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Exmark FrontRunner Diesel - page 1
FRONTRUNNER TM DIESEL MODELS For Serial Nos. 720,000 & Higher Part No. 4500-227 Rev . A ...
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Exmark FrontRunner Diesel - page 2
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 ...
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Exmark FrontRunner Diesel - page 3
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 ...
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Exmark FrontRunner Diesel - page 4
Contents Introduction .. .. . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . . .. 3 Safety .. . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . 5 Safety Aler t Symbol . . . . . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . ...
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Exmark FrontRunner Diesel - page 5
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 ...
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Exmark FrontRunner Diesel - page 6
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 rell the fuel tank or drain the machine indoor s o ...
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Exmark FrontRunner Diesel - page 7
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 ...
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Exmark FrontRunner Diesel - page 8
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 ...
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Exmark FrontRunner Diesel - page 9
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 ...
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Exmark FrontRunner Diesel - page 10
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 afxed to the replaced components . • If an ...
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Exmark FrontRunner Diesel - page 11
Safety 103-1636 103-5881 103-7218 107-2102 107-21 12 1 1 ...
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Exmark FrontRunner Diesel - 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 12 ...
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Exmark FrontRunner Diesel - page 13
Safety 109-2698 1. Cylinder—extend 3. Fast 2. Cylinder—retract 4. Slow 109-3637 109-7949 19426-87881 19426-87903 109-2360 13 ...
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Exmark FrontRunner Diesel - page 14
Specications Specications Model Numbers Serial Nos: 720,000 and Higher FR25KD Systems Engine • Engine Specications: 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 ...
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Exmark FrontRunner Diesel - page 15
Specications • 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 ...
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Exmark FrontRunner Diesel - page 16
Specications • 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) Deector Up 53.3 inches (135.4 cm) 61.4 inches (156 cm) 73.4 inches (186 cm) Deector Down 64.0 inches (163 cm) 72.0 inches (183 cm) 8 ...
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Exmark FrontRunner Diesel - page 17
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 ...
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Exmark FrontRunner Diesel - page 18
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 . ...
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Exmark FrontRunner Diesel - page 19
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 ...
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Exmark FrontRunner Diesel - page 20
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 ...
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Exmark FrontRunner Diesel - page 21
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. ...
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Exmark FrontRunner Diesel - page 22
Operation CAUTION This unit does not ha ve proper tur n signals, lights, reecti 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 ...
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Exmark FrontRunner Diesel - page 23
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 ...
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Exmark FrontRunner Diesel - page 24
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 ...
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Exmark FrontRunner Diesel - page 25
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 ...
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Exmark FrontRunner Diesel - page 26
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 ...
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Exmark FrontRunner Diesel - page 27
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 ...
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Exmark FrontRunner Diesel - page 28
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 ...
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Exmark FrontRunner Diesel - page 29
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. ...
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Exmark FrontRunner Diesel - page 30
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 ...
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Exmark FrontRunner Diesel - page 31
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 ...
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Exmark FrontRunner Diesel - page 32
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 ...
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Exmark FrontRunner Diesel - page 33
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 ...
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Exmark FrontRunner Diesel - page 34
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/ ...
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Exmark FrontRunner Diesel - page 35
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 ...
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Exmark FrontRunner Diesel - page 36
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 ...
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Exmark FrontRunner Diesel - page 37
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 ...
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Exmark FrontRunner Diesel - page 38
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 ...
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Exmark FrontRunner Diesel - page 39
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 ...
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Exmark FrontRunner Diesel - page 40
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 ...
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Exmark FrontRunner Diesel - page 41
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 ...
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Exmark FrontRunner Diesel - page 42
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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Exmark FrontRunner Diesel - page 43
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Exmark FrontRunner Diesel - page 44
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 ...
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