Exmark Frontrunner 720,000 & Higher Serial Nos. - Lubricate Brake Handle Pivot; Lubricate Brake Rod Bushings; Lubricate Motion Control Bronze Bushings; Lubricate Motion Control Shaft

Maintenance
spacernutstotheaxle.Removetheaxle(with
theotherspacernutstillassembledtoit)from
thewheelassembly.
5.Pryoutseals,andinspectbearingsforwearor
damageandreplaceifnecessary.
6.PackthebearingswithaNGLIgrade#1
multi-purposegrease.
7.Insertonebearing,onenewsealintothewheel.
Note:Seals(ExmarkP/N103-0063)mustbe
replaced.
8.Iftheaxleassemblyhashadbothspacernuts
removed(orbrokenloose),applyathreadlocking
adhesivetoonespacernutandthreadontothe
axlewiththewrenchatsfacingoutward.Do
Notthreadspacernutallofthewayontotheend
oftheaxle.Leaveapproximately1/8inch(3mm)
fromtheoutersurfaceofthespacernuttothe
endoftheaxleinsidethenut.
9.Inserttheassemblednutandaxleintothewheel
onthesideofthewheelwiththenewsealand
bearing.
10.Withtheopenendofthewheelfacingup,ll
theareainsidethewheelaroundtheaxlefullof
NGLIgrade#1multi-purposegrease.
11.Insertthesecondbearingandnewsealintothe
wheel.
12.Applyathreadlockingadhesivetothe2ndspacer
nutandthreadontotheaxlewiththewrenchats
facingoutward.
13.Torquethenutto75-80in-lb(8-9N-m),loosen,
thenre-torqueto20-25in-lb(2-3N-m).Make
sureaxledoesnotextendbeyondeithernut.
14.Reinstallthesealguardsoverthewheelhuband
insertwheelintocasterfork.Reinstallcasterbolt
andtightennutfully.
Important:Topreventsealandbearingdamage,
checkthebearingadjustmentoften.Spinthe
castertire.Thetireshouldnotspinfreely
(morethan1or2revolutions)orhaveanyside
play.Ifthewheelspinsfreely,adjusttorqueon
spacernutuntilthereisaslightamountofdrag.
Reapplythreadlockingadhesive.
LubricateBrakeHandlePivot
ServiceInterval:Every160hours
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Tiltseatforward.
3.Lubricatebronzebushingsonbrakehandlepivot
withaspraytypelubricantorlightoil.
LubricateBrakeRod
Bushings
ServiceInterval:Every160hours
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Tiltseatforwardandraisehood.
3.Lubricatebronzebushingsoneachendofthe
brakerodshaftwithaspraytypelubricantor
lightoil(bushingsarelocatedtotheinsideofthe
angebearings).
LubricateMotionControl
BronzeBushings
ServiceInterval:Every160hours
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Unhookseatlatchandtiltseatup.
3.Lubricatebronzebushingsonangebearings
securingthemotioncontrolarmshaftswitha
lightoiloraspraytypelubricant.
LubricateMotionControl
Shaft
ServiceInterval:Yearly
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Tiltseatforward.
3.Removetabatrearofmotioncontrolshaft.
4.Pullmotioncontrolshaftoutandlubricatewith
anNGLIgrade#2multi-purposegungrease.
5.Re-installshaftandtab.
LubricateSteeringLinkage
RodEnds
ServiceInterval:Every160hours
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
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