Exmark Turf ranger, Operator'S Manual

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Page 2: ... Long term exposure to vapors has caused cancer in laboratory animals WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness HOW TO AVOID THE HAZARD Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass c...

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: ...7 Hydrostatic Ground Drive System 9 10 2 8 Tires 10 2 9 Deck 10 2 10 Dimensions 11 3 ASSEMBLY INSTRUCTIONS 3 1 to 3 8 Assembly 11 16 4 CONTROLS 16 17 5 OPERATION INSTRUCTIONS 5 1 Pre Start 17 5 2 Mowing 17 18 5 3 Transporting 18 19 6 MAINTENANCE ADJUSTMENTS 6 1 Periodic Maintenance 19 27 6 2 Adjustments 27 33 7 WASTE DISPOSAL 7 1 Motor Oil Disposal 33 7 2 Battery Disposal 33 8 TROUBLE SHOOTING 8 1...

Page 6: ... 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 Keep in mind that the operator or user is responsibl...

Page 7: ...e and highly explosive WHAT CAN HAPPEN A fire or explosion from gasoline 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 rem...

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: ...TO AVOID THE HAZARD Do not operate the machine without guards shields and safety devices in place and working Keep hands feet hair jewelry or clothing away from rotating parts 1 4 1 Give complete undivided attention to the job at hand 1 4 2 Mow only in daylight or good artificial light keeping away from holes and hidden hazards NEVER carry passengers DO NOT operate the mower when children or other...

Page 10: ...the grass catcher 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 1 4 15 The fuel system is provided with a shut off valve The fuel shut off valve is used to shut off the fuel when a The machine will not be used for a few days b During transport to and from the job c When pa...

Page 11: ...ed 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 tightness 1 5 10 Keep all guards shields and all safety devices in place and in safe working condition 1 5 11 Frequently check for worn...

Page 12: ...lean dry surface Smooth to remove any air bubbles 1 6 6 Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower PART NO 1 513747 LOCATION Top Front of Battery Cover FMD524 FMD604 units only PART NO 103 2239 LOCATION Top of Mower Deck Beneath Center Shield PART NO 103 2432 LOCATION Left Side of Brake Lever P...

Page 13: ...of Mower Deck PART NO 1 543620 LOCATION On Intake Screen Below Fuel Tank PART NO 1 543896 LOCATION Under Engine Deck on Wood Blocks for Shipping PART NO 98 5954 LOCATION Under Belt Shields FMD523 FMD603 units only PART NO 1 613100 LOCATION Top of Mower Deck Beneath Center Shield STATIONARY IDLER POSITION TURF RANGER BELT ROUTING STATIONARY IDLER DECK DRIVE BELT TR 52 543749 TR 60 543523 TTH 52 60 ...

Page 14: ...erated by the right foot Provides forward and reverse speed control with little effort Motion control pedal and linkages are protected by the motion override device when the parking brake is engaged 2 5 3 Parking Brake Lever Engages park brake and locks drive system in neutral Neutral lockout system prevents accidental engagement of drive system when park brake is engaged and protects hydro transa...

Page 15: ...ht Adjusts in 1 2 1 3 cm increments from 1 1 2 3 8 cm to 4 1 2 11 5 cm 2 9 8 Deck Mounting Full floating deck is attached to out front support frame Removable for servicing Can be raised by one touch electro mechanical ball screw deck lift system for servicing and cleaning or to transfer weight to drive wheels which aides in climbing hills 2 10 DIMENSIONS 2 10 1 Overall Width without deck deflecto...

Page 16: ...ANT Make sure the negative battery cables are disconnected 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...

Page 17: ... a level surface and remove vent caps DANGER POTENTIAL HAZARD Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns WHAT CAN HAPPEN Swallowing electrolyte can be fatal or if it touches skin can cause severe burns HOW TO AVOID THE HAZARD Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do not swallow elect...

Page 18: ...washers and whizlock nuts from bolt bag in front two holes Install flat washers between seat frame and seat rails Mount seat to two rear bolts which have springs on them by removing the top whizlock nuts installing seat frame and replacing nuts Reinstall cushion to seat frame 3 4 Mount the rear tire and wheel assembly with a 5 8 11 x 10 1 2 bolt and torque nut Tighten torque nut just enough to cre...

Page 19: ...k nut to the outside for the two front bolt holes on each side of the mower deck support frame See Figure 1 Tighten until spring washers are flat FIGURE 1 HARDWARE AND SUPPORT PIN LOCATION FOR DECK SUPPORT FRAME For FMD524 and 604 units Secure using eight 8 3 8 16 x 1 1 4 bolts disc spring washers and whizlock nuts NOTE Place spring washer cone side against bolt head cupped side away from head and...

Page 20: ...ired Follow the instructions in the kit 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 FIGURE 3 IDLER PULLEY KIT AND LOCATION 3 7 7 Install mower d...

Page 21: ...as reached it s limit a ratcheting sound is heard When this ratcheting sound is heard release switch lever momentarily reverse switch to move actuator just off the fully extended or retracted position 4 4 PTO Engagement Located on right 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 O...

Page 22: ...ounter clockwise until caught under spring latch to release drive system Pull spring latch out far enough to allow lever to rotate 1 8 turn clockwise to engage drive system NOTE Do Not tow machine or transmission damage may result FIGURE 4 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...

Page 23: ...et throttle to midway position The switch must be pulled out to the ROTATE position to engage the blades Accelerate to full throttle to begin mowing 5 2 4 Stopping PTO Set throttle to idle position Push in on the switch to the Stop position to stop the blades 5 3 TRANSPORTING 5 3 1 Transporting a Unit Use a heavy duty trailer to transport the machine When the machine is on the trailer lower the cu...

Page 24: ... WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or other bystanders HOW TO AVOID THE HAZARD Remove the key from the ignition switch and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s WARNING POTENTIAL HAZARD The engine can become very hot WHAT CAN HAPPEN Touching a hot ...

Page 25: ...ing 6 1 3 Clean transmission cooling compartment Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Clean all debris from screens that encompass cooling compartment and then remove the compartment screen c Clean all debris from the fan blades and the cooling fins for the transmission d Replace the compartment screen 6 1 4 Clean grass build up under mower deck a...

Page 26: ...out from under the deck causing serious injury or property 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 i Remove jack stands or equivalent support and lower de...

Page 27: ...artment cover c Remove foam pre cleaner element and wash in warm water with detergent Rinse until all traces of detergent are eliminated and squeeze out excess water DO NOT wring Air dry Saturate with engine oil and squeeze out excess oil d Check paper element Gently tap the flat side of the paper element to dislodge any dirt DO NOT wash or use pressurized air to clean paper element Replace if dir...

Page 28: ...of sight gauge If not clean area around hydraulic reservoir cap remove cap and add oil as specified in Section 2 7 Specifications Replace cap WARNING POTENTIAL HAZARD Hydraulic fluid escaping under pressure can penetrate skin and cause injury WHAT CAN HAPPEN Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gang...

Page 29: ...ts 7 amps 30 Minutes 12 2 12 4 50 75 16 volts 7 amps 1 Hour 12 0 12 2 25 50 14 4 volts 4 amps 2 Hours 11 7 12 0 0 25 14 4 volts 4 amps 3 Hours 11 7 or less 0 14 4 volts 2 amps 6 Hours or More For Serial Nos 251 999 and Lower Check battery electrolyte level Service Interval 40 hrs a Stop engine and remove ignition key b Remove battery cover c Remove vent caps from battery If needed fill with water ...

Page 30: ...once a year Remove hex plug and cap Thread grease zerk in hole and pump with grease until it oozes out around top bearing Remove grease zerk and thread plug back in Place cap back on 6 1 14 Lubricate caster wheel hubs Service interval 40 hours for unit with grease zerks Once yearly for units without grease zerks a Identify which type of caster wheel is installed on the unit If there is a grease ze...

Page 31: ...el filter is installed in the fuel line between the fuel tank and the engine Replace with Kohler P N 2405002 when necessary 6 1 17 Lubrication of steering yoke pivot Service Interval Monthly a The steering yoke pivot is permanently sealed and should require no additional lubrication If there is evidence of seal leakage replace the seals or bearings and fill with SAE No 2 multi purpose grease or wh...

Page 32: ...nance required for servicing the engine 6 1 22 Wheel hub slotted nut torque specification a Tighten the slotted nut on the transaxle tapered shaft and torque to 100 ft lbs b After proper torque has been applied turn the nut until the next set of slots lines up with the cross hole in the shaft c Replace cotter pin NOTE Do not use anti seize compound on the wheel hub 6 1 23 Thread locking adhesives ...

Page 33: ...d in b to prevent damage to the rollers and or bolt failure See Figure 6 NOTE When anti scalp rollers are placed in these positions reduced deck flotation will result 6 2 2 Transmission drive belt tension adjustment No adjustment necessary 6 2 3 Mower deck drive belt No adjustment necessary 6 2 4 Blade drive belt tension No adjustment necessary 6 2 5 Neutral Centering Adjustment a The Neutral Cent...

Page 34: ... underside of the engine deck Loosen jam nut d from the ball joint which connects the override assembly f to the engine deck anchor mounting See Figure 6 e Start engine Operator must be in seat to crank engine Open to full throttle f Adjust neutral centering device length by rotating the neutral centering device barrel clockwise or counterclockwise until wheels stop turning or no longer creep Tigh...

Page 35: ...rake 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 d Adjust two 5 16 x 1 1 2 carriage bolts in the hydro control arm in or out until the head contacts the butterfly plate and then tighten...

Page 36: ... gap should measure 1 16 See Figure 11 c If adjustment is required remove clevis pin at foot pedal end and turn yoke in or out as required to obtain the 1 16 gap FIGURE 11 MOTION CONTROL LINKAGE ADJUSTMENT 6 2 11 Seat Switch Adjustment a Stop engine wait for all moving parts to stop and remove key b With operator out of seat adjust the seat switch to provide a 1 16 clearance between the switch plu...

Page 37: ...in the chains loosen the rear jam nuts connecting the eyebolts to cross link bars then equally tighten each forward jam nut until slack is taken up Retighten the forward jam nuts onto the links e If the unit tends to turn left when handle bar is positioned for straight forward travel adjust by shortening the right hand link threading jam nuts closer to eye end of the eyebolt and lengthening the le...

Page 38: ... can be fatal or if it touches skin can cause severe burns HOW TO AVOID THE HAZARD Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do not swallow electrolyte Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is being repl...

Page 39: ...art contact your authorized Exmark service dealer or distributor IMPORTANT It is essential that all Operator Safety Mechanisms be connected and in proper operating conditions prior to the use of the mower ENGINE TROUBLESHOOTING When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following tables list some common causes of ...

Page 40: ...ne 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 Normally Open ...

Page 41: ... expense of delivering the mower to the dealer for warranty work nor the expense of returning it back to the owner after repair or replacement Our responsibility in respect to claims is limited to making the required repairs or replacements and no claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower Proof of purchase may be required ...

Page 42: ...charges or travel charges vi loss or damage to person or property other than that covered by the terms of this warranty vii any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty or viii attorney s fees There are no representations or warranties which have been authorized and provided to the buyer of the turf equipment other than as set forth in thi...

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Page 44: ...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 2001 PART NO 103 1786 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 MFG CO INC ...