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Exmark TR23KC manual

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Table of contents for the manual

  • Page 1

    For Turf Ranger Serial Nos. 510,000 & Higher and FMD524 & FMD6 0 4 Serial Nos. 510,000 & Higher Part No. 103-9192[...]

  • Page 2

    i WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment . W HAT CAN HAPPEN ♦ Failure to f ollow safe operating practices can r esult in ser ious operator inj ur y or even death. HOW TO AVOI D T HE HAZARD ♦ Keep all shields, guar ds, and saf ety devices (especially the gr ass discharge system) in place and in pr oper working [...]

  • Page 3

    ii EXMARK PA RTS PLUS ® PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not ha ve the Exmark part in stock, Exmark w ill 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 "dow n" unit at the time of r[...]

  • Page 4

    iii CONGRAT ULA TIO NS on the purchase of your Exmark Mower. This product has been caref ully designed and m anufact ured to g ive you a maximum amount of dependability and years of tr ouble- f ree oper at ion. OPERA TOR'S M A NUAL This manual cont ains assem bly, oper at ing , maint enance, adj ustment , and saf ety instructi ons for your Ex [...]

  • Page 5

    iv TA BLE OF CONTENTS 1. SA FETY PA GE 1.1 Sa f ety A lert S ymb ol ...................................................................................... 1 1.2 Trai ning ........................................................................................................ 1 1.3 Prepar ation .......................................................[...]

  • Page 6

    - 1 - 1.SA FETY 1.1 SA FETY A LERT SYMBOL Thi s SA FETY A LERT SYMBOL is used bot h in t his m anual and on the machine to identif y import ant saf ety messages which must be f ollowed to avoid accidents. This symbol means: A TTENTION! BECOME ALERT! YOUR SA FETY IS INVOLVED ! The saf ety alert symbol appears above infor mation, which alerts you to [...]

  • Page 7

    - 2 - 1.3.4 Thoroug hly inspect the area where the eq uipm ent is t o be used and r em ove all stones, stick s, wires, bones, and other f oreig n objects, which may damage t he equipment or cause per sonal inj ur y to the operator or bystanders. 1.3.5 Always set the park brak e befor e starting the engine. WA RNING POTENT IAL HAZARD ♦ Engine exha[...]

  • Page 8

    - 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely f lam m able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignit e g asoline vapors. A f ir e or explosion from g asoline can burn you, others, and cause property damag e. HOW TO AVOI D T HE HAZARD ♦ Purchase and store g asoline only in an approved[...]

  • Page 9

    - 4 - 1.4 OPERA TION Although hazard control and acci dent prevent i on are partiall y dependent upon the design and configurat i on of t he equi pment, these f act ors are al so dependent upon the awareness, concern, prudence, and proper t r ai ni ng of t he personnel involved in t he operat i on, t r ansport , maintenance, and st orage of t he eq[...]

  • Page 10

    - 5 - DA NGER POTENT IAL HAZARD ♦ Mow ing on wet grass or steep slopes can cause sliding and loss of cont r ol. W HAT CAN HAPPEN ♦ W heels dr opping over edges, dit ches, steep bank s, or water can cause rollovers, which may result in serious injury, death or dr owning. HOW TO AVOI D T HE HAZARD ♦ Mow up and down slopes. ♦ Do not mow slopes[...]

  • Page 11

    - 6 - 1.4.7 Never operate the mower with defect ive guards, shields, or covers. Always have safety shields, g uar ds, switches, and ot her devices in place and in proper working condit ion. 1.4.8 Do Not change t he eng ine governor set t ing s or overspeed the eng ine. O per at ing an engine at excessive speed may increase the hazard of per sonal i[...]

  • Page 12

    - 7 - 1.5 MAINTENA NCE A ND STORA G E 1.5.1 For engine m aint enance, f ollow the engine m anuf actur er ’s recom mendations precisely as stated in the eng ine manual. 1.5.2 Disconnect the batt ery cable for m t he negative batt er y post when the unit will be allowed to sit for m or e t han 30 days without use. 1.5.3 Allowing batteries to st and[...]

  • Page 13

    - 8 - PART NO. 1- 553049 LOCATIO N: On Top Front LH Surf ace of Mower Dec k 1.6 SA FETY SIGNS 1.6.1 Keep all safet y sig ns leg ible. Remove all gr ease, dirt, and debr is f rom saf ety signs and instr uct ional labels. 1.6.2 Safet y sig ns m ust be r eplaced if t hey are m issing or illegible. 1.6.3 W hen new components ar e inst alled, be sure th[...]

  • Page 14

    - 9 - PART NO. 103- 2248 LOCATI ON: Steering Console PART NO. 1- 403005 LOCATIO N: LH & RH Front T op Surfac e of Mower Deck PART NO. 1- 543620 LOCAT ION: On Intake Screen Below Fuel T ank PART NO. 1- 543896 LOCATI ON: Under Engine Deck on W ood Block s f or Shipping PART NO. 98- 5954 LOCAT ION: Under Belt Shields Type A Anti-Scalp Rollers O nl[...]

  • Page 15

    - 10 - 2. SPECIFICA TIONS 2.1 MODEL NUMBER : TR23 KC 2.2 ENGINE 2.2.1 Eng ine Specif ications: See your eng ine owners manual. 2.2.2 3600 RPM (No Load) 2.3 FUEL SYSTEM 2.3.1 Capacity: 5. 0 g al. (18. 9 L.) 2.3.2 T ype of Fuel: Regular unleaded g asoline 87 octane or hig her. I n count ries using the r esear ch m et hod, it should be a 90 octane min[...]

  • Page 16

    - 11 - 2.8 TIRES Rear Drive Front Caster (FMD Units) Type Pneum atic Pneum atic Pneum atic Size 18 x 7.50-8 20 x 10.00-8 11 x 4-5 Quantity 1 2 2 Tread T urf saver Turf m ate Smooth Ply Rating 4 4 4 Pressur e 14 psi (97 k Pa) 20 psi ( 138 kPa) 16 ps i (110 k Pa) 2.9 MOW E R DECK 2.9.1 Model Numbers: FMD604 and FM D 524 2.9.1 Cutting W idth: 60 in. ([...]

  • Page 17

    - 12 - 3. A SSEM BLY INSTRUCTIONS 3.1 Uncrate tractor and mow er deck . 3.2 SERVICE BA TTERY : The ma chine is ship ped with a filled lead ac id batte ry. 3.2.1 Remove battery cover fr om machine. DA NGER POTENT IAL HAZARD ♦ Charging t he bat tery may produce explosive gasses W HAT CAN HAPPEN ♦ Battery gasses can explode causing ser ious inj ur[...]

  • Page 18

    - 13 - (black) cable t o the negat ive terminal on the bat tery. Reinstall insulat or boots. Reinstall batter y cover. NOTE: If time does not per m it char g ing the bat tery, or if charg ing equipment is not available, connect the neg ative battery cables and run t he vehicle continuously for 20 t o 30 minutes to suf f iciently charge the bat tery[...]

  • Page 19

    - 14 - 3.8.2 Remove mower deck support f rame f rom m ower deck by removing t he t wo hairpins and spacers f rom the f ront deck support pins and r em ove the hairpins and spacers fr om the rear deck support pins. 3.8.3 Lift up on suppor t fr am e unt il it clears the suppor t pins. Posit ion support fr am e so the arms ar e on each side of the t r[...]

  • Page 20

    - 15 - Locate two holes along the back center section of the m ower deck . Install the stationary idler and r elat ed par t s in the lef t hand hole location as shown in Figure 3. See the belt r out ing decal on deck. Be sur e t he coned end of t he disc spr ing is against t he head of the bolt as illust rated (See Fig ure 3). FIGURE 3 IDLER PULLEY[...]

  • Page 21

    - 16 - 4.3 Elect r o- m echanical deck lif t contr ol: Switch is located on lef t side of contr o l console. Mov ing the t og gle switch lever f or ward will lower the cutting deck . Moving the lever backward will raise the deck. Nor mal operation is with the act uat or f ully extended. The actuator has an int er nal clut ch to prot ect it f rom ex[...]

  • Page 22

    - 17 - FIGURE 4 DRIVE WHEEL RELEASE LEVER 5. OPERA TION INSTRUCTIONS 5.1 PRE-STA RT 5.1.1 Fill fuel t ank . For best results use only clean, f resh reg ular g r ade unleaded gasoline with an octane rating of 87 or hig her. Reg ular gr ade leaded g asoline may also be used; however, combustion chamber and cylinder head will requir e more f requent s[...]

  • Page 23

    - 18 - Rotate ig nit ion switch to “OFF” posit ion. Remove the k ey to prevent children or other unauthor ized persons f rom st ar ting eng ine. Close fuel shut - of f valve w hen machine will not be used for a f ew days, when transport ing , and when the unit is park ed inside a building. 5.2.3 Engag ing PTO : DA NGER POTENT IAL HAZARD ♦ The[...]

  • Page 24

    - 19 - to simulate a f ull width ramp. Dr ive f orward to load and drive back ward to unload fr om a t railer. Do not dr ive backward to load or drive f orward to unload a tr ailer . Ramp should be long enoug h so that the ang les between the ramp and t he ground and t he r am p and t he t railer or t r uck do not exceed 15 ° . After unit is loade[...]

  • Page 25

    - 20 - c) Clean area around dipstick . Rem ove dipstick and wipe oil off . Reinser t the dipstick. Do not scr ew into place. Remove dipstick and r ead t he oil level. d) If the oil level is low, add oil to bring the oil up t o t he “ FULL” mar k on the dipstick. Use oil as specif ied in Eng ine O wner’s Manual. Do Not overf ill. IMPORT A NT: [...]

  • Page 26

    - 21 - e) Clean out any grass build-up f rom under side of deck and in dischar g e chute. 6.1.5 Check mower blades . Service Inte rval: Da ily a) Disengag e PTO. b) Raise deck using lif t act uat or . c) Stop engine, wait f or all moving par t s to stop, and remove key. d) Lift deck and secure in raised posit ion as st at ed in Section 6.1. 4. e) I[...]

  • Page 27

    - 22 - 3) Install blade bolt and spr ing disc washer. Be sure the spring disc washer cone is installed towards the bolt head. Place a block of wood between front or r ear baf f les and the blade then tor que the blade bolts to 55-60 f t- lbs. (75-81 N- m ) . FIGURE 6 BLA DE BOLT INSTA LLAT ION IMPO RTANT : DO NO T use components ot her than t he or[...]

  • Page 28

    - 23 - IMPORT A NT : I t is essential that all O per at or Saf e t y Mechanism be connected and in proper working condition prior t o use f or m owing. 6.1.7 Check f or loose hardware : Servic e Interval : Daily a) Stop eng ine, wait f or all m oving parts t o st op, and rem ove k ey. b) Visually inspect machine f or any loose hardware or any other[...]

  • Page 29

    - 24 - 6.1.11 Check tire pr essur es : Servic e Interval : 40 hr s. a) Stop eng ine, wait f or all m oving parts t o st op, and rem ove k ey. b) Inf late tir es t o pr essur es specif ied in Section 2. 8 ( Specificat ions) . c) See Section 8.1 f or f urt her infor m at ion. NOT E: Do not ad d any ty pe of tire liner o r foam fill mate rial to the t[...]

  • Page 30

    - 25 - LUBRICA TION CHART FI TTIN G L O C ATIONS INIT IA L PUMPS NO of PLA CES SERVICE INT ERV AL 1. Front Cast er W heel hubs w/o zerk *0 2 Year ly 2. Front Cast er Pivots *0 2 Year ly 3. Drive W heel Bearings 1 2 200 hours 4. Engine Deck Pivots 1 2 40 hours 5. Steering Column 1 1 40 hours 6. Idler Pivots , Mower Deck 1 2 Year ly 7. Rear Steer ing[...]

  • Page 31

    - 26 - i) Insert t he assem bled nut and axle into the wheel on the side of t he wheel with the new seal and bearing. h) W ith the open end of the wheel facing up, fill t he area inside the wheel around the axle f ull of NGLI g rade #1 mult i- purpose gr ease. i) Insert t he second bear ing and new seal into the wheel. j) Apply a thread locking adh[...]

  • Page 32

    - 27 - Turn f ilter clock wise until rubber seal contact s t he f ilter adapt er, and then tig ht en t he filt er an additional 2/3 t o 3/4 tur n. Use only Exmark (Part No. 1- 513211) or Eaton (Part No. 103144) f ilt er element s. d) Start eng ine and run several minutes. g) Check hydraulic oil level as outlined in 6.1. 10. 6.1.20.2 Chang e hydraul[...]

  • Page 33

    - 28 - 6.2 A DJUSTMENTS IMPORTA NT: Disengage PTO, shut off engine, w ait for al l moving parts to stop, and remove key before servici ng, cl eani ng or maki ng any adjustments to the unit. 6.2.1 Cutting heig ht and anti- scalp r oller adj ustment . CA UTION POTENT IAL HAZARD ♦ W hen m ower deck is not installed or t he two front support rod hair[...]

  • Page 34

    - 29 - c) Adjust ant i- scalp r ollers f or Norm al O per ating Condit ions. Place rollers in one of t he posit ions shown in Figure 9. Roller s will mainta in 3/ 4 in. (19 mm) clearance to the g round to m inim ize goug ing and roller wear or dam ag e. For Maximum Deck Flot at i on, place r oller s one hole position lower. Rollers should maintain [...]

  • Page 35

    - 30 - WA RNING POTENT IAL HAZARD ♦ Engine must be r unning and drive wheels must be turning so m ot ion cont r ol adj ustment can be perf ormed. W HAT CAN HAPPEN ♦ Contact with moving parts or hot surf aces m ay cause personal injury. HOW TO AVOI D T HE HAZARD ♦ Keep fing er s, hands, and clothing clear of r ot at ing components and hot surf[...]

  • Page 36

    - 31 - FIGURE 10 NEUT RAL CENTERING DEVICE A DJUSTMENT 6.2.6 Parking Brak e Q uadr ant Adjustm ent a) Stop engine, wait for all m oving parts t o st op, and rem ove k ey. b) Loosen the two 5/16 x 18 screws (a), that clam p t he br ak e quadr ant t o t he engine deck . c) Pull parking br ake lever towards the oper at or to t he br ak e “on” posi[...]

  • Page 37

    - 32 - b) Remove inlet screen and f an. c) Engag e par k ing brak e. Loosen the j am nuts securing the two 5/16 x 1-1/2” carriage bolt s t o t he hydro control arm . Be sur e the hydro control ar m is in the neutral posit ion as out lined in the previous adjust m ent ( 6.2.5) and t he parking br ak e is adjust ed as per pr evious adjust m ent ( 6[...]

  • Page 38

    - 33 - FIGURE 14 MOTIO N CO NTROL LINKA GE A DJUSTMENT 6.2.11 Seat Switch Adjustment a) Stop engine, wait for all m oving parts t o st op, and rem ove k ey. b) W ith operator out of seat, adj ust the seat switch to pr ovide a 1/16” clearance between the switch plunger and the seat fr am e ( See Figure 15) . c) To adj ust , loosen t he top nut sec[...]

  • Page 39

    - 34 - 6.2.13 Steering Chain Adj ust m ent a) Stop engine, wait f or all moving par ts to st op, and remove ke y. b) Position the steer ing handle bar so that it point s the unit st r aig ht f orward (the rear steer ing wheel should be in line wi th the rider m ain f ram e channel) . c) Check to see if t he chains ar e loose. d) To tak e up slack i[...]

  • Page 40

    - 35 - 7. WA STE DISPOSAL 7.1 MOTOR OIL DISPOSAL. Engine oil and hydraulic oil are both pollut ant s to the environm ent . Dispose of used oil at a certif ied recycling cent er or according t o your st at e and local regulat ions. 7.2 BA TTERY DISPOSAL DA NGER POTENT IAL HAZARD ♦ Battery electr olyte cont ains sulf uric acid, which is poisonous a[...]

  • Page 41

    - 36 - N O T E : Af ter car ef ully checking t he above steps, at t empt t o st ar t the engine. I f it does not start , cont act your authorized Exmark ser vice dealer. IMPORT A NT : It is essent ial t hat all O perator Saf ety Mechanisms be connected and in proper operat ing conditions prior t o t he use of the m ower. ENGINE TROUBLESHOOTING W he[...]

  • Page 42

    - 37 - 9. WIRING DIA GRAMS Engine Deck Wiring Di agram Note: All connectors ar e viewed from the wire input side of the connector. N.O. = Nor mally Open Console Wiring Di agram Note: All connectors ar e viewed from the wire input side of the connector. N.O. = Nor mally Open[...]

  • Page 43

    - 37 - 10. 2-Yea r Limited Wa rranty Exmark Turf Equipment (For units pur chased on or af ter Oc tober 1, 2004) Conditions and Products Covered Exmark M fg. Co. Inc. and its affiliate, Exmark W arranty Company, pursuant to an agreement betw een them, jointly warrant on the terms and conditions herein, that w e will repair, replace or adjust any par[...]

  • Page 44

    - 38 - NOTES[...]

  • Page 45

    - 38 - NOTES[...]

  • Page 46

    - 39 - SERVICE RECORD Date Description of W ork Done Serv ice Done By[...]

  • Page 47

    - 40 -[...]

  • Page 48

    SEE EXMA RK’S COMPLETE LINE OF A CCESSORIES RIDING A CCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT K IT MICRO-MULCH SY ST EM ROLL OVER PROTECT ION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONT AINER TURF ST RIPER ULTRA VAC COLLECT ION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WA LK BEHIND ACCESSORIES GRASS CATCH[...]