Exmark Diesel - Manuals - manualsarea.com

Page 2 - WARNING; CALIFORNIA

WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of itsconstituents are known to the State ofCalifornia to cause cancer, birth defects,and other reproductive harm. Important: When the mower is used or operated on any California forest, brush or grass coveredland, a working sp...

Page 3 - Introduction; CONGRATULATIONS

Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefullydesigned and manufactured to give you a maximumamount of dependability and years of trouble-freeoperation. This manual contains operating, maintenance,adjustment, and safety instructions for your Exmark...

Page 4 - Contents

Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...

Page 5 - Safety; Safety Alert Symbol; Safe Operating Practices; Training; CAUTION

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both inthis manual and on the machine to identify importantsafety messages which must be followed to avoidaccidents This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Figure 2 1. Safety alert symbol The s...

Page 6 - DANGER; Avoid prolonged breathing of vapors.; Operation

Safety DANGER In certain conditions diesel is extremelyflammable and vapors are explosive. A fire or explosion from diesel can burn you,others, and cause property damage. • Fill the fuel tank outdoors in an openarea, when the engine is cold. Wipe upany diesel that spills. • Never refill the fuel tan...

Page 7 - Slope Operation

Safety WARNING Operating a FrontRunner tractor without anapproved Exmark front mount attachmentincreases the possibility of forward tip over.Tip-over could cause serious injury or death. When operating a FrontRunner tractorwithout an approved Exmark front mountattachment, observe the following: • Li...

Page 8 - Do Not mow slopes when grass is wet.; Drive slowly and carefully.

Safety DANGER Operating on wet grass or steep slopes cancause sliding and loss of control. Wheelsdropping over edges, ditches, steep banks, orwater can cause rollovers, which may resultin serious injury, death or drowning. • Do Not mow slopes when grass is wet. • Do Not mow near drop-offs or near wa...

Page 9 - Maintenance and Storage

Safety Maintenance and Storage • Disengage drives, lower implement, set parkingbrake, stop engine and remove key or disconnectspark plug wire. Wait for all movement to stopbefore adjusting, cleaning or repairing. • Keep engine, engine area, and pump drive beltcompartment free from accumulation of gr...

Page 10 - Safety and Instructional Decals

Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease,dirt and debris from safety signs and instructionallabels. • Replace all worn, damaged, or missing safetysigns. • When replacement components are installed, besure that current safety signs are affixed to there...

Page 14 - Specifications; Model Numbers

Specifications Specifications Model Numbers Serial Nos: 720,000 and Higher FR25KD Systems Engine • Engine Specifications: See your Engine Owner’sManual • RPM: Full Speed: 3870 +50/-100 RPM (NoLoad) Idle: 1400 ±50 RPM (No Load) Fuel System • Capacity: 8.5 gal. (32 L) • Type of Fuel: Diesel fuel, 40 c...

Page 15 - Hydrostatic Ground Drive System; Cutting Deck

Specifications • Mounting: Hinged to tilt up for access tohydraulic pumps, battery and other components.The seat is held in the tilted position with alinkage. Adjustable fore and aft seat track. • Armrests: Standard seat: foam padded flip-uparmrests. Optional suspension seat: moldedadjustable flip-u...

Page 16 - Dimensions; Minimum Turning Radius; Torque Requirements

Specifications • Mulching Kit: Optional • Bagger: Optional Dimensions Overall Width: 52 inchDeck 60 inchDeck 72 inchDeck WithoutDeck 49.0 inches(124.5 cm) 49.0 inches(124.5 cm) 53.0 inches(135 cm) DeflectorUp 53.3 inches(135.4 cm) 61.4 inches(156 cm) 73.4 inches(186 cm) DeflectorDown 64.0 inches(163...

Page 17 - Product Overview; Controls; Motion Control Levers; Park Brake Lever; Ignition Switch

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: Determine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control levers located o...

Page 18 - Do Not overtighten. Do

Operation and “START”. Insert key into switch and rotateclockwise to the “ON” position. Rotate clockwise tothe next position to engage the starter (key must beheld against spring pressure in this position). Note: Brake must be engaged, motion control levers out (neutral lock position), and PTO switc...

Page 19 - Operating Instructions; Starting the Engine

Operation The buzzer is a warning signal that the engineis overheating or the oil pressure is low. See the Troubleshooting section. Pre-Start Fill fuel tank. For best results use only clean, freshdiesel fuel, with a cetane rating of 40 higher Note: Do Not use kerosene or gasoline instead of diesel f...

Page 20 - Do Not crank the engine; Engaging the PTO; Operator must be in seat before the; Disengaging the PTO; Use caution when making turns.

Operation Glow Plug Chart Ambient Temperature Hold Glow Plugs On Above 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 continuous use 20 seconds The glow plug light, located near the glowplug switch, will illuminate when the ...

Page 21 - Driving Forward; Driving in Reverse; Transporting; Transporting a Unit; Do Not transport FrontRunner

Operation before the motion control levers can be moved inor the engine will stop. When levers are centered in the T-slot the drivesystem is in the neutral position. With levers movedout in the T-slot the drive system is in the neutral lockposition (Figure 6). Figure 6 1. Handles Out (NeutralLock) 5...

Page 22 - Loading a Unit; Do Not attempt to turn the unit

Operation CAUTION This unit does not have proper turnsignals, lights, reflective markings, or aslow moving vehicle emblem. Driving on astreet or roadway without such equipmentis dangerous and can lead to accidentscausing personal injury. Driving on a streetor roadway without such equipment may alsob...

Page 23 - Maintenance

Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING While maintenance or adjustments are beingmade, someone could start the engine.Accidental starting of the engine couldseriously injure you or other bystanders. Remove the key f...

Page 24 - Periodic Maintenance; Check Engine Oil Level; Check Engine Coolant Level; Service Interval: Before each use or daily; Keep out of reach of children and pets.

Maintenance Maintenance Service Interval Maintenance Procedure Every 4,000 hours • Change engine coolant. Dex-Cool © extended life coolant (orange color) Monthly • Check the battery charge. Yearly • Grease the fold lock pin.• Grease the rear caster pivot.• Grease the belt idlers.• Grease the motion ...

Page 25 - Change Engine Coolant; extended; Service Interval: Monthly

Maintenance Change Engine Coolant Service Interval: Every 4,000 hours/Every 4 years (whichever comesfirst) Dex-Cool © © © extended life coolant (orange color) 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. Machine mustbe positioned on level surface. 2. Tilt ...

Page 27 - pull; Check Seat Belt; Check for Loose Hardware; Service Air Cleaner; Do Not; Change Engine Oil; Service Interval: After the first 5 hours

Maintenance Figure 9 Left Side—Inside of Hitch Shown 1. PTO “Kill” Switch 2. PTO Switch Arm 3. Lower deck until arm Does Not contact the switch. Run the engine at half throttle and pull up on the PTO engagement switch. The PTO must not engage . Note: If machine does not pass any of these tests, Do N...

Page 28 - Check Hydraulic Oil Level; Check Tire Pressures; Service Interval: Every 40 hours; Check Condition Of Belts; Service Interval: Every 40 hours

Maintenance 4. Remove the oil drain plug. Allow oil to drain then replace the drain plug. 5. Replace the oil filter every other oil change. Clean around oil filter and unscrew filter to remove.Before reinstalling new filter, apply a thin coatingof oil on the surface of the rubber seal. Turnfilter cl...

Page 29 - Pump Drive Belt Tension and; Lubricate Grease Fittings; See chart for service intervals.; Lubricate Rear

Maintenance 2. Check pump and PTO drive belts. 3. Belts are spring tensioned and no adjustment is necessary. See Pump Drive Belt Tension and Replacement sections in Adjustments. Lubricate Grease Fittings Note: See chart for service intervals. 1. Stop engine, wait for all moving parts to stop, and re...

Page 30 - To prevent seal and bearing damage,; Lubricate Brake Handle Pivot; Service Interval: Every 160 hours

Maintenance the other spacer nut still assembled to it) fromthe wheel assembly. 5. Pry out seals, and inspect bearings for wear or damage and replace if necessary. 6. Pack the bearings with a NGLI grade #1 multi-purpose grease. 7. Insert one bearing, one new seal into the wheel. Note: Seals (Exmark ...

Page 31 - Drain Water from Fuel Tank; Service Interval: As required; Change Fuel Filter; Service Interval: Every 400 hours or as; Service Interval: After the first 250 hours

Maintenance Lubricate Steering LinkageRod Ends Service Interval: Every 160 hours 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Tilt seat forward. 3. Lubricate each end of both steering linkage rods with a spray lubricant or light oil Drain Water from Fue...

Page 32 - Service Interval: After the first 100 hours; Thread Locking Adhesives

Maintenance CAUTION Raising the mower for service or maintenancerelying solely on mechanical or hydraulicjacks could be dangerous. The mechanical orhydraulic jacks may not be enough supportor may malfunction allowing the unit to fall,which could cause injury. Do Not rely solely on mechanical or hydr...

Page 33 - Adjustments; Pump Drive Belt Tension

Maintenance Adjustments Note: Disengage PTO, shut off engine, wait for all moving parts to stop, engage parking brake, andremove key before servicing, cleaning, or making anyadjustments to the unit. Pump Drive Belt Tension Self-tensioning - No adjustment necessary. Pump Drive BeltReplacement 1. Stop...

Page 34 - Temporarily

Maintenance 6. If necessary, turn the thin nyloc nut to obtain the 2 1/2 inches (6.4 cm) spring length. 7. Engage the park brake. Measure the gap between the thin nyloc nut and the park brake clevis.The gap should measure 1/8 inch (3.2 mm) (seeFigure 15). Figure 15 1. Yoke 4. Thin nyloc nut 2. Park ...

Page 37 - Cleaning; Waste Disposal; Motor Oil Disposal; Do Not swallow electrolyte.

Maintenance Cleaning Clean Engine CoolingSystem Service Interval: Before each use or daily (May be required moreoften in dry or dirtyconditions.) 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Wipe debris from radiator screen in front of radiator. Rotate ...

Page 38 - Troubleshooting; condition prior to mower use.

Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, do not overlook the simple causes. For example: starting problems could be causedby an empty fuel tank. The followi...

Page 40 - Schematics; Electrical Diagram

Schematics Schematics Electrical Diagram 5 RED 1 3 . S T A R T POSITION 1 . OFF 2 . R UN B + I + S CIRCUIT "MAKE" X + Y NONE B + I + A IGNITION SWITCH N O TE : CONNEC T ORS VIEWED F R OM TERMINAL END TERMINAL CONNECTIONS TERMINAL A V O L T A GE REGUL A T OR TERMINAL B B A TTE R Y TERMINAL I ...

Page 41 - Hydraulic Diagram

Schematics Hydraulic Diagram CASE DRAIN CHARGE PUMP HIGH PRESSURE G007220 BYPASS VALVE BYPASS VALVE HIGH PRESSUREREVERSE HIGH PRESSUREFORWARD HIGH PRESSUREREVERSE HIGH PRESSUREFORWARD 41

Page 44 - M I D - M O U N T R I D I N G AC C E S S O R I E S; SEE EXMARK’S COMPLETE LINE OF ACCESSORIES; WALK-BEHIND ACCESSORIES

M I D - M O U N T R I D I N G AC C E S S O R I E S SEE EXMARK’S COMPLETE LINE OF ACCESSORIES WALK-BEHIND ACCESSORIES GRASS CATCHER LAZERLOCKER MICRO-MULCH SYSTEM TURF STRIPER STANDON CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LAZERLOCKER LIGHT KIT MICRO-MULCH SYSTEM OPERATOR C...