Exmark Frontrunner FR23KC User manual

Brand: Exmark

Model: Frontrunner FR23KC

Category: Lawnmowers

Type: User manual

FRONTRUNNERTM

AIR-COOLEDMODELS

ForSerialNos.

720,000&Higher

PartNo.4500-218Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,or

otherreproductiveharm.

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.

IndustrialParkBox808

Beatrice,NE68310

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.

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.....................10

Specications.......................................................14

ModelNumbers............................................14

Systems.........................................................14

Dimensions...................................................16

TorqueRequirements....................................17

ProductOverview................................................17

Operation.............................................................18

Controls........................................................18

Pre-Start........................................................19

OperatingInstructions..................................19

Transporting.................................................22

Maintenance.........................................................23

RecommendedMaintenanceSchedule(s)...........23

PeriodicMaintenance.......................................24

CheckEngineOilLevel.................................24

CheckBatteryCharge....................................24

CheckSafetyInterlockSystem.......................25

CheckRolloverProtectionsSystems(Roll

Bar)Pins...................................................26

CheckSeatBelt..............................................26

CheckforLooseHardware............................26

ServiceAirCleaner........................................26

ChangeEngineOil........................................26

CheckHydraulicOilLevel.............................27

CheckTirePressures.....................................27

CheckConditionOfBelts..............................28

LubricateGreaseFittings...............................28

LubricateRearCasterWheelHub(s)...............28

LubricateBrakeHandlePivot........................29

LubricateBrakeRodBushings.......................29

LubricateMotionControlBronze

Bushings...................................................29

LubricateMotionControlShaft.....................29

LubricateSteeringLinkageRodEnds.............29

CheckSparkPlugs.........................................30

ChangeHydraulicSystemFilter.....................30

CheckWheelHubLocknuts..........................30

ThreadLockingAdhesives.............................30

DielectricGrease...........................................31

Adjustments.....................................................31

PumpDriveBeltTension...............................31

PumpDriveBeltReplacement.......................31

ParkBrakeAdjustment..................................31

MotionControlLinkageAdjustment.............32

WeightTransferSpringAdjustment...............33

CasterPivotBearingsPre-Load

Adjustment...............................................34

Cleaning...........................................................34

CleanEngineCoolingSystem........................34

RemoveAccumulatedDebrisfrom

Engine(Briggs&StrattonUnits

Only).........................................................34

RemoveEngineShroudsandCleanCooling

Fins...........................................................35

WasteDisposal..............................................35

Troubleshooting...................................................36

Schematics...........................................................38

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.

Safety

DANGER

Incertainconditionsgasolineisextremely

ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn

you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen

area,whentheengineiscold.Wipeup

anygasolinethatspills.

•Neverrellthefueltankordrainthe

machineindoorsorinsideanenclosed

trailer.

•DoNotllthefueltankcompletely

full.Addgasolinetothefueltankuntil

thelevelis1/4to1/2inch(6–13mm)

belowthebottomofthellerneck.This

emptyspaceinthetankallowsgasoline

toexpand.

•Neversmokewhenhandlinggasoline,

andstayawayfromanopenameor

wheregasolinefumesmaybeignitedby

spark.

•Storegasolineinanapprovedcontainer

andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.

Neverremovethecapofthefueltankor

addfuelwhenengineisrunningorwhen

theengineishot.

•Iffuelisspilled,DoNotattempttostart

theengine.Moveawayfromtheareaof

thespillandavoidcreatinganysourceof

ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust

systeminplaceandinproperworking

condition.

DANGER

Incertainconditionsduringfueling,static

electricitycanbereleasedcausingaspark

whichcanignitegasolinevapors.Areor

explosionfromgasolinecanburnyouand

othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe

groundawayfromyourvehiclebefore

lling.

•DoNotllgasolinecontainersinsidea

vehicleoronatruckortrailerbedbecause

interiorcarpetsorplastictruckbedliners

mayinsulatethecontainerandslowthe

lossofanystaticcharge.

•Whenpractical,removegas-powered

equipmentfromthetruckortrailerand

refueltheequipmentwithitswheelson

theground.

•Ifthisisnotpossible,thenrefuelsuch

equipmentonatruckortrailerfroma

portablecontainer,ratherthanfroma

gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe

used,keepthenozzleincontactwiththe

rimofthefueltankorcontaineropening

atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.

Long-termexposuretovaporshascaused

cancerinlaboratoryanimals.Failuretouse

cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas

tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperator’spresencecontrols,

safetyswitches,andshieldsareattachedand

functioningproperly.DoNotoperateunlessthey

arefunctioningproperly.

Safety

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.

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

Safety

transportingthemowertoandfromtheareato

bemowed.

•Beawareofthemowerdischargepathanddirect

dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence

ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe

machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning

onslopesaslossoftractionand/ortip-overcould

occur.Theoperatorisresponsibleforsafeoperation

onslopes.

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.

Safety

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.

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.

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

103-3270

103-5881

Safety

103-7218

107-2102

107-2112

109-2355

109-2356

1.Fast3.Neutral

2.Slow

4.Reverse

Safety

109-2357

1.Fast4.Reverse

2.Slow

5.ParkBrake—Release

3.Neutral6.ParkBrake—Engage

109-2358

109-2377

109-2396

109-3637

Safety

109-7413

1.Cylinder—extend4.Slow

2.Cylinder—retract5.Choke—on

3.Fast

6.Choke—off

109-7949

109-2360

Specications

ModelNumbers

SerialNos:720,000andHigher

FR23KC;FR27KC;FR31BV

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s

Manual

•RPM:FullSpeed:3750±50RPM(NoLoad)

Idle:1500RPM

FuelSystem

•Capacity:8.5gal.(32L)

•TypeofFuel:Regularunleadedgasoline,87

octaneorhigher.

•FuelFilter:

–Kohler:

In-line15MicronKohlerP/N2405010.

–Briggs&Stratton:

In-line30MicronBriggsP/N695327.

•FuelShut-OffValve:1/4turnincrements(“ON”,

“OFF”).

•Fuelgaugeinrighthandfueltank.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

–Kohler:15amps

–Briggs&Stratton:20amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:

–Kohler:

One15ampandtwo20ampbladetype

–Briggs&Stratton:

One15amp,one20amp,andone30amp

bladetype

SafetyInterlockSystem

•PTOmustbedisengaged,brakeengaged,and

motioncontrolleversout(neutrallock)tostart

engine.(Itisnotnecessaryfortheoperatortobe

intheseattostarttheengine.)

•OperatormustbeinseatwhenPTOisengaged,

brakeisdisengaged,ormotioncontrolleversare

movedinorenginewillstop.

•Enginewillstopifthemotioncontrollevers

aremovedfromneutralpositionwhilebrakeis

engaged.

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto

threeheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe

respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementLever:EngagesdrivetoPTO

(mowerdeck).

•ParkingBrakeLever:Engagesparkingbrakeby

pullingback.

Seat

•Type:Standardseatwithhighback,foampadded

(internalsuspension)andarmrestsandintegral

safetyswitch.

Optionalseataccessories:

–Customridesuspensionsystemtoenhance

StandardSeat.

–Deluxesuspensionseatwithhighback,low

prolefoam-in-placecushion(dampened,

adjustablespringsuspension)andarmrests.

Specications

•Mounting:Hingedtotiltupforaccessto

hydraulicpumps,batteryandothercomponents.

Theseatisheldinthetiltedpositionwitha

linkage.Adjustableforeandaftseattrack.

•Armrests:Standardseat:foampaddedip-up

armrests.Optionalsuspensionseat:molded

adjustableip-uparmrests.

•SeatSafetySwitch:Internaltothebottomseat

cushion,nonserviceable.Timedelaymodule

incorporatedintotheSafetyInterlockSystem

eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:

–27HPKohler&31HPBriggs&Stratton

Units:TwoHydroGearPR16ccvariable

displacementpistonpumps.

–23HPKohlerUnits:TwoHydroGearPJ

12ccvariabledisplacementpistonpumps.

•WheelMotors:HydroGearplanetaryreduction

motors.

•HydraulicOilType:UseMobil115W-50

Syntheticmotoroil.

•HydraulicOilCapacity:

–27HPKohler&31HPBriggs&Stratton

Units:5.2qt.(4.9L)

–23HPKohlerUnits:4.0qt.(3.8L)

•HydraulicFilter:Replaceablecartridgetype.

P/N103-2146:25microns,Nobypass

•Speeds:

–27HPKohler&31HPBriggs&Stratton

Units:

0-10.5mph(16.9km/hr)forward

0-6.6mph(10.6km/hr)reverse

–23HPKohlerUnits:

0-8.7mph(14.0km/hr)forward

0-5.7mph(9.2km/hr)reverse

•Drivewheelreleasevalvesallowmachinetobe

movedwhenengineisnotrunning.

Tires&Wheels

27HPKohler&31HPBriggs&StrattonUnits

Drive

Front

Caster

RearCaster

(DualTail

Wheel)

Pneumatic

(Air-Filled)

Semi-

Pneumatic

Semi-

Pneumatic

Quantity

222

TreadAT101

SmoothSmooth

Size24x

12.00-12

9x3.50-413x6.5-6

PlyRating

Pressure

9psi

(62kPa)

23HPKohlerUnits

Drive

Front

Caster

RearCaster

(SingleTail

Wheel)

Pneumatic

(Air-Filled)

Semi-

Pneumatic

Semi-

Pneumatic

Quantity

221

Tread

TurfmateSmoothSmooth

Size23x

10.50-10

9x3.50-413x6.5-6

PlyRating

Pressure

13psi

(90kPa)

CuttingDeck

(SoldSeparately)

•ModelNumbers:

–FR524

–FR604

–FR724

•CuttingWidth:

–52inch(132cm)

–60inch(152cm)

–72inch(183cm)

•Discharge:Side

•BladeSize:(3ea.)

–52inchDeck:18.00inches(45.7cm)

Specications

–60inchDeck:20.50inches(52.1cm)

–72inchDeck:24.50inches(62.2cm)

•BladeSpindles:Solidsteelspindleswith13/4

inch(4.45cm)I.D.bearings.

•DeckDrive:“B”-Sectionbeltfromjackshafton

decktobladespindles.

•Deck:Fulloatingdeckisattachedtoout-front

supportframe,removableforservice.Six

anti-scalprollersprovidemaximumturf

protection.Deckdesignallowsforbagging,

mulchingorsidedischarge.

•DeckDepth:

–52inchDeck:5.5inches(14.0cm)

–60inchDeck:5.5inches(14.0cm)

–72inchDeck:5.5inches(14.0cm)

•CuttingHeightAdjustment:Adjustsfrom11/2

inches(3.8cm)to5inches(12.7cm)innitely

variable.

•MulchingKit:Optional

•Bagger:Optional

Dimensions

OverallWidth:

52inch

Deck

60inch

Deck

72inch

Deck

Without

Deck

49.0inches

(124.5cm)

49.0inches

(124.5cm)

53.0inches

(135cm)

Deector

53.3inches

(135.4cm)

61.4inches

(156cm)

73.4inches

(186cm)

Deector

Down

64.0inches

(163cm)

72.0inches

(183cm)

84.3inches

(214cm)

OverallLength:

23HPKohler27HPKohler&

31HPBriggs&

Stratton

Withoutdeck

andoorpan

folded

80.4inches

(204.2cm)

82.3inches

(209.0cm)

52inchDeck112.4inches

(285.5cm)

114.3inches

(290.3cm)

23HPKohler27HPKohler&

31HPBriggs&

Stratton

60inchDeck112.4inches

(285.5cm)

114.3inches

(290.3cm)

72inchDeck114.3inches

(290.3cm)

OverallHeight:

RollBar-UpRollBar-Down

69.2inches(175.8cm)50.7inches(128.8cm)

TreadWidth:(CentertoCenterof

Tires,Widthwise)

27HPKohler&31HPBriggs&StrattonUnits

52inchDeck60inchDeck72inchDeck

41.4inches

(105.2cm)

41.4inches

(105.2cm)

45.4inches

(115.3cm)

23HPKohlerUnits

52inchDeck60inchDeck72inchDeck

38.9inches

(98.8cm)

38.9inches

(98.8cm)

WheelBase:(CenterofCasterTireto

CenterofDriveTire)

•27HPKohler&31HPBriggs&StrattonUnits:

51.2inches(130.0cm)

•23HPKohlerUnits:54.1in(137.4cm)

MinimumTurningRadius

•27HPKohler&31HPBriggs&StrattonUnits:

55.25inches(140.3cm)

•23HPKohlerUnits:56.3in(143.0cm)

CurbWeight:

Withoutdeck911lb(413kg)

52inchDeck

1303lb(591kg)

60inchDeck

1348lb(611kg)

72inchDeck

1397lb(634kg)

ProductOverview

TorqueRequirements

BoltLocation

Torque

EngineMountingBolts

30-35ft-lb(41-47N-m)

WheelLugNuts

90-95ft-lb(122-129N-m)

WheelMotorMounting

Bolts

72-77ft-lb(98-104N-m)

WheelHubLockNut210-250ft-lb

(285-339N-m)

RolloverProtectionSystem

(RollBar)MountingBolts

30-35ft-lb(41-47N-m)

ClutchRetainingBolt

(securedwiththreadlocker)

55-60ft-lb(75-81N-m)

ProductOverview

Figure4

1.FuelCap4.SeatBelt

2.RollBar

5.MotionControlLever

3.Controls

6.ParkingBrakeLever

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrolleverslocatedoneachsideofthe

consolecontroltheforwardandreversemotionof

themachine.Theleverscontroltheowofhydraulic

oilfromthehydrostaticpumptothedrivewheel

motorforeachside.

Movingtheleversforwardorbackwardturnsthe

wheelonthesamesideforwardorinreverse.Wheel

speedisproportionaltotheamounttheleveris

moved.

Movingtheleversoutwardfromthecenterposition

intotheT-slotlocksthemintheneutralposition

(Figure6).

ChokeControl

Locatedonrightfueltankconsole.

Thechokeisusedtoaidinstartingacoldengine.

Movingthechokeleverforwardwillputthechokein

the“ON”positionandmovingthechokelevertothe

rear,tothedetent,willputthechokeinthe“OFF”

position.DoNotrunawarmenginewithchokein

the“ON”position.

ThrottleControl

Locatedonrightfueltankconsole.

Thethrottleisusedtocontrolenginespeed.Moving

thethrottleleverforwardwillincreaseenginespeed

andmovingthethrottlelevertotherearwilldecrease

enginespeed.Movingthethrottleforwardintothe

detentisfullthrottle.

ParkBrakeLever

Locatedonleftsideofunit,betweentheseatandthe

dummytank.

Thebrakeleverengagesaparkingbrakeonthedrive

wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe

brake.

Theunitmustbetieddownandbrakeengagedwhen

transporting.

IgnitionSwitch

Locatedonrightfueltankconsole.

Theignitionswitchisusedtostartandstopthe

engine.Theswitchhasthreepositions“OFF”,“ON”

and“START”.Insertkeyintoswitchandrotate

clockwisetothe“ON”position.Rotateclockwiseto

thenextpositiontoengagethestarter(keymustbe

heldagainstspringpressureinthisposition).

Note:Brakemustbeengaged,motioncontrollevers

out(neutrallockposition),andPTOswitch“OFF”

tostartengine.(Itisnotnecessaryfortheoperator

tobeintheseattostarttheengine.)

HourMeter

Locatedontherightfueltankconsole.

Thehourmeterisconnectedtoapressureswitch

installedintheengineblockanditrecordsthe

numberofhoursthattheenginehasrun.Ifthe

ignitionswitchisleftonwithoutenginerunning,

hourmeterwillnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot

alerttheoperatoriftheengineoilislow .

FuelShut-OffValve

Locatedinfuellinebyfueltankandfuellter.

Thefuelshut-offvalveisusedtoshutoffthefuel

whenthemachinewillnotbeusedforafewdays,

duringtransporttoandfromthejobsite,andwhen

parkedinsideabuilding.

Rotatethevalve1/4turnclockwisetoshutofffuel.

Rotatethevalve1/4turncounterclockwisetoturn

onfuel.

FuelGauge

Locatedattherearoftherightfueltank.

Thefuelgaugemonitorstheamountoffuelinthe

rightfueltankonly.Thelefttankdoesnotholdfuel.

Operation

DriveWheelReleaseValves

Locatedonthetopleftfrontcornerofhydrostatic

pumps.

Drivewheelreleasevalvesareusedtoreleasethe

hydrostaticdrivesystemtoallowthemachinetobe

pushedwithouttheenginerunning.

Withawrench,turnbothvalvesoneturn

counterclockwisetoreleasedrivesystem.Turn

clockwisetoresetsystem.DoNotovertighten.Do

Nottowmachine.

•For27HPKohler&31HPBriggs&Stratton

Units:Usea5/8inchwrenchtoturnthevalves.

•For23HPKohlerUnits:Usea7/16inchwrench

toturnthevalves.

PTOEngagementSwitch

Locatedonrightfueltank.

Switchmustbepulledouttothe“ROTATE”

positiontoengagetheblades.Switchispushedinto

the“STOP”positiontostoptheblades.

HydraulicLiftSwitch

Locatedonrightfueltankconsole.

Thehydraulicliftswitchisusedtoraiseandlower

themowerdeck.

Pushthefrontportionofthehydraulicliftswitch

downtoraisethemowerdecktothedesiredheight.

Pushtherearportionofthehydraulicliftswitch

downtolowerthemowerdecktothedesiredheight.

Pre-Start

Fillfueltanks.Forbestresultsuseonlyclean,fresh

regulargradeunleadedgasolinewithanoctanerating

of87orhigher.Regulargradeleadedgasolinemay

alsobeused;however,combustionchamberand

cylinderheadwillrequiremorefrequentservice.See

EngineOwner’sManual.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

thatthefuellevelrisesabovealevelthatis1/2inch

(13mm)belowthebottomofthellernecktoallow

forfuelexpansionandpreventfuelspillage.

Makesureyouunderstandthecontrols,their

locations,theirfunctions,andtheirsafety

requirements.

RefertotheMaintenancesectionandperformallthe

necessaryinspectionandmaintenancesteps.

OperatingInstructions

RaisetheRolloverProtectionSystem

(ROPS)

Important:Lowertherollbaronlywhen

absolutelynecessary.

1.Removethehairpincotterpinsandremovethe

tworollbarpins(Figure5).

2.Raisetherollbartotheuprightpositionand

installthetwopinsandsecurethemwiththe

hairpincotterpins(Figure5).

Important:Alwaysusetheseatbeltwiththe

rollbarintheraisedposition.Ensurethatthe

rearpartoftheseatissecuredwiththeseat

latch.

Figure5

1.Rollbar3.Pin

2.Raisedposition4.Hairpincotterpin

Operation

OpentheFuelShut-OffValve

Thefuelshut-offvalveislocatedontherightsideof

unitinfuellinenexttothefuellter.Raisetherear

hoodtoaccessfuelshut-offvalve.

StartingtheEngine

1.Movethemotioncontrolleversouttotheneutral

lockposition.

2.Pullupandbackontheparkingbrakeleverto

engagetheparkingbrake.

3.PushinonthePTOswitchtothe“STOP”

position.

Note:Itisnotnecessaryfortheoperatortobe

intheseattostarttheengine.

4.Placethethrottlemidwaybetweenthe“SLOW”

and“FAST”positions.

5.Onacoldengine,pushthechokeleverforward

intothe“ON”position.

Onawarmengine,leavethechokeinthe“OFF”

position.

6.Turnignitionswitchtothe“START”position.

Releasetheswitchassoonastheenginestarts.

Important:DoNotcranktheengine

continuouslyformorethantensecondsata

time.Iftheenginedoesnotstart,allowa60

secondcool-downperiodbetweenstarting

attempts.Failuretofollowtheseguidelines

canburnoutthestartermotor.

7.Ifthechokeisinthe“ON”position,gradually

returnchoketothe“OFF”positionastheengine

warmsup.

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck

aredangerous.Bladecontactcancause

seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower

ormowerdeckwhenthebladesareengaged.

DANGER

Anuncovereddischargeopeningwillallow

objectstobethrowninanoperator’sor

bystander’sdirection.Also,contactwiththe

bladecouldoccur.Thrownobjectsorblade

contactcancauseseriousinjuryordeath.

Neveroperatethemowerwiththedischarge

deectorraised,removed,oralteredunless

thereisagrasscollectionsystemormulch

kitinplaceandworkingproperly.

ThePTOpush-pullswitchengagesthecuttingblades.

Besurethatallpersonsareclearofthemowerdeck

anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe

PTOcanbeengaged.

1.Setthethrottletothe“MIDWAY”position.

2.PullthePTOswitchoutwardtothe“ROTATE”

position.

3.Placethethrottleinthe“FAST”positiontobegin

mowing.

DisengagingthePTO

1.Setthethrottletothe“MIDWAY”position.

2.PushthePTOswitchintothe“STOP”position

todisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movethemotioncontrolleversouttotheneutral

lockposition.

4.Engagetheparkingbrake.

5.Placethethrottlemidwaybetweenthe“SLOW”

and“FAST”positions.

6.Allowtheenginetorunforaminimumof15

seconds,thenturntheignitionswitchtothe

“OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother

unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalvewhenthemachine

willnotbeinuseforafewdays,when

transporting,orwhentheunitisparkedinside

abuilding.

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Exmark Frontrunner FR23KC User manual

Brand: Exmark

Model: Frontrunner FR23KC

Category: Lawnmowers

Type: User manual

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Exmark Frontrunner FR23KC User manual

Exmark Frontrunner FR23KC User manual

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