Exmark Frontrunner manual Service Interval 160 hrs

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d)Remove one of the spacer nuts from the axle assembly in the caster wheel. Note that thread locking adhesive has been

applied to lock the spacer nuts to the axle. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly.

e) Pry out seals, and inspect bearings for

FIGURE 7

wear or damage and replace if necessary.

f)Pack the bearings with a NGLI grade #1 multi-purpose grease.

g)Insert (1) bearing, (1) new seal into the wheel.

NOTE: Seals (Exmark PN 103-0063) must be replaced.

h)If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to (1) spacer nut and thread onto the axle with the wrench flats facing outward. Do not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut.

i)Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.

j)With the open end of the wheel facing up, fill the area inside the wheel around the axle full of NGLI grade #1 multi-purpose grease.

k)Insert the second bearing and new seal into the wheel.

l)Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward.

m)Torque the nut to 75-80 in-lbs. (8-9 N-m), loosen, then re-torque to

20-25 in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut.

n)Re-install the seal guards over the wheel hub and insert wheel into caster fork. Re-install caster bolt and tighten nut fully.

IMPORTANT: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust torque on spacer nut until there is a slight amount of drag. Re-apply threadlocking adhesive.

4.1.18Lubricate the brake handle pivot:

Service Interval: 160 hrs.

a)Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

b)Tilt seat forward.

c)Lubricate bronze bushings on brake handle pivot with a spray type lubricant or light oil.

4.1.19Lubricate the brake rod bushings:

Service Interval: 160 hrs.

a)Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

b)Tilt seat forward and raise hood.

c)Lubricate bronze bushings on each end of the brake rod shaft with a spray type lubricant or light oil (bushings are located to the inside of the flange bearings).

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Contents Model No Serial No Potential Hazard Exmark Parts PLUS→ Program Operators Manual Table of Contents Safety Alert Symbol SafetyYour Safety is Involved TrainingCarbon monoxide can kill you Diesel fuel is flammable Operation When feasible, avoid operating the equipment in wet grass There is no rollover protection when the roll bar is down Page Maintenance and Storage Safety Signs Page Page Specifications Hydrostatic Ground Drive System DimensionsTires Torque Requirements Operation InstructionsControls Glow Plug Chart Page PRE-START Operating InstructionsRotating blades under the mower deck are dangerous Transporting Tip-over of the unit could cause serious injury or death Periodic Maintenance Maintenance & AdjustmentsService Interval Daily Service Interval Monthly Service Interval Daily Check starting circuit Service Interval Daily or more often in dry conditionsCheck the kill circuits Check the PTO circuit PTO must not engageService air cleaner Potential Hazard Service Interval 40 hrs Service Interval 40 hrDo not overtighten Service Interval Refer to chart Service Interval Once YearlyService Interval 160 hrs Service Interval Yearly Service Interval 400 hrs. or as requiredFirst Interval 250 hrs Normal Interval Yearly Adjustments Spring Tensioned No adjustment necessaryPage Potential Hazard Set neutral Page Weight transfer springs may have stored energy Waste Disposal Battery DisposalMotor OIL Disposal Mower Cuts Unevenly Trouble ShootingMower Pulls Left or Right W/LEVERS Fully Forward Engine will not StartTroubleshooting Table Engine Warning SystemsElectrical Diagram Hydraulic Diagram Year Limited Warranty Exmark Turf Equipment Page Page Page See EXMARK’S Complete Line of Accessories