Exmark Frontrunner Manuel

109-4336 Rev. A

Page 1 of 4

Loose Parts

Note: Use the chart below to verify that all parts have been shipped.

109-4333 Dealer Literature Pack

Part # Description Qty Use

323-8

98-5975

3290-357

283-69

1-323142

Cap Screw, Hex 3/8-16 x 1-1/2

Washer, Belleville

Nut, Hex Flange 3/8-16

Pin, Clevis 1/2 x 3-1/2

Nut, Push 1/2

Installing the Rollover Protection System (Roll Bar)

103-1309 Warranty Registration Form 1 Fill out and return to Exmark

103-2106

1-603511 Key, Exmark Ignition

Key, Standard Ignition 1

1 Unit ignition

109-4332 Literature Pack

Part # Description Qty Use

------------

109-3498

Manual, Operator’s

Manual, Parts

DVD, Exmark Safety Video

1 Read and view before operating machine

110-3850 Manual, Engine Operator’s 1 For Units with Kubota Engines

Installing the Rollover Protection

System (Roll Bar)

For Units with the roll bar shipped loose:

1. Remove sides and top of crate from the base.

2. Remove roll bar components from the crate.

3. Remove roll bar tubes from sides of crate.

4. Locate the left and right lower roll bar tubes.

5. Align lower bar tubes along rear engine frame

6. Loosely install four 3/8-16 x 1-1/2 capscrews, four

spring disc washers, and four 3/16-18 whizlock

nuts to secure the rollbar to the frame of the unit.

(Fig. 1)

NOTE: Be sure the spring disk washer cone is

installed towards the head of the capscrew.

FIGURE 1

FRONTRUNNER™ DIESEL

SETUP INSTRUCTIONS

For Serial Nos. 670,000 and Highe

109-4336 Rev. A

Page 2 of 4

FIGURE 2

7. Locate the latch pin assemblies (pin and hairpin

connected with a lanyard).

8. Insert a 1/2 x 3-1/2 clevis pin into the bent tab

washer on the lanyard of each pin assembly. (See

Fig. 2)

NOTE: Make sure the bent tab in the washer is

towards the head of the clevis pin.

9. Lightly oil the inside surfaces of the ear-shaped

plates at the upper end of the lower roll bar tubes

10. Locate the upper u-shaped section of the roll bar.

Install the upper roll bar section using the two 1/2

x 3-1/2 clevis pins and two 1/2 push nuts. Make

sure upper roll bar can pivot freely.

NOTES:

Make sure the pin and push nuts are installed

with the push nut to the inside of the roll bar.

Make sure the tab on the lanyard washer is

installed as shown.

11. Raise the roll bar into the upright position and

secure with the latch pin assemblies on each side.

Install latch pin from outer surface of roll bar

assembly and secure with the hairpin to the inside.

12. Torque all lower roll bar hardware attached to the

machine frame to 30-35 ft-lbs. (41-47 N-m).

For Units with the roll bar shipped already

assembled to unit:

1. Remove top and sides from crate.

2. Loosen the mounting hardware that retains the

rollbar to each side of the unit. (Fig. 3)

3. Rotate the roll bar upwards and forward until the

remaining three holes in the mounting plate are

aligned with the holes in the unit frame.

4. Loosely install three 3/8-16 x 1-1/2” capscrews,

three spring disc washers, and three 3/16-18

whizlock nuts to secure the rollbar to the frame of

the unit. (Fig. 3)

NOTE: Be sure the spring disk washer cone is

installed towards the head of the capscrew.

5. Lightly oil the inside surfaces of the ear-shaped

plates at the upper end of the lower roll bar tubes.

6. Raise the roll bar into the upright position and

secure with the latch pin assemblies on each side.

Install latch pin from outer surface of roll bar

assembly and secure with the hairpin to the

inside.

7. Torque all lower roll bar hardware attached to the

machine frame to 30-35 ft-lbs. (41-47 N-m).

FIGURE 3

Installing Drive Wheels

1. Raise the front of the unit approximately 10-12”

and support it with jack stands or equivalent

support.

CAUTION

POTENTIAL HAZARD

♦Raising the front of the unit for assembly

relying solely on mechanical or hydraulic jacks

could be dangerous.

WHAT CAN HAPPEN

♦The mechanical or hydraulic jacks may not be

enough support or may malfunction allowing

the unit to fall, which could cause injury.

HOW TO AVOID THE HAZARD

♦DO NOT rely solely on mechanical or hydraulic

jacks for support. Use adequate jack stands or

equivalent support.

2. Remove the 1/2-20 drive wheel nuts (installed

on studs of drive motors) and retain for wheel

mounting. Remove and discard shipping

brackets mounted on wheel hubs.

109-4336 Rev. A

Page 3 of 4

3. Mount drive wheels with the valve stem to the

outside of the unit. Secure using four (4) 1/2-20

wheel nuts removed in step 2.

Torque to 95 ft-lbs (128 NxM).

Checking Tire Air Pressure

1. Check the air pressure in the drive tires.

Proper inflation for the drive tires is 9 psi (62

kPa). Adjust if necessary.

2. The mower deck casters and rear caster tires are

semi-pneumatic. No adjustment is necessary.

Servicing the Battery

The machine is shipped with a filled lead acid

battery.

1. Stop engine, wait for all moving parts to stop, and

remove key. Engage parking brake.

2. Tilt seat forward and raise hood to gain access to

the battery

3. Remove battery cover from machine.

DANGER

POTENTIAL HAZARD

♦Charging the battery may produce explosive

gasses

WHAT CAN HAPPEN

♦Battery gasses can explode causing serious

injury.

HOW TO AVOID THE HAZARD

♦Keep sparks, flames, or cigarettes away from

battery.

♦Ventilate when charging or using battery in an

enclosed space.

♦Make sure venting path of battery is always

open once battery is filled with acid.

2. Check the voltage of the battery with a digital

voltmeter. Locate the voltage reading of the battery

in the table below and charge the battery for the

recommended time interval to bring the charge up

to a full charge of 12.6 volts or greater.

IMPORTANT: Make sure the negative battery

cables are disconnected and the battery charger

used for charging the battery has an output of 16

volts and 7 amps or less to avoid damaging the

battery (see chart below for recommended charger

settings).

Voltage

Reading Percent

Charge

Maximum

Charger

Settings

Charging

Interval

12.6 or greater 100% 16 volts /

7 amps No Charging

Required

12.4 – 12.6 75 – 100% 16 volts /

7 amps 30 Minutes

12.2 – 12.4 50 – 75% 16 volts /

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 less 0% 14.4 volts /

2 amps 6 Hours

or More

CAUTION

POTENTIAL HAZARD

♦If the ignition is in the “ON” position there is

potential for sparks and engagement of

components.

WHAT CAN HAPPEN

♦Sparks could cause an explosion or moving

parts could accidentally engage causing

personal injury.

HOW TO AVOID THE HAZARD

♦Be sure ignition switch is in the “OFF” position

before charging the battery.

3. Connect the negative battery cables.

NOTE: If the positive cable is also

disconnected, connect the positive (red) cable

to the positive battery terminal first, then the

negative (black) cable to the negative battery

terminal. Slip insulator boot over the positive

terminal.

NOTE: If time does not permit charging the

battery, or if charging equipment is not available,

connect the negative battery cables and run the

vehicle continuously for 20 to 30 minutes to

sufficiently charge the battery.

Servicing the Engine

Engine is shipped with oil; check oil level and if

necessary fill to the appropriate level with oil as

specified in Engine Owner’s Manual.

Servicing the Hydraulic Oil

The machine is shipped with hydraulic oil in the

reservoir.

1. Run the machine for approximately 15 minutes

to allow any extra air to purge out of the

hydraulic system.

WARNING: Battery posts, terminals, and related

accessories contain lead compounds, chemicals

known to the State of California to cause cancer and

reproductive harm. Wash hands after handling.

109-4336 Rev. A

Page 4 of 4

2. Check hydraulic reservoir and if necessary fill the

reservoir to the appropriate level with Mobil 1

15W-50 synthetic motor oil.

3. Replace hydraulic reservoir cap and tighten until

snug. Do not overtighten.

NOTE: The baffle is labeled “HOT” and “COLD”.

The oil level varies with the temperature of the oil.

The “HOT” level shows the level of oil when it is at

225°F (107°C). The “COLD” level shows the level of

the oil when it is at 75°F (24°C). Fill to the

appropriate level depending upon the temperature of

the oil. For example: If the oil is about 150° F (65°C).

Fill to halfway between the “HOT” and “COLD” levels.

If the oil is at room temperature (about 75° F (24°C)),

fill only to the “COLD” level.

Checking Unit Tracking

Operate unit with both drive levers pushed to the full

forward position. Verify that the unit tracks in a straight

line. If not, adjust motion control linkages to correct

tracking as described in Operator’s Manual Adjustment

Section 4.2.5.

WARNING

POTENTIAL HAZARD

♦Operating a FrontRunner tractor without an

approved Exmark front mount attachment

increases the possibility of forward tip over.

WHAT CAN HAPPEN

♦Tip-over could cause serious injury or death.

HOW TO AVOID THE HAZARD

♦When operating a FrontRunner tractor without

an approved Exmark front mount attachment,

observe the following:

9Limit operation to minimum required to

install a different front mount attachment.

9Minimize speed and use extreme caution.

9Only operate on a flat level surface.

9Do not operate up or down a trailer ramp.

9Avoid sudden acceleration or deceleration.

Checking Safety Interlock System

1. Check starting circuit. The starter should crank

with the parking brake engaged, PTO

disengaged, the operator in the seat, and motion

control levers moved out in the neutral lock

position.

Disengage parking brake. The starter must not

crank.

Engage parking brake and engage PTO. The

starter must not crank.

Disengage parking brake and move each drive

lever in separately. Starter must not crank. Move

both drive levers in. Starter must not crank.

2. Check the kill circuits. Run engine at one-third

throttle, disengage parking brake and raise off of

seat (but do not get off of machine) engine must

stop after approx. 1/2 second has elapsed.

Run engine at one-third throttle, engage PTO

and raise off of seat (but do not get off of

machine) engine must stop after 1/2 second has

elapsed.

Run engine at one-third throttle, with brake

disengaged, move levers in and raise off seat

(but do not get off of machine) engine must stop

after 1/2 second has elapsed.

Run engine at one-third throttle, with brake

engaged, move left motion control lever in -

engine must stop.

Repeat moving the right lever in, then moving

both levers in - engine must stop whether

operator is on seat or not.

3. Check the PTO circuit: Open the folding deck

latches, disengage the park brake, move the

motion control levers in to neutral, and

disengage the PTO. Lower the deck until the

PTO switch arm is no longer depressing the

PTO “kill” switch. See Figure 4.

FIGURE 4

Run the engine at half throttle and pull up on the

PTO engagement switch.

The PTO must not engage.

NOTE: If machine does not pass any of these

tests, diagnose and repair any malfunctions

before final delivery to customer.

IMPORTANT: It is essential that operator safety

mechanisms be connected and in proper

operating condition prior to use for mowing.

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