Exmark Turf Ranger FMD524 Operator's Manual
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Exmark Turf Ranger FMD524 Operator's Manual

Exmark mower operator's manual
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Download this manual See also: Operator's Manual
For Turf Ranger
Serial Nos. 440,000 & Higher
and
FMD524 & FMD604
Serial Nos. 440,000 & Higher
Part No. 103-4867

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Summary of Contents for Exmark Turf Ranger FMD524

  • Page 1 For Turf Ranger Serial Nos. 440,000 & Higher FMD524 & FMD604 Serial Nos. 440,000 & Higher Part No. 103-4867...
  • 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. Exmark, or its distributors and dealers, accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication.
  • 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 1.1 Safety Alert Symbol... 1 1.2 Training ... 1 1.3 Preparation ... 1-3 1.4 Operation ... 4-6 1.5 Maintenance & Storage... 7 1.6 Safety Signs... 8-9 2. SPECIFICATIONS 2.1 Model Number... 10 2.2 Engine... 10 2.3 Fuel System ...

  • Page 6: Safety Alert Symbol

    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. 1.3.5 Always set the park brake before starting the engine. 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 Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. HOW TO AVOID THE HAZARD Mow up and down slopes.
  • Page 11 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.

  • Page 12: Maintenance & Storage

    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 form 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.

  • Page 13: Safety Signs

    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 your authorized Exmark equipment dealer or distributor or from Exmark Mfg. Co. Inc. 1.6.5 Safety signs may be affixed by peeling off the backing to expose the adhesive surface.
  • Page 14 PART NO. 103-2248 LOCATION: Steering Console PART NO. 98-5954 LOCATION: Under Belt Shields 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. 1-323540 LOCATION: Front of Mower Deck, Top Surface PART NO.

  • Page 15: Specifications

    2.7.4 Hydraulic Oil Capacity: 8.5 qts. (8.0 L.) 2.7.5 Filter: Replaceable cartridge type Exmark P/N 1-513211: 10 micron, 18 psi bypass 2.7.6 Speeds: 0 - 6.4 mph (10.2 km/hr) forward; 0 - 3.2 mph (5.1 km/hr) reverse 2.7.7 Drive wheel release lever allows machine to be moved when engine is not running.

  • Page 16: Tires

    2.8 TIRES Type Size Quantity Tread Ply Rating Pressure 2.9 MOWER DECK 2.9.1 Model Numbers: FMD604 and FMD 524 2.9.1 Cutting Width: 60 in. (152.4 cm.) 2.9.2 Discharge: Right Side 2.9.3 Optional Mulch Kit and Bagger available. 2.9.4 Blade Size: 60"...

  • Page 17: Assembly Instructions

    3. ASSEMBLY INSTRUCTIONS 3.1 Uncrate tractor and mower deck. 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 hands after handling. The machine is shipped with a filled lead acid battery. 3.2.1 Remove battery cover from machine.
  • Page 18 (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.
  • Page 19 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 and secure.

  • Page 20: Position Discharge Chute

    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).
  • Page 21 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.

  • Page 22: Controls

    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.

  • Page 23: Transporting

    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: POTENTIAL HAZARD The rotating blades under the mower deck are...

  • Page 24: Maintenance And Adjustments

    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 .
  • Page 25 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. If the oil level is low, add oil to bring the oil up to the “FULL” mark on the dipstick.
  • Page 26 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 27 1/2 second has elapsed. NOTE: If machine does not pass any of these tests, Do Not operate. Contact your authorized EXMARK Servicing Dealer. IMPORTANT: It is essential that all Operator Safety Mechanism be connected and in proper working condition prior to use for mowing.
  • Page 28 6.1.9 Check hydraulic oil level: Service Interval: 40 hrs. Make sure mower is on a level surface. Stop engine, wait for all moving parts to stop. 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 specified in Section 2.7 (Specifications).

  • Page 29: Lubrication Chart

    Pry out seals, and inspect bearings for 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. NOTE: Seals (Exmark PN 103-0063) must be replaced. LUBRICATION CHART INITIAL PUMPS...
  • Page 30 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.
  • Page 31 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, and then tighten the filter an additional 2/3 to 3/4 turn. Use only Exmark (Part No. 1-513211) or Eaton (Part No. 103144) filter elements.

  • Page 32: Adjustments

    6.1.25 Mobil HTS grease (or food-grade antisieze) is used in the following locations: Between the cutter housing spindle and bearings. Between the cutter housing spindle and sheave. 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 contact.
  • Page 33 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 7. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize gouging and roller wear or damage.
  • Page 34 6.2.5 Neutral Centering Adjustment 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. POTENTIAL HAZARD Engine must be running and drive wheels must be turning so motion control adjustment can be performed.
  • Page 35 NEUTRAL CENTERING DEVICE ADJUSTMENT 6.2.6 Parking Brake Quadrant Adjustment Stop engine, wait for all moving parts to stop, and remove key. Loosen the two 5/16 x 18 screws (a), that clamp the brake quadrant to the engine deck. Pull parking brake lever towards the operator to the brake “on” position (b). Check linkage to ensure that they butt up against the over-centering stop bolt (c), and retighten the two 5/16-18 screws (See Figure 9).
  • Page 36 Remove inlet screen and fan. 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).

  • Page 37: Electric Clutch Adjustment

    MOTION CONTROL LINKAGE ADJUSTMENT 6.2.11 Seat Switch Adjustment Stop engine, wait for all moving parts to stop, and remove key. With 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). To adjust, loosen the top nut securing the seat switch to the seat rail weldment.

  • Page 38: Adjustments

    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.

  • Page 39: Waste Disposal

    7. WASTE DISPOSAL 7.1 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. 7.2 BATTERY DISPOSAL POTENTIAL HAZARD Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns WHAT CAN HAPPEN...
  • Page 40 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.

  • Page 41: Wiring Diagrams

    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.

  • Page 42: Warranty

    (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 43 - 38 -...

  • Page 44: Grass Catcher

    METRO ULTRA VAC GRASS CATCHER MICRO-MULCH 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 ® ® ®...

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