Exmark Turf Ranger FMD604, Operator'S 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: ...om eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES 0...

Page 3: ...bmitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 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 The following res...

Page 4: ...wer maintain its maximum efficiency and promote safe operation 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 st...

Page 5: ... 11 2 8 Tires 11 2 9 Deck 11 2 10 Dimensions 11 2 11 Torque Requirements 11 3 ASSEMBLY INSTRUCTIONS 3 1 to 3 12 Assembly 12 15 4 OPERATION INSTRUCTIONS 4 1 Controls 15 17 4 2 Pre Start 17 4 3 Operation Instructions 17 20 4 4 Transporting 21 5 MAINTENANCE ADJUSTMENTS 5 1 Periodic Maintenance 21 30 5 2 Adjustments 30 35 6 WASTE DISPOSAL 6 1 Motor Oil Disposal 36 6 2 Battery Disposal 36 7 TROUBLE SHO...

Page 6: ...perator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 1 2 4 Avoid mowing while people especially children or pets are nearby Ke...

Page 7: ...can burn you others and cause property damage HOW TO AVOID THE HAZARD DO NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only outdoors Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when t...

Page 8: ...e then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignited by electrical sparks ...

Page 9: ...stall and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without...

Page 10: ...ocks tree limbs etc from the mowing area Tall grass can hide obstacles Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control 1 4 5 Use EXTREME caution when backing up LOOK BEHIND YOU 1 4 6 Stop the blades when crossing surfaces other than grass if mower must be tilted for transportation and when transporting the mower to and fro...

Page 11: ...tive terminal post on the starter solenoid switch this post has the positive battery cable attached to it b Connect the negative or ground cable from the negative post on the booster battery to the engine block as far away from the battery as possible c Disconnect battery cables in the reverse order afterstarting 1 5 MAINTENANCE AND STORAGE 1 5 1 For engine maintenance follow the engine manufactur...

Page 12: ...ying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by locking drive levers in neutral and shutting off the engine before performing any work on the hydraulic system 1 6 RIDING ATTACHMENTS Use only Exmark rid...

Page 13: ...3 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 of Console PART NO 103 5354 LOCATION Console PART NO 1 303102 LOCATION Upper Handles ...

Page 14: ...eck Next to Muffler PART NO 1 553049 LOCATION On Top Front LH Surface of Mower Deck PART NO 1 323540 LOCATION Front of Mower Deck Top Surface PART NO 1 413214 LOCATION Right Side of Hydro Control Crank Arm PART NO 1 523552 LOCATION On Top of Hydraulic Tank PART NO 103 1077 LOCATION On Top Front RH Surface of Mower Deck PART NO 98 5954 LOCATION Under LH RH Center Belt Shields PART NO 103 2432 LOCAT...

Page 15: ...and PTO disengaged to start engine Release of OPC levers will cause the engine to stop if speed control lever is not in neutral and or PTO is engaged Park brake must be disengaged to move speed control out of neutral or engine will kill 2 5 STEERING CONTROL Fingertip drive control levers provide independent speed control braking and neutral to each drive wheel for moving forward or reverse stoppin...

Page 16: ... to 4 1 2 11 5 cm 2 9 9 Deck Mounting Full floating deck is attached to out front support frame removable for service 2 10 DIMENSIONS 2 10 1 Overall Width w 52 Deck w 60 Deck Discharge chute down 64 2 163 1 cm 72 2 183 4 cm Discharge chute up 53 4 135 6 cm 61 4 156 0 2 10 2 Overall Length w 52 Deck w 60 Deck w ECS Handles 83 4 211 8 cm 83 4 211 8 cm w Standard Pistol Grip Handles 82 2 208 8 cm 82 ...

Page 17: ...nnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart below for recommended charger settings Voltage Reading Percent Charge Maximum Charger Settings Charging Interval 12 6 or greater 100 16 volts 7 amps No Charging Required 12 4 12 6 75 100 16 volts 7 amps 30 Minutes 12 2 12 4 50 75 16 volts 7 amps 1 Hour ...

Page 18: ...ck support pins and by removing the two hairpins and spacers from the rear deck support pins See Figure 1 3 5 3 Install mower deck support frame to tractor engine deck and secure using 8 3 8 16 x 1 1 4 screws 8 disc spring washers and 8 whizlock nuts from bolt bag See Figure 1 NOTE Place spring washer cone side against bolt head cupped side away from head and install to outside of support frame as...

Page 19: ...d idler Position the belt into the V groove of the mower deck drive sheave Carefully release the spring loaded idler Install the center belt shield 3 5 7 Adjust cutting height of deck and anti scalp rollers See Adjustment Section 5 2 1 3 6 POSITION DISCHARGE CHUTE Loosen two 2 5 16 nyloc nuts attaching discharge chute Lower the discharge chute into position Retighten nyloc nuts until chute is snug...

Page 20: ...operator s position When the levers are released the OPC system senses that the operator has moved from the normal operating position and will kill the engine if either the speed control lever is not in the neutral position or the PTO is engaged 4 1 2 Drive Levers Located on each side of the upper handle assembly directly below the handle grips See Figure 3 These levers individually control the sp...

Page 21: ...trol out of neutral or engine will kill 4 1 8 Ignition Switch Located on the control console The ignition switch is used to start and stop the engine The ignition switch has three positions Off On and Start Insert key into switch and rotate clockwise to the On position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Operator mus...

Page 22: ...and cylinder head will require more frequent service See Engine Owner s Manual Do not add oil to gasoline Do Not overfill fuel tank Never fill the fuel tank so that the fuel level rises above a level that is 1 2 below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage 4 2 2 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary inspection an...

Page 23: ...D 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 HOW TO AVOID THE HAZARD Be sure the pins protruding through the slots of each neutral lock latch are completely engaged in the rear slot of ...

Page 24: ... carefully release the drive levers See Figure 5 c To place the drive levers in the reverse position squeeze the drive levers past the neutral position See Figure 5 d FIGURE 5 DRIVE LEVER NEUTRAL LOCK LATCH OPERATION 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 po...

Page 25: ... HOW TO AVOID THE HAZARD DO NOT put hands or feet under the mower or mower deck when the PTO is engaged DANGER POTENTIAL HAZARD An uncovered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blade could occur WHAT CAN HAPPEN Thrown objects or blade contact can cause serious injury or death HOW TO AVOID THE HAZARD Never operate the mow...

Page 26: ...opes Do not rely solely on the parking brake to hold the machine on the trailer Be sure that the trailer has all necessary lighting and marking as required by law and use a safety chain 5 MAINTENANCE ADJUSTMENTS WARNING POTENTIAL HAZARD While maintenance or adjustments are being made someone could start the engine WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or othe...

Page 27: ...Excessive debris around the engine cooling air intake and around the hydraulic pumps can create a fire hazard HOW TO AVOID THE HAZARD Clean all debris from around the engine and hydraulic pumps daily a Stop engine wait for all moving parts to stop and remove key b Clean all debris from engine air intake screen around engine shrouding and around the hydraulic pumps 5 1 3 Clean grass build up under ...

Page 28: ...damage 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 Torque the blade bolt to 115 120 ft lbs 156 163 N m h Remove jack stands or equivalent support and lower deck to ground FIGURE 6 BLADE BOLT INSTALLATION 5...

Page 29: ...er c Remove paper element Check the condition of the inner element Replace if dirty bent or damaged d Check the condition of the inner element Replace whenever it appears dirty typically every other time the paper element is replaced Clean the base around the inner element before removing so dirt does not get into the engine e DO NOT wash or use pressurized air to clean paper element or inner elem...

Page 30: ...25 14 4 volts 4 amps 3 Hours 11 7 or less 0 14 4 volts 2 amps 6 Hours or More 5 1 9 Check hydraulic oil level Service Interval 40 hr a Stop engine and wait for all moving parts to stop b Clean area around hydraulic reservoir cap and remove cap c Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 15W 50 synthetic motor oil Replace hydraulic reservoir...

Page 31: ...ined when changing filter unless it is felt that oil has been contaminated Changing oil unnecessarily could damage the hydraulic system by introducing contaminates into the system 5 1 11 Hydraulic system air purge procedure Air must be purged from the hydraulic system when any hydraulic components including oil filter are removed or any of the hydraulic lines are disconnected The critical area for...

Page 32: ...ated in Section 5 2 5 5 1 12 Check tire pressures Service Interval 40 hrs a Stop engine wait for all moving parts to stop and remove key Check air pressure in tires recommended tire pressure is rear 12 14 psi front casters 15 17 psi b Inflate tires to pressures stated above Measure circumference of each drive tire Adjust tire pressures within the above range to try to make tire circumferences matc...

Page 33: ...assembly e Pry out seals and inspect bearings for wear or damage and replace if necessary f Pack the bearings with a NGLI grade 1 multi purpose grease g Insert 1 bearing 1 new seal into the wheel NOTE Seals Exmark PN 103 0063 must be replaced h 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 wre...

Page 34: ...ud cleanout covers or cooling shrouds will cause engine damage due to overheating 5 1 18 Change fuel filter Service Interval As Required a A fuel filter is installed in the fuel line between the fuel tank and the engine Replace when necessary For Kohler engines use Kohler P N 2405002 For Kawasaki engines use Kawasaki P N 49019 7001 5 1 19 Wheel hub slotted nut torque specification When tightening ...

Page 35: ...ot 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 rise suddenly WHAT CAN HAPPEN If the unit rises suddenly injury may occur HOW TO AVOID THE HAZARD Securely hold down the front end of the unit when the mower deck is not installed or front support rod hairpins are re...

Page 36: ... roller bolts and nuts are installed with the spring disc washer between head of the bolt and mounting bracket Torque to 40 45 ft lbs 54 61 N m or loss of roller may result d When operating in extremely rough conditions it may be necessary to position the anti scalp rollers one or two holes higher than described in c to prevent damage to the rollers and or bolt failure See Figure 10 NOTE When anti...

Page 37: ...ove the switch fore and aft FIGURE 11 NEUTRAL SAFETY SWITCH ADJUSTMENT b 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 position as shown in Figures 4 5 and move the speed control leve...

Page 38: ...control lever in the neutral position This adjustment is again made with rear of machine on jack stands and engine running at full throttle OPC levers will have to be held down whenever speed control lever is moved out of neutral position Note The neutral lock latches should still be unlocked and in the forward position 2 Loosen the front nut on left hydro control link as shown in Figure 13 Turn t...

Page 39: ...ive lever upward until it reaches the neutral position and engage neutral lock latches See Figure 14 If the tire rotates in either direction the length of the drive lever linkage will need to be adjusted 2 For Standard Pistol Grip Handles Adjust the linkage length by releasing the drive lever and removing clevis pin and rotating the linkage in the lower swivel Lengthen the linkage if the tire is t...

Page 40: ...e left and right hand sides Note In medium or heavy duty positions the drive lever forces at the upper handle will also be increased FIGURE 15 HYDRO PUMP SPRING TENSION SETTING 5 2 7 Throttle Control Adjustment a Loosen cable clamp on engine and position throttle control at the control console within 1 4 6 mm from the upper end of the slot Pull on cable assembly at lower end where it attaches to t...

Page 41: ...the drive tire pressures and tire circumferences See 5 1 12 b Turn knob on the right hydro control linkage in the direction that the mower needs to be adjusted to Turn the knob in 1 4 turn increments until the mower tracks correctly 7 2 MOWER CUTS UNEVENLY a Check the drive tire pressures and tire circumferences See 5 1 12 A more uniform cutting height may be obtained with higher tire pressure on ...

Page 42: ... do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following tables list some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing or adjustment procedures such as valves governor etc Have this work done by your Engine Service Dealer ENGINE TROUBLESHOOTING TABLE PROBLEM NO ...

Page 43: ... 38 8 HYDRAULIC SCHEMATIC ...

Page 44: ... 39 9 WIRING DIAGRAMS ...

Page 45: ...purchase sales receipt to the Exmark Service Dealer If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be retu...

Page 46: ... 41 SERVICE RECORD Date Description of Work Done Service Done By ...

Page 47: ...L O P E T H IS IS A 1 0 S L O P E TH IS IS A 5 S L O P E ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC EXAMPLE COMPARE SLOPE WITH FOLDED EDGE FOLD ALONG APPROPRIATE LINE T H I S I S A 2 0 S L O P E ...

Page 48: ...VAC ULTRA VAC QDS GRASS CATCHER SELF STEERING SULKY MICRO MULCH ACCESSORY WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1997 2003 PART NO 103 4869 EXMARK MFG CO INC 402 223 6300 INDUSTRIAL PARK BOX 808 FAX 402 223 5489 BEATRICE NE 68310 ALL RIGHTS RESERVED PRINTED IN U S A ...