FRONTRUNNERTM
AIR-COOLED MODELS
For Serial Nos.
720,000 & Higher
Part No. 4500-218 Rev. A
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Introduction
CONGRATULATIONS on the purchase of your
Exmark Mower. This product has been carefully
designed and manufactured to give you a maximum
amount of dependability and years of trouble-free
operation.
This manual contains operating, maintenance,
adjustment, and safety instructions for your Exmark
mower.
BEFORE OPERATING YOUR MOWER,
CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
Figure 1
1. Model and serial number location
By following the operating, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
Model No.
Serial No.
If additional information is needed, or should you
require trained mechanic service, contact your
authorized Exmark equipment dealer or distributor.
All Exmark equipment dealers and distributors are
kept informed of the latest methods of servicing
and are equipped to provide prompt and efficient
service in the field or at their service stations. They
carry ample stock of service parts or can secure them
promptly for you from the factory.
All Exmark parts are thoroughly tested and inspected
before leaving the factory, however, attention is
required on your part if you are to obtain the fullest
measure of satisfaction and performance.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
numbers on the product. Write the numbers in the
space provided.
3
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Caster Pivot Bearings Pre-Load
Contents
Introduction ........................................................... 3
Engine (Briggs & Stratton Units
Lubricate Motion Control Bronze
4
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Safety
• Never let children or untrained people operate
Safety
Safety Alert Symbol
this manual and on the machine to identify important
safety messages which must be followed to avoid
accidents
or service the equipment. Local regulations may
restrict the age of the operator.
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
Preparation
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
• Evaluate the terrain to determine what accessories
and attachments are needed to properly and
safely perform the job. Only use accessories and
attachments approved by Exmark.
• Wear appropriate clothing including safety glasses,
substantial footwear, long trousers, and hearing
protection. Do Not operate when barefoot or
when wearing open sandals. Long hair, loose
clothing or jewelry may get tangled in moving
parts.
Figure 2
1. Safety alert symbol
The safety alert symbol appears above information
which alerts you to unsafe actions or situations
and will be followed by the word DANGER,
WARNING, or CAUTION.
CAUTION
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
This machine produces sound levels in
excess of 85 dBA at the operator’s ear and
can cause hearing loss through extended
periods of exposure.
WARNING: Black lettering / Orange background.
Indicates a potentially hazardous situation which, if
not avoided, Could result in death or serious injury.
Wear hearing protection when operating this
machine.
CAUTION: Black lettering / Yellow background.
Indicates a potentially hazardous situation which, if
not avoided, May result in minor or moderate injury.
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects which can be
thrown by the machine and may cause personal
injury to the operator or bystanders.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
Safe Operating Practices
Training
• Read the Operator’s Manual and other training
material. If the operator(s) or mechanic(s) can
not read English it is the owner’s responsibility to
explain this material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained.
The owner is responsible for training the users.
5
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Safety
DANGER
DANGER
In certain conditions gasoline is extremely
flammable and vapors are explosive.
In certain conditions during fueling, static
electricity can be released causing a spark
which can ignite gasoline vapors. A fire or
explosion from gasoline can burn you and
others and cause property damage.
A fire or explosion from gasoline can burn
you, others, and cause property damage.
• Fill the fuel tank outdoors in an open
area, when the engine is cold. Wipe up
any gasoline that spills.
• Always place gasoline containers on the
ground away from your vehicle before
filling.
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
• Do Not fill gasoline containers inside a
vehicle or on a truck or trailer bed because
interior carpets or plastic truck bed liners
may insulate the container and slow the
loss of any static charge.
• Do Not fill the fuel tank completely
full. Add gasoline to the fuel tank until
the level is 1/4 to 1/2 inch (6–13 mm)
below the bottom of the filler neck. This
empty space in the tank allows gasoline
to expand.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
• Never smoke when handling gasoline,
and stay away from an open flame or
where gasoline fumes may be ignited by
spark.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• Store gasoline in an approved container
and keep it out of the reach of children.
• If a gasoline dispenser nozzle must be
used, keep the nozzle in contact with the
rim of the fuel tank or container opening
at all times until fueling is complete.
• Add fuel before starting the engine.
Never remove the cap of the fuel tank or
add fuel when engine is running or when
the engine is hot.
WARNING
• If fuel is spilled, Do Not attempt to start
the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors has caused
cancer in laboratory animals. Failure to use
caution may cause serious injury or illness.
• Do Not operate without entire exhaust
system in place and in proper working
condition.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Keep away from eyes and skin.
• Never siphon by mouth.
• Check that the operator’s presence controls,
safety switches, and shields are attached and
functioning properly. Do Not operate unless they
are functioning properly.
6
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Safety
• Be sure all drives are in neutral and parking brake
is engaged before starting engine. Use seat belts.
Operation
• Never operate the mower with damaged guards,
shields, or covers. Always have safety shields,
guards, switches and other devices in place and in
proper working condition.
WARNING
Operating engine parts, especially the
muffler, become extremely hot. Severe burns
can occur on contact and debris, such as
leaves, grass, brush, etc. can catch fire.
• Never mow with the discharge deflector raised,
removed or altered unless there is a grass
collection system or mulch kit in place and
working properly.
• Allow engine parts, especially the muffler,
to cool before touching.
• Do Not change the engine governor setting or
overspeed the engine.
• Remove accumulated debris from muffler
and engine area.
• Stop engine, wait for all moving parts to stop,
remove key and engage parking brake:
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered, or
brush-covered unimproved land.
– Before checking, cleaning or working on the
mower.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
damage and make repairs before restarting
and operating the mower).
WARNING
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can
kill you.
– Before clearing blockages.
– Whenever you leave the mower.
• Stop engine, wait for all moving parts to stop, and
engage parking brake:
Do Not run engine indoors or in a small
confined area where dangerous carbon
monoxide fumes can collect.
– Before refueling.
– Before dumping the grass catcher.
WARNING
WARNING
Operating a FrontRunner tractor without an
approved Exmark front mount attachment
increases the possibility of forward tip over.
Tip-over could cause serious injury or death.
Hands, feet, hair, clothing, or accessories can
become entangled in rotating parts. Contact
with the rotating parts can cause traumatic
amputation or severe lacerations.
When operating a FrontRunner tractor
without an approved Exmark front mount
attachment, observe the following:
• Do Not operate the machine without
guards, shields, and safety devices in
place and working properly.
• Limit operation to minimum required to
install a different front mount attachment.
• Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
• Minimize speed and use extreme caution.
• Only operate on a flat level surface.
• NEVER carry passengers. DO NOT operate
the mower when people, especially children, or
pets are in the area.
• Do Not operate up or down a trailer ramp.
• Avoid sudden acceleration or deceleration.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
• Operate only in daylight or good artificial light,
keeping away from holes and hidden hazards.
• Stop the blades, slow down, and use caution when
crossing surfaces other than grass and when
7
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Safety
transporting the mower to and from the area to
be mowed.
• Be aware of the mower discharge path and direct
discharge away from others.
• Do Not operate the mower under the influence
of alcohol or drugs.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
Slope Operation
Figure 3
Use Extreme caution when mowing and/or turning
on slopes as loss of traction and/or tip-over could
occur. The operator is responsible for safe operation
on slopes.
1. Safe Zone-Use the mower here on slopes less than 15
degrees
2. Danger Zone-Use a walk behind mower and/or hand
trimmer near drop-offs and water.
3. Water
DANGER
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
Operating on wet grass or steep slopes can
cause sliding and loss of control. Wheels
dropping over edges, ditches, steep banks, or
water can cause rollovers, which may result
in serious injury, death or drowning.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Do Not mow slopes when grass is wet.
• Do Not mow near drop-offs or near water.
• Avoid sudden stops when mowing downhill
because the mower may tip forwards.
• Do Not mow slopes greater than 15
degrees.
• Be aware that loss of traction may occur going
uphill. Weight transfer to the rear wheels may
cause drive wheels to slip and cause loss of
braking and steering.
• Reduce speed and use extreme caution
on slopes.
• Avoid sudden turns or rapid speed
changes.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
• Follow the manufacturer’s recommendations for
wheel weights or counter weights to improve
stability.
• Use a walk behind mower and/or a hand trimmer
near drop-offs, ditches, steep banks or water.
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control.
Using the Rollover Protection System
(ROPS)
A Rollover Protection System (roll bar) is installed
on the unit.
8
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Safety
negative terminal first and the positive last.
Reconnect positive first and negative last.
WARNING
There is no rollover protection when the roll
bar is down. Wheels dropping over edges,
ditches, steep banks, or water can cause
rollovers, which may result in serious injury,
death or drowning.
• Use care when checking blades. Wrap the blade(s)
or wear gloves, and use caution when servicing
them. Only replace blades. Never straighten or
weld them.
• Keep hands and feet away from moving parts.
If possible, Do Not make adjustments with the
engine running.
• Keep the roll bar in the raised and locked
position and use seat belt.
• Charge batteries in an open well ventilated area,
away from spark and flames. Unplug charger
before connecting or disconnecting from battery.
Wear protective clothing and use insulated tools.
• Lower the roll bar only when absolutely
necessary.
• Do Not wear seat belt when the roll bar
is down.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Drive slowly and carefully.
• Raise the roll bar as soon as clearance
permits.
• Check all bolts frequently to maintain proper
tightness.
• Frequently check for worn or deteriorating
components that could create a hazard.
• Check carefully for overhead clearances (i.e.
branches, doorways, and electrical wires) before
driving under any objects and Do Not contact them.
• All replacement parts must be the same as
or equivalent to the parts supplied as original
equipment.
Maintenance and Storage
• Disengage drives, lower implement, set parking
brake, stop engine and remove key or disconnect
spark plug wire. Wait for all movement to stop
before adjusting, cleaning or repairing.
WARNING
Hydraulic fluid escaping under pressure
can penetrate skin and cause injury. Fluid
accidentally injected into the skin must be
surgically removed within a few hours by a
doctor familiar with this form of injury or
gangrene may result.
• Keep engine, engine area, and pump drive belt
compartment free from accumulation of grass,
leaves, excessive grease or oil, and other debris
which can accumulate in these areas. These
materials can become combustible and may result
in a fire.
• Make sure all hydraulic fluid hoses
and lines are in good condition and
all hydraulic connections and fittings
are tight before applying pressure to
hydraulic system.
• Let engine cool before storing and Do Not store
near flame or any enclosed area where open pilot
lights or heat appliances are present.
• Keep body and hands away from pinhole
leaks or nozzles that eject high pressure
hydraulic fluid.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• Use cardboard or paper, not your hands,
to find hydraulic leaks.
• Use jack stands to support components when
required.
• Safely relieve all pressure in the hydraulic
system by placing the motion control
levers in neutral and shutting off the
engine before performing any work on
the hydraulic system.
• Carefully release pressure from components with
stored energy.
• Disconnect battery or remove spark plug wire
before making any repairs. Disconnect the
9
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Safety
Safety and Instructional Decals
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• New safety signs may be obtained from
your authorized Exmark equipment dealer or
distributor or from Exmark Mfg. Co. Inc.
• Replace all worn, damaged, or missing safety
signs.
• Safety signs may be affixed by peeling off the
backing to expose the adhesive surface. Apply
only to a clean, dry surface. Smooth to remove
any air bubbles.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• Familiarize yourself with the following safety signs
and instruction labels. They are critical to the safe
operation of your Exmark commercial mower.
• If an attachment or accessory has been installed,
make sure current safety signs are visible.
98-4361
98-5954
103-2076
1-513747
103-3270
1-523552
103-5881
1-643339
10
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Safety
103-7218
107-2112
109-2355
109-2356
1. Fast
2. Slow
3. Neutral
4. Reverse
107-2102
11
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Safety
109-2396
109-2357
4. Reverse
1. Fast
2. Slow
3. Neutral
5. Park Brake—Release
6. Park Brake—Engage
109-3637
109-2358
109-2377
12
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