsIntroduction...3Safety...

TroubleshootingProblemPossibleCauseCorrectiveAction1.Engineloadisexcessive1.Reducethegroundspeed.2.Oillevelinthecrankcaseislow .2.Addoiltothecrankcase

SchematicsSchematicsElectricalDiagram—27HPKohlerBATT (POS)CIRCUITBREAKERBATT (NEG)BLACKBLACKORANGEORANGEMOTOR (FWD)MOTOR (REV)REDREDBLACKBLACKGREY / B

SchematicsElectricalDiagram–31HPBriggs&Stratton3IASBXY SEAT DELAYMODULE CONTROL SEAT DELAYMODULE INPUT SEATSWITCH PTOCLUTCH PTO SWITCHGR

SchematicsElectricalLogicSchematic–27HPKohler DK. GREENFUEL SOLENOIDREGULATORENGINE KILLOIL PRESSURESTARTERSOLENOID DK. GREEN DK. GREEN

SchematicsElectricalLogicSchematic–31HPBriggs&StrattonSTART SOLENOID51243REDORANGERED 40 AMPCIRCUITBREAKERBLACKYELLOW / BLACKBLACKAUX 15A - 12V OU

SchematicsHydraulicDiagramCASE DRAINCHARGE PUMPHIGH PRESSUREG007220BYPASS VALVEBYPASS VALVEHIGH PRESSUREREVERSEHIGH PRESSUREFORWARDHIGH PRESSUREREVERS

Conditions and Products CoveredExmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant

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ServiceRecordDate:DescriptionofWorkDone:ServiceDoneBy:49

SafetySafetySafetyAlertSymbolThisSafetyAlertSymbol(Figure2)isusedbothinthismanualandonthemachinetoidentifyimportantsafetymessageswhichmustbefollowedto

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MID-MOUNT RIDING ACCESSORIES AND OPTIONSSEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONSWALK-BEHIND ACCESSORIES AND OPTIONSGRASS CATCHERMICRO-MUL

SafetyDANGERIncertainconditionsgasolineisextremelyammableandvaporsareexplosive.Areorexplosionfromgasolinecanburnyou,others,andcausepropertydamage.•F

SafetyOperationWARNINGOperatingengineparts,especiallythemufer,becomeextremelyhot.Severeburnscanoccuroncontactanddebris,suchasleaves,grass,brush,etc.c

Safety•Stoptheblades,slowdown,andusecautionwhencrossingsurfacesotherthangrassandwhentransportingthemowertoandfromtheareatobemowed.•Beawareofthemowerdi

SafetyWARNINGThereisnorolloverprotectionwhentherollbarisdown.Wheelsdroppingoveredges,ditches,steepbanks,orwatercancauserollovers,whichmayresultinserio