1. Manuals
  2. Brands
  3. Exmark Manuals
  4. Lawn Mower
  5. Turf Ranger FMD604
  6. Operator's manual

Exmark FMD604 Operator's Manual

Ride-on mower
Hide thumbs Also See for FMD604:
Table of Contents

Advertisement

Quick Links

For Turf Tracer
Serial Nos. 440,000 & Higher
and
FMD524 & FMD604
Serial Nos. 440,000 & Higher
Part No. 103-4869

Advertisement

Table of Contents
loading

Related Manuals for Exmark FMD604

Summary of Contents for Exmark FMD604

  • Page 1 For Turf Tracer Serial Nos. 440,000 & Higher FMD524 & FMD604 Serial Nos. 440,000 & Higher Part No. 103-4869...
  • Page 2 Replacements may be ordered through the engine manufacturer. Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously.
  • Page 3 UPS Exmark bills the distributor for parts and shipping charges, where applicable. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the program.
  • Page 4 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS 1. SAFETY ...PAGE 1.1 Safety Alert Symbol... 1 1.2 Training ... 1 1.3 Preparation ... 1-3 1.4 Operation ... 4-6 1.5 Maintenance & Storage... 6-7 1.6 Riding Attachments ... 7 1.7 Safety Signs..7-10 2. SPECIFICATIONS 2.1 Model Number...

  • Page 6: Safety

    MAY result in minor or moderate injury. 1.2 TRAINING 1.2.1 Regard the Exmark mower as a piece of power 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.
  • Page 7 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. POTENTIAL HAZARD Engine exhaust contains carbon monoxide, which is an odorless deadly poison.
  • Page 8 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. HOW TO AVOID THE HAZARD Purchase and store gasoline only in an approved container.

  • Page 9: Operation

    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.
  • Page 10 POTENTIAL HAZARD Mowing on wet grass or steep slopes can cause sliding and loss of control. WHAT CAN HAPPEN Loss of control and/or loss of operator’s footing could result in a fall with an arm or leg getting under the mower or engine deck, which may result in serious injury or death.

  • Page 11: Maintenance & Storage

    1.4.13 Stop the engine and wait for all moving parts to stop: Before removing grass catcher. Before refueling. Before making height adjustments. 1.4.14 Before stopping the engine, place the throttle control midway between the “slow” and “fast” positions. Allow the engine to run a minimum of 15 seconds, then stop the engine.

  • Page 12: Riding Attachments

    1.6 RIDING ATTACHMENTS Use only Exmark riding attachments. The use of other than Exmark riding attachments may create a hazardous condition resulting in injury. 1.7 SAFETY SIGNS 1.7.1 Keep all safety signs legible.
  • Page 13 Decals for ECS Handle units only: PART NO. 103-1541 LOCATION: Console Decals for Pistol Grip Handle units only: PART NO. 103-5354 LOCATION: Console Decals for all units: PART NO. 1-303508 LOCATION: On Top RH Surface of Mower Deck PART NO. 103-2242 LOCATION: LH Side of Console PART NO.
  • Page 14 PART NO. 1-323540 LOCATION: Front of Mower Deck Top Surface PART NO. 1-403143 LOCATION: RH Rear Surface of Engine Deck PART NO. 1-513747 LOCATION: Top Rear of Battery Cover PART NO. 1-523552 LOCATION: On Top of Hydraulic Tank PART NO. 103-1077 LOCATION: On Top Front RH Surface of Mower Deck PART NO.

  • Page 15: Specifications

    PART NO. 103-2239 LOCATION: Top of Mower Deck Beneath Center Shield 2. SPECIFICATIONS 2.1 MODEL NUMBER: TT23KCC; TT23KAC; TT20KC 2.2 ENGINE 2.2.1 Engine Specifications: See your Engine Owner's 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.

  • Page 16: Wheel Drive System

    Tread... Turf Master... Smooth Ply Rating ... 4 ... 4 Pressure ... 14 psi (90 kPa) ...16 psi (152 kPa) 2.9 MOWER DECK 2.9.1 Model Numbers: FMD604 and FMD524 2.9.2 Cutting Width: 60 in. (152.4 cm.) 52 in. (132.1 cm.) 2.9.3 Discharge: Right Side 2.9.4...

  • Page 17: Assembly Instructions

    3. ASSEMBLY INSTRUCTIONS 3.1 UNCRATE UNIT 3.1.1 Remove tractor and mower deck from crates. 3.2 SERVICE BATTERY: WARNING: Battery posts, terminals, and related accessories contain lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash The machine is shipped with a filled lead-acid battery.
  • Page 18 NOTE: If the positive cable is also disconnected, connect the positive (red) cable first, then the negative (black) cable. Slip insulator boot over the positive terminal. 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.
  • Page 19 3.5.5 Mower Deck Stationary Idler Installation: Locate the two holes along the back center section of the deck and install the stationary idler and related parts (from bolt bag) in the right hand hole. See Figure 2. Be sure the coned end of the disc spring washer is against the head of the bolt.

  • Page 20: Operation Instructions

    NOTE: The baffle is labeled “HOT” and “COLD”. The oil level varies with the temperature of the oil. The “HOT” level shows the level of oil when it is at 225°F (107°C). The “COLD” level shows the level of the oil when it is at 75°F (24°C). Fill to the appropriate level depending upon the temperature of the oil.
  • Page 21 STANDARD PISTOL GRIP HANDLES DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION 4.1.4 PTO Engagement: Switch is located on left side of control console. The switch must be pulled out to the ”Rotate” position to engage the blades. The switch is pushed in to the “Stop”...

  • Page 22: Pre-Start

    4.1.11 Drive Wheel Release Valves: Located on the left rear corner of the hydrostatic pumps. Drive wheel release valves are used to release the hydro-static drive system to allow the machine to be moved by hand without the engine running. With a 5/8 wrench, turn both valves one turn counter-clockwise to release the drive system.
  • Page 23 4.3.2 Stopping Engine: Lock drive levers in neutral, disengage PTO, move speed control lever to neutral, and engage park brake. Move throttle to the “midway” position. Allow engine to run a minimum of 15 seconds. Rotate ignition switch to “Off” position. Remove key to prevent children or other unauthorized persons from starting engine.
  • Page 24 POTENTIAL HAZARD If the neutral lock latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position. WHAT CAN HAPPEN If the drive levers slip into the drive position the unit could lurch forward and cause injury or property damage.
  • Page 25 right hand drive lever back into the reverse position while the opposite drive lever is in a forward position at an equal but opposite speed. For reverse: Squeeze both drive levers into the reverse position. For smooth operation of this machine, avoid quick, jerky movements of the drive levers.

  • Page 26: Transporting

    4.4 TRANSPORTING POTENTIAL HAZARD Loading the mower onto a trailer without strong enough or properly supported ramps could be dangerous. WHAT CAN HAPPEN The ramps could collapse causing the unit to fall, which could cause injury. HOW TO AVOID THE HAZARD Use proper ramps that are secured to the truck or trailer.

  • Page 27: Periodic Maintenance

    5.1 PERIODIC MAINTENANCE 5.1.1 Check engine oil level. Service Interval: See Engine Owner's Manual Stop engine, wait for all moving parts to stop and make sure unit is on a level surface. Check with engine cool. Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick.
  • Page 28 HOW TO AVOID THE HAZARD Replace the blade bolt after striking a foreign object. (Use only Exmark replacement parts PN 103-0862 – blade bolt and PN 103-0865 – spring disc washer). DO NOT lubricate the threads of the bolt or spindle before assembly.
  • Page 29 If machine does not pass any of these tests, DO NOT operate. Contact your authorized EXMARK SERVICE DEALER. IMPORTANT: It is essential that all Operator Safety Mechanisms, be in place and in proper operating condition prior to mowing.
  • Page 30 Service Interval: After First 250 hrs, then yearly thereafter. Note: Use only Exmark P/N 1-513211 for Summer use above 32 F (0 C) or P/N 1-523541 for Winter use below 32 F (0 C). (Refer to Section 2.6.2 for filter specifications) Place unit on a level surface.
  • Page 31 IMPORTANT: Before re-installing new filter, fill it completely with Mobil 1 15W-50 and apply a thin coat of oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts the filter adapter. Do not tighten yet. d) Fill reservoir as stated in Section 5.1.9.
  • Page 32 NOTE: It is necessary to lightly touch the charge pump cap with your hand to check the pump temperature. If the cap is too hot to touch, turn off engine. The pumps may be damaged if the pump becomes too hot. If either drive wheel still does not rotate continue with step (d).
  • Page 33 Pack the bearings with a NGLI grade #1 multi-purpose grease. Insert (1) bearing, (1) new seal into the wheel. NOTE: Seals (Exmark PN 103-0063) must be replaced. 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.
  • Page 34 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.

  • Page 35: Adjustments

    NOTE: Care must be used not to bond the bearing, next to each OPC hub, to the cross shaft which could cause binding of the OPC levers and erratic operation. Fuel tank studs where studs are inserted into tank. NOTE: When installing the nuts onto the fuel tank studs, fully tighten the nyloc nut and back off 1/2 turn.
  • Page 36 LEFT HAND SIDE SHOWN CUTTING HEIGHT ADJUSTMENT ANTI-SCALP ROLLER BOLT INSTALLATION ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of the positions shown in Figure 10. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize gouging and roller wear or damage.
  • Page 37 5.2.4 Blade drive belt tension: No adjustment necessary. 5.2.5 Hydro Drive Linkage Adjustment: Adjust Speed Control Linkage and Neutral Safety Switch 1. Stop engine and wait for all moving parts to stop. 2. Move speed control lever (located on console) to the full forward position and check orientation of tabs on the ends of the speed control crank.
  • Page 38 FIGURE 12 HYDRO DRIVE LINKAGE ADJUSTMENT 4. Loosen the nut against the neutral control linkage yoke as shown in Figure 12. 5. Adjust the neutral control linkage until the respective drive wheel stops when the lever is pulled against the neutral spring (neutral position). Turn the adjusting bolt approximately 1/4 turn clockwise if the wheel is turning in reverse or turn the bolt approximately 1/4 turn counter- clockwise if the wheel is turning forward.
  • Page 39 Recheck the left drive wheel rotation to see if further adjustment is necessary - be sure the speed control lever is in the neutral position. If inconsistent neutral occurs, check to be sure both springs are properly tightened on the speed control lever under the console - especially the rear pivot spring.

  • Page 40: Adjustments

    Tracking Adjustment 1. Stop engine and wait for all moving parts to stop. Raise rear of machine, remove jack stands, and carefully lower machine to the ground. 2. Check the drive tire pressures and tire circumferences. See 5.1.12. 3. Run the unit and observe the tracking on a level, smooth, hard surface such as concrete or asphalt.

  • Page 41: Waste Disposal

    6. WASTE DISPOSAL 6.1 MOTOR OIL DISPOSAL 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. 6.2 BATTERY DISPOSAL POTENTIAL HAZARD Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns WHAT CAN HAPPEN...
  • Page 42 NOTE: After carefully checking the above steps, attempt to start the engine. If it does not start, contact your authorized Exmark service dealer. ENGINE TROUBLESHOOTING When a problem occurs, do not overlook the simple causes. For example, starting problems could be caused by an empty fuel tank.

  • Page 43: Hydraulic Schematic

    8. HYDRAULIC SCHEMATIC - 38 -...

  • Page 44: Wiring Diagrams

    9. WIRING DIAGRAMS - 39 -...

  • Page 45: Transmission

    (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship. This warranty applies to Exmark turf equipment sold in the US or Canada. This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer.
  • Page 46 SERVICE RECORD Date Description of Work Done Service Done By - 41 -...
  • Page 47 ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) - 42 -...

  • Page 48: Grass Catcher

    MICRO-MULCH The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or ©1997-2003 EXMARK MFG. CO. INC. INDUSTRIAL PARK BOX 808 BEATRICE, NE 68310 ALL RIGHTS RESERVED LAZER Z LAZER Z ®...

This manual is also suitable for:

Turf tracerTurf tracer tt23kccTurf tracer tt23kacTurf tracer tt20kc

Table of Contents