Exmark FrontRunner Diesel User Manual Page 1

FRONTRUNNERTMDIESELMODELSForSerialNos.720,000&HigherPartNo.4500-227Rev.A

SafetySafetyandInstructionalDecals•Keepallsafetysignslegible.Removeallgrease,dirtanddebrisfromsafetysignsandinstructionallabels.•Replaceallworn,damage

Safety103-1636103-5881103-7218107-2102107-211211

Safety109-2355109-23561.Fast3.Neutral2.Slow4.Reverse109-23571.Fast4.Reverse2.Slow5.ParkBrake—Release3.Neutral6.ParkBrake—Engage109-2358109-2377109-239

Safety109-26981.Cylinder—extend3.Fast2.Cylinder—retract4.Slow109-3637109-794919426-8788119426-87903109-236013

SpecicationsSpecicationsModelNumbersSerialNos:720,000andHigherFR25KDSystemsEngine•EngineSpecications:SeeyourEngineOwner’sManual•RPM:FullSpeed:3870+

Specications•Mounting:Hingedtotiltupforaccesstohydraulicpumps,batteryandothercomponents.Theseatisheldinthetiltedpositionwithalinkage.Adjustableforean

Specications•MulchingKit:Optional•Bagger:OptionalDimensionsOverallWidth:52inchDeck60inchDeck72inchDeckWithoutDeck49.0inches(124.5cm)49.0inches(124.5c

OperationProductOverviewFigure41.FuelCap4.SeatBelt2.RollBar5.MotionControlLever3.Controls6.ParkingBrakeLeverOperationNote:Determinetheleftandrightside

Operationand“START”.Insertkeyintoswitchandrotateclockwisetothe“ON”position.Rotateclockwisetothenextpositiontoengagethestarter(keymustbeheldagainstspri

OperationThebuzzerisawarningsignalthattheengineisoverheatingortheoilpressureislow .SeetheTroubleshootingsection.Pre-StartFillfueltank.Forbestresultsus

WARNINGCALIFORNIAProposition65WarningDieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocausecancer,birthdefects,andotherrepro

OperationGlowPlugChartAmbientTemperatureHoldGlowPlugsOnAbove50°F(10°C)NONEED50°F(10°C)to23°F(-5°C)Approximately5secondsBelow23°F(-5°C)Approximately10s

Operationbeforethemotioncontrolleverscanbemovedinortheenginewillstop.WhenleversarecenteredintheT-slotthedrivesystemisintheneutralposition.Withleversmo

OperationCAUTIONThisunitdoesnothaveproperturnsignals,lights,reectivemarkings,oraslowmovingvehicleemblem.Drivingonastreetorroadwaywithoutsuchequipment

MaintenanceMaintenanceNote:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.WARNINGWhilemaintenanceoradjustmentsarebeingmade,so

MaintenanceMaintenanceServiceIntervalMaintenanceProcedureEvery4,000hours•Changeenginecoolant.Dex-Cool©extendedlifecoolant(orangecolor)Monthly•Checkthe

MaintenanceChangeEngineCoolantServiceInterval:Every4,000hours/Every4years(whichevercomesrst)Dex-Cool© ©©extendedlifecoolant(orangecolor)1.Stopengine,

Maintenancebatteryperformanceandlife,rechargebatteriesinstoragewhentheopencircuitvoltagedropsto12.4volts.Note:Topreventdamageduetofreezing,batteryshou

MaintenanceFigure9LeftSide—InsideofHitchShown1.PTO“Kill”Switch2.PTOSwitchArm3.LowerdeckuntilarmDoesNotcontacttheswitch.Runtheengineathalfthrottleandpu

Maintenance4.Removetheoildrainplug.Allowoiltodrainthenreplacethedrainplug.5.Replacetheoilltereveryotheroilchange.Cleanaroundoillterandunscrewlterto

Maintenance2.CheckpumpandPTOdrivebelts.3.Beltsarespringtensionedandnoadjustmentisnecessary.SeePumpDriveBeltTensionandReplacementsectionsinAdjustments.

IntroductionCONGRATULATIONSonthepurchaseofyourExmarkMower.Thisproducthasbeencarefullydesignedandmanufacturedtogiveyouamaximumamountofdependabilityandy

Maintenancetheotherspacernutstillassembledtoit)fromthewheelassembly.5.Pryoutseals,andinspectbearingsforwearordamageandreplaceifnecessary.6.Packthebear

MaintenanceLubricateSteeringLinkageRodEndsServiceInterval:Every160hours1.Stopengine,waitforallmovingpartstostop,andremovekey.Engageparkingbrake.2.Tilt

MaintenanceCAUTIONRaisingthemowerforserviceormaintenancerelyingsolelyonmechanicalorhydraulicjackscouldbedangerous.Themechanicalorhydraulicjacksmaynotb

MaintenanceAdjustmentsNote:DisengagePTO,shutoffengine,waitforallmovingpartstostop,engageparkingbrake,andremovekeybeforeservicing,cleaning,ormakinganya

Maintenance6.Ifnecessary,turnthethinnylocnuttoobtainthe21/2inches(6.4cm)springlength.7.Engagetheparkbrake.Measurethegapbetweenthethinnylocnutandthepar

MaintenanceFigure171.Loosenjamnut2.Pumpcontrolrodlinkage3.Usewrenchtoturndoublenuts9.Movethemotioncontrolleverstothereverseposition.Returnthemotioncon

MaintenanceFigure191.Motioncontrollever3.Fenderknob2.Leftfender3.Slidethefenderforwardandtwistupwardandoutwardtoremove.4.Toadjusttheweighttransferspri

MaintenanceCleaningCleanEngineCoolingSystemServiceInterval:Beforeeachuseordaily(Mayberequiredmoreoftenindryordirtyconditions.)1.Stopengine,waitforallm

TroubleshootingTroubleshootingImportant:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperatingconditionpriortomoweruse.Whenaprobl

TroubleshootingProblemPossibleCauseCorrectiveAction1.Engineloadisexcessive.1.Reducethegroundspeed.2.Oillevelinthecrankcaseislow.2.Addoiltothecrankcase

ContentsIntroduction...3Safety...

SchematicsSchematicsElectricalDiagram5RED13. STARTPOSITION1. OFF2. RUNB + I + SCIRCUIT "MAKE"X + YNONEB + I + AIGNITION SWITCHNOTE: CONNEC

SchematicsHydraulicDiagramCASE DRAINCHARGE PUMPHIGH PRESSUREG007220BYPASS VALVEBYPASS VALVEHIGH PRESSUREREVERSEHIGH PRESSUREFORWARDHIGH PRESSUREREVERS

Conditions and Products CoveredExmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant

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MID-MOUNT RIDING ACCESSORIESSEE EXMARK’S COMPLETE LINE OF ACCESSORIESWALK-BEHIND ACCESSORIESGRASS CATCHERLAZERLOCKERMICRO-MULCH SYSTEMTURF STRIPERSTAN

SafetySafetySafetyAlertSymbolThisSafetyAlertSymbol(Figure2)isusedbothinthismanualandonthemachinetoidentifyimportantsafetymessageswhichmustbefollowedto

SafetyDANGERIncertainconditionsdieselisextremelyammableandvaporsareexplosive.Areorexplosionfromdieselcanburnyou,others,andcausepropertydamage.•Fillt

SafetyWARNINGOperatingaFrontRunnertractorwithoutanapprovedExmarkfrontmountattachmentincreasesthepossibilityofforwardtipover.Tip-overcouldcauseseriousi

SafetyDANGEROperatingonwetgrassorsteepslopescancauseslidingandlossofcontrol.Wheelsdroppingoveredges,ditches,steepbanks,orwatercancauserollovers,whichm

SafetyMaintenanceandStorage•Disengagedrives,lowerimplement,setparkingbrake,stopengineandremovekeyordisconnectsparkplugwire.Waitforallmovementtostopbef