Related Manuals for Exmark FrontRunner Diesel
Summary of Contents for Exmark FrontRunner Diesel
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Page 1: Diesel Models
FRONTRUNNER DIESEL MODELS For Serial Nos. 720,000 & Higher Part No. 4500-227 Rev. A... - Page 2 Replacements may be ordered through the engine manufacturer. Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously.
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Page 3: Introduction
All Exmark parts are thoroughly tested and inspected before leaving the factory, however, attention is required on your part if you are to obtain the fullest measure of satisfaction and performance. -
Page 4: Table Of Contents
Contents Introduction ... 3 Safety ... 5 Safety Alert Symbol ... 5 Safe Operating Practices ... 5 Safety and Instructional Decals ... 10 Specifications ... 14 Model Numbers ... 14 Systems ... 14 Dimensions... 16 Torque Requirements ... 16 Product Overview ... 17 Operation ... -
Page 5: Safety
• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by Exmark. • Wear appropriate clothing including safety glasses, substantial footwear, long trousers, and hearing protection. - Page 6 Safety DANGER In certain conditions diesel is extremely flammable and vapors are explosive. A fire or explosion from diesel can burn you, others, and cause property damage. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any diesel that spills.
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Page 7: Slope Operation
Tip-over could cause serious injury or death. When operating a FrontRunner tractor without an approved Exmark front mount attachment, observe the following: • Limit operation to minimum required to install a different front mount attachment. - Page 8 Safety DANGER Operating on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. • Do Not mow slopes when grass is wet. •...
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Page 9: Maintenance And Storage
Maintenance and Storage • Disengage drives, lower implement, set parking brake, stop engine and remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing. • Keep engine, engine area, and pump drive belt compartment free from accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas. -
Page 10: Safety And Instructional Decals
1-643339 • New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg. Co. Inc. • Safety signs may be affixed by peeling off the backing to expose the adhesive surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles. - Page 11 Safety 103-1636 103-5881 103-7218 107-2102 107-2112...
- Page 12 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...
- Page 13 109-2698 1. Cylinder—extend 3. Fast 2. Cylinder—retract 4. Slow 109-3637 109-7949 19426-87881 19426-87903 109-2360 Safety...
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Page 14: Specifications
Specifications Specifications Model Numbers Serial Nos: 720,000 and Higher FR25KD Systems Engine • Engine Specifications: See your 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) •... -
Page 15: Hydrostatic Ground Drive System
• Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other components. The seat is held in the tilted position with a linkage. Adjustable fore and aft seat track. • Armrests: Standard seat: foam padded flip-up armrests. Optional suspension seat: molded adjustable flip-up armrests. -
Page 16: Dimensions
Specifications • Mulching Kit: Optional • Bagger: Optional Dimensions Overall Width: 52 inch 60 inch Deck Deck Without 49.0 inches 49.0 inches Deck (124.5 cm) (124.5 cm) Deflector 53.3 inches 61.4 inches (135.4 cm) (156 cm) Deflector 64.0 inches 72.0 inches Down (163 cm) (183 cm) -
Page 17: Product Overview
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: Determine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control levers located on each side of the console control the forward and reverse motion of... -
Page 18: Coolant Temperature Gauge
Operation and “START”. Insert key into switch and rotate clockwise to the “ON” position. Rotate clockwise to the next position to engage the starter (key must be held against spring pressure in this position). Note: Brake must be engaged, motion control levers out (neutral lock position), and PTO switch “OFF”... -
Page 19: Pre-Start
The buzzer is a warning signal that the engine is overheating or the oil pressure is low. See the Troubleshooting section. Pre-Start Fill fuel tank. For best results use only clean, fresh diesel fuel, with a cetane rating of 40 higher Note: Do Not use kerosene or gasoline instead of diesel fuel. -
Page 20: Stopping The Engine
Operation Glow Plug Chart Ambient Temperature Hold Glow Plugs On NO NEED Above 50°F (10°C) 50°F (10°C) to 23°F (-5°C) Approximately 5 seconds Below 23°F (-5°C) Approximately 10 seconds Limit of continuous use 20 seconds The glow plug light, located near the glow plug switch, will illuminate when the switch is depressed. -
Page 21: Transporting
Transporting Transporting a Unit Important: Do Not transport FrontRunner tractor without an approved Exmark front mount attachment. Use a heavy-duty trailer or truck to transport the machine. Lock brake and block wheels. Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. - Page 22 Operation CAUTION This unit does not have proper turn signals, lights, reflective markings, or a slow moving vehicle emblem. Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury. Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and/or fines.
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Page 23: Maintenance
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders. Remove the key from the ignition switch, engage parking brake, and pull the wire(s) off the spark plug(s) before you do any... -
Page 24: Periodic Maintenance
Maintenance Maintenance Service Maintenance Procedure Interval • Change engine coolant. Dex-Cool© extended life coolant (orange color) Every 4,000 hours • Check the battery charge. Monthly • Grease the fold lock pin. • Grease the rear caster pivot. • Grease the belt idlers. •... -
Page 25: Change Engine Coolant
Change Engine Coolant Service Interval: Every 4,000 hours/Every 4 years (whichever comes first) Dex-Cool© © © extended life coolant (orange color) 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. Machine must be positioned on level surface. 2. -
Page 26: Check Safety Interlock System
Maintenance battery performance and life, recharge batteries in storage when the open circuit voltage drops to 12.4 volts. Note: To prevent damage due to freezing, battery should be fully charged before putting away for winter storage. Check the voltage of the battery with a digital voltmeter. -
Page 27: Check Rollover Protections Systems (Roll Bar) Pins
PTO engagement switch. The PTO must not engage. Note: If machine does not pass any of these tests, Do Not operate. Contact your authorized EXMARK SERVICE DEALER. Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing. -
Page 28: Check Hydraulic Oil Level
Maintenance 4. Remove the oil drain plug. Allow oil to drain then replace the drain plug. 5. Replace the oil filter every other oil change. Clean around oil filter and unscrew filter to remove. Before reinstalling new filter, apply a thin coating of oil on the surface of the rubber seal. -
Page 29: Lubricate Grease Fittings
2. Check pump and PTO drive belts. 3. Belts are spring tensioned and no adjustment is necessary. See Pump Drive Belt Tension and Replacement sections in Adjustments. Lubricate Grease Fittings Note: See chart for service intervals. 1. Stop engine, wait for all moving parts to stop, and remove key. -
Page 30: Lubricate Brake Handle Pivot
6. Pack the bearings with a NGLI grade #1 multi-purpose grease. 7. Insert one bearing, one new seal into the wheel. Note: Seals (Exmark P/N 103-0063) must be replaced. 8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward. -
Page 31: Lubricate Steering Linkage Rod Ends
Filter Service Interval: After the first 250 hours Yearly thereafter Note: Use only Exmark Part No. 103-2146. 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Carefully clean area around filter. It is important that no dirt or contamination enter hydraulic system. -
Page 32: Check Wheel Hub Locknuts
Maintenance CAUTION Raising the mower for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury. Do Not rely solely on mechanical or hydraulic jacks for support. -
Page 33: Adjustments
Adjustments Note: Disengage PTO, shut off engine, wait for all moving parts to stop, engage parking brake, and remove key before servicing, cleaning, or making any adjustments to the unit. Pump Drive Belt Tension Self-tensioning - No adjustment necessary. Pump Drive Belt Replacement 1. -
Page 34: Motion Control Linkage Adjustment
Maintenance 6. If necessary, turn the thin nyloc nut to obtain the 2 1/2 inches (6.4 cm) spring length. 7. Engage the park brake. Measure the gap between the thin nyloc nut and the park brake clevis. The gap should measure 1/8 inch (3.2 mm) (see Figure 15). -
Page 35: Reverse Indicator Adjustment
Figure 17 1. Loosen jam nut 2. Pump control rod linkage 3. Use wrench to turn double nuts 9. 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). -
Page 36: Rear Caster Pivot Bearings Pre-Load Adjustment
Maintenance Figure 19 1. Motion control lever 3. Fender knob 2. Left fender 3. Slide the fender forward and twist upward and outward to remove. 4. To adjust the weight transfer springs, fold the mower deck and front frame and lock in service position. -
Page 37: Cleaning
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 remove key. Engage parking brake. 2. Wipe debris from radiator screen in front of radiator. -
Page 38: Troubleshooting
Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of trouble. - Page 39 Problem Engine overheats. Mower pulls left or right (with levers fully forward). Machine does not drive. Abnormal vibration. Warning buzzer emits continuous beep. (See also Engine overheats). Warning buzzer emits intermittent beep. Possible Cause 1. Engine load is excessive. 2. Oil level in the crankcase is low. 3.
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Page 40: Schematics
Schematics Schematics ORANGE VIOLET YELLOW/BLACK YELLOW/BLACK BLACK/WHITE PINK BLACK BLACK PINK/BLACK BLACK/GREEN YELLOW/BLACK GRAY GRAY ORANGE ORANGE VIOLET ORANGE ORANGE GRAY GRAY GRAY/BLACK BLACK BROWN BROWN BLACK BLACK ORANGE YELLOW/RED BLUE BLUE BLACK BLACK Electrical Diagram BROWN/BLACK BROWN/BLACK PINK/BLACK BLACK BLACK BROWN/BLACK YELLOW/BLACK... -
Page 41: Hydraulic Diagram
BYPASS VALVE HIGH PRESSURE FORWARD Hydraulic Diagram HIGH PRESSURE REVERSE HIGH PRESSURE FORWARD HIGH PRESSURE CHARGE PUMP CASE DRAIN Schematics BYPASS VALVE HIGH PRESSURE REVERSE G007220... - Page 42 • Attorney's fees. No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower. Some states do not allow exclusions of incidental or consequential damages, so the above exclusions and limitations may not apply to you.
- Page 44 SEE EXMARK’S COMPLETE LINE OF ACCESSORIES MID-MOUNT RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LAZERLOCKER LIGHT KIT MICRO-MULCH SYSTEM OPERATOR CONTROLLED DISCHARGE OUT-FRONT RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DUAL-TAIL WHEEL FLOOR PAN EXTENDER...