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Exmark FMD 604 manual

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Table of contents for the manual

  • Page 1

    For Turf Ranger Serial Nos. 440,000 & Higher and FMD524 & FMD604 Serial Nos. 440,000 & Higher Part No. 103-4867[...]

  • Page 2

    i 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. HO W TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system) in place and in proper working condition. ♦[...]

  • Page 3

    ii 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 requ[...]

  • Page 4

    iii 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 assembly, operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERATI[...]

  • Page 5

    iv TABLE OF CONTENTS 1. SAFETY PAGE 1.1 Safety Alert Symbol ...................................................................................... 1 1.2 Training ........................................................................................................ 1 1.3 Preparation .................................................................[...]

  • Page 6

    - 1 - 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 a lert symbol appears above information, which alerts you to unsafe actions o[...]

  • Page 7

    - 2 - 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. 1.3.5 Always set the park brake before starting the engine. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carb[...]

  • Page 8

    - 3 - DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite gasoline vapors. A fire or explosion from gasoline can burn you, others, and cause property damage. HO W TO AVOID THE HAZARD ♦ Purchase and store gasoline only in an approved container. ♦ A[...]

  • Page 9

    - 4 - 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 [...]

  • Page 10

    - 5 - 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 banks, or water can cause rollovers, which may result in serious injury, death or drowning. HO W TO AVOID THE HAZARD ♦ Mow up and down slopes. ♦ Do not mow slopes when grass [...]

  • Page 11

    - 6 - 1.4.7 Never operate the mower with defective guards, shields, or covers. Always have safety shields, guards, switches, and other devices in place and in proper working condition. 1.4.8 Do Not change the engine governor settings or overspeed the engine. Operating an engine at excessive speed may increase the hazard of personal injury. 1.4.9 Di[...]

  • Page 12

    - 7 - 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 for m 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 peri[...]

  • Page 13

    - 8 - 1.6 SAFETY SIGNS 1.6.1 Keep all safety signs legible. Remove all grease, dirt, and debris from safety signs and instructional labels. 1.6.2 Safety signs m ust be replaced if they are missing or illegible. 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 m[...]

  • Page 14

    - 9 - PART NO. 103-2248 LOCATION: Steering Console PART NO. 1-403005 LOCATION: LH & RH Front Top Surface of Mower Deck PART NO. 1-543620 LOCATION: On Intake Screen Below Fuel Tank PART NO. 1-543896 LOCATION: Under Engine Deck on Wood Blocks for Shipping PART NO. 98-5954 LOCATION: Under Belt Shields PART NO. 1-323540 LOCATION: Front of Mower Dec[...]

  • Page 15

    - 10 - 2. SPECIFICATIONS 2.1 MODEL NUMBER : TR23KC 2.2 ENGINE 2.2.1 Engine Specifications : See your engine owners manual. 2.2.2 3600 RPM (No Load) 2.3 FUEL SYSTEM 2.3.1 Capacity : 5.0 gal. (18.9 L.) 2.3.2 Type of Fuel : Regular unleaded gasoline 87 octane or higher. In countries using the research method, it should be a 90 octane minimum . 2.3.3 F[...]

  • Page 16

    - 11 - 2.8 TIRES Rear Drive Front Caster (FMD Units) Type Pneumatic Pneumatic Pneumatic Size 18 x 7.50-8 20 x 10.00-8 11 x 4-5 Quantity 122 Tread Turfsaver Turfmate Smooth Ply Rating 444 Pressure 14 psi (97 kPa) 20 psi (138 kPa) 16 psi (110 kPa) 2.9 MOWER DECK 2.9.1 Model Numbers : FMD604 and FMD 524 2.9.1 Cutting W idth: 60 in. (152.4 cm.) 52 in. [...]

  • Page 17

    - 12 - 3. ASSEMBLY INSTRUCTIONS 3.1 Uncrate tractor and mower deck . 3.2 SERVICE BATTERY : The machine is shipped with a filled lead acid battery. 3.2.1 Remove battery cover from machine. DANGER POTENTIAL HAZARD ♦ Charging the battery may produce explosive gasses WHAT CAN HAPPEN ♦ Battery gasses can explode causing serious injury. HO W TO AVOID[...]

  • Page 18

    - 13 - (black) cable to the negative terminal on the battery. Reinstall insulator boots. Reinstall battery cover. NOTE: If time does not permit charging the battery, or if charging equipment is not available, connect the negative battery cables and run the vehicle continuously for 20 to 30 minutes to sufficiently charge the battery. PART NO. 1-5137[...]

  • Page 19

    - 14 - 3.8.2 Remove mower deck support frame from mower deck by removing the two hairpins and spacers from the front deck support pins and remove the hairpins and spacers from the rear deck support pins. 3.8.3 Lift up on support frame until it clears the support pins. Position support frame so the arms are on each side of the tractor engine deck an[...]

  • Page 20

    - 15 - Locate two holes along the back center section of the mower deck. Install the stationary idler and related parts in the left hand hole location as shown in Figure 3. See the belt routing decal on deck. Be sure the coned end of the disc spring is against the head of the bolt as illustrated (See Figure 3). FIGURE 3 IDLER PULLEY KIT AND LOCATIO[...]

  • Page 21

    - 16 - 4.3 Electro-mechanical deck lift control : Switch is located on left side of control console. Moving the toggle switch lever forward will lower the cutting deck. Moving the lever backward will raise the deck. Normal operation is with the actuator fully extended. The actuator has an internal clutch to protect it from excessive loads. When rai[...]

  • Page 22

    - 17 - FIGURE 4 DRIVE WHEEL RELEASE LEVER 5. OPERATION INSTRUCTIONS 5.1 PRE-START 5.1.1 Fill fuel tank. For best results use only clean, fresh regular grade unleaded gasoline with an octane rating of 87 or higher. Regular grade leaded gasoline may also be used; however, combustion chamber and cylinder head will require more frequent service. See En[...]

  • Page 23

    - 18 - Rotate ignition switch to “OFF” position. Remove the key to prevent children or other unauthorized persons from starting engine. Close fuel shut-off valve when machine will not be used for a few days, when transporting, and when the unit is parked inside a building. 5.2.3 Engaging PTO : DANGER POTENTIAL HAZARD ♦ The rotating blades und[...]

  • Page 24

    - 19 - to simulate a full width ramp. Drive forward to load and drive backward to unload from a trailer. Do not drive backward to load or drive forward to unload a trailer. 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 ° . After unit is loaded on the trailer low[...]

  • Page 25

    - 20 - c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick. Do not screw into place. Remove dipstick and read the oil level. d) If the oil level is low, add oil to bring the oil up to the “FULL” mark on the dipstick. Use oil as specified in Engine Owner’s Manual. Do Not overfill. IMPORTANT: Do not operate th[...]

  • Page 26

    - 21 - c) Stop engine, wait for all moving parts to stop, and remove key. d) Block up using proper safety precautions. e) Clean out any grass build-up from underside of deck and in deck discharge chute. f) Inspect blades and sharpen or replace as required. g) If blade removal is necessary, be careful for the sharp cutting edges of the blades. h) Re[...]

  • Page 27

    - 22 - b) Check kill circuits : Run engine at one-third throttle with PTO and parking brake disengaged ; lift yourself off the seat (but do not get off the machine) engine must stop after 1/2 second has elapsed. c) Run engine at one-third throttle with PTO and parking brake engaged ; lift yourself off the seat (but do not get off the machine) engin[...]

  • Page 28

    - 23 - 6.1.9 Check hydraulic oil level : Service Interval : 40 hrs. a) M ake sure mower is on a level surface. b) Stop engine , wait for all moving parts to stop. c) Visually inspect the sight gauge on hydraulic tank. Oil level should be visible to top of sight gauge. If not, clean area around hydraulic reservoir cap, remove cap, and add oil as spe[...]

  • Page 29

    - 24 - Note: Be sure to check idler on tran smission drive belt. Disassemble, clean and grease pivot bushing if necessary. 6.1.13 Lubricate grease fittings . a) Stop engine, wait for all moving parts to stop, and remove key. b) Lubricate fittings with one to two pumps NGLI grade #2 multi-purpose gun grease . Refer to the following chart for fitting[...]

  • Page 30

    - 25 - h) If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to (1) spacer nut and thread onto the axle with the wrench flats facing outward. Do not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer surface of the spacer nut to the end of[...]

  • Page 31

    - 26 - b) Carefully clean area around filter. It is important that no dirt or contamination enters the hydraulic system. c) Unscrew filter and remove. IMPORTANT: Before reinstalling new filter, fill it with Mobil 1 15 W- 50 and apply a thin coat of oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts the filter ad[...]

  • Page 32

    - 27 - 6.1.25 Mobil HTS grease (or food-grade antisieze) is used in the following locations: a) Between the cutter housing spindle and bearings. b) Betwee n the cutter housing spindle and sheave. c) Under top cutter housing bearing guard. 6.1.26 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of cont[...]

  • Page 33

    - 28 - FIGURE 6 CUTTING HEIGHT ADJUSTMENT FIGURE 7 ANTI-SCALP ROLLER BOLT INSTALLATION ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT c) Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of the positions shown in Figure 7. Rollers will maintain 3 /4 in. (19 mm) clearance to the ground to minimize gouging and roller we[...]

  • Page 34

    - 29 - 6.2.5 Neutral Centering Adjustment a) The Neutral Centering Device adjustment should be made with the engine running at full throttle. First raise and securely block up the frame so that the drive wheels can rotate freely without contacting the ground. WARNING POTENTIAL HAZARD ♦ Engine must be running and drive wheels must be turning so mo[...]

  • Page 35

    - 30 - FIGURE 8 NEUTRAL CENTERING DEVICE ADJUSTMENT 6.2.6 Parking Brake Quadrant Adjustment a) Stop engine, wait for all moving parts to stop, and remove key. b) Loosen the two 5/16 x 18 screws (a), that clamp the brake quadrant to the engine deck. c) P ull parking brake lever towards the operator to the brake “on” position (b). d) Check linkag[...]

  • Page 36

    - 31 - b) Remove inlet screen and fan. c) Engage parking brake. Loosen the jam nuts securing the two 5/16 x 1-1/2” carriage bolts to the hydro control arm. Be sure the hydro control arm is in the neutral position as outlined in the previous adjustment (6.2.5) and the parking brake is adjusted as per previous adjustment (6.2.6). d) Adjust two 5/16[...]

  • Page 37

    - 32 - FIGURE 12 MOTION CONTROL LINKAGE ADJUSTMENT 6.2.11 Seat Switch Adjustment a) Stop engine, wait for all mo ving parts to stop, and remove key. b) W ith operator out of seat, adjust the seat switch to provide a 1/16” clearance between the switch plunger and the seat frame (See Figure 13). c) To adjust, loosen the top nut securing the seat sw[...]

  • Page 38

    - 33 - 6.2.13 Steering Chain Adjustment a) Stop engine, wait for all moving parts to stop, and remove key. b) Position the steering handle bar so that it points the unit straight forward (the rear steering wheel should be in line with the rider main frame channel). c) Check to see if the chains are loose. d) To take up slack in the chains, loosen t[...]

  • Page 39

    - 34 - 7. WASTE DISPOSAL 7.1 MOTOR OIL D ISPOSAL. Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at a certified recycling center or according to your state and local regulations. 7.2 BATTERY DISPOSAL DANGER POTENTIAL HAZARD ♦ Battery electrolyte contains sulfuric acid, which is poisonous and can cause sev[...]

  • Page 40

    - 35 - NOTE: After carefully checking the above steps, attempt to start the engine. If it does not start, contact your authorized Exmark service dealer. IMPORTANT : It is essential that all Operator Safety Mechanisms be connected and in proper operating conditions prior to the use of the mower. ENGINE TROUBLESHOOTING When a problem occurs, do not o[...]

  • Page 41

    - 36 - 9. WIRING DIAGRAMS Engine Deck Wiring Diagram Note: All connectors are viewed from the wire input side of the connector. N.O. = Normally Open Console Wiring Diagram Note: All connectors are viewed from the wire input side of the connector. N.O. = Normally Open[...]

  • Page 42

    - 37 - 10. Limited Warranty Exmark Turf Equipment 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 r[...]

  • Page 43

    - 38 -[...]

  • Page 44

    SEE EXM ARK’S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z ® LAZER Z ® HP LAZER Z ® XP LAZER Z ® CT TURF RANGER ® VIKING HYDRO TURF TRACER ® TURF TRACER ® HP METRO ® METRO ® HP ULTRA VAC ™ ULTRA VAC ™ QDS GRASS CATCHER SELF STEERING SULKY MICRO-MULCH ™ ACCESSORY WARNING The engine exhaust from this product contains chemicals kno[...]