Exmark FrontRunner 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 arr ester 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 v e you a maximum 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 which m ust be follo wed to av oid accidents This symbol means: ATTENTION! BECOME ALERT! Y OUR SAFETY IS INV OL VED! 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 front mount attachment increases the possibility of forw ard tip ov er . Tip-ov er could cause serious injur y or death. When operating a F rontRunner tractor without an approved Exmark front mount attachment, obser ve the following: • Limit operation to minimum required[...]

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 ers, which may result in serious injur y , death or drowning . • Do Not mow slopes when grass is wet. • Do Not mow near drop-offs or near w ater . • Do Not mow slopes great[...]

Safety Maintenance and Storage • Disengag e driv es , lo wer implement, set parking brake , stop engine and remov e key 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 , ex cessiv e g [...]

Safety Safety and Instructional Decals • Keep all safety signs legible . Remo ve all g rease , dirt and debris from safety signs and instructional labels . • R eplace all worn, damaged, or missing safety signs . • When replacement components are installed, be sure that cur rent safety signs are afxed to the replaced components . • If an [...]

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 g al. (32 L) • T ype of Fuel: Diesel fuel, 40 cetane or higher . • Fuel Fil[...]

Specications • Mounting: Hinged to tilt up for access to hy draulic pumps , battery 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 S[...]

Specications • Mulching Kit: Optional • Bag ger : Optional Dimensions Overall W idth: 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) 8[...]

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 eac h side of the console control the forw ar[...]

Operation and “STAR T”. Inser t key into switc h and rotate clockwise to the “ON” position. R otate clockwise to the next position to engag e the starter (key must be held against spring pressure in this position). Note: Brak e m ust be engag ed, 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 kerosene or g asoline instead of diesel fuel. F ailure to obser ve this caution will[...]

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 ers can be mo v ed in or the engine will stop. When lev ers are centered in the T -slot the drive system is in the neutral position. With lev ers mo ved out in the T -slot the drive system is in the neutral loc k 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 mar kings, or a slow mo ving v ehicle emblem. Dri ving 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 an[...]

Maintenance Maintenance Note: Deter mine the left and right sides of the mac hine from the normal 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 s witch, engage par kin[...]

Maintenance Maintenance Ser vice Inter val 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 lock pin. • Grease the rear caster piv ot. • Grease the belt idlers . • Grease the motion control pi vots . • 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 , wait for all moving parts to stop , and remov e key . Engag e parking brake . Machine m ust be positioned on level surface. 2. Tilt seat forward and raise the hood up to[...]

Maintenance batter y perfor mance and life, recharge batteries in storage when the open circuit voltage drops to 12.4 volts . Note: T o prev ent damage due to freezing, battery should be fully c harged before putting a way for winter storag e . Check the voltage of the battery with a digital voltmeter . Locate the v oltage reading of the battery 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 switch. The PTO must not engage . Note: If machine does not pass any of these tests , Do Not operate . Contact y our authorized E[...]

Maintenance 4. R emov e the oil drain plug . Allow oil to drain then replace the drain plug . 5. R eplace the oil lter every other oil c hange. 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 rubber 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 , wait for all moving parts to stop , and remov e k ey . Engag e parking brak e. [...]

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 g rade #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 , wait for all moving parts to stop , and remov e k ey . Engag e parking brak e. 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 f or 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 suppor t 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 adequa[...]

Maintenance Adjustments Note: Disengag e PTO , shut off engine , wait for all mo ving parts to stop , engag e parking brak e, and remov e key before servicing, 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 , wait for all moving parts [...]

Maintenance 6. If necessar y , turn the thin nyloc nut to obtain the 2 1/2 inches (6.4 cm) spring length. 7. Engag e the park brake . 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 levers to the reverse position. R eturn the motion control levers to neutral. The wheels m ust stop turning (or slightly creep in rev erse). 10. Stop engine and wait for all moving parts to stop . R emov e jumper wire fr[...]

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 w eight transfer springs , fold the mower deck and front frame and lock in ser vice position. See Dec k Man ual for complete instr uctions . W ARNING W eight transfer springs may hav e [...]

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 , wait for all moving parts to stop , and remov e k ey . Engag e parking brak e. 2. Wipe debris from radiator screen in front of radiator . Rotate engine cov er forw ard, pull out radiat[...]

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 ov erlook 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. Reduce the ground speed. 2. Oil level in the crankcase is lo w . 2. Add oil to the crankcase. 3. Dir ty air lter . 3. Clean or replace the air cleaner element. 4. Coolant lev el is lo w . 4. Add coolant. 5. Debris on or around radiator. 5. R emov e debr[...]

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 REGULAT OR 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 TOR CONTR OLLED DISCHARGE ROLL O VER PRO TECTION SYSTEM (ROPS) SNO[...]