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Exmark Frontrunner - page 1
Engine Model No. and Spec. No. (Code) Engine Serial No. (E /No) Date Purchased Place Model No. and Serial No. Label Her e (Included in Literature Pack) or Fill in Below Model No. Seri al No. CONGRA TULA TION S on the purchase of your new E xmark mower . This produc t has been carefully designed and manufactured to give you a maximum amount of depen ...
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Exmark Frontrunner - page 2
i WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment. W HAT CAN HAPPEN ♦ Failure to f ollow safe operating pr act ices can result in serious operator inj ur y or even death. HOW TO AVO ID THE HAZARD ♦ Keep all shields, guar ds, and saf ety devices (especially the grass discharge system) in place and in pr oper working con ...
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Exmark Frontrunner - page 3
ii EXMARK PA RTS PLUS ® PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not have the Ex mark part in stock, Exmark w ill get the parts to the dealer the nex t business day or the part will be FREE* Guaranteed!! How the Program Works 1. If dealer does not have part in stock for a "dow n" unit at the time of ...
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Exmark Frontrunner - page 4
iii CONGRAT ULA TIONS on the purchase of your Exmark mower. T his product has been caref ully designed and manuf actured t o give you a maximum amount of dependability and years of tr ouble- f ree operat ion. OPERA TOR'S MA NUA L This manual cont ains oper at ing , maintenance, adj ustment, and saf ety instructi ons for y our E xmark mow er. B ...
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Exmark Frontrunner - page 5
iv TA BLE OF CONTENTS 1 . S A F E T Y P A G E 1.1 Safety Ale rt Sy mbol ....................................................................................... 1 1.2 Trai nin g ......................................................................................................... 1 1.3 Preparat ion ................................................ ...
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Exmark Frontrunner - page 6
1 1. SA FETY 1.1 SA FETY A LERT SYMBOL This SAFET Y ALERT SYMBOL is used both in this manual and on t he m achine t o identif y import ant safet y messages which must be followed to avoid accidents. T his symbol means: A TTENTION! BECOME A LERT! YOUR SA FETY IS INVOLVED! The saf ety alert symbol appears above inform at ion which alerts you to unsaf ...
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Exmark Frontrunner - page 7
2 CA UTION POTENT IAL HAZARD ♦ This machine pr oduces sound levels in excess of 85 dBA at the oper at or’s ear when in operation. W HAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss. HOW TO AVO ID THE HAZARD ♦ W ear hear ing protection when operating this mach ine. 1.3.3 W hile ...
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Exmark Frontrunner - page 8
3 DA NGER POTENT IAL HAZARD ♦ Diesel fuel is f lammable. W HAT CAN HAPPEN ♦ A fire f rom diesel f uel can burn you, others, and cause pr oper t y damag e. HOW TO AVO ID THE HAZARD ♦ DO NOT sm ok e while refueling, and st ay away fr om an open f lame or where f uel fum es m ay be ig nit ed by spark . ♦ Refuel only outdoors. ♦ Store f uel i ...
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Exmark Frontrunner - page 9
4 1.4 OPERA TION Although hazard control and acci dent prevent ion are partiall y dependent upon t he design and configurat i on of t he equipment, these f act ors are al so dependent upon the awareness, concern, prudence, and proper t r ai ni ng of the personnel invol ved i n the operation, t r ansport , mai nt enance, and storage of the equipment ...
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Exmark Frontrunner - page 10
5 1.4.3 W hen f easible, avoid operating t he equipment in wet g r ass. WA RNING POTENT IAL HAZARD ♦ Operating a FrontRunner t r act or without an approved Exmark f ront mount attachment incr eases the possibility of for ward tip over. W HAT CAN HAPPEN ♦ Tip-over could cause serious injur y or death. HOW TO AVO ID THE HAZARD ♦ W hen operat in ...
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Exmark Frontrunner - page 11
6 • See inside the back cover t o det er m ine the approximate slope angle of the area to be mowed. • Use a walk behind mower and/or a hand tr im m e r near dr op- off s, ditches, st eep banks or water. T his area can be dangerous, see Fig ure 1. FIGURE 1 • Progre ssively great er car e is needed as t he slope increases. • Alway s avoid sud ...
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Exmark Frontrunner - page 12
7 • Be certain that t he seat belt can be released q u ick ly if the machine is dr iven or rolls into ponds of water. • Check caref ully for overhead clearances ( i. e. br anches, doorways, and electrical wires) bef or e dr iving under any object s and do not cont act them. 1.4.6 Use EXTREME caution when backing up. LOOK BEHI ND YO U! 1.4.7 Sto ...
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Exmark Frontrunner - page 13
8 1.5 MAINTENA NCE AND STORA GE 1.5.1 For engine m aint enance, f ollow the engine manuf acturer’s r ecom m endat ions precisely as stated in the eng ine manual. 1.5.2 Disconnect the batt ery cable from t he negative batter y post when the unit will be allowed to sit for m or e t han 30 days without use. 1.5.3 Allowing batteries to st and f or an ...
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Exmark Frontrunner - page 14
9 WA RNING POTENT IAL HAZARD ♦ Hydraulic fluid escaping under pr essur e can penetrate sk in and cause injury. W HAT CAN HAPPEN ♦ Fluid accidentally injected into t he skin must be surg ically removed within a few hours by a doctor f amiliar with this for m of injury or g ang rene may result. HOW TO AVO ID THE HAZARD ♦ Make sure all hydraulic ...
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Exmark Frontrunner - page 15
10 1.6.3 W hen new components are inst alled, be sur e t hat current saf ety signs are aff ixed to the replaced components. 1.6.4 New safety signs may be obtained f rom Exmark Mfg. Co. I nc. 1.6.5 Safet y signs m a y be af f ixed by peeling off the backing t o expose the adhesive surf ace. Apply only to a clean, dr y surf ace. Smooth t o r e m ove ...
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Exmark Frontrunner - page 16
11 PART NO. 107- 2102 LOCATIO N: Inside Surfac e of Upper Roll Bar PART NO. 109- 2355 LOCATI ON: Outside of each W eight T ransf er Bell Crank PART NO. 109- 2357 LOCATI ON: Top of Console, LH Side PART NO. 109- 2360 LOCATIO N: Front of Cons ole PART NO. 109- 2377 LOCATI ON: On Hydraulic Cy linder PART NO. 109- 2396 LOCATI ON: Top of Seat Support Pl ...
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Exmark Frontrunner - page 17
12 2. SPECIFICA TIONS 2.1 MODEL NUMBER: FR25KD 2.2 ENGINE 2.2.1 Engine Specif icat ions: 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 2.3.1 Capacity: 8.5 g al ( 32 L) 2.3.2 Type of Fuel: Diesel fuel, 40 cet ane or higher. 2.3.3 Fuel Filter: 2 I n-line 15 Mi ...
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Exmark Frontrunner - page 18
13 2.7.3 Seat Saf et y Switch: Int ernal to the bot t om seat cushion, non serviceable. Time delay module incorporat ed int o t he Safety Int er lock System eliminates roug h ground cut - out s. 2.7.4 Armrests: Standard seat: foam padded flip-up armrests. Optional suspension seat: m olded adj ustable flip- up armrests. 2.8 HYDROSTATIC GROUND DRIVE ...
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Exmark Frontrunner - page 19
14 2.12 TORQUE REQUIREMENTS Bolt Location T o r q u e W heel Lug Nuts ............................................................. 90- 95 ft-lbs. (122-129 N-m) W heel M otor Mounti ng Bolt s ............................................ 72- 77 ft-lbs. (98-104 N-m) Rol lov er Protection Sy stem (Rol l Bar) M ounting Bolts ....... 30-35 f t -lbs. (41 ...
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Exmark Frontrunner - page 20
15 Pulling the l evers back f rom t he neut ral position will cause the respective drive wheels to rotate in a reverse direct ion ( s pr ing tension can be f elt when moving into reverse f rom neut r al) . To tur n t o the left while backing, move the lef t lever f orward toward neutral. T o turn to t he right while backing , move the rig ht lever ...
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Exmark Frontrunner - page 21
16 NOTE: A glow plug lig ht, located t o t he rear of the glow plug switch, will illuminate when the switch is depressed. The g low plug light indicates t he g low plugs are preheat ing the combust ion cham ber . 3.1.8 Hour Meter : Located on t he r ight f uel t ank console. T he hour m eter runs when the alternat or is char g ing and it recor ds t ...
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Exmark Frontrunner - page 22
17 3.1.15 Alternator Charging Lig ht : Located t o t he rear of t he key switch. Light will come on when the alternator is not char g ing. 3.1.16 Low Oil Pressure Light : Located to the r ear of the k ey switch with the alternator light. Lig ht will come on when engine oil pressure is low or lost. NOTE: T his switch is not a low oil level sensor an ...
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Exmark Frontrunner - page 23
18 d) Mov e the throt tle to the “SLO W ” ( if in “MIDW AY”) and let the engine warm up a few minutes bef ore moving the t hr ot tle to the “FAST ” position. 3.3.3 Eng aging PTO : DA NGER POTENT IAL HAZARD ♦ The rot at ing blades under the mower deck are dang erous. W HAT CAN HAPPEN ♦ Blade contact can cause serious inj ur y or kill ...
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Exmark Frontrunner - page 24
19 3.4 TRA NSPORTING IMPORT A NT: Do not transport Front Runner t ractor without an approved Exmark f ront mount att achm ent . 3.4.1 Transpor t ing a Unit : Use a heavy-duty trailer or t ruck to t ransport the m achine. Engage t he park brak e and block the wheels. Securely f a st en t he m achine to the trailer or t r uck with straps, chains, cab ...
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Exmark Frontrunner - page 25
20 WA RNING POTENT IAL HAZARD ♦ Loading a unit on a t r ailer or truck increases the possibility of tip-over. W HAT CAN HAPPEN ♦ Tip-over of t he unit could cause serious injury or death. HOW TO AVO ID THE HAZARD ♦ Use extreme caution when operating a unit on a ramp. ♦ Use only a single, f ull width ramp; DO NOT use individual ramps f or ea ...
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Exmark Frontrunner - page 26
21 4. M A INTENA NCE & ADJUSTMENTS WA RNING POTENT IAL HAZARD ♦ W hile maint enance or adjustments ar e being made, som eone could st ar t the engine. W HAT CAN HAPPEN ♦ Accidental start ing of the eng ine could seriously injure you or other bystanders. HOW TO AVO ID THE HAZARD ♦ Remove the key f rom the ig nit ion switch and engage par k ...
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Exmark Frontrunner - page 27
22 4.1.2 Check eng ine coolant level : Service Interval : Dai l y a) Stop engine and wait f or all m oving par ts to stop. Make sur e m achine is on a level surface. b) Tilt seat up and t ilt hood f orward to g ain access t o t he cooling area. c) Check with engine cold. d) View coolant level in overflow bottle on the lef t side of the eng ine. Coo ...
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Exmark Frontrunner - page 28
23 recommended t im e int er val to bring the char g e up to a full char ge of 12. 6 volts or great er. IMPORT A NT: M ake sure the neg at ive battery cables are disconnected and the batter y charg er used f or charg ing the batter y has an output of 16 volts and 7 amps or less to avoid damag ing the batter y (see char t below f or recommended char ...
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Exmark Frontrunner - page 29
24 Repeat again m oving t he ri ght lever in , then m oving bot h l evers i n - engine must initia te shu tdown w hether operator is on seat or not . c) Check the PTO circui t : See the FR524 and FR604 Operat or ’s manual to become f amiliar with the deck operat ion. Open the f olding deck latches, disengage the park br ake, move the motion cont ...
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Exmark Frontrunner - page 30
25 4.1.9 Service air cleaner : Fi rst Servi ce I nterval: 50 hrs. Normal I nt erval : 100 hrs Repl acement I nterval: 600 hrs ( M ore of t en under severe condi t i ons.) See Engi ne manual f or additional i nf ormat i on. a) St op engine, wait f or all moving parts t o st op, and remove k ey. Eng age parking br ak e. b) T ilt seat f orward and rai ...
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Exmark Frontrunner - page 31
26 Drain coolant when engine is cool. Coolant m a y be drained f rom the r adiat or by loosening the drain cock in the left r ear corner. T he eng ine block may be drained by removing the lower radiator hose and/ or by opening the drain cock fr om t he eng ine block. T he engine drain cock m ay be accessed on the r ig ht side of t he unit and is lo ...
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Exmark Frontrunner - page 32
27 f) Operate engine unt il t he engine therm ost at opens and coolant is circulat ing throug h t he r adiat or core. As air is pur g ed fr om t he eng ine block and the coolant level drops, add additional coolant t o t he radiator. g) W hen the r adiat or is com pletely full and no additional coolant can be added, continue running t he eng ine and ...
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Exmark Frontrunner - page 33
28 c) AT101 (Bar Lug) dr ive tires should be inflated t o 9 psi ( 62 k pa). d) Turf mate dr ive tires should be inf lated to 13 psi (90 k pa). e) The rear cast er t ir es ar e sem i- pneum at ic and do not need to be inflat ed. NOT E: Do not ad d any type of tire line r or foa m fill material to the tires . Excessive loads created by foam f illed t ...
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Exmark Frontrunner - page 34
29 d) Remove one of the spacer nut s from t he axle assembly in the caster wheel. Note that thr ead lock ing adhesive has been applied to lock t he spacer nut s to the axle. Remove the axle (with the other spacer nut still assem bled t o it) f r om the wheel assembly. e) Pry out seals, and inspect bear ing s for wear or damage and replace if necess ...
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Exmark Frontrunner - page 35
30 4.1.20 Lubricate the m otion control bronze bushings : Service Interval: 160 hrs. a) St op engine, wait f or all moving parts t o st op, and remove k ey. Eng age parking br ak e. b) T ilt seat f orward. c) Lubricate bronze bushings on t he flange bear ing s securing the m ot ion control arm shaf ts with a light oil or a spray type lubricant. 4.1 ...
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Exmark Frontrunner - page 36
31 4.1.25 Fuel priming procedure : a) Unit is equipped with an electr ic pr im ing pump. T urn key on to let elect ric pump run f or at least 30 seconds bef ore starting . b) Start eng ine using procedure in Sect ion 3.3.2. IMPORTANT: DO NOT over cr ank engine. O ver cr ank ing eng ine can dam ag e the start er and/ or the f uel solenoid. I f eng i ...
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Exmark Frontrunner - page 37
32 4.1.27 W heel Hub – lock nut t or q ue specificat ion Service Interval: Af t er Fi rst 100 hrs Then every 500 hrs thereafter W hen tig htening the lock nut on the wheel motor t aper ed shaf t: a) T orq ue the lock nut to 125 f t-lbs (169 N-m). NOTE: Do not use ant isieze on w heel hub. 4.1.28 Fuel Tank – m ounting hardware specif ication W h ...
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Exmark Frontrunner - page 38
33 c) T o tighten alt er nator belt, loosen bot h upper and lower alternator m ount ing bolts. Rot at e alt ernator out, away fr om eng ine and re-tig hten hardware to secure in place. d) W hen proper ly tensioned, t he alternator belt will def lect 1/4”-3/8” (7-9 mm) while applyi ng 22 pounds of force t o the belt midway between alternator and ...
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Exmark Frontrunner - page 39
34 FIGURE 12 h) If t he link age does not m easur e 7- 3/ 8” (18.7 cm) or st ill does not disengag e as desired, rem ove the bolt t hat secures the ball j oint t o the brake lever and loosen the jam nut next t o t he ball j oint. Rotat e t he ball j oint in half- turns counter-clock wise until desired disengagem ent is obtained. i) Repeat procedu ...
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Exmark Frontrunner - page 40
35 Set neutral: a) Remove the electr ical connect ion from t he seat safet y sw itch, located dir ect ly in fr ont of the seat switch assembly. b) The neut r al adjustment m ust be m ade with the dr ive wheels turning . Raise t he fr am e and place on j ack stands so that dr ive wheels can rotate f reely. Temporarily install a j umper wire across t ...
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Exmark Frontrunner - page 41
36 FIGURE 14 d) Check where lever is relat ive to not ch in neut ral plate (should be cent er ed allowing lever to pivot outward to the neut r al lock position) . e) If adjustment is needed, loosen the nut ag ainst the yoke and while applying slight r ear ward pressur e on t he m otion control lever, t ur n t he head of the adjustment bolt in the a ...
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Exmark Frontrunner - page 42
37 WA RNING POTENT IAL HAZARD ♦ W eig ht t ransfer spr ing s m ay have stored energy. W HAT CAN HAPPEN ♦ Removing the weight tr ansfer spr ing s without releasing the st or ed ener gy can cause serious injury HOW TO AVO ID THE HAZARD ♦ Fold mower deck and f ront f r am e and lock in service position t o r em ove spring tension and release sto ...
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Exmark Frontrunner - page 43
38 CA UTION POTENT IAL HAZARD ♦ Raising the unit f or service or maintenance relying solely on mechanical or hydraulic jacks could be dang erous. W HAT CAN HAPPEN ♦ The mechanical or hydraulic j ack s may not be enough suppor t or m ay malf unct ion allowing the unit to f all, which could cause injury. HOW TO AVO ID THE HAZARD ♦ DO NOT r ely ...
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Exmark Frontrunner - page 44
39 If a bat t ery is being replaced or if the unit cont aining the batter y is no long er oper at ing and is being scrapped, t ak e the batt er y to a local cer t if ied recycling center . If no local recycling is available return t he battery to any certif ied batter y reseller . 6. TROUBLE SHOOTING 6.1 M OWER PULLS LEFT OR RIGHT ( W/LEVERS FULLY ...
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Exmark Frontrunner - page 45
40 TROUBLESHOOTING TA BLE PROBLEM NO FUEL IMPROPER FUEL WATER OR DIRT IN FUEL LIN E DIRTY AIR FILTER ENGINE OVERLOADED BLOCKED FUEL FILTERS INCORRECT OIL L EVEL INSU FFICIENT BATTERY CHARGE FAN PUMP BELT MISSING DIRTY RADIATOR CORE Will not start X X X X X X Hard starting X X X X X X Stops suddenly X X X X X Lacks power X X X X X Operates erratical ...
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Exmark Frontrunner - page 46
41 7. ELECTRICA L DIA GRAM ...
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Exmark Frontrunner - page 47
42 8. HYDRA ULIC DIA GRAM ...
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Exmark Frontrunner - page 48
43 9. 2-Y ear L imited Warran ty Exmark Tu rf Equipment (For units pur chased on or af ter October 1, 2004) Conditions and Products Covered Exmark M fg. Co. Inc. and its affiliate, Ex mark W arranty Company, pursuant to an agreement betw een them, jointly warrant on the terms and conditions herein, that w e will repair, replace or adjust any part m ...
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Exmark Frontrunner - page 49
44 NOTES ...
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Exmark Frontrunner - page 50
45 NOTES ...
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Exmark Frontrunner - page 51
46 ...
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Exmark Frontrunner - page 52
® M FG . CO. IN C. SEE EXMA RK’S COMPLETE LINE OF A CCESSORIES RIDING A CCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT K IT MICRO-MULCH SY STEM ROLL OVER PROTECT ION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONT AINER TURF STRIPER ULTRA VAC COLLECT ION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WA LK BEHIND A CCE ...
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