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Exmark FMD604 manual

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Table of contents for the manual

  • Page 1

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

  • Page 2

    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. ♦ S[...]

  • Page 3

    - i - 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 req[...]

  • Page 4

    - ii - 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 OPER[...]

  • Page 5

    - iii - TABLE OF CONTENTS 1. SAFETY ............................................................................................. PAGE 1.1 Safety Alert Symbol ...................................................................................... 1 1.2 Training .........................................................................................[...]

  • Page 6

    - 1 - 1. SAFETY 1.1 SAFETY ALERT SY MBOL 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 alert symbol appears above information which alerts you to unsafe actions or[...]

  • 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. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison. WHAT CAN HAP[...]

  • 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 ♦ 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. HO W TO AVOID THE HAZARD ♦ Mow across sl[...]

  • Page 11

    - 6 - 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 stopp ing 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 engin[...]

  • Page 12

    - 7 - 1.5.7 Gasoline powered equipment or fuel containers sho uld not be stored in a basement or any enclosed area where open pilot lights or heat appliances are present. 1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly. 1.5.9 Check all bolts frequently to maintain proper tightn[...]

  • Page 13

    - 8 - Decals for ECS Handle units only: Decals for Pistol Grip Handle units only: Decals for all units: PART NO. 103-1541 LOCATION: Console PART NO. 1-303508 LOCATION: On Top RH Surface of Mower Deck PART NO. 1-303517 LOCATION: LH Side of Rear Surface of Engine Deck PART NO. 103-2242 LOCATION: LH Side of Console PART NO. 103-2243 LOCATION: RH Side [...]

  • Page 14

    - 9 - PART NO. 1-403005 LOCATION: LH & RH Front Top Surface of Mower Deck PART NO. 1-403143 LOCATION: RH Rear Surface of Engine Deck PART NO. 1-513747 LOCATION: Top Rear of Battery Cover PART NO. 1-513746 LOCATION: Surface of Engine Deck Next to Muffler PART NO. 1-553049 LOCATION: On Top Front LH Surface of Mower Deck PART NO. 1-323540 LOCATION[...]

  • Page 15

    - 10 - 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. In countries using the research method, it should be a 90 oc[...]

  • Page 16

    - 11 - 2.6.5 Drive wheel release valves allow machine to be moved when the engine is not running 2.7 WHEEL DRIVE SYS TEM: Drive wheels are direct coupled to Parker wheel drive motors with 1.0" (25.4 mm) tapered shaft. 2.8 TIRES Drive Front Caster Size .......................... 18 x 8.50-8 .......................... 11 x 4.0-5 Quantity .......[...]

  • Page 17

    - 12 - 3. ASSEMBLY INSTRUCTIONS 3.1 UNCRATE UNIT 3.1.1 Remove tractor and mower deck from crates. 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 [...]

  • Page 18

    - 13 - 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 [...]

  • Page 19

    - 14 - FIGURE 1 SUPPORT PIN LOCATION 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. Tighten hardware[...]

  • Page 20

    - 15 - 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. For example[...]

  • Page 21

    - 16 - STANDARD PISTOL GRIP HANDLES ECS HANDLES FIGURE 3 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 op[...]

  • Page 22

    - 17 - 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. W ith a 5/8 wrench, turn both valves one turn counter-clockwise to release the drive system. Turn clock[...]

  • Page 23

    - 18 - 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 engi[...]

  • Page 24

    - 19 - CAUTION 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. HO W TO AVOID THE HAZARD ♦ Be sure the drive lev[...]

  • Page 25

    - 20 - 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: S queeze both drive levers into the reverse position. For smooth operation of this machine, avoid qu ick, jerky movements of the drive levers. Move the drive levers smoothly and deliberate[...]

  • Page 26

    - 21 - 4.4 TRANSPORTING WARNING 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. HO W TO AVOID THE HAZARD ♦ Use proper ramps that are secured to the truck or trailer. ♦ Keep [...]

  • Page 27

    - 22 - 5.1 PERIODIC MAINTE NANCE 5.1.1 Check engine oil level . Service Interval: See Engine Owner's Manual a) Stop engine, wait for all moving parts to stop and make sure unit is on a level surface. b) Check with engine cool. c) Clean area around dipstick. Remove dipstick and wipe oi l off. Reinsert the dipstick. DO NOT screw into place. Remo[...]

  • Page 28

    - 23 - d) Clean out any grass build-up from underside of deck and in deck discharge chute. e) Inspect blades and sharpen or replace as required. f) If blade removal is necessary, be careful of the sharp cutting edges of the blades. g) Re-install the blades (if they were removed) by placing a block of wood between the front or rear baffles and the b[...]

  • Page 29

    - 24 - Try to start with OPC levers depressed , speed control lever in neutral and PTO engaged - starter MUST NOT crank. b) Check OPC circuits. Clear the area. Run engine at one-third throttle, then, with drive levers and neutral lock latches in neutral lock position , move the speed control lever out of neutral and release OPC levers engine MUST s[...]

  • Page 30

    - 25 - f) Start the engine and check for leaks. Stop engine and recheck oil level. 5.1.8 Check the battery charge . Allowing the batteries to stand for an extended period without recharging them will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries in storage when the open circuit [...]

  • Page 31

    - 26 - IMPORTANT: Before re-installing new filter, fill it completely 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 adapter. Do not tighten yet. d) Fill reservoir as stated in Section 5.1.9. e) Loosen filter 1/2 turn and allow a small amount of oil to[...]

  • Page 32

    - 27 - 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 s tep (d). d) Thoroughly clean the area around each of the charge pump housin[...]

  • Page 33

    - 28 - ∗ See 5.1.14 Section c) for special lubrication instructions on the front caster pivots and Section 5.1.15 for special lubrication instructions on the front caster wheel hubs. No. 4 (Idler Pivot (Pump Drive)) Located Under Engine Deck No. 3 & 4 (Idler Pivots) Disassemble and grease once a month under a “No Load” condition. c) Lubri[...]

  • Page 34

    - 29 - l) Re-install the sea l 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. If the wheel spins f[...]

  • Page 35

    - 30 - 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. b) 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. This allows for normal [...]

  • Page 36

    - 31 - FIGURE 9 CUTTING HEIGHT ADJUSTMENT FIGURE 10 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 10. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize gouging and roller w[...]

  • Page 37

    - 32 - 5.2.4 Blade drive belt tension : No adjustment necessary. 5.2.5 Hydro Drive Linkage Adjustment : a) 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 c[...]

  • Page 38

    - 33 - 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 i[...]

  • Page 39

    - 34 - 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. Repeat above adjustments if necessa[...]

  • Page 40

    - 35 - e) 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 o bserve the tracking on a level, smooth, hard surface such as concrete or asphalt. 4. If[...]

  • Page 41

    - 36 - 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 DANGER POTENTIAL HAZARD ♦ Battery electrolyte contains sulfuric acid, which is poisonous and can cause sever[...]

  • Page 42

    - 37 - h) Check for loose or faulty wiring connections. If it is nec essary to disconnect wire connectors, Do Not pull on the wires. i) Check for corrosion at all wiring connections. Even minor corrosion may cause a faulty connection. Clean connector terminals thoroughly, apply dielectric grease and reconnect. IMPORTANT: It is essential that all op[...]

  • Page 43

    - 38 - 8. HYDRAULIC SCHEMATIC[...]

  • Page 44

    - 39 - 9. WIRING DIAGRAMS[...]

  • Page 45

    - 40 - 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 46

    - 41 - SERVICE RECORD Date Description of Work Done Service Done By[...]

  • Page 47

    - 42 - T H I S I S A 1 5 ° S L O P E T H I S I S A 1 0 ° S L O P E T H I S I S A 5 ° S L O P E ALIGN THIS EDGE WITH A VERTICAL SUR FACE (TREE, BUILDING, FENCE POS T , POLE ETC.) EX A M P L E : C O M P A R E S L O PE W I T H F O L D E D E D G E . F O L D A L O N G A PP R O P R I A T E L I N E T H I S I S A 2 0 ° S L O P E[...]

  • Page 48

    ® M FG. CO. INC. SEE EXM ARK’S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z ® LAZER Z ® CT LAZER Z ® HP LAZER Z ® XP 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 cont[...]