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Exmark Frontrunner FR25KD, Operator'S Manual

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Exmark Frontrunner FR25KD Operator'S Manual Download Page 18

13 

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. 
 

 

       Optional suspension seat: molded adjustable flip-up

 

armrests.  

2.8  HYDROSTATIC GROUND DRIVE SYSTEM 

2.8.1  Hydrostatic Pumps:  Two Hydro Gear PR 16 cc variable displacement piston pumps. 

2.8.2  Wheel Motors:  Hydro Gear planetary reduction motors. 

2.8.3  Hydraulic Oil Type:  Use Mobil 1 15W-50 Synthetic Motor Oil. 

2.8.4  Hydraulic Oil Capacity:  5.2 qt. (4.9 L.) 

2.8.5  Hydraulic Filter: Replaceable cartridge type. 

 

 

 

  P/N 103-2146: 25 microns, No bypass  

2.8.6  Speeds:  0-10.5 mph (16.9 km/hr) forward 

 0-6.6mph (10.6 km/hr) reverse 

2.8.7  Drive wheel release valves allow machine to be moved when engine is not running. 

2.9  TIRES

 

Drive Front 

Caster 

Rear Caster 

(Dual Tail Wheel) 

 

Pneumatic (Air-Filled) 

Pneumatic (Air-Filled) 

Semi-Pneumatic 

Semi-Pneumatic 

Quantity 2 

2 

2 

2 

Tread AT101  Turfmate 

Smooth 

Smooth 

Size 

24 x 12.00-12 

23 x 10.50-10 

9 x 3.50-4 

13 x 6.5-6 

Ply Rating 

4 

4 

 

 

Pressure 

9 psi (62 kPa) 

13 psi (90 kPa) 

 

 

2.10  MOWER DECK 

(Sold Separately) 

2.10.1

 

Models 

FR524 FR604 

Discharge

 

Side Discharge

 

Side Discharge

 

Cutting Width 

52 in. (132 cm) 

60 in. (152 cm) 

 2.11 

DIMENSIONS

 

2.11.1    Overall Width:

 

w/52” Deck 

w/60” Deck 

without deck

 

49.0 in. (124.5 cm) 

49.0 in. (124 cm) 

deflector up

 

53.3 in. (135.4 cm) 

61.4 in. (156 cm) 

deflector down

 

64.0 in. (163 cm) 

72.0 in. (183 cm) 

 

 

2.11.2    Overall Length:

 

 

without deck & floor pan folded 

82.3 in. (209.0 cm) 

w/52” Deck

 

114.3 in. (290.3 cm) 

w/60” Deck

 

114.3 in. (290.3 cm) 

 

 

2.11.3    Overall Height: 

Roll Bar - Up 

Roll Bar - Down 

 

69.2 in. (175.8 cm)

50.7 in. (128.8 cm) 

 

2.11.4    Curb Weight: 

without Deck 

1163 lbs. (528 kg) 

 w/52” 

Deck 

1555 lbs. (705 kg) 

 w/60” 

Deck 

1600 lbs. (726 kg) 

 

2.11.5  Tread Width (Center to Center of Drive Wheels):  41.4 in. (105.2 cm) 
2.11.6  Wheel Base (Center of Drive Wheel to Center of Rear Caster Wheel):  
 

51.2 in. (130.0 cm) 

2.11.7  Minimum Turning Radius:  55.25” 

For Exmark Mower Parts Call 606-678-9623 or 606-561-4983

www.mymowerparts.com

Summary of Contents for Frontrunner FR25KD

Page 1: ...er 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 on the is located right side of the unit under the fuel tank For ease of ordering and reference we suggest record the information requested in the following identification table that you Place Model No and Serial No Label Here Included in Li...

Page 2: ...ff mower unless seat platform is provided Keep others off mower WARNING POTENTIAL HAZARD Diesel fuel is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness HOW TO AVOID THE HAZARD Avoid prolonged breathing of vapors Keep face away from nozzle and fuel tank container opening Kee...

Page 3: ... Exmark by 3 00 p m central time the Distributor pays for the part and freight 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 The following restrictions apply The Exmark Parts Plus P...

Page 4: ...mote safe operation 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 They carry ample stock of service pa...

Page 5: ...2 12 Torque Requirements 14 3 OPERATION INSTRUCTIONS 3 1 Controls 14 17 3 2 Pre Start 17 3 3 Operating Instructions 17 19 3 4 Transporting 19 20 4 MAINTENANCE ADJUSTMENTS 4 1 Periodic Maintenance 21 32 4 2 Adjustments 32 37 5 WASTE DISPOSAL 5 1 Motor Oil Disposal 38 5 2 Battery Disposal 38 6 TROUBLESHOOTING 6 1 Mower Pulls Left or Right 38 6 2 Mower Cuts Unevenly 38 6 3 Engine Will Not Start 39 6 ...

Page 6: ... 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 If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or peop...

Page 7: ... barefoot or when wearing open sandals 1 3 4 Thoroughly inspect the area where the equipment is to be used and remove all stones sticks wires bones and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders WARNING POTENTIAL HAZARD Engine exhaust contains carbon monoxide which is an odorless deadly poison WHAT CAN HAPPEN Carbon monoxide can kill...

Page 8: ...e Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot Never fill the fuel tank so that the fuel level rises above a level that is 1 2 below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage If fuel is spilled DO NOT attempt to start the engine Move away from the area of the spill and avoid creating any source of ignit...

Page 9: ...ore touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe ...

Page 10: ...te up or down a trailer ramp 9 Avoid sudden acceleration or deceleration 1 4 4 Use EXTREME caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes DANGER POTENTIAL HAZARD Mowing on wet grass or steep slopes can cause sliding and loss of control WHAT CAN HAPPEN Wheels dropping over edges ditches steep bank...

Page 11: ... machine Remove or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles Use extreme care with attachments These can change the stability of the machine and cause loss of control Follow the manufacturer s recommendations for wheel weights or counterweights to improve stability 1 4 5 A Rollover Protection System roll bar is installed on the unit DANGER POTEN...

Page 12: ... for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop the engine and wait for all moving parts to stop Engage parking brake Before refueling Before dumping the grass catcher 1 4 14 Before stopping the engine place the throttle control to the slow position Allow the engine to run a minimum of 15 seconds then stop the engin...

Page 13: ...ich can accumulate in these areas These materials can become combustible and may result in a fire 1 5 5 Store fuel in a container specifically designed for this purpose in a cool dry place 1 5 6 Keep the mower and fuel container in locked storage to prevent children from playing or tampering with them 1 5 7 Diesel powered equipment or fuel containers should not be stored in a basement or any enclo...

Page 14: ...ks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system WARNING POTENTIAL HAZARD Fuel system components are under high pressure WHAT CAN HAPPEN The use of impro...

Page 15: ...3746 LOCATION Outside of rear muffler guard PART NO 1 513747 LOCATION LH Side of Battery Holder PART NO 1 523552 LOCATION Top Surface of Hydraulic Tank PART NO 1 643339 LOCATION On top of Radiator PART NO 103 2076 LOCATION On Top of Radiator PART NO 103 7218 LOCATION On Seat Support Plate PART NO 103 0233 LOCATION On Front of the Fan Shroud PART NO 109 2358 LOCATION On Control Panel PART NO 109 23...

Page 16: ...f Console LH Side PART NO 109 2360 LOCATION Front of Console PART NO 109 2377 LOCATION On Hydraulic Cylinder PART NO 109 2396 LOCATION Top of Seat Support Plate PART NO 109 3637 LOCATION Back of Seat PART NO 109 2698 LOCATION On Control Panel PART NO 107 2112 LOCATION Top of Floor Pan For Exmark Mower Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 17: ... the motion control levers are moved from neutral position while brake is engaged 2 5 COOLING SYSTEM 2 5 1 Fan Belt driven with continuous operation with engine running 2 5 2 Coolant Liquid 50 50 mix of DexCool extended life antifreeze and water 2 5 3 Coolant Capacity 4 quarts 2 6 OPERATOR CONTROLS 2 6 1 Steering and Motion Control Separate levers on each side of the console control speed and dire...

Page 18: ... Air Filled Semi Pneumatic Semi Pneumatic Quantity 2 2 2 2 Tread AT101 Turfmate Smooth Smooth Size 24 x 12 00 12 23 x 10 50 10 9 x 3 50 4 13 x 6 5 6 Ply Rating 4 4 Pressure 9 psi 62 kPa 13 psi 90 kPa 2 10 MOWER DECK Sold Separately 2 10 1 Models FR524 FR604 Discharge Side Discharge Side Discharge Cutting Width 52 in 132 cm 60 in 152 cm 2 11 DIMENSIONS 2 11 1 Overall Width w 52 Deck w 60 Deck witho...

Page 19: ...lot 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 See Figure 2 FIGURE 2 By moving both levers an equal amount forward or back from the neutral position the machine can be caused to move forward or backward in a straight line Movement of the left lever forward will cause the left drive wheel to rotate in a forward di...

Page 20: ...ngine speed and moving throttle lever to the rear will decrease engine speed 3 1 5 Brake Lever Located on left side of unit between the seat and the dummy tank The brake lever engages a parking brake on the drive wheels Pull the lever up to engage the brake Push the lever down to disengage the brake The unit must be tied down and brake engaged when transporting 3 1 6 Ignition Switch Located on the...

Page 21: ... the gauge 3 1 11 Coolant Temperature Light Located on the right fuel tank console The light will come on if the engine is overheating and an alarm will sound See Section 3 1 13 3 1 12 Glow Plug Light Located on the right fuel tank console The glow plug light comes on when the glow plugs are preheating the combustion chamber This happens when the glow switch is depressed and while the engine is cr...

Page 22: ...T 3 2 1 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 Never fill the fuel tank so that the fuel level rises above a level that is 1 2 below the bottom of the filler neck to allow for ...

Page 23: ...AZARD DO NOT put hands or feet under the mower or mower deck when the blades are engaged DANGER POTENTIAL HAZARD An uncovered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blade could occur WHAT CAN HAPPEN Thrown objects or blade contact can cause serious injury or death HOW TO AVOID THE HAZARD Never operate the mower with the dis...

Page 24: ...k the wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure the trailer with a safety chain CAUTION POTENTIAL HAZARD This unit does not have proper turn signals lights reflective markings or a slow moving vehicle emblem These items are required to drive on a pub...

Page 25: ...full width ramp is required If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper ang...

Page 26: ...rea 4 1PERIODIC MAINTENANCE 4 1 1 Check engine oil level Service Interval Daily a Stop engine and wait for all moving parts to stop Make sure unit is on a level surface b Tilt seat forward and raise hood to gain access to access to engine area c Check with engine cold d Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick and push it all the way down into the tube Remo...

Page 27: ... or touching a hot radiator may cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system CAUTION POTENTIAL HAZARD Engine coolant is toxic WHAT CAN HAPPEN Swallowing coolant can cause poisoning HOW TO AVOID THE HAZARD Do not swallow Keep out of reach of children and pets 4 1 3 Check battery charg...

Page 28: ... the engine 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 Try to start with operator in seat parking brake engaged PTO engaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the left mot...

Page 29: ...nd remove key Engage parking brake b Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating 4 1 7 Check rollover protections system roll bar pins Service Interval Daily a Make sure latch pin and hair pin are fully installed and lanyard is in good condition b Check seat belt for cuts or wear Replace if necessary 4 1 8 S...

Page 30: ...et h Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 full turn i Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in engine owner s manual DO NOT overfill j Start the engine at idle for 5 minutes Stop engine and wait three minutes then check the oil level If required add oil to bring leve...

Page 31: ...W TO AVOID THE HAZARD Do not operate machine without the covers in place Keep fingers hands and clothing clear of rotating components Shut off engine wait for all moving parts to stop and engage parking brake Remove the ignition key before performing maintenance e With the cap off the radiator start the engine Refer to Section 3 3 2 f Operate engine until the engine thermostat opens and coolant is...

Page 32: ...COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level 4 1 12 Check auxiliary hydraulic oil level Service Interval If there is evidence of a leak or the hydraulic cylinder does not perform normally a Retract the hydraulic cylinder b Stop engine and wait for all moving parts to stop c Tilt the seat forward d Locate the auxiliary hydraulic power unit reservoir See ...

Page 33: ... Hitch and Cylinder Pivots 2 4 40 hrs 2 Fold Pivot Pin 2 2 100 hrs 3 Fold Lock Pin 2 2 yearly 4 Rear Caster Pivot 0 1 yearly 5 Belt Idlers 1 2 yearly 6 Motion Control Pivots 1 2 yearly 7 Transfer Spring Ends 1 4 yearly 8 Dual Tail Wheel Pivot 2 1 40 hrs See Section 4 1 15 c for special lubrication instructions on the rear caster pivots and Section 4 1 16 for special lubrication instructions on the...

Page 34: ... Make sure axle does not extend beyond either nut n Re install the seal guards over the wheel hub and insert wheel into caster fork Re install caster bolt and tighten nut fully IMPORTANT To prevent seal and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque...

Page 35: ...cock approximately 1 turn c Drain out any water d When fuel begins to flow from the tank tighten the drain cock e Prime the fuel system See Section 4 1 24 f Start engine Check for leaks IMPORTANT Water or other contaminants in fuel can severely damage fuel pump and or the other engine components g If any water was drained run engine for approximately 2 minutes to flush any remaining water out of t...

Page 36: ...y solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support e Raise the drive wheels off of the ground and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely f Start engine and move throttle control ahead to full throttle position Move the motion control levers to the full speed and run for several minutes S...

Page 37: ...ake b Remove pump drive belt c Route new belt onto sheaves as shown in the decal located on the top of the radiator See Figure 8 FIGURE 8 4 2 3 Alternator belt tension a Stop engine wait for all moving parts to stop and remove key Engage parking brake b Tilt seat forward and raise hood c To tighten alternator belt loosen both upper and lower alternator mounting bolts Rotate alternator out away fro...

Page 38: ...ed nut See Figure 11 g If park brake does not fully disengage when the lever is disengaged check the brake rod linkage assembly The assembly should measure 7 3 8 18 7 cm from the center of the ball joint to the center of the lower end of the linkage rod See Figure 8 FIGURE 12 h If the linkage does not measure 7 3 8 18 7 cm or still does not disengage as desired remove the bolt that secures the bal...

Page 39: ...rom the seat safety switch located directly in front of the seat switch assembly b The neutral adjustment must be made with the drive wheels turning Raise the frame and place on jack stands so that drive wheels can rotate freely Temporarily install a jumper wire across the terminals in the connector of the wiring harness c Start the engine d Run the unit at least 5 minutes with the drive levers at...

Page 40: ...k until the clevis pin on arm below pivot shaft contacts the end of the slot just beginning to put pressure on spring See Figure 14 FIGURE 14 d Check where lever is relative to notch in neutral plate should be centered allowing lever to pivot outward to the neutral lock position e If adjustment is needed loosen the nut against the yoke and while applying slight rearward pressure on the motion cont...

Page 41: ...ront frame and lock in service position See Deck Manual for complete instructions WARNING POTENTIAL HAZARD Weight transfer springs may have stored energy WHAT CAN HAPPEN Removing the weight transfer springs without releasing the stored energy can cause serious injury HOW TO AVOID THE HAZARD Fold mower deck and front frame and lock in service position to remove spring tension and release stored ene...

Page 42: ... malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent 4 2 8 Rear caster pivot bearings pre load adjustment a Remove dust cap from caster and tighten nyloc nut until washers are flat Back the nyloc off 1 4 of a turn to properly set the pre load on the bearings Not...

Page 43: ...ng is available return the battery to any certified battery reseller 6 TROUBLE SHOOTING 6 1 MOWER PULLS LEFT OR RIGHT W LEVERS FULLY FORWARD a Refer to Tracking Adjustment Section 4 2 5 b Check air pressure in drive tires AT101 Bar Lug drive tires should be inflated to 9 psi 62 kpa Turf Mate drive tires should be inflated to 13 psi 90 kpa Semi pneumatic casters do not require inflation 6 2 MOWER C...

Page 44: ...ank 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 adjustments procedures such as valves governor etc Have this work done by your Engine Service Dealer TROUBLESHOOTING TABLE PROBLEM NO FUEL IMPROPER FUEL WATER OR DIRT IN FUEL LINE DIRTY AIR FILTER ENGINE OVERLOADED BLOCKED FUEL FILTERS INC...

Page 45: ...low the engine and engine components to cool 3 Check the coolant level If necessary fill with coolant as described in Section 4 1 2 4 Remove any debris on or around the radiator that may restrict airflow 5 Check to see if the water pump alternator belt is intact If belt is missing do not run unit as unit can overheat and damage the engine See Engine Service Dealer b When the engine is running and ...

Page 46: ...41 7 ELECTRICAL DIAGRAM For Exmark Mower Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 47: ...42 8 HYDRAULIC DIAGRAM For Exmark Mower Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 48: ...s or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated...

Page 49: ... instructions must be warranted for the warranty period of two years If any such part fails during the period of warranty coverage it must be repaired or replaced by Exmark Manufacturing Company Any such part repaired or replaced under the warranty must be warranted for a time not less than the remaining warranty period B Any warranted part that is scheduled only for regular inspection in the writ...

Page 50: ...45 NOTES For Exmark Mower Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 51: ...46 For Exmark Mower Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com ...

Page 52: ... ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER STANDON WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 2006 PART NO 109 4289 Rev A EXMARK MFG CO INC 402 223 6300 INDUSTRIAL PARK BOX 808 FAX 402 223 5489 BEATRICE NE 68310 ALL RIGHTS RESERVED PRINTED I...

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