Exmark Frontrunner FR25KD Operator's Manual
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Exmark Frontrunner FR25KD Operator's Manual

Exmark Frontrunner FR25KD Operator's Manual

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For Exmark Mower Parts Call 606-678-9623 or 606-561-4983
manufactured to give you a maximum amount of dependability and years of trouble-free operation. If additional information
is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor.
If you need to order replacement parts from your dealer, always give the model number and serial number of your equipment
as well as the part number, description and quantity of the part needed.
The Serial No. plate
that you
record the information requested in the following identification table.
Place Model No. and Serial No. Label Here
(Included in Literature Pack)
Model No.
Serial No.
on the purchase of your new Exmark equipment. This product has been carefully designed and
is located
on the
right side of the unit under the fuel tank For ease of ordering and reference, we suggest
or Fill in Below
www.mymowerparts.com
MFG. CO. INC.
.
Date Purchased
For Serial Nos.
600,000 & Higher
®
TM
Part No. 109-4289 Rev. A

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Summary of Contents for Exmark Frontrunner FR25KD

  • Page 1 If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor. If you need to order replacement parts from your dealer, always give the model number and serial number of your equipment as well as the part number, description and quantity of the part needed.
  • Page 2 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦...
  • Page 3 3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time, Exmark pays for the part and freight. 4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark pays for the part.
  • Page 4 If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor. All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations.

  • Page 5: Table Of Contents

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 TABLE OF CONTENTS 1. SAFETY PAGE Safety Alert Symbol ..................1 Training ......................1 Preparation....................1-3 Operation ....................4-7 Maintenance & Storage ................8-9 Safety Signs ..................... 9-11 2. SPECIFICATIONS Model Number ..................... 12 Engine ......................

  • Page 6: Safety Alert Symbol

    MAY result in minor or moderate injury. 1.2 TRAINING 1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit. 1.2.2 Read the instructions carefully. Familiarize yourself with the controls and the proper use of the equipment.
  • Page 7 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 CAUTION POTENTIAL HAZARD ♦ This machine produces sound levels in excess of 85 dBA at the operator’s ear when in operation. WHAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss.
  • Page 8 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 DANGER POTENTIAL HAZARD ♦ Diesel fuel is flammable. WHAT CAN HAPPEN ♦ A fire from diesel fuel can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD ♦ DO NOT smoke while refueling, and stay away from an open flame or where fuel fumes may be ignited by spark.

  • Page 9: Operation

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 1.4 OPERATION Although hazard control and accident prevention are partially dependent upon the design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the equipment.
  • Page 10 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 1.4.3 When feasible, avoid operating the equipment in wet grass. WARNING POTENTIAL HAZARD ♦ Operating a FrontRunner tractor without an approved Exmark front mount attachment increases the possibility of forward tip over.
  • Page 11 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 • See inside the back cover to determine the approximate slope angle of the area to be mowed. • Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep banks or water.
  • Page 12 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 • Be certain that the seat belt can be released quickly if the machine is driven or rolls into ponds of water. • Check carefully for overhead clearances (i.e. branches, doorways, and electrical wires) before driving under any objects and do not contact them.

  • Page 13: Maintenance & Storage

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 1.5 MAINTENANCE AND STORAGE 1.5.1 For engine maintenance, follow the engine manufacturer’s recommendations precisely as stated in the engine manual. 1.5.2 Disconnect the battery cable from the negative battery post when the unit will be allowed to sit for more than 30 days without use.

  • Page 14: Safety Signs

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 WARNING POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure can penetrate skin and cause injury. WHAT CAN HAPPEN ♦ Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
  • Page 15 1.6.3 When new components are installed, be sure that current safety signs are affixed to the replaced components. 1.6.4 New safety signs may be obtained from Exmark Mfg. Co. Inc. 1.6.5 Safety signs may be affixed by peeling off the backing to expose the adhesive surface.
  • Page 16 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 PART NO. 107-2112 PART NO. 109-2357 LOCATION: Top of Floor Pan LOCATION: Top of Console, LH Side PART NO. 109-2377 LOCATION: On Hydraulic Cylinder PART NO. 109-2396 PART NO. 107-2102 LOCATION: Top of Seat Support...

  • Page 17: Specifications

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 2. SPECIFICATIONS 2.1 MODEL NUMBER: FR25KD 2.2 ENGINE 2.2.1 Engine Specifications: See your Engine Owner’s Manual 2.2.2 RPM: Full Speed: 3870 RPM (No Load) +50/-100 RPM Idle: 1400 RPM (No Load) ±50 RPM 2.3 FUEL SYSTEM...

  • Page 18: Hydrostatic Ground Drive System

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 2.7.3 Seat Safety Switch: Internal to the bottom seat cushion, non serviceable. Time delay module incorporated into the Safety Interlock System eliminates rough ground cut-outs. 2.7.4 Armrests: Standard seat: foam padded flip-up armrests.

  • Page 19: Torque Requirements

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 2.12 TORQUE REQUIREMENTS Bolt Location Torque Wheel Lug Nuts .............90-95 ft-lbs. (122-129 N-m) Wheel Motor Mounting Bolts..........72-77 ft-lbs. (98-104 N-m) Rollover Protection System (Roll Bar) Mounting Bolts ..30-35 ft-lbs. (41-47 N-m) Clutch Retaining Bolt (secured with threadlocker)....55-60 ft-lbs. (75-81 N-m) 3.
  • Page 20 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 Pulling the levers back from the neutral position will cause the respective drive wheels to rotate in a reverse direction (spring tension can be felt when moving into reverse from neutral). To turn to the left while backing, move the left lever forward toward neutral. To turn to the right while backing, move the right lever forward toward neutral.
  • Page 21 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 GLOW PLUG CHART Ambient Temperature Hold Glow Plugs On Above 50°F (10°C) NO NEED 50°F (10°C) to 23°F (-5°C) Approx. 5 seconds Below 23°F (-5°C) Approx. 10 seconds Limit of continuous use 20 seconds 3.1.7...

  • Page 22: Pre-Start

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 b) When the engine is running and the buzzer emits intermittent beeps, the buzzer is warning the user that the engine oil pressure is low. Perform the following steps. Turn the unit off, allow the engine and engine components to cool.
  • Page 23 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 c) Turn the ignition switch to the “ON” position. Depress the glow plug switch and the glow plug light will turn on. Hold switch according to chart in section 3.1.6. Turn the ignition switch to the “START” position. Release the ignition switch as soon as the engine starts.

  • Page 24: Transporting

    Rotate ignition switch to “OFF” position. Remove the key to prevent children or other unauthorized persons from starting engine. 3.4 TRANSPORTING IMPORTANT: Do not transport FrontRunner tractor without an approved Exmark front mount attachment. 3.4.1 Transporting a Unit: Use a heavy-duty trailer or truck to transport the machine.
  • Page 25 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 WARNING POTENTIAL HAZARD ♦ Loading a unit on a trailer or truck increases the possibility of tip-over. WHAT CAN HAPPEN ♦ Tip-over of the unit could cause serious injury or death. HOW TO AVOID THE HAZARD ♦...

  • Page 26: Maintenance & Adjustments

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 4. MAINTENANCE & ADJUSTMENTS WARNING POTENTIAL HAZARD ♦ While maintenance or adjustments are being made, someone could start the engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could seriously injure you or other bystanders.
  • Page 27 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 4.1.2 Check engine coolant level Service Interval: Daily Stop engine and wait for all moving parts to stop. Make sure machine is on a level surface. Tilt seat up and tilt hood forward to gain access to the cooling area.
  • Page 28 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 recommended time interval to bring the charge up to a full charge of 12.6 volts or greater. IMPORTANT: Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery (see chart below for recommended charger settings).
  • Page 29 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 Check the PTO circuit: See the FR524 and FR604 Operator’s manual to become familiar with the deck operation. Open the folding deck latches, disengage the park brake, move the motion control levers in to neutral, and disengage the PTO.
  • Page 30 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 Check the condition of the inner element. Replace whenever it appears dirty, typically every other time the paper element is replaced. Clean the base around the inner element before removing, so dirt does not get into the engine.
  • Page 31 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 FIGURE 4 c) Tighten engine and radiator drain cocks. Reinstall lower hose (if removed). d) Fill radiator with a 50/50 mix of water and Dex-Cool © coolant, allowing some room (approximately 1/2” (1.27 cm)) for expansion. Add 50/50 coolant mix to overflow bottle on the left side of the engine as required to bring the level up to the indicator line on the bottle.
  • Page 32 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 cap is completely seated by pressing down firmly while turning until the cap stops. Once the cap is installed, the engine may be stopped. 4.1.11 Check hydraulic oil level: Service Interval: 40 hr.
  • Page 33 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 NOTE: Do not add any type of tire liner or foam fill material to the tires. Excessive loads created by foam filled tires may cause failures to the hydro drive system, frame, and other components. Foam filling tires will void the warranty.
  • Page 34 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 spacer nut still assembled to it) from the wheel assembly. Pry out seals, and inspect bearings for wear or damage and replace if necessary. Pack the bearings with a NGLI grade #1 multi-purpose grease.
  • Page 35 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 Lubricate bronze bushings on the flange bearings securing the motion control arm shafts with a light oil or a spray type lubricant. 4.1.20 Lubricate the motion control shaft: Service Interval: Yearly. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.
  • Page 36 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 4.1.25 Change hydraulic system filter: First Interval: 250 hrs. Normal Interval: Yearly. NOTE: Use only Exmark Part No.103-2146 Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

  • Page 37: Adjustments

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 Square head setscrews on Hydro pump control arms. Sheave retaining bolt in the end of engine crankshaft. Caster wheel spacer nuts. Fuel tank bulkhead fitting nuts. Motion control tab retaining bolt. 4.1.28 Dielectric grease is used on blade type electrical connections to prevent corrosion and loss of contact.
  • Page 38 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 FIGURE 9 c) Disengage the park brake. Measure the length of the park brake spring. The spring should measure 2.5” (6.4cm). See Figure 10. FIGURE 10 d) If necessary, turn the thin nyloc nut to obtain the 2.5” (6.4cm) spring length.
  • Page 39 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 4.2.5 Motion control linkage adjustment: WARNING POTENTIAL HAZARD ♦ Engine must be running and drive wheels must be turning so motion control adjustment can be performed. WHAT CAN HAPPEN ♦ Contact with moving parts or hot surfaces may cause personal injury.
  • Page 40 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 FIGURE 13 Move the motion control levers to the reverse position. Return the motion control levers to neutral. The wheels must stop turning (or slightly creep in reverse). Stop engine and wait for all moving parts to stop. Remove jumper wire from wire harness connector and plug connector into seat switch.
  • Page 41 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 4.2.7 Weight transfer spring adjustment: Weight transfer springs are assembled from the factory to apply the maximum amount of weight onto the drive wheels. This setting provides the greatest amount of traction. Some conditions may require the rear wheel lift to be reduced.
  • Page 42 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 FIGURE 16 Re-install the left fender. To adjust right side, raise the unit and place on jackstands, remove wheel and repeat steps steps d) through f). CAUTION POTENTIAL HAZARD ♦ Raising the unit for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous.

  • Page 43: Waste Disposal

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 5. WASTE DISPOSAL 5.1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at a certified recycling center or according to your state and local regulations.

  • Page 44: Engine Will Not Start

    NOTE: After carefully checking the above steps, attempt to start the engine. If it does not start, contact your authorized Exmark service dealer. IMPORTANT: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use.
  • Page 45 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 6.4.4 Coolant Temperature Light: Located on the right fuel tank console. The light will come on if the engine is overheating. 6.4.5 Warning Buzzer: Located behind the seat under the engine cover on the right hand side of the engine fan shroud.

  • Page 46: Electrical Diagram

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 7. ELECTRICAL DIAGRAM www.mymowerparts.com...

  • Page 47: Hydraulic Diagram

    For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 8. HYDRAULIC DIAGRAM www.mymowerparts.com...

  • Page 48: Warranty

    Exmark service dealer replace or adjust any part manufactured by Exmark and found within the warranty period. This warranty extends only to by us (in the exercise of our reasonable discretion) to be turf equipment operated under normal conditions.

  • Page 49: Evaporative Emission Control Warranty

    Manufacturing Company cannot deny warranty solely for the lack of receipts. As the equipment owner, you should however be aware that Exmark Manufacturing Company may deny you warranty coverage if your emission warranty parts have failed due to abuse, neglect, or improper maintenance or unapproved modifications.
  • Page 50 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 NOTES www.mymowerparts.com...
  • Page 51 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 52 For Exmark Mower Parts Call 606-678-9623 or 606-561-4983 SEE EXMARK’S COMPLETE LINE OF ACCESSORIES RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT MICRO-MULCH SYSTEM ROLL OVER PROTECTION SYSTEM (ROPS) SNOW BLADE SUN SHADE...

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