Exmark Diesel manual

FRONTRUNNER TM DIESEL MODELS For Serial Nos. 720,000 & Higher Part No. 4500-227 Rev . A[...]

W ARNING CALIFORNIA Proposition 65 W ar ning Diesel engine exhaust and some of its constituents are known to the State of Califor nia to cause cancer , bir th defects, and other reproductive har m. Important: When the mo wer is used or operated on an y Califor nia forest, br ush or grass co vered land, a w orking spark ar rester must be attached to[...]

Introduction CONGRATULATIONS on the purc hase of y our Exmark Mower . This product has been carefully designed and manufactured to gi ve you a maxim um amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for your Exmark mow er . BEFORE OPERATING YOUR MOWER, C[...]

Contents Introduction .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 3 Safety .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . 5 Safety Aler t Symbol . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . [...]

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both in this manual and on the mac hine to identify important safety messag es whic h must be follo wed to av oid accidents This symbol means: ATTENTION! BECOME ALERT! Y OUR SAFETY IS INV OLVED! Figure 2 1. Safety alert symbol The safety alert symbol appears abov e infor [...]

Safety DANGER In certain conditions diesel is extr emely ammable and v apors are explosi ve. A re or explosion from diesel can bur n y ou, others, and cause proper ty damage. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any diesel that spills. • Never rell the fuel tank or drain the machine indoor s o[...]

Safety W ARNING Operating a F rontRunner tractor without an approv ed Exmark fr ont mount attachment increases the possibility of forw ard tip o ver . Tip-ov er could cause serious injur y or death. When operating a F rontRunner tractor without an approved Exmark front mount attachment, obser v e the following: • Limit operation to minimum requir[...]

Safety DANGER Operating on w et grass or steep slopes can cause sliding and loss of control. W heels dropping ov er edges, ditches, steep banks, or w ater can cause rollov er s, which may result in serious injur y , death or drowning . • Do Not mow slopes when grass is wet. • Do Not mo w near drop-of fs or near w ater . • Do Not mow slopes gr[...]

Safety Maintenance and Storage • Disengag e dri ves , low er implement, set parking brake , stop engine and remov e k ey or disconnect spark plug wire . W ait for all mov ement to stop before adjusting, cleaning or repairing . • Keep engine, engine area, and pump driv e belt compartment free from accumulation of g rass , leav es , excessiv e g [...]

Safety Safety and Instructional Decals • Keep all safety signs legible . R emov e all grease, dirt and debris from safety signs and instr uctional labels . • R e place all worn, damaged, or missing safety signs . • When replacement components are installed, be sure that cur rent safety signs are afx ed to the replaced components . • If a[...]

Safety 103-1636 103-5881 103-7218 107-2102 107-21 12 1 1[...]

Safety 109-2355 109-2356 1. Fast 3. Neutral 2. Slow 4. Reverse 109-2357 1. Fast 4. Reverse 2. Slow 5. Park Brake—Release 3. Neutral 6. Park Brake—Engage 109-2358 109-2377 109-2396 12[...]

Safety 109-2698 1. Cylinder—extend 3. Fast 2. Cylinder—retract 4. Slow 109-3637 109-7949 19426-87881 19426-87903 109-2360 13[...]

Specications Specications Model Numbers Serial Nos: 720,000 and Higher FR25KD Systems Engine • Engine Specications: See y our Engine Owner’ s Manual • RPM: Full Speed: 3870 +50/-100 RPM (No Load) Idle: 1400 ±50 RPM (No Load) Fuel System • Capacity: 8.5 gal. (32 L) • T ype of Fuel: Diesel fuel, 40 cetane or higher . • Fuel Filt[...]

Specications • Mounting: Hing ed to tilt up for access to hy draulic pumps , batter y and other components . The seat is held in the tilted position with a linkage. Adjustable fore and aft seat trac k. • Ar mrests: Standard seat: foam padded ip-up ar mrests . Optional suspension seat: molded adjustable ip-up ar mrests . • Seat Safety[...]

Specications • Mulching Kit: Optional • Bag ger : Optional Dimensions Overall Width: 52 inch Deck 60 inch Deck 72 inch Deck Without Deck 49.0 inches (124.5 cm) 49.0 inches (124.5 cm) 53.0 inches (135 cm) Deector Up 53.3 inches (135.4 cm) 61.4 inches (156 cm) 73.4 inches (186 cm) Deector Down 64.0 inches (163 cm) 72.0 inches (183 cm) 84[...]

Operation Product Overview Figure 4 1. Fuel Cap 4. Seat Belt 2. Roll Bar 5. Motion Control Lever 3. Controls 6. Parking Brake Lever Operation Note: Deter mine the left and right sides of the machine from the nor mal operating position. Controls Motion Control Levers The motion control lev ers located on each side of the console control the forw ard[...]

Operation and “STAR T”. Inser t key into switch and rotate clockwise to the “ON” position. R otate cloc kwise to the next position to engag e the starter (key must be held against spring pressure in this position). Note: Brake must be eng aged, motion control lev ers out (neutral lock position), and PTO switc h “OFF” to start engine . ([...]

Operation The buzzer is a war ning signal that the engine is overheating or the oil pressure is low . See the T roubleshooting section. Pre-Start Fill fuel tank. F or best results use only clean, fresh diesel fuel, with a cetane rating of 40 higher Note: Do Not use k erosene or gasoline instead of diesel fuel. F ailure to obser v e this caution wil[...]

Operation Glow Plug Chart Ambient T emperature Hold Glo w Plugs On Abov e 50°F (10°C) NO NEED 50°F (10°C) to 23°F (-5°C) Approximately 5 seconds Below 23°F (-5°C) Approximately 10 seconds Limit of contin uous use 20 seconds The glo w plug light, located near the glo w plug switch, will illuminate when the switch is depressed. The glo w plug[...]

Operation before the motion control lev er s can be mov ed in or the engine will stop. When lev ers are centered in the T -slot the driv e system is in the neutral position. With lev ers mov ed out in the T -slot the dri ve system is in the neutral lock position (Figure 6). Figure 6 1. Handles Out (Neutral Lock) 5. Neutral 2. Handles In (Neutral) 6[...]

Operation CAUTION This unit does not ha ve proper tur n signals, lights, reecti ve markings, or a slow mo ving v ehicle emblem. Driving on a street or road w ay without such equipment is dangerous and can lead to accidents causing personal injur y . Dri ving on a street or roadway without such equipment may also be a violation of State laws and [...]

Maintenance Maintenance Note: Deter mine the left and right sides of the mac hine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental star ting of the engine could seriously injure y ou or other bystanders. Remo ve the key from the ignition switch, engage par kin[...]

Maintenance Maintenance Ser vice Inter v al Maintenance Procedure Every 4,000 hours • Change engine coolant. Dex-Cool © extended life coolant (orange color) Monthly • Check the battery charge. Y early • Grease the fold loc k pin. • Grease the rear caster pi vot. • Grease the belt idlers . • Grease the motion control pivots . • Grease[...]

Maintenance Change Engine Coolant Service Interval: Every 4,000 hours/Every 4 years (whichever comes rst) Dex-Cool © © © extended life coolant (orange color) 1. Stop engine , w ait for all moving parts to stop , and remov e k ey . Engag e parking brake . Machine must be positioned on level surface. 2. Tilt seat forward and raise the hood up t[...]

Maintenance batter y perfor mance and life , recharge batteries in storage when the open circuit voltage drops to 12.4 volts . Note: T o prevent damage due to freezing, battery should be fully c harged before putting aw ay for winter storag e . Check the voltage of the battery with a digital voltmeter . Locate the voltage reading of the batter y in[...]

Maintenance Figure 9 Left Side—Inside of Hitch Shown 1. PT O “Kill” Switch 2. PT O Switch Arm 3. Lower deck until arm Does Not contact the switch. R un the engine at half throttle and pull up on the PTO engag ement switc h. The PTO must not engage . Note: If machine does not pass any of these tests , Do Not operate . Contact your authorized E[...]

Maintenance 4. R emove the oil drain plug . Allow oil to drain then replace the drain plug . 5. R e place the oil lter every other oil change. Clean around oil lter and unscrew lter to remove . Before reinstalling new lter , apply a thin coating of oil on the surface of the rubber seal. T urn lter cloc kwise until r ubber seal contac[...]

Maintenance 2. Check pump and PTO dri ve belts . 3. Belts are spring tensioned and no adjustment is necessar y . See Pump Dri ve Belt T ension and Replacement sections in Adjustments . Lubricate Grease Fittings Note: See char t for ser vice inter v als. 1. Stop engine , w ait for all moving parts to stop , and remov e key . Engage parking brake . 2[...]

Maintenance the other spacer nut still assembled to it) from the wheel assembly . 5. Pr y out seals , and inspect bearings for wear or damage and replace if necessary . 6. P ack the bearings with a NGLI grade #1 multi-purpose g rease . 7. Insert one bearing, one new seal into the wheel. Note: Seals (Exmark P/N 103-0063) must be replaced. 8. If the [...]

Maintenance Lubricate Steering Linkage Rod Ends Service Interval: Every 160 hours 1. Stop engine , w ait for all moving parts to stop , and remov e key . Engage parking brake . 2. Tilt seat forward. 3. Lubricate eac h end of both steering linkage rods with a spra y lubricant or light oil Drain W ater from Fuel T ank Service Interval: As required 1.[...]

Maintenance CAUTION Raising the mo wer for ser vice or maintenance relying solely on mechanical or hy draulic jacks could be dangerous. The mechanical or hy draulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injur y . Do Not rely solely on mechanical or h ydraulic jacks for suppor t. Use adequate[...]

Maintenance Adjustments Note: Disengag e PTO , shut off engine , w ait for all mo ving par ts to stop , engag e parking brake , and remov e k ey before ser vicing, cleaning, or making any adjustments to the unit. Pump Drive Belt T ension Self-tensioning - No adjustment necessar y . Pump Drive Belt Replacement 1. Stop engine , w ait for all moving p[...]

Maintenance 6. If necessar y , turn the thin nyloc n ut to obtain the 2 1/2 inches (6.4 cm) spring length. 7. Engag e the park brak e. Measure the gap betw een the thin nyloc n ut and the park brake clevis . The gap should measure 1/8 inc h (3.2 mm) (see Figure 15). Figure 15 1. Y oke 4. Thin nyloc nut 2. Park brake spring 5. Inner ange nut 3. 1[...]

Maintenance Figure 17 1. Loosen jam nut 2. Pump control rod linkage 3. Use wrench to turn double nuts 9. Mov e the motion control lev ers to the reverse position. R eturn the motion control levers to neutral. The wheels m ust stop tur ning (or slightly creep in rev erse). 10. Stop engine and w ait for all moving parts to stop . R emove jumper wire [...]

Maintenance Figure 19 1. Motion control lever 3. Fender knob 2. Left fender 3. Slide the fender forward and twist upw ard and outward to remov e. 4. T o adjust the weight transfer springs , fold the mower deck and front frame and lock in ser vice position. See Deck Manual for complete instr uctions . W ARNING W eight transfer springs may have stor [...]

Maintenance Cleaning Clean Engine Cooling System Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) 1. Stop engine , w ait for all moving parts to stop , and remov e key . Engage parking brake . 2. Wipe debris from radiator screen in front of radiator . R otate engine cov er forward, pull out radiato[...]

T roubleshooting T roubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mow er use. When a problem occurs , do not o verlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes o[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e. 1. R educe the ground speed. 2. Oil lev el in the crankcase is lo w . 2. Add oil to the crankcase . 3. Dirty air lter . 3. Clean or replace the air cleaner element. 4. Coolant level is lo w . 4. Add coolant. 5. Debris on or around radiator . 5. R emove deb[...]

Schematics Schematics Electrical Diagram 5 RED 1 3. ST ART POSITION 1. OFF 2. RUN B + I + S CIRCUIT "MAKE" X + Y NONE B + I + A IGNITION SWITCH NOTE: CONNECTORS VIEWED FROM TERMINAL END TERMINAL CONNECTIONS TERMINAL A V OLT AGE REGULA TOR TERMINAL B BA TTERY TERMINAL I HOUR METER, A UX HYD, PTO SWITCH TERMINAL S ST ART RELAY TERMINAL X SE[...]

Schematics Hydraulic Diagram CASE DRAIN CHARGE PUMP HIGH PRESSURE G007220 BYP ASS V AL VE BYP ASS V AL VE HIGH PRESSURE REVERSE HIGH PRESSURE FOR W ARD HIGH PRESSURE REVERSE HIGH PRESSURE FOR W ARD 41[...]

Conditions and Products Co vered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty Company , pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair , replace or adjust any part manufactured by Exmark and found by us (in the ex ercise of our reasonable discretion) to be defectiv e in fa[...]

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MID-MOUNT RIDING A CCESSORIES SEE EXMARK’S COMPLETE LINE OF A CCESSORIES W ALK-BEHIND A CCESSORIES GRASS CA TCHER LAZERLOCKER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LAZERLOCKER LIGHT KIT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED DISCHARGE ROLL O VER PRO TECTION SYSTEM (ROPS) SNO[...]