Exmark FMD524 Operator's Manual
Exmark mower operator's manual
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- Operator's manual (44 pages) ,
- Operator's manual (20 pages) ,
- Setup instructions (4 pages)
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Summary of Contents for Exmark FMD524
- Page 1 For Turf Tracer Serial Nos. 510,000 & Higher FMD524 & FMD604 Serial Nos. 510,000 & Higher Part No. 103-9190...
- 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 3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time, Exmark pays for the part and freight. 4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark pays for the part.
- 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.
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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 ..7-9 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 ♦...
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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.
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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 LOCATION: Console PART NO. 1-303517 LOCATION: LH Side of Rear Surface of Engine Deck For FMD524 & FMD604 Units with SN 540,000 & Higher PART NO. 103-7491 LOCATION: On Top Front RH Surface of Mower Deck PART NO. 1-303508 LOCATION: On Top RH Surface of Mower Deck PART NO.
- Page 14 LOCATION: On Top Front LH Surface of Mower Deck PART NO. 103-2239 LOCATION: Top of Mower Deck Beneath Center Shield For FMD524 & FMD604 Units with SN 410,000 – 439,999 PART NO. 103-1077 Front RH Side of Mower Deck LOCATION: PART NO.
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Page 15: Specifications 2.1 Model Number
2. SPECIFICATIONS 2.1 MODEL NUMBER: TT23KCC; TT23KAC; TT20KCC 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. In countries using the research method, it should be a 90 octane minimum. -
Page 16: Tires
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: Drive Wheels
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: Position Discharge Chute
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 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” position to stop the blades. Operator must have operator presence control levers depressed when PTO is engaged or engine will stop.
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Page 22: Controls
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 4.3.4 Drive Wheel Engagement/Turning: With drive levers locked in “neutral”, shift speed control lever to desired forward speed. Slowly squeeze and hold both drive levers in the neutral position and rotate both neutral lock latches from the neutral lock position to the forward position. DO NOT squeeze both drive levers all the way back, this will cause the drive wheels to engage in the reverse direction.
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Page 25: 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 ♦... -
Page 26: 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 27 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 28 HOW TO AVOID THE HAZARD ♦ Always re-install original Exmark blades, blade bushings, spring disc washers, and blade bolts in the correct positions as shown.
- 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. 5.1.6 Check for loose hardware.
- 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 Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground. Run machine to allow any other air to be purged from the hydraulic system and recheck the oil level. If either drive wheel does not rotate, one or both of the charge pumps (located on the top of the main pump as shown in Figure 7) may have lost their “prime”.
- Page 32 If either drive wheel still does not rotate, stop and repeat steps (d) and (e) above for the respective pump. If wheels rotate slowly, the system may prime after additional running. Check oil level as stated in Section 5.1.10. Allow unit to run several minutes after the charge pumps are “primed” with drive system in the full speed position.
- 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 Remove cooling shroud cleanout covers (Kohler) or cooling shrouds (Kawasaki) from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine which can cause improper cooling. Make sure cooling shroud cleanout covers or cooling shrouds are properly reinstalled.
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Page 35: Adjustments
5.2 ADJUSTMENTS IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop, and remove key before servicing, cleaning, or making adjustments to the unit. 5.2.1 Cutting height and anti-scalp roller adjustment. POTENTIAL HAZARD ♦ When mower deck is not installed or the two front support rod hairpins are removed, the unbalanced weight of the tractor or tractor with mounted mower deck support frame may cause the front of the unit to... - Page 36 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. For Maximum Deck Flotation, place rollers one hole position lower. Rollers should maintain 1/4 in.
- Page 37 FIGURE 11 NEUTRAL SAFETY SWITCH ADJUSTMENT Adjust Neutral Control Linkages 1. Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground. 2. Start the engine and move the throttle ahead to the full throttle position. Place the neutral lock latches in the “forward”...
- Page 38 7. After adjustments are made and the wheels stop when the drive lever is in the neutral position, tighten the nut against the yokes. Adjust Hydro Control Linkage: 1. Place the speed control lever in the “neutral” position. This adjustment is again made with rear of machine on jack stands and engine running at full throttle.
- Page 39 if the tire is turning in reverse and shorten the linkage if the tire is creeping forward. Tighten the jam nuts at both ends. Release and re- engage the neutral lock checking that the tire stops. Continue this process until the tire is at a dead stop. DRIVE LEVER AND LATCH IN NEUTRAL POSITION 3.
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Page 40: Waste Disposal
5.2.8 Electric Clutch Adjustment No adjustment necessary. 5.2.9 Park Brake Adjustment: Shut off engine and wait for all moving parts to stop. Disengage the park brake. Remove the hairpin in the park brake linkage. Turn the linkage in the yoke until there is 3/16”... -
Page 41: Mower Cuts Unevenly
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 42 ENGINE TROUBLESHOOTING TABLE IMPROPER PROBLEM FUEL FUEL Will not start Hard starting Stops suddenly Lacks power Operates erratically Knocks or pings Skips or misfires Backfires Overheats High fuel consumption FAULTY DIRT IN DIRTY AIR ENGINE SPARK FUEL LINE FILTER OVERLOADED PLUG - 37 - BLOCKED...
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Page 43: Hydraulic Schematic
8. HYDRAULIC SCHEMATIC - 38 -... -
Page 44: Wiring Diagram
9. WIRING DIAGRAM - 39 -... -
Page 45: 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. -
Page 46: Service Record
SERVICE RECORD Date Description of Work Done Service Done By - 40 -... - Page 47 ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) - 41 -...
- Page 48 ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES contains chemicals known to the State of California to cause cancer, birth defects, or ©1997-2005 EXMARK MFG. CO. INC. INDUSTRIAL PARK BOX 808 BEATRICE, NE 68310 ALL RIGHTS RESERVED LINE OF ACCESSORIES...
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