For Turf Ranger Serial Nos. 440,000 & Higher and FMD524 & FMD604 Serial Nos. 440,000 & Higher Part No.
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. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system) in place and in proper working condition. ♦ Stop engine and wait for all moving parts to stop. Remove spark plug wire(s) or remove key before adjusting, servicing, or performing maintenance.
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 request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus shipment of six (6) line items or less. 2.
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 OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
TABLE OF CONTENTS 1. SAFETY 1.1 1.2 1.3 1.4 1.5 1.6 PAGE Safety Alert Symbol...................................................................................... 1 Training ........................................................................................................ 1 Preparation ............................................................................................... 1-3 Operation ..................................................................................................
1.SAFETY 1.1 SAFETY ALERT SYMBOL 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 situations and will be followed by the word DANGER, WARNING, or CAUTION. DANGER: White lettering / Red background.
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. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison. WHAT CAN HAPPEN ♦ Carbon monoxide can kill you.
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 ♦ Purchase and store gasoline only in an approved container. ♦ Always place gasoline containers on the ground away from your vehicle before filling.
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.
DANGER 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 ♦ Mow up and down slopes. ♦ Do not mow slopes when grass is wet. ♦ Do not mow near drop-offs or near water. ♦ Do not mow slopes greater than 15 degrees. ♦ Reduce speed and use extreme caution on slopes.
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. 1.4.9 Disengage PTO before starting engine. 1.4.10 Start the engine carefully with feet well away from the blades. 1.4.
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.
1.6 SAFETY SIGNS 1.6.1 Keep all safety signs legible. Remove all grease, dirt, and debris from safety signs and instructional labels. 1.6.2 Safety signs must be replaced if they are missing or illegible. 1.6.3 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.
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 PART NO. 1-323540 LOCATION: Front of Mower Deck, Top Surface PART NO. 1-543896 LOCATION: Under Engine Deck on Wood Blocks for Shipping PART NO.
2. SPECIFICATIONS 2.1 MODEL NUMBER: TR23KC 2.2 ENGINE 2.2.1 Engine Specifications: See your engine owners 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 octane minimum. 2.3.3 Fuel Filter: Replaceable in-line 2.3.4 Fuel Shut-Off Valve: 1/4 turn 2.4 ELECTRICAL SYSTEM 2.4.1 Charging System: Flywheel alternator 2.4.
2.8 TIRES Type Size Quantity Tread Ply Rating Pressure Rear Drive Pneumatic 18 x 7.50-8 1 Turfsaver 4 14 psi (97 kPa) Pneumatic 20 x 10.00-8 2 Turfmate 4 20 psi (138 kPa) Front Caster (FMD Units) Pneumatic 11 x 4-5 2 Smooth 4 16 psi (110 kPa) 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: 2.9.
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.
(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. PART NO. 1-513747 LOCATION: Battery Cover 3.3 INSTALL SEAT: Remove seat cushion from seat frame. Remove seat frame from crate and discard mounting hardware.
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. Secure using eight (8) 3/8-16 x 1 1/4” bolts, disc spring washers, and whizlock nuts.
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). 3/8 WHIZLOCK NUT 3/8 HEX CAP SCREW 3.8.7 FIGURE 3 IDLER PULLEY KIT AND LOCATION Install mower deck drive belt. NOTE: Make sure to use proper belt for your deck.
4.3 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. When raising or lowering the deck and the actuator has reached it’s limit, a "ratcheting" sound is heard.
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 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. See Engine Owner's Manual. Note: Fuel tank may appear loose at set-up, however, once fuel is added, tank will slowly expand to fit tank straps. Do not add oil to gasoline.
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: DANGER POTENTIAL HAZARD ♦ The rotating blades under the mower deck are dangerous. WHAT CAN HAPPEN ♦ Blade contact can cause serious injury or kill you.
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°. After unit is loaded on the trailer lower the cutting deck and fully extend actuator for transport.
c) 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. d) If the oil level is low, add oil to bring the oil up to the “FULL” mark on the dipstick. Use oil as specified in Engine Owner’s Manual. Do Not overfill. IMPORTANT: Do not operate the engine with the oil level below the “LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark. 6.1.
c) Stop engine, wait for all moving parts to stop, and remove key. d) Block up using proper safety precautions. e) Clean out any grass build-up from underside of deck and in deck discharge chute. f) Inspect blades and sharpen or replace as required. g) If blade removal is necessary, be careful for the sharp cutting edges of the blades.
b) Check kill circuits: Run engine at one-third throttle with PTO and parking brake disengaged; lift yourself off the seat (but do not get off the machine) engine must stop after 1/2 second has elapsed. c) Run engine at one-third throttle with PTO and parking brake engaged; lift yourself off the seat (but do not get off the machine) engine must stop after 1/2 second has elapsed. NOTE: If machine does not pass any of these tests, Do Not operate. Contact your authorized EXMARK Servicing Dealer.
6.1.9 Check hydraulic oil level: Service Interval: 40 hrs. a) Make sure mower is on a level surface. b) Stop engine, wait for all moving parts to stop. c) Visually inspect the sight gauge on hydraulic tank. Oil level should be visible to top 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. 6.1.10 Check tire pressures: Service Interval: 40 hrs.
Note: Be sure to check idler on transmission drive belt. Disassemble, clean and grease pivot bushing if necessary. 6.1.13 Lubricate grease fittings. a) Stop engine, wait for all moving parts to stop, and remove key. b) Lubricate fittings with one to two pumps NGLI grade #2 multi-purpose gun grease. Refer to the following chart for fitting locations and lubrication schedule. LUBRICATION CHART FITTING LOCATIONS 1. Front Caster Wheel hubs w/o zerk 2. Front Caster Pivots 3. Drive Wheel Bearings 4.
h) i) h) i) 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. Do not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.
b) Carefully clean area around filter. It is important that no dirt or contamination enters the hydraulic system. c) Unscrew filter and remove. IMPORTANT: Before reinstalling new filter, fill it with Mobil 1 15W50 and apply a thin coat of oil on the surface of the rubber seal. 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.
6.1.25 Mobil HTS grease (or food-grade antisieze) is used in the following locations: a) Between the cutter housing spindle and bearings. b) Between the cutter housing spindle and sheave. c) Under top cutter housing bearing guard. 6.1.26 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact. 6.
LEFT HAND SIDE SHOWN FIGURE 6 CUTTING HEIGHT ADJUSTMENT FOR CUTTING HEIGHTS ABOVE 3.5” (8.89 CM) USE THE BOTTOM HOLE THE ROLLERS WILL STILL BE EFFECTIVE AGAINST SCALPING FIGURE 7 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 7. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize gouging and roller wear or damage.
6.2.5 Neutral Centering Adjustment a) The Neutral Centering Device adjustment should be made with the engine running at full throttle. First raise and securely block up the frame so that the drive wheels can rotate freely without contacting the ground. 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.
FIGURE 8 NEUTRAL CENTERING DEVICE ADJUSTMENT 6.2.6 Parking Brake Quadrant Adjustment a) Stop engine, wait for all moving parts to stop, and remove key. b) Loosen the two 5/16 x 18 screws (a), that clamp the brake quadrant to the engine deck. c) Pull parking brake lever towards the operator to the brake “on” position (b). d) 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 9).
b) Remove inlet screen and fan. c) 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). 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 jam nuts (See Figure 11).
FIGURE 12 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 plunger and the seat frame (See Figure 13). c) To adjust, loosen the top nut securing the seat switch to the seat rail weldment. Adjust the bottom nut until the 1/16” between plunger and seat frame has been obtained. Tighten the top nut.
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. d) To take up slack 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.
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 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.
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. 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 troubles.
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.
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 reasonable discretion) to be defective in factory materials or workmanship. This warranty applies to Exmark turf equipment sold in the US or Canada.
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SEE EXMARK’S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z® LAZER Z® HP LAZER Z® XP LAZER Z® CT 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 contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. ©1997 – 2003 EXMARK MFG. CO. INC.
