For Serial Nos. 670,000 & Higher TM CONGRATULATIONS on the purchase of your new Exmark mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor.
WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system) in place and in proper working condition. ♦ Stop engine, wait for all moving parts to stop and engage parking brake. Disconnect battery ground or remove key before adjusting, servicing, or performing maintenance.
EXMARK PARTS PLUS® PROGRAM EFFECTIVE DATE: September 1, 1995 Program If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!! How the Program Works 1. If dealer does not have part in stock for a "down" unit at the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus® shipment of six (6) line items or less. 2.
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. OPERATOR'S MANUAL This manual contains operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
TABLE OF CONTENTS 1. SAFETY 1.1 1.2 1.3 1.4 1.5 1.6 PAGE Safety Alert Symbol ....................................................................................... 1 Training ......................................................................................................... 1 Preparation................................................................................................. 1-3 Operation ...................................................................................................
1. SAFETY 1.1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents. This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER, WARNING, or CAUTION. DANGER: White lettering / Red background.
CAUTION POTENTIAL HAZARD ♦ This machine produces sound levels in excess of 85 dBA at the operator’s ear when in operation. WHAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss. HOW TO AVOID THE HAZARD ♦ Wear hearing protection when operating this machine. 1.3.3 While mowing, always wear substantial footwear and long trousers. Do not operate equipment when barefoot or when wearing open sandals. 1.3.
DANGER POTENTIAL HAZARD ♦ Diesel fuel is flammable. WHAT CAN HAPPEN ♦ A fire from diesel fuel can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD ♦ DO NOT smoke while refueling, and stay away from an open flame or where fuel fumes may be ignited by spark. ♦ Refuel only outdoors. ♦ Store fuel in an approved container and keep it out of the reach of children. ♦ Add fuel before starting the engine.
1.4 OPERATION Although hazard control and accident prevention are partially dependent upon the design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the equipment. It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing.
1.4.3 When feasible, avoid operating the equipment in wet grass. WARNING POTENTIAL HAZARD ♦ Operating a FrontRunner tractor without an approved Exmark front mount attachment increases the possibility of forward tip over. WHAT CAN HAPPEN ♦ Tip-over could cause serious injury or death. HOW TO AVOID THE HAZARD ♦ When operating a FrontRunner tractor without an approved Exmark front mount attachment, observe the following: 9 Limit operation to minimum required to install a different front mount attachment.
• • See inside the back cover to determine the approximate slope angle of the area to be mowed. Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep banks or water. This area can be dangerous, see Figure 1. FIGURE 1 • • 1.4.5 Progressively greater care is needed as the slope increases. Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope. • Avoid sudden stops when mowing downhill.
• • Be certain that the seat belt can be released quickly if the machine is driven or rolls into ponds of water. Check carefully for overhead clearances (i.e. branches, doorways, and electrical wires) before driving under any objects and do not contact them. 1.4.6 Use EXTREME caution when backing up. LOOK BEHIND YOU! 1.4.7 Stop the blades when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed. 1.4.
1.5 MAINTENANCE AND STORAGE 1.5.1 For engine maintenance, follow the engine manufacturer’s recommendations precisely as stated in the engine manual. 1.5.2 Disconnect the battery cable from the negative battery post when the unit will be allowed to sit for more than 30 days without use. 1.5.3 Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life.
WARNING POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure can penetrate skin and cause injury. WHAT CAN HAPPEN ♦ Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. HOW TO AVOID THE HAZARD ♦ Make sure all hydraulic fluid hoses and lines are in good condition an all hydraulic connections and fittings are tight before applying pressure to hydraulic system.
1.6.3 When new components are installed, be sure that current safety signs are affixed to the replaced components. 1.6.4 New safety signs may be obtained from Exmark Mfg. Co. Inc. 1.6.5 Safety signs may be affixed by peeling off the backing to expose the adhesive surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles. 1.6.6 Familiarize yourself with the following safety signs and instruction labels. They are critical to the safe operation of your Exmark commercial mower.
PART NO. 107-2112 LOCATION: Top of Floor Pan PART NO. 109-2357 LOCATION: Top of Console, LH Side PART NO. 109-2377 LOCATION: On Hydraulic Cylinder PART NO. 107-2102 LOCATION: Inside Surface of Upper Roll Bar PART NO. 109-2396 LOCATION: Top of Seat Support Plate PART NO. 109-2355 LOCATION: Outside of each Weight Transfer Bell Crank PART NO. 109-3637 LOCATION: Back of Seat PART NO. 109-2698 LOCATION: On Control Panel PART NO.
2. SPECIFICATIONS 2.1 MODEL NUMBER: FR25KD 2.2 ENGINE 2.2.1 2.2.2 Engine Specifications: See your Engine Owner’s Manual RPM: Full Speed: 3870 RPM (No Load) +50/-100 RPM Idle: 1400 RPM (No Load) ±50 RPM 2.3 FUEL SYSTEM 2.3.1 2.3.2 2.3.3 Capacity: 8.5 gal (32 L) Type of Fuel: Diesel fuel, 40 cetane or higher. Fuel Filter: 2 In-line 15 Micron Kubota P/N 12581-43012, before and after the electric fuel pump. 2.4 ELECTRICAL SYSTEM 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.
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.
2.12 TORQUE REQUIREMENTS Bolt Location Torque Wheel Lug Nuts .............................................................90-95 ft-lbs. (122-129 N-m) Wheel Motor Mounting Bolts............................................72-77 ft-lbs. (98-104 N-m) Rollover Protection System (Roll Bar) Mounting Bolts .......30-35 ft-lbs. (41-47 N-m) Clutch Retaining Bolt (secured with threadlocker)..............55-60 ft-lbs. (75-81 N-m) Wheel Hub Slotted Nut .............................................minimum 125 ft-lbs.
Pulling the levers back from the neutral position will cause the respective drive wheels to rotate in a reverse direction (spring tension can be felt when moving into reverse from neutral). To turn to the left while backing, move the left lever forward toward neutral. To turn to the right while backing, move the right lever forward toward neutral. CAUTION POTENTIAL HAZARD ♦ Machine can spin very rapidly by positioning one lever too much ahead of the other.
NOTE: A glow plug light, located to the rear of the glow plug switch, will illuminate when the switch is depressed. The glow plug light indicates the glow plugs are preheating the combustion chamber. 3.1.8 Hour Meter: Located on the right fuel tank console. The hour meter runs when the alternator is charging and it records the number of hours that the engine has run. If the ignition switch is left on without engine running, hour meter will not run. 3.1.
3.1.15 Alternator Charging Light: Located to the rear of the key switch. Light will come on when the alternator is not charging. 3.1.16 Low Oil Pressure Light: Located to the rear of the key switch with the alternator light. Light will come on when engine oil pressure is low or lost. NOTE: This switch is not a low oil level sensor and will not alert the operator if the engine oil level is low. 3.1.17 Drive Wheel Release Valves: Located on the top left front corner of hydrostatic pumps.
d) Move the throttle to the “SLOW” (if in “MIDWAY”) and let the engine warm up a few minutes before moving the throttle to the “FAST” position. 3.3.3 Engaging PTO: DANGER POTENTIAL HAZARD ♦ The rotating blades under the mower deck are dangerous. WHAT CAN HAPPEN ♦ Blade contact can cause serious injury or kill you. HOW TO AVOID THE HAZARD ♦ DO NOT put hands or feet under the mower or mower deck when the blades are engaged.
3.4 TRANSPORTING IMPORTANT: Do not transport FrontRunner tractor without an approved Exmark front mount attachment. 3.4.1 Transporting a Unit: Use a heavy-duty trailer or truck to transport the machine. Engage the park brake and block 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.
WARNING POTENTIAL HAZARD ♦ Loading a unit on a trailer or truck increases the possibility of tip-over. WHAT CAN HAPPEN ♦ Tip-over of the unit could cause serious injury or death. HOW TO AVOID THE HAZARD ♦ Use extreme caution when operating a unit on a ramp. ♦ Use only a single, full width ramp; DO NOT use individual ramps for each side of the unit. ♦ If individual ramps must be used, use enough ramps to create an unbroken ramp surface wider than the unit.
4. MAINTENANCE & ADJUSTMENTS WARNING POTENTIAL HAZARD ♦ While maintenance or adjustments are being made, someone could start the engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD ♦ Remove the key from the ignition switch and engage parking brake. Disconnect the negative battery cable before you do any maintenance. WARNING POTENTIAL HAZARD ♦ The engine can become very hot.
4.1.2 Check engine coolant level: a) b) c) d) e) Service Interval: Daily Stop engine and wait for all moving parts to stop. Make sure machine is on a level surface. Tilt seat up and tilt hood forward to gain access to the cooling area. Check with engine cold. View coolant level in overflow bottle on the left side of the engine. Coolant level should be at the indicator line on the overflow bottle. If the coolant level is low, remove the cap to the overflow bottle and fill to the indicator line.
recommended time interval to bring the charge up to a full charge of 12.6 volts or greater. IMPORTANT: Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery (see chart below for recommended charger settings). Voltage Reading 12.6 or greater 12.4 – 12.6 12.2 – 12.4 12.0 – 12.2 11.7 – 12.0 11.7 or less 4.1.
Repeat again moving the right lever in, then moving both levers in - engine must initiate shutdown whether operator is on seat or not. c) Check the PTO circuit: See the FR524 and FR604 Operator’s manual to become familiar with the deck operation. Open the folding deck latches, disengage the park brake, move the motion control levers in to neutral, and disengage the PTO. Lower the deck until the PTO switch arm is no longer depressing the PTO “kill” switch. See Figure 3.
4.1.9 Service air cleaner: First Service Interval: 50 hrs. Normal Interval: 100 hrs Replacement Interval: 600 hrs (More often under severe conditions.) See Engine manual for additional information. a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. b) Tilt seat forward and raise hood to gain access to the air cleaner. c) Loosen retaining clips and remove air cleaner compartment cover. d) Remove outer paper element. Check the condition of the paper element.
Drain coolant when engine is cool. Coolant may be drained from the radiator by loosening the drain cock in the left rear corner. The engine block may be drained by removing the lower radiator hose and/or by opening the drain cock from the engine block. The engine drain cock may be accessed on the right side of the unit and is located as shown in Figure 4. FIGURE 4 c) Tighten engine and radiator drain cocks. Reinstall lower hose (if removed).
f) Operate engine until the engine thermostat opens and coolant is circulating through the radiator core. As air is purged from the engine block and the coolant level drops, add additional coolant to the radiator. g) When the radiator is completely full and no additional coolant can be added, continue running the engine and install the radiator cap. Make sure that the cap is completely seated by pressing down firmly while turning until the cap stops. Once the cap is installed, the engine may be stopped.
c) d) e) AT101 (Bar Lug) drive tires should be inflated to 9 psi (62 kpa). Turfmate drive tires should be inflated to 13 psi (90 kpa). The rear caster tires are semi-pneumatic and do not need to be inflated. NOTE: Do not add any type of tire liner or foam fill material to the tires. Excessive loads created by foam filled tires may cause failures to the hydro drive system, frame, and other components. Foam filling tires will void the warranty. 4.1.15 Check condition of belts: Service Interval: 40 hrs. 4.
d) e) f) g) h) i) j) k) l) Remove one of the spacer nuts from the axle assembly in the caster wheel. Note that thread locking adhesive has been applied to lock the spacer nuts to the axle. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly. Pry out seals, and inspect bearings for FIGURE 7 wear or damage and replace if necessary. Pack the bearings with a NGLI grade #1 multi-purpose grease. Insert (1) bearing, (1) new seal into the wheel.
4.1.20 Lubricate the motion control bronze bushings: Service Interval: 160 hrs. 4.1.21 a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. b) Tilt seat forward. c) Lubricate bronze bushings on the flange bearings securing the motion control arm shafts with a light oil or a spray type lubricant. Lubricate the motion control shaft: Service Interval: Yearly. 4.1.22 a) Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.
4.1.25 Fuel priming procedure: a) Unit is equipped with an electric priming pump. Turn key on to let electric pump run for at least 30 seconds before starting. b) Start engine using procedure in Section 3.3.2. IMPORTANT: DO NOT over crank engine. Over cranking engine can damage the starter and/or the fuel solenoid. If engine does not start within 10 seconds allow electric pump to run for 30 seconds before cranking again. 4.1.26 Change hydraulic system filter: a) b) c) First Interval: 250 hrs.
4.1.27 Wheel Hub – lock nut torque specification Service Interval: After First 100 hrs Then every 500 hrs thereafter When tightening the lock nut on the wheel motor tapered shaft: a) Torque the lock nut to 125 ft-lbs (169 N-m). NOTE: Do not use antisieze on wheel hub. 4.1.28 Fuel Tank – mounting hardware specification When installing the nuts on the fuel tank studs, fully tighten the nyloc nut and back off 1/2 turn.
c) d) 4.2.4 To tighten alternator belt, loosen both upper and lower alternator mounting bolts. Rotate alternator out, away from engine and re-tighten hardware to secure in place. When properly tensioned, the alternator belt will deflect 1/4”-3/8” (7-9 mm) while applying 22 pounds of force to the belt midway between alternator and crankshaft pulley. Park Brake Adjustment: Check to make sure each brake is adjusted properly. a) Stop engine, wait for all moving parts to stop, and remove key.
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 ball joint to the brake lever and loosen the jam nut next to the ball joint. Rotate the ball joint in half-turns counter-clockwise until desired disengagement is obtained. i) 4.2.5 Repeat procedure for other side.
a) b) c) d) e) Set neutral: Remove the electrical connection from the seat safety switch, located directly in front of the seat switch assembly. 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. Start the engine.
FIGURE 14 4.2.7 d) Check where lever is relative to notch in neutral plate (should be centered allowing lever to pivot outward to the neutral lock position).
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 energy before performing any maintenance or adjustments on the weight transfer springs.
CAUTION POTENTIAL HAZARD ♦ Raising the unit for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury. HOW TO AVOID THE HAZARD ♦ 4.2.8 DO NOT rely solely on mechanical or hydraulic jacks for support.
If a battery is being replaced or if the unit containing the battery is no longer operating and is being scrapped, take the battery to a local certified recycling center. If no local recycling 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).
X Lacks power X X X X X X X X X Operates erratically X X X X X Skips or misfires X X X Overheats X X High fuel consumption X X DIRTY RADIATOR CORE Stops suddenly X X FAN PUMP BELT MISSING X X INSUFFICIENT BATTERY CHARGE DIRTY AIR FILTER X X INCORRECT OIL LEVEL WATER OR DIRT IN FUEL LINE X X Will not start BLOCKED FUEL FILTERS IMPROPER FUEL Hard starting X X PROBLEM ENGINE OVERLOADED NO FUEL TROUBLESHOOTING TABLE X X X X X 6.4 ENGINE WARNING SYSTEMS 6.4.
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9. 2-Year Limited Warranty Exmark Turf Equipment (For units purchased on or after October 1, 2004) Conditions and Products Covered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty 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 exercise of our reasonable discretion) to be defective in factory materials or workmanship for a period of two years.
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT MICRO-MULCH SYSTEM ROLL OVER PROTECTION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONTAINER TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO-MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER STANDON Check us out on the Web: www.exmark.
