FRONTRUNNERTM
AIR-COOLED MODELS
For Serial Nos.
720,000 & Higher
Part No. 4500-219 Rev. A
Download from Www.Somanuals.com. All Manuals Search And Download.
READ OPERATOR’S MANUAL BEFORE
OPERATING OR SERVICING EXMARK EQUIPMENT.
TABLE OF CONTENTS
Description
Page
Auxiliary Hydraulic Group ................................................. 17
Decals .............................................................................. 23
Electrical Diagram 23HP & 27HP ..................................... 19
Electrical Diagram 31HP................................................... 20
Electrical Logic Schematic 23HP & 27HP......................... 21
Electrical Logic Schematic 31HP...................................... 22
Electrical Group................................................................ 18
Engine Group 23HP & 27HP ............................................ 13
Engine Group 31HP.......................................................... 14
Fuel Group........................................................................ 12
Hydraulic Group...........................................................15-16
Main Frame Group...........................................................3-6
Motion Control Group ....................................................... 11
Park Brake Group............................................................. 10
PTO Drive Group................................................................ 9
Rear Frame Group 23HP.................................................... 7
Rear Frame Group 27HP & 31HP ...................................... 8
2
Download from Www.Somanuals.com. All Manuals Search And Download.
MAIN FRAME GROUP
Item
DESCRIPTION
Qty.
Item
DESCRIPTION
Qty.
Part No.
Part No.
1
2
3
1-323142
109-2365
109-3339
1-633008
109-3338
1-633859
1-803035
98-5975
Nut, Push 1/2.........................................2
Bumper..................................................4
29 3296-7
30 109-0768
31 109-3547
32 109-2008
33 109-2009
34O 109-2005
35 109-2360
36 3256-14
37 3296-39
38 109-3637
39 110-0883
40 242-50
41 283-69
42 322-5
Nut, Nyloc 7/16-20................................. 2
Skirt, Rubber.......................................... 1
Asm, Front Console W/Decal ................ 1
Cushion, Seat Bottom/W Switch............ 1
Grp, Seat Track ..................................... 1
Asm, Seat W/Decal ............................... 1
Decal, Top Console ............................... 1
Washer, #10 Std.................................... 9
Nut, Nyloc 3/8-16................................... 4
Decal, Service Aid ................................. 1
Kit, Seatbelt........................................... 1
Nut, Lug 1/2-20...................................... 8
Pin, Clevis 1/2 x 3 1/2............................ 2
Screw, HH 5/16-18 x 1........................... 8
Screw, HH 5/16-18 x 1 1/2..................... 2
Screw, HH 3/8-16 x 1............................. 2
Screw, HH 3/8-16 x 1 1/2....................... 8
Screw, HH 3/8-16 x 1 3/4....................... 2
Screw, HH 7/16-20 x 1........................... 2
Nut, Nyloc 5/16-18................................. 4
Washer, 5/16 Std................................... 6
Washer, 3/8 Std..................................... 1
Nut, Whizlock 3/8-16 ............................. 8
Asm, Wheel & Tire (LH) (27 & 31HP) .... 1
Wheel.................................................... 1
Tire, 24x12-12 4 Ply............................... 1
Asm, Wheel & Tire (RH) (27 & 31HP).... 1
Wheel.................................................... 1
Tire, 24x12-12 4 Ply............................... 1
Asm, Wheel & Tire (23HP).....................2
Tire, 23x10.5-12 4 Ply............................2
WheWel.................................................2
4
5
6
7
8
9
Frame, Seat...........................................1
Rivet 3/16 x 1/4......................................9
Washer, Spring Disc 3/8 ........................8
Cushion, Armrest LH..............................1
Cushion, Armrest RH.............................1
Decal, Exmark Logo...............................2
Seat, Back .............................................1
Asm, ROPS Fold Pin .............................2
Spacer, Seat Track ................................2
Screw, HWH 1/4-20 x 3/4 Taptite...........11
Link, Seat Stop ......................................2
Asm, Seat Frame...................................1
103-0291
103-0292
103-2882
10 103-3520
11Q 103-4553
12 1-543401
13 103-8383
14 103-5161
15ꢀ 103-6761
43 322-7
44 323-6
45 323-8
16 103-6765-03 Latch, Seat ............................................1
46 323-9
17 32128-33
18 9264964
19 32128-20
20 3296-73
21 103-8316
22 103-8826
23 103-6761
24 1-633080
25X 109-2817
26 107-2102
27 107-3155
Nut, Whizlock 1/4-20..............................2
Bolt, HWH 5/16-18 x 3/4 Tap .................4
Nut, Whizlock 5/16-18............................16
Nut, Nyloc 1/4-20 ...................................2
Spring ....................................................1
Link, Lower Seat Stop............................2
Plate, Seat Mount ..................................1
Bushing..................................................2
Kit, ROPS ..............................................1
Decals, Warning ....................................1
Cotter, Hair Pin Double Loop .................2
47 3212-4
48 3296-29
49 3256-3
50 3256-4
51 3290-357
52 109-3479
109-3156
103-6771
53 109-3478
109-3156
103-6771
28 109-3633-03 Spacer, Seat Mount ...............................2
Exmark black touch up spray paint – Gloss black
Q
X
Includes ROPS fold pin plus hairpin, item #27.
Rollover protection frame is serviced as a complete assembly only. Includes complete ROPS frame, mounting
hardware, fold pivot and locking hardware, seat frame assembly item #15 and seat belt assembly item #39.
Includes armrests and seat back decal. Does not include seat belt or tracks.
Does not include item #19 or #48.
O
ꢀ
3
Download from Www.Somanuals.com. All Manuals Search And Download.
MAIN FRAME GROUP
4
Download from Www.Somanuals.com. All Manuals Search And Download.
MAIN FRAME GROUP (cont.)
Item
DESCRIPTION
Qty.
Item
DESCRIPTION
Qty.
Part No.
Part No.
1
2
3
4
5
6
7
8
9
1-513747
1-523157
1-643189
1-643339
1-806003
1-806005
1-808285
5-0652
Decal, Battery ........................................1
Washer..................................................4
Keeper, Rubber Latch............................2
Belt Routing, Decal ................................1
Hairpin, Cotter........................................2
Hairpin, Cotter........................................1
Pin, Clevis 3/8 x 1 1/8 ............................2
Spacer ...................................................4
Pin .........................................................2
Decal, Warning ......................................2
Decal, Danger........................................1
Pin .........................................................2
Tube, Pump Link Spacer .......................2
Ring, Retaining ......................................4
Decal, 3750 Rpm ...................................1
Decal, Guard..........................................2
Decal, Pump Fan Warning.....................1
Asm, Frame W/Decals...........................1
Latch, Hitch............................................2
Decal, Danger........................................1
Bumper, Rubber.....................................2
Asm, Hitch .............................................1
32 109-1256-03 Arm, Pivot.............................................. 2
33 109-1257-03 Hook, Hood............................................ 2
34 109-2114
35 109-2857
36 109-2777
Decal, Frontrunner................................. 1
Asm, Hood............................................. 1
Asm, Hood Support W/Decals .............. 1
Asm, Hood Support W/Decals
(27 & 31 HP)
109-6070
1
37 109-2004
38 32128-20
39 109-2355
40 109-2356
41 109-2357
42 109-2396
43 302-19
44 322-3
Roller, Lock Lever.................................. 2
Nut, Whizlock 5/16-18 ........................... 4
Decal, Spring Loaded ............................ 2
Decal, Motion Control ............................ 1
Decal, Motion Cntl/Park Brake............... 1
Decal, Pump Drive Release................... 1
Zerk, 1/4-28 Str...................................... 2
Screw, HH 5/16-18 x 3/4........................ 4
Screw, HH 5/16-18 x 7/8........................ 8
Screw, HH 3/8-16 x 2 1/4....................... 2
Screw, HH 3/8-16 x 1 1/2....................... 2
Screw, HH 1/2-13 x 4 1/2....................... 2
Ring, Retaining...................................... 4
Washer, 5/16 SAE................................. 20
Washer, 3/8 SAE................................... 4
Washer, 1/2 SAE................................... 8
Washer, 5/8 SAE................................... 2
Rivet ...................................................... 4
Nut, Nyloc 1/2-13................................... 2
Nut, Nyloc 5/16-18................................. 8
Nut, Nyloc 3/8-16................................... 4
E-Ring ................................................... 2
Decal, FrontRunner ............................... 1
93-2699
10 98-4361
11 98-5954
12 100-1663
13 103-1166
14 32151-36
15 103-3270
16 103-5881
17 103-7218
18 109-6069
19 103-9727
20 107-2112
21 107-8042
22 109-0075
45 322-4
46 323-11
47 323-8
48 325-18
49 32120-47
50 3256-23
51 3256-24
52 3256-26
53 3256-27
54 3269-24
55 3296-23
56 3296-29
57 3296-39
58 32120-19
59 109-2114
23 109-0080-03 Wld, Hitch..............................................1
24 109-0325
25 109-0411
26 109-0435
27 109-0450
28 109-2772
29 109-2773
30 109-2774
31 109-0634
Pin, Full Fold..........................................1
Spring ....................................................2
Bushing..................................................4
Asm, Spring...........................................2
Asm, Floorpan W/Decal.........................1
Asm, Spring Bellcrank W/Decal (RH).....1
Asm, Spring Bellcrank W/Decal (LH) .....1
Wld, Spring Anchor................................4
Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).
Exmark black touch up spray paint – Gloss black
5
Download from Www.Somanuals.com. All Manuals Search And Download.
MAIN FRAME GROUP (cont.)
6
Download from Www.Somanuals.com. All Manuals Search And Download.
REAR FRAME GROUP 23HP
Item
Description
Qty.
Item
Description
Qty.
Part No.
Part No.
1
2
3
4
5
6
7
8
9
1-513746
1-543508
1-543509
1-543511
1-633508
1-633585
1-643188
1-811010
103-0063
Decal, Muffler.........................................2
Cup, Bearing Tapered Roller..................2
Cone, Bearing Tapered Roller................2
Seal, Grease..........................................1
Washer, Spring Disc..............................3
Bearing, Cone Tapered Roller................2
Latch......................................................2
Plug .......................................................1
Seal, Double Lip.....................................2
Guard, Seal............................................2
Spacer, Nut............................................2
Asm, Caster Wheel................................1
Rivet ......................................................4
Cap, Grease ..........................................1
Axle, Caster ...........................................1
Asm, Single Tailwheel............................1
18 103-9789-03 Guard, Hose .......................................... 1
19 103-9868-03 Wld, Caster Fork ................................... 1
20 105-7699
21 109-2769
Strip, Seal.............................................. 2
Kit, Rear Guard...................................... 1
22 109-0414-03 Cover, Muffler........................................ 1
23 322-3
Screw, HH 5/16-18 x 3/4........................ 5
Screw, HH 3/8-16 x 1............................. 4
Screw, HH 1/2-13 x 9 1/2....................... 1
Screw, HH 1/2-13 x 1 1/4....................... 6
Washer, 5/16 SAE................................. 5
Washer, 3/8 Std..................................... 2
Nut, Whizlock 3/8-16 ............................. 4
Nut, Nyloc 1/2-13................................... 1
Nut, Nyloc 3/4-10................................... 1
Nut, Whizlock 5/16-18 ........................... 5
Nut, Whizlock 1/2-13 ............................. 6
24 323-6
25 325-39
26 325-5
10 103-2768
11 103-3051
12 103-3799
13 923786
27 3256-23
28 3256-4
29 3290-357
30 3296-23
31 3296-51
32 32128-20
33 32128-49
14 103-4882
15 103-5156
16 103-6704
17 103-6748-03 Wld, Rear Caster Hub............................1
Exmark black touch up spray paint – Gloss black
7
Download from Www.Somanuals.com. All Manuals Search And Download.
REAR FRAME GROUP 27HP & 31HP
Item
Description
Qty.
Item
Description
Qty.
Part No.
Part No.
1
2
3
4
5
6
7
8
9
1-513746
1-543508
1-543509
1-543511
1-633508
1-633585
1-643188
1-811010
103-0063
Decal, Muffler.........................................2
Cup, Bearing Tapered Roller..................4
Cone, Bearing Tapered Roller................4
Seal, Grease..........................................2
Washer, Spring Disc..............................6
Bearing, Cone Tapered Roller................4
Latch......................................................2
Plug .......................................................2
Seal, Double Lip.....................................4
Guard, Seal............................................4
Spacer, Nut............................................4
Rivet ......................................................4
Asm, Caster Wheel................................2
Cap, Grease ..........................................2
Axle, Caster ...........................................2
Bearing, Sleeve......................................2
22 103-9868-03 Wld, Caster Fork ................................... 2
23 103-9974
24 105-7699
25 109-2769
109-6071
Washer.................................................. 1
Strip, Seal.............................................. 2
Asm, Rear Guard W/Decals (27 HP) ..... 1
Asm, Rear Guard W/Decals (31 HP) ..... 1
26 109-0414-03 Cover, Muffler (27 HP)........................... 1
109-5580-03 Cover, Muffler (31 HP)........................... 1
27 302-19
28 322-3
Zerk, 1/4-28 Str...................................... 1
Screw, HH 5/16-18 x 3/4........................ 5
Screw, HH 3/8-16 x 1............................. 4
Screw, HH 1/2-13 x 9 1/2....................... 2
Screw, HH 1/2-13 x 1 1/4....................... 6
Screw, HH 5/8-11 x 5 3/4....................... 1
Washer, 5/16 SAE................................. 5
Washer, 3/8 Std..................................... 2
Nut, Whizlock 3/8-16 ............................. 4
Nut, Nyloc 1/2-13................................... 2
Nut, Nyloc 3/4-10................................... 2
Nut, Nyloc 5/8-11................................... 1
Nut, Whizlock 5/16-18 ........................... 5
Nut, Whizlock 1/2-13 ............................. 6
10 103-2768
11 103-3051
12 923786
29 323-6
30 325-39
31 325-5
13 103-3799
14 103-4882
15 103-5156
16 103-6825
32 327-24
33 3256-23
34 3256-4
35 3290-357
36 3296-23
37 3296-51
38 3296-53
39 32128-20
40 32128-49
17 103-7957-03 Wld, Dual Caster Tube...........................1
18 103-8347 Asm, Dual Rear Wheels.........................1
19 103-9045-03 Wld, Rear Frame Dual Wheel................1
20 103-9051 Bearing, Thrust ......................................2
21 103-9789-03 Guard, Hose ..........................................1
Exmark black touch up spray paint – Gloss black
8
Download from Www.Somanuals.com. All Manuals Search And Download.
|