FRONTRUNNER TM DIESEL MODELS For Serial Nos. 720,000 & Higher Part No. 4500-227 Rev.
WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Important: When the mower is used or operated on any California forest, brush or grass covered land, a working spark arrester must be attached to the muffler. If not, the operator is violating state law, Section 4442 Public Resource Code. To acquire a spark arrester for your unit, see your Engine Service Dealer.
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY. Figure 1 1.
Contents Alternator Belt Tension ................................. 33 Park Brake Adjustment.................................. 33 Motion Control Linkage Adjustment ............. 34 Reverse Indicator Adjustment........................ 35 Weight Transfer Spring Adjustment ............... 35 Rear Caster Pivot Bearings Pre-Load Adjustment ............................................... 36 Cleaning ........................................................... 37 Clean Engine Cooling System ........................
Safety Safety • Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. Safety Alert Symbol • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property.
Safety DANGER WARNING In certain conditions diesel is extremely flammable and vapors are explosive. Diesel fuel is harmful or fatal if swallowed. Long-term exposure to vapors has caused cancer in laboratory animals. Failure to use caution may cause serious injury or illness. A fire or explosion from diesel can burn you, others, and cause property damage. • Avoid prolonged breathing of vapors. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any diesel that spills.
Safety – Before dumping the grass catcher. WARNING WARNING Operating a FrontRunner tractor without an approved Exmark front mount attachment increases the possibility of forward tip over. Tip-over could cause serious injury or death. Hands, feet, hair, clothing, or accessories can become entangled in rotating parts. Contact with the rotating parts can cause traumatic amputation or severe lacerations.
Safety • Watch for ditches, holes, rocks, dips and rises that change the operating angle, as rough terrain could overturn the machine. 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. • Avoid sudden stops when mowing downhill because the mower may tip forwards. • Be aware that loss of traction may occur going uphill.
Safety Maintenance and Storage WARNING • 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. These materials can become combustible and may result in a fire.
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels. • Replace all worn, damaged, or missing safety signs. • When replacement components are installed, be sure that current safety signs are affixed to the replaced components. • If an attachment or accessory has been installed, make sure current safety signs are visible.
Safety 103-1636 103-5881 103-7218 107-2102 107-2112 11
Safety 109-2355 109-2358 109-2356 1. Fast 2. Slow 109-2377 3. Neutral 4. Reverse 109-2396 109-2357 1. Fast 2. Slow 3. Neutral 4. Reverse 5. Park Brake—Release 6.
Safety 109-7949 19426-87881 109-2698 1. Cylinder—extend 2. Cylinder—retract 3. Fast 4.
Specifications Specifications Model Numbers Serial Nos: 720,000 and Higher FR25KD Systems Cooling System Engine • Fan: Belt driven with continuous operation with engine running. • Engine Specifications: See your Engine Owner’s Manual • RPM: Full Speed: 3870 +50/-100 RPM (No Load) Idle: 1400 ±50 RPM (No Load) • Coolant Liquid: 50/50 mix of DexCool© extended life antifreeze and water. • Coolant Capacity: 4 quarts Fuel System Operator Controls • Capacity: 8.5 gal.
Specifications • 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. Caster • Armrests: Standard seat: foam padded flip-up armrests. Optional suspension seat: molded adjustable flip-up armrests. • 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.
Specifications Curb Weight: • Mulching Kit: Optional • Bagger: Optional Dimensions Without deck 1163 lb (528 kg) 52 inch Deck 1555 lb (705 kg) 60 inch Deck 1600 lb (726 kg) 72 inch Deck 1660 lb (753 kg) 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) Bolt Location Torque Wheel Lug Nuts 90-95 ft-lb (122-129 N-m) Deflector Up 53.3 inches (135.4 cm) 61.4 inches (156 cm) 73.
Operation Product Overview 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 the machine. The levers control the flow of hydraulic oil from the hydrostatic pump to the drive wheel motor for each side. Moving the levers forward or backward turns the wheel on the same side forward or in reverse.
Operation The hydraulic lift switch is used to raise and lower the mower deck. 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). Push the front portion of the hydraulic lift switch down to raise the mower deck to the desired height. Note: Brake must be engaged, motion control levers out (neutral lock position), and PTO switch “OFF” to start engine.
Operation 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. Failure to observe this caution will damage the engine. Do Not add oil to fuel. Do Not overfill fuel tank.
Operation The PTO push-pull switch engages the cutting blades. Be sure that all persons are clear of the mower deck and discharge area before engaging PTO. Glow Plug Chart Ambient Temperature Hold Glow Plugs On Above 50°F (10°C) NO NEED Important: Operator must be in seat before the PTO can be engaged. 1. Set the throttle to the “MIDWAY” position. 2. Pull the PTO switch outward to the “ROTATE” position. 3. Place the throttle in the “FAST” position to begin mowing.
Operation before the motion control levers can be moved in or the engine will stop. When levers are centered in the T-slot the drive system is in the neutral position. With levers moved out in the T-slot the drive system is in the neutral lock position (Figure 6). Figure 7 1. Handles Out (Neutral Lock) 2. Handles In (Neutral) 3. Front of Unit Figure 6 1. Handles Out (Neutral Lock) 2. Handles In (Neutral) 3. Front of Unit 4. Forward 5. Neutral 6. Reverse 7. Neutral Lock 4. Forward 5.
Operation near a slope, position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible. 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.
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING 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. The engine can become very hot. Touching a hot engine can cause severe burns. Allow the engine to cool completely before service or making repairs around the engine area.
Maintenance Maintenance Service Interval Every 4,000 hours Monthly Yearly Maintenance Procedure • Change engine coolant. Dex-Cool© extended life coolant (orange color) • Check the battery charge. • • • • • • • • Grease the fold lock pin. Grease the rear caster pivot. Grease the belt idlers. Grease the motion control pivots. Grease the transfer spring ends. Lubricate the caster wheel hub(s). Lubricate the motion control shaft. Change the hydraulic filter. Periodic Maintenance 4.
Maintenance Change Engine Coolant WARNING Service Interval: Every 4,000 hours/Every 4 years (whichever comes © extended first) Dex-Cool© life coolant (orange color) Engine compartment contains open belt drives, fans, and other rotating components that can cause injury. Fingers, hands, loose clothing, or jewelry can get caught by the rotating fan and drive shaft. 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. Machine must be positioned on level surface.
Maintenance Try to start with operator in seat, parking brake disengaged, PTO disengaged and motion control levers in the neutral lock position - starter must not crank. 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.
Maintenance Check for Loose Hardware Service Interval: Before each use or daily 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Visually inspect machine for any loose hardware or any other possible problem. Tighten hardware or correct the problem before operating. Service Air Cleaner Service Interval: Every 50 hours (May need more often under severe conditions. See the Engine Owner’s Manual for additional information.) 1.
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. Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 2/3 to 3/4 turn. 6. Clean around oil fill cap and remove cap. Fill to specified capacity and replace cap. 7.
Maintenance 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. Engage parking brake. 2. Lubricate fittings with one to two pumps of NGLI grade #2 multi-purpose gun grease. Refer to the following chart for fitting locations and lubrication schedule.
Maintenance Lubricate Brake Handle Pivot the other spacer nut still assembled to it) from the wheel assembly. Service Interval: Every 160 hours 5. Pry out seals, and inspect bearings for wear or damage and replace if necessary. 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 6. Pack the bearings with a NGLI grade #1 multi-purpose grease. 2. Tilt seat forward. 3. Lubricate bronze bushings on brake handle pivot with a spray type lubricant or light oil. 7.
Maintenance Lubricate Steering Linkage Rod Ends Change Fuel Filter Service Interval: Every 400 hours or as required. Service Interval: Every 160 hours A fuel filter is installed between the fuel tank and fuel pump, and between the fuel pump and the engine. Replace when necessary. 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Tilt seat forward. Replacement Filters 3.
Maintenance • Pump drive sheave set screws. CAUTION • Line shaft sheave setscrews. 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. • Square head setscrews on Hydro pump control arms. • Sheave retaining bolt in the end of engine crankshaft. • Caster wheel spacer nuts.
Maintenance Adjustments Park Brake Adjustment 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. Check to make sure brake is adjusted properly. 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Tilt seat forward and raise hood. 3. Pull the brake lever up into the engaged position. Pump Drive Belt Tension 4.
Maintenance 6. If necessary, turn the thin nyloc nut to obtain the 2 1/2 inches (6.4 cm) spring length. remove the bolt that secures the ball joint to the brake lever and loosen the jam nut next to the ball joint. Rotate the ball joint in half-turns counterclockwise until desired disengagement is obtained. 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). 11. Repeat procedure for other side.
Maintenance Figure 18 1. Motion control lever 2. End of slot 3. Yoke 4. Loosen here 5. Turn bolt here 4. Check where lever is relative to notch in neutral plate (should be centered allowing lever to pivot outward to the neutral lock position). Figure 17 5.
Maintenance Figure 20 Right-Hand Side of Unit Shown 1. Re-install spring in outer holes to reduce spring tension. 2. Weight transfer spring. Figure 19 1. Motion control lever 2. Left fender 3. Fender knob 3. Remove e-ring and washer. 7. Re-install the left fender. 3. Slide the fender forward and twist upward and outward to remove. 8. For additional weight transfer adjustment, repeat steps 4 through 7 on the right side of the unit. 4.
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 remove key. Engage parking brake. 2. Wipe debris from radiator screen in front of radiator. Rotate engine cover forward, pull out radiator screen, and wipe debris from radiator core as required. Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment.
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. Do not attempt to service or replace major items or any items that call for special timing of adjustment procedures (such as valves, governor, etc.).
Troubleshooting Problem Engine overheats. Possible Cause Corrective Action 1. Engine load is excessive. 1. Reduce the ground speed. 2. 3. 4. 5. 6. 2. 3. 4. 5. 6. Oil level in the crankcase is low. Dirty air filter. Coolant level is low. Debris on or around radiator. Water pump or alternator belt is worn, loose, or broken. Add oil to the crankcase. Clean or replace the air cleaner element. Add coolant. Remove debris. Contact an Authorized Service Dealer.
TERMINAL X TERMINAL I 3. START 2. RUN 1.
Schematics Hydraulic Diagram BYPASS VALVE BYPASS VALVE HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE G007220 HIGH PRESSURE CHARGE PUMP CASE DRAIN 41
2-Year Limited Warranty Exmark Turf Equipment (For units purchased on or after October 1, 2004) Contact any Exmark Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our website at www.exmark.com. U.S. Customers may also call 402-223-6375. Conditions and Products Covered Exmark Mfg. Co. Inc.
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES MID-MOUNT RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM ROLL OVER PROTECTION SYSTEM (ROPS) DECK LIFT ASSIST KIT SNOW BLADE HITCH KIT SUN SHADE LAZERLOCKER TRASH CONTAINER LIGHT KIT TURF STRIPER MICRO-MULCH SYSTEM ULTRA VAC COLLECTION SYSTEM OPERATOR CONTROLLED DISCHARGE ULTRA VAC QUICK DISPOSAL SYSTEM OUT-FRONT RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL-TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KI
