Exmark Turf Ranger TR23KC Operator's Manual
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Exmark Turf Ranger TR23KC Operator's Manual

Exmark zero turn riding mower operator's manual
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For Turf Ranger
Serial Nos. 510,000 & Higher
and
FMD524 & FMD604
Serial Nos. 510,000 & Higher
Part No. 103-9192

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Summary of Contents for Exmark Turf Ranger TR23KC

  • Page 1 For Turf Ranger Serial Nos. 510,000 & Higher FMD524 & FMD604 Serial Nos. 510,000 & Higher Part No. 103-9192...
  • 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 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.

  • 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 ♦...
  • 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 ♦...

  • 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 ♦...
  • 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 Type A Anti-Scalp Rollers Only – See Figure 7 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.) 52 in. (132.1 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: Controls

    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 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: Operation Instructions

    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 ♦...

  • Page 24: Maintenance & 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 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 28 IMPORTANT: It is essential that all Operator Safety Mechanism be connected and in proper working condition prior to use for mowing. 6.1.7 Check for loose hardware: Service Interval: Daily Stop engine, wait for all moving parts to stop, and remove key. Visually inspect machine for any loose hardware or any other possible problem.
  • Page 29 6.1.11 Check tire pressures: Service Interval: 40 hrs. Stop engine, wait for all moving parts to stop, and remove key. Inflate tires to pressures specified in Section 2.8 (Specifications). See Section 8.1 for further information. NOTE: Do not add any type of tire liner or foam fill material to the tires. Excessive loads created by foam filled tires may cause failures to the hydro drive system, frame, and other components.
  • Page 30 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 31 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of NGLI grade #1 multi-purpose grease. Insert the second bearing and new seal into the wheel.
  • Page 32 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. d) Start engine and run several minutes.

  • Page 33: Adjustments

    6.2 ADJUSTMENTS IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop, and remove key before servicing, cleaning or making any adjustments to the unit. 6.2.1 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 34 Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of the positions shown in Figure 9. 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 35 WARNING POTENTIAL HAZARD ♦ Engine must be running and drive wheels must be turning so motion control adjustment can be performed. WHAT CAN HAPPEN ♦ Contact with moving parts or hot surfaces may cause personal injury. HOW TO AVOID THE HAZARD ♦...
  • Page 36 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 11).
  • Page 37 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 38 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 15). To adjust, loosen the top nut securing the seat switch to the seat rail weldment.
  • Page 39 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 40: 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 ♦...
  • Page 41 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 42: 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 43: 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 44 NOTES - 38 -...
  • Page 45 NOTES - 38 -...

  • Page 46: Service Record

    SERVICE RECORD Date Description of Work Done Service Done By - 39 -...
  • Page 47 - 40 -...
  • 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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