Exmark FrontRunner Diesel User manual

FRONTRUNNERTM
DIESELMODELS
ForSerialNos.
720,000&Higher
PartNo.4500-227Rev.A

WARNING
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof
Californiatocausecancer,birthdefects,
andotherreproductiveharm.
Important:Whenthemowerisusedoroperated
onanyCaliforniaforest,brushorgrasscovered
land,aworkingsparkarrestermustbeattached
tothemufer.Ifnot,theoperatorisviolating
statelaw,Section4442PublicResourceCode.To
acquireasparkarresterforyourunit,seeyour
EngineServiceDealer.
ThissparkignitionsystemcomplieswithCanadian
ICES-002Cesystèmed’allumageparètincellede
vèhiculeestconformeàlanormeNMB-002du
Canada
TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.
KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2006–2008—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE683102
Contactusatwww.Exmark.com.
PrintedintheUSA.
AllRightsReserved

Introduction
CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.
Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
3

Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals.....................10
Specications.......................................................14
ModelNumbers............................................14
Systems.........................................................14
Dimensions...................................................16
TorqueRequirements....................................16
ProductOverview................................................17
Operation.............................................................17
Controls........................................................17
Pre-Start........................................................19
OperatingInstructions..................................19
Transporting.................................................21
Maintenance.........................................................23
RecommendedMaintenanceSchedule(s)...........23
PeriodicMaintenance.......................................24
CheckEngineOilLevel.................................24
CheckEngineCoolantLevel..........................24
ChangeEngineCoolant.................................25
CheckBatteryCharge....................................25
CheckSafetyInterlockSystem.......................26
CheckRolloverProtectionsSystems(Roll
Bar)Pins...................................................27
CheckSeatBelt..............................................27
CheckforLooseHardware............................27
ServiceAirCleaner........................................27
ChangeEngineOil........................................27
CheckHydraulicOilLevel.............................28
CheckTirePressures.....................................28
CheckConditionOfBelts..............................28
LubricateGreaseFittings...............................29
LubricateRearCasterWheelHub(s)...............29
LubricateBrakeHandlePivot........................30
LubricateBrakeRodBushings.......................30
LubricateMotionControlBronze
Bushings...................................................30
LubricateMotionControlShaft.....................30
LubricateSteeringLinkageRodEnds.............31
ChangeFuelFilter.........................................31
ChangeHydraulicSystemFilter.....................31
CheckWheelHubLocknuts..........................32
ThreadLockingAdhesives.............................32
DielectricGrease...........................................32
Adjustments.....................................................33
PumpDriveBeltTension...............................33
PumpDriveBeltReplacement.......................33
AlternatorBeltTension.................................33
ParkBrakeAdjustment..................................33
MotionControlLinkageAdjustment.............34
ReverseIndicatorAdjustment........................35
WeightTransferSpringAdjustment...............35
RearCasterPivotBearingsPre-Load
Adjustment...............................................36
Cleaning...........................................................37
CleanEngineCoolingSystem........................37
WasteDisposal..............................................37
Troubleshooting...................................................38
Schematics...........................................................40
4

Safety
Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
1.Safetyalertsymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.
CAUTION
Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.
Wearhearingprotectionwhenoperatingthis
machine.
•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
5

Safety
DANGER
Incertainconditionsdieselisextremely
ammableandvaporsareexplosive.
Areorexplosionfromdieselcanburnyou,
others,andcausepropertydamage.
•Fillthefueltankoutdoorsinanopen
area,whentheengineiscold.Wipeup
anydieselthatspills.
•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.
•DoNotllthefueltankcompletelyfull.
Adddieseltothefueltankuntilthelevel
is1/4to1/2inch(6–13mm)belowthe
bottomofthellerneck.Thisempty
spaceinthetankallowsdieseltoexpand.
•Neversmokewhenhandlingdiesel,and
stayawayfromanopenameorwhere
dieselfumesmaybeignitedbyspark.
•Storedieselinanapprovedcontainerand
keepitoutofthereachofchildren.
•Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.
•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
WARNING
Dieselfuelisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleanddiesel
tank/containeropening.
•Keepawayfromeyesandskin.
•Neversiphonbymouth.
•Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
Operation
WARNING
Operatingengineparts,especiallythe
mufer,becomeextremelyhot.Severeburns
canoccuroncontactanddebris,suchas
leaves,grass,brush,etc.cancatchre.
•Allowengineparts,especiallythemufer,
tocoolbeforetouching.
•Removeaccumulateddebrisfrommufer
andenginearea.
•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.
DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.
6

Safety
WARNING
OperatingaFrontRunnertractorwithoutan
approvedExmarkfrontmountattachment
increasesthepossibilityofforwardtipover.
Tip-overcouldcauseseriousinjuryordeath.
WhenoperatingaFrontRunnertractor
withoutanapprovedExmarkfrontmount
attachment,observethefollowing:
•Limitoperationtominimumrequiredto
installadifferentfrontmountattachment.
•Minimizespeedanduseextremecaution.
•Onlyoperateonaatlevelsurface.
•DoNotoperateupordownatrailerramp.
•Avoidsuddenaccelerationordeceleration.
•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.Useseatbelts.
•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly.
•DoNotchangetheenginegovernorsettingor
overspeedtheengine.
•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.
•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:
–Beforerefueling.
–Beforedumpingthegrasscatcher.
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.
•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
•NEVERcarrypassengers.DONOToperate
themowerwhenpeople,especiallychildren,or
petsareinthearea.
•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.
•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.
•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.
7

Safety
DANGER
Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Wheels
droppingoveredges,ditches,steepbanks,or
watercancauserollovers,whichmayresult
inseriousinjury,deathordrowning.
•DoNotmowslopeswhengrassiswet.
•DoNotmowneardrop-offsornearwater.
•DoNotmowslopesgreaterthan15
degrees.
•Reducespeedanduseextremecaution
onslopes.
•Avoidsuddenturnsorrapidspeed
changes.
•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
•Useawalkbehindmowerand/orahandtrimmer
neardrop-offs,ditches,steepbanksorwater.
(Figure3).
Figure3
1.SafeZone-Usethemowerhereonslopeslessthan15
degrees
2.DangerZone-Useawalkbehindmowerand/orhand
trimmerneardrop-offsandwater.
3.Water
•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
•Avoidsuddenstopswhenmowingdownhill
becausethemowermaytipforwards.
•Beawarethatlossoftractionmayoccurgoing
uphill.Weighttransfertotherearwheelsmay
causedrivewheelstoslipandcauselossof
brakingandsteering.
•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.
UsingtheRolloverProtectionSystem
(ROPS)
ARolloverProtectionSystem(rollbar)isinstalled
ontheunit.
WARNING
Thereisnorolloverprotectionwhentheroll
barisdown.Wheelsdroppingoveredges,
ditches,steepbanks,orwatercancause
rollovers,whichmayresultinseriousinjury,
deathordrowning.
•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.
•Lowertherollbaronlywhenabsolutely
necessary.
•DoNotwearseatbeltwhentherollbar
isdown.
•Driveslowlyandcarefully.
•Raisetherollbarassoonasclearance
permits.
•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,andelectricalwires)before
drivingunderanyobjectsanddonotcontactthem.
8

Safety
MaintenanceandStorage
•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.
•Keepengine,enginearea,andpumpdrivebelt
compartmentfreefromaccumulationofgrass,
leaves,excessivegreaseoroil,andotherdebris
whichcanaccumulateintheseareas.These
materialscanbecomecombustibleandmayresult
inare.
•LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.
•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.
•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplaceblades.Neverstraightenor
weldthem.
•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.
•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.
•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
•Checkallboltsfrequentlytomaintainproper
tightness.
•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.
•Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.
•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.
•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.
WARNING
Fuelsystemcomponentsareunderhigh
pressure.Theuseofimpropercomponents
canresultinsystemfailure,fuelleakageand
possibleexplosion.
Useonlyapprovedfuellinesandclampsfor
highpressuresystems.
9

Safety
SafetyandInstructionalDecals
•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
•Replaceallworn,damaged,ormissingsafety
signs.
•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
103-2076
1-513747
1-523552
1-643339
98-4361
98-5954
103-0223
10