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Exmark FMD524 User's Manual

Contents

1. NI N3aD HAUT 5 annoy 714153 2 eim Q 9 8 Gg 588 5 2 uds BN TI ama 50 127011 T 9 18 311 t YA A A388 m OMG 131A 303080 Fal E ad EN 033 B Id 2 XN 18 31 LHM aw i ANW 22v 8 3LIHN7Y 18 29 IE MT QISSTWSNVAL 218 3 IB 31 IHM NOVA SONYA AIO I831NI JAS HM 095019 2118 NANOS H DR HJLIMS H GS9VONA SAAFI 290 095070 SI HOLIMS JILIN aH HILIMS AJA 3BIM SA0LIANNOJ SALON A389 01 S9NVAO 1TD HOLIMS OL NADSB NI HOLTMS AN do 1815 1 8 W 9 71 LINJAL 111509 S TWNIWAAL TWNIWaSL 1 WNIWS31 8 WNIWASL TIDY 3NISN3 IWNIWASL IS 431815 S ASSLLV 8 D NNIWS3L 1 1 ALIJAS 3NI9N3
2. PAGE TT Safety Alert 5 1 12 antes 1 Nt 1 3 i xeu 4 6 1 5 Maintenance 8 Fr dae s be Sp 6 7 1 6 Riding Attachments coner ped 7 de a MA go ee 7 9 2 SPECIFICATIONS 2 1 Model NUMBER so nes cede RM EE eae ee 10 2 2 eo ae 10 223 SUC SY SECM EA 10 27 MI 10 2 5 Steering Brake Gonlrol peor oo Rica aes cana ncaa Rosacea 10 ZEB CUm 10 2er Wheel Drive 58161151 1 10 2 STI eS oo esti qtti ade ted aus 11 0 M 14 ax UBI uri me 11 2 11 Torque 11 3 ASSEMBLY INSTRUCTIONS 3 110 3 12 Assembly poet pan pt reu pa 12 15 4 OPERATION INSTRUCTIONS 6 detent eck ette ees bonnes eret patei ent
3. HYDRAULIC OIL USE ONLY MOBIL 1 SAE 15W 50 SYNTHETIC ENGINE OIL FILL TO TOP OF BAFFLE HOT SURFACE PART NO 1 523552 LOCATION On Top of Hydraulic Tank 2 SPECIFICATIONS 2 1 MODEL NUMBER 23 TT23KAC 20 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 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 Charging Capacity 15 amp 2 4 3 Battery Type BCI Group U1 235 amps at O 2 4 4 Battery Voltage 12 Volt Polarity negative ground 2 4 5 Fuses blade type 20 amp to charging circuit 20 amp to electric clutch 2 4 6 Safety Interlock System Operator must have OPC Operator Presence Control levers held in contact with handle grips speed control lever in neutral and PTO disengaged to start engine Release of OPC levers will cause the engine to stop if soeed 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 mo
4. Change hydraulic system filter Service Interval After First 250 hrs then yearly thereafter Note Use only Exmark P N 1 513211 for Summer use above 32 F 0 C or P N 1 523541 for Winter use below 32 F 0 C Refer to Section 2 6 2 for filter specifications a Place unit on a level surface Stop engine wait for all moving parts to stop and remove key b Carefully clean area around filter It is important that no dirt or contamination enters the hydraulic system c Unscrew filter to remove and allow oil to drain from reservoir IMPORTANT Before re installing new filter fill it completely with Mobil 1 15W 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 10 Loosen filter 1 2 turn and allow a small amount of oil to leak from the oil filter this allows air to be purged from the oil filter and supply hose from the hydraulic reservoir Turn filter clockwise until rubber seal contacts the filter adapter Then tighten the filter an additional 2 3 to 3 4 turn 25 5 1 12 f Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground Run machine to allow any other air to be purged from the hydraulic system and recheck the oil level g If either drive wheel does not rotate one both of the charge pumps located
5. CUTTING HEIGHT ADJUSTMENT 1 5 38 CUTTING 2 0 51 HEIGHT 2 5 64 3 0 76 INCHES mm DECK 3 5 90 4 0 102 SUPPORT PIN 480114 FOR MAXIMUM FLOTATION ROLLERS MAY BE POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM OF 1 4 6 4 mm GROUND CLEARANCE NEVER POSITION THE ROLLERS TO SUPPORT MOWER DECK PART NO 1 553049 LOCATION On Top Front LH Surface of Mower Deck 1 553049 J BELT ROUTING 103 2239 DECK DRIVE BELT TR 52 1 543749 TR 60 4 1 543523 TTH 52 amp 60 1 603306 TURF RANGER ONLY BLADE DRIVE BELT 52 103 2329 60 4 1 633173 STATIONARY IDLER STATIONARY IDLER STATIONARY IDLER POSITION TURF POSITION TURF TRACER HYDRO RANGER PART NO 103 2239 LOCATION Top of Mower Deck Beneath Center Shield CAUTION Loose or Damaged Blade Bolt may allow blade to come out from under deck at HIGH SPEED Replace Blade Bolt after striking a foreign object Torque Blade Bolt to 115 120 FT LBS 156 163N SEE OPERATOR S MANUAL 109 077 For FMD524 amp FMD604 Units with SN 410 000 439 999 PART NO 103 1077 LOCATION Front RH Side of Mower Deck am PART NO 103 2432 LOCATION Parking Brake Lever DRIVE WHEEL RELEASE Use 5 8 wrench One turn counterclockwise to release Do not over tighten Ke 103 4935 PART NO 103 4935 LOCATION Left Rear Top Corner of Engine Deck
6. WHAT CAN HAPPEN lf the drive levers slip into the drive position the unit could lurch forward and cause injury or property damage HOW TO AVOID THE HAZARD sure the drive levers are past the roller and securely seated at the bottom of the neutral lock latches To place the drive levers in the forward position slightly squeeze the drive levers while placing thumbs on the outer thumb lobe of the neutral lock latches or the index finger on the front lobe and rotate them from under the drive levers Slowly and carefully release the drive levers See Figure 4 c To place the drive levers in the reverse position squeeze the drive levers past the neutral position See Figure 4 0 IN NEUTRAL LOCKED IN NEUTRAL d DRIVE LEVER DRIVE LEVER IN FORWARD REVERSE FIGURE 4 DRIVE LEVER NEUTRAL LOCK LATCH OPERATION 18 4 3 4 4 3 5 4 3 6 4 3 7 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 position and rotate both neutral lock latches from the neutral lock position to the forward position DO NOT squeeze both drive levers all the way back this will cause the drive wheels to engage in the reverse direction For straight ahead motion Smoothly release both drive levers to engage drive wheels For turning Squeez
7. 15 17 ZR Bd he uu LC 17 4 3 Operation Instructions user gie pe eun en ha ix ne ee 17 19 44 Transporting engi he 20 5 MAINTENANCE amp ADJUSTMENTS 5 1 Periodic 20 29 5 2 FAC ot 30 35 6 WASTE DISPOSAL 671 Motor Or Dis pOS all iie a en oeae ae Le onde te duae updates 35 6 2 Battery Disposal cii cote t e des Lt tet unen eee t aene ecd etus 35 7 TROUBLE SHOOTING 7 1 Mower Tracks Left or ERR d nh RS Et ond 35 7 2 Mower Cuts aoc dee o ex tere 36 7 3 Engine Will Not Start nece enne tea 36 37 8 HYDRAULIC 5 38 9 WIRING DIAGRAM s oni trat a d abt a ma ied 39 10 WARRANTY nds ut dee pet drea pues utem ped tat 40 1 SAFETY 1 1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL A 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 W
8. Shut off engine and remove key before engine are stopped adjusting servicing or cleaning Use extreme caution when operating on slopes Do NOT operate on slopes greater than 20 Mow across slope NOT up and down A CAUTION Do NOT mow wet slopes 5 Hearing protection recommended PART NO 103 1541 LOCATION Console STOP ENGINE BEFORE REACHING UNDERNEATH 1 303517 p OPEN BELT DRIVE PART NO 1 303517 LOCATION LH Side of Rear Surface of Engine Deck 55 60 ft lbs 75 81 Torque Blade Bolts to 103 7491 For FMD524 amp FMD604 Units with SN 540 000 amp Higher PART NO 103 7491 LOCATION On Top Front RH Surface of Mower Deck WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 ACAUTION MUFFLER AND SHIELDS MAY EXCEED 150 F 1 513746 PART NO 1 303508 LOCATION On Top RH Surface of Mower Deck A DANGER COVER IS MISSING DO NOT OPERATE 98 5954 THIS UNIT WHEN COVER IS NOT IN PLACE PART NO 98 5954 LOCATION Under LH RH amp Center Belt Shields PART NO 1 513746 LOCATION Surface of Engine Deck Next to Muffler Console ENHANCED CONTROL SYSTEM PART NO 103 2243 LOCATION RH Side of Console ITEM 1 ROLLER 2 BUSHING 3 SPRING WASHER 774 38 16 X 4 BOLT 5 MOUNT BRACKET 6 FLAT
9. JILIN SNUTIO3NNUJ ANNIWSL HJLINS 39 10 2 Year Limited Warranty Exmark Turf Equipment For units purchased on or after October 1 2004 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 for a period of two years This warranty applies to Exmark turf equipment purchased on or after October 1 2004 sold in the US or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Products Warranty Period e All Products except as noted below 2 years e All Attachments and Accessories 1 year e Metro 21 Series 1 year e Belts and Tires 90 days 1 Year Prorated Warranty is covered by engine manufacturer e Battery e Engine Please refer to the engine manufacturer s warranty statement that is included in the literature packet We are not authorized to handle warranty adjustments on engines This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following e
10. SNOW BLADE SUN SHADE TRASH CONTAINER TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER Check us out on the Web www exmark com 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 2005 EXMARK MFG CO INC PART NO 103 9190 INDUSTRIAL PARK BOX 808 402 223 6300 BEATRICE NE 68310 ALL RIGHTS RESERVED PRINTED IN U S A FAX 402 223 5489 AIK MFG CO INC
11. Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Service air cleaner Service Interval 50 hrs more oflen under severe conditions See Engine manual for additional information a Stop engine wait for all moving parts to stop and remove key b Loosenretaining clips and remove air cleaner compartment cover 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 element f Reinstall elements Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips Change engine oil Service Interval See Engine Owner s Manual NOTE Change oil after first five 5 hours of operation Follow engine manufacturers recommendations for future oil changes a Stop engine wait for all moving parts to stop and remove key b Drain oil while engine is warm from operation C Oil drain valve is located on the right hand side of Kohler engines and the left hand side for Kawasaki e
12. Stop engine and wait for all moving parts to stop b Install hairpin clips in the holes for the desired cutting height See Figure 9 IMPORTANT To maintain correct cutting height and rake check the following for proper adjustment 1 The front and rear hairpins are in the same holes with the proper spacers under the hair pins See Figure 8 2 The tire pressures are set as directed in Section 5 1 13 3 The length of the rear deck support link assemblies should average 6 89 approximately 6 7 8 17 5 cm from the center of the balljoint to the center of the farthest hole See Figure 9 NOTE All 4 pins must equally support the weight of the deck Adjustment in the length of the rear deck support assemblies may be necessary If one side is longer than 6 89 17 5 cm than the opposite side must be shorter by the same amount 250 4 _ LEFT HAND SIDE SHOWN FIGURE 9 CUTTING HEIGHT ADJUSTMENT 30 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 wear or damage For Maximum Deck Flotation place rollers one hole position lower Rollers should maintain 1 4 in 6 4 mm clearance to ground Do Not adjust rollers to support the deck Be sure roller bolts and nuts are installed with the spring disc washer between head of the bolt and mounting
13. 13 HYDRO CONTROL LINKAGE SWIVEL ADJUSTMENT After adjusting the left hydro control linkage move the speed control lever to the mid speed position and then back to the neutral position 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 necessary Place the speed control lever in neutral Adjust the right side linkage by turning the quick track knob counter clockwise until the tire begins to rotate forward Begin to retighten the knob clockwise about 1 4 turn at a time stopping to move the speed control forward and back to neutral Recheck the drive wheel rotation to see if further adjustment is necessary The spring that keeps tension on the knob should normally not need adjustment However if adjustment is needed adjust to where length of spring is about 1 2 5 cm between washers Adjust spring length by turning nut at front of spring d Drive Lever Linkage Adjustment 1 With rear of machine still on jack stands and engine running at full throttle move the speed control lever to the midway position Move the respective drive lever upward until it reaches the neutral position and engage neutral lock latches See Figure 14 If the tire rotates in eithe
14. 4 2 3 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 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 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary inspection and maintenance steps Make sure you understand the controls their locations their functions and their safety requirements 4 3 OPERATING INSTRUCTIONS 4 3 1 Starting Engine Open fuel valve Operator must have Operator Presence Control OPC levers depressed the PTO disengaged and speed control lever in neutral On a cold engine place the throttle midway between the Slow and Fast positions and place the choke in the position On a warm engine place the throttle lever midway between Slow and Fast positions and leave the choke in the Off position Turn ignition switch to Start position Release the switch as soon as the engine starts On a cold engine gradually return choke to the position after engine starts and warms up IMPORTANT Do not crank the engine continuously for more than ten
15. 7 amps or less to avoid damaging the battery see chart below for recommended charger settings Voltage Percent Maximum internal Reading Charge Charger Settings ging 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 12 0 12 2 25 5096 14 4 volts 4 amps 2 Hours 11 7 12 0 0 2596 14 4 volts 4 amps 3 Hours 11 7 or less 096 14 4 volts 2 amps 6 Hours or More CAUTION POTENTIAL HAZARD Ifthe ignition is in the ON position there is potential for sparks and engagement of components WHAT CAN HAPPEN Sparks could cause an explosion or moving parts could accidentally engage causing personal injury HOW TO AVOID THE HAZARD Besure ignition switch is in the OFF position before charging the battery 3 2 3 Connect the negative battery cables 12 3 4 DRIVE WHEELS 3 4 1 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 to 30 minutes to sufficiently charge the battery A WARNING a BATTERY CONTAINS SULFURIC ACID AVOID CONTACT OR USE BOOS
16. Drive Electric clutch mounted on engine shaft Blades driven by two belts with self tensioning idlers 2 9 7 Adjustable anti scalp rollers 6 ea 2 9 8 Cutting Height Adjusts in 1 2 1 3 cm increments from 1 1 2 3 8 cm 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 Length w 52 Deck w 60 Deck 83 4 211 8 cm 83 4 211 8 cm 2 10 3 Curb Weight w 52 Deck w 60 Deck 720 Ibs 327 kg 760 Ibs 345 kg Weights will vary slightly depending on engine and handle option 2 10 4 Overall Height 45 114 3 cm 2 10 5 Width to outside of tires 45 8 116 3 cm 2 11 TORQUE REQUIREMENTS BOLT LOCATION TORQUE Cutter Housing Spindle Nut secured with threadlocker 140 145 ft lbs 190 197 N m Blade Mounting Bolt EE oerte nd 55 60 ft Ibs 75 81 N m Mower Deck Support Engine Deck Mount 30 35 ft Ibs 41 47 N m Anti Scalp Roller See Figure 9 Type A Whizlock 440 224 2 2 40 45 ft lbs 54 61 N m Type B Hex 50 55 ft lbs 68 75 N m Type eerte 30 35
17. Located on the control console s right side The throttle is used to control engine speed Moving the throttle control forward will increase engine speed and moving it to the rear will decrease engine speed Speed Control Lever Located in middle of control console it controls the maximum forward speed and is infinitely variable from neutral 0 mph to 6 75 mph Park brake must be disengaged to move speed control out of neutral or engine will kill 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 position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Operator must have speed control lever in neutral OPC levers depressed and PTO disengaged to start engine When engine starts release key Hour Meter Located on the left hand side of console just above the PTO switch The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run If ignition switch is left on without engine running hour meter will not run NOTE This switch is not a low oil sensor and will not alert the operator if the engine oil is low Fuel Shut Off Valve Installed in the fuel line midway between the tank and engine The fuel shut off
18. NGLI grade 1 multi purpose grease i Insert the second bearing and new seal into the wheel j Apply a thread locking adhesive to the 274 spacer nut and thread onto the axle with the wrench flats facing outward k Torque the nut to 75 80 8 9 N m loosen then re torque to 20 25 in lbs 2 3 N m Make sure axle does not extend beyond either nut Re install the seal 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 freely adjust torque on spacer nut until there is a slight amount of drag Re apply threadlocking adhesive 5 1 17 Check spark plugs Service Interval 160 hrs a Remove spark plugs check condition and adjust plug gap or replace with new plugs See Engine Owner s Manual 5 1 18 Remove engine shrouds and clean cooling fins Service Interval 80 hrs a Stop engine wait for all moving parts to stop and remove key 28 5 1 19 5 1 20 5 1 21 5 1 22 5 1 23 Remove cooling shroud cleanout covers Kohler or cooling shrouds Kawasaki from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause improper cooling c sure cooling shroud cleanout covers or cool
19. Pickup and delivery charges to and from any authorized Exmark Service Dealer e Any damage or deterioration due to normal use wear and tear or exposure e Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments e Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance e repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service 1 Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S Customers may also call 402 223 6375 2 Bring the product and your proof of 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 serviceQexmark com 40 Owner s Responsibilities The Exmark turf equipment
20. The PTO switch engages the cutting blades Be sure that all persons are clear of mower deck and discharge area before engaging the PTO Set 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 PTO Disengagement Push in on the switch to the Stop position to stop the blades 19 4 4 TRANSPORTING A 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 HOW TO AVOID THE HAZARD Use proper ramps that are secured to the truck trailer Keep feet and legs out from under the unit when loading and unloading If necessary use assistance when loading Be sure the fuel shut off valve is closed Use a heavy duty trailer to transport the machine Engage neutral lock latches and park brake then block wheels Securely fasten the machine to the trailer with straps chains cables or ropes 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 amp ADJUSTMENTS A WARNING POTENTIAL HAZARD While maintenance or adjustments are being made someone could start the engine WHA
21. WASHER 7 WHIZLOCK NUT 587 MUST BE GRADE 8 BOLT AND WASHERS MUST 9 BE INSTALLED AS SHOWN IN DIAGRAM TORQUE NUT eee 9 TO 35 45 FT LBS Type A Anti Scalp Rollers Only See Figure 9 PART NO 1 323540 LOCATION Front of Mower Deck Top Surface KEEP HANDS and FEET AWAY PART NO 1 403005 LOCATION LH amp RH Front Top Surface of Mower Deck Use Only Exmark Riding Attachments Use of Other Riding Attachments May Create a Hazardous Condition Resulting in Injury 1 403143 E 7 ENGAGE PART NO 1 403143 P LOCATION RH Rear Surface of Engine Deck PARK BRAKE 2 WARNING ee BATTERY CONTAINS SULFURIC ACID AVOID CONTACT OR USE BOOSTER CABLES OR ADJUST POST CONNECT AND ALWAYS SHIELD EYES FACE SKIN AND CLOTHING IONS WITHOUT PROPER TRAINING IN EVENT OF AN FROM BATTERY CIGARETTES FLAMES OR SPARKS ACCIDENT FLUSH WITH WATER AND CALL A PHYSICIAN RELEASE COULD CAUSE BATTERY TO EXPLODE DO NOT CHARGE IMMEDIATELY KEEP OUT OF REACH OF CHILDREN PART NO 1 413214 LOCATION Right Side of Hydro Control Crank Arm PART NO 1 513747 LOCATION Top Rear of Battery Cover p A WARNING DISENGAGE BLADE CLUTCH SHUT OFF ENGINE AND REMOVE KEY BEFORE MAKING ADJUSTMENTS SERVICING OR CLEANING DECK ANTI SCALP ROLLER ADJUSTMENT FOR NORMAL OPERATING CONDITIONS PLACE ROLLERS IN POSITIONS SHOWN FOR 3 4 19 mm GROUND CLEARANCE CUTTING HEIGHT INCHES mm 2 0 51
22. bracket Two types of anti scalp roller assemblies are available See Figure 10 to determine which assembly has been installed on the unit Torque hardware as specified or loss of roller may result Type Torque the 3 8 whizlock nut to 40 45 ft lbs 54 61 Type B Torque the 3 8 nyloc nut to 30 35 ft lbs 41 47 N m Torque the 3 8 24x2 Gr 8 hex capscrew to 50 55 ft lbs 68 75 N m G0270 TYPE TYPEB ANTI SCALP ROLLER j MOUNTING BRACKET CUTTING HEIGHT SPRING DISC WASHER Y mm CONE TOWARDS BOLT HEAD iP 1 5 38 ae FRONT LEFT ANTI SCALP RR CUTTING HEIGHT 2061 Neng BRACKET SHOWN INCHES mm UNS Ik 2 5 64 PEE 2 0 51 TYPE 38 24 x 2 y O hs Eisen 1 i 0 ies 3 0 76 3 5 90 4 0 102 O 3 5 90 45 114 TORQUE 50 55 08 68 75 FOR CUTTING HEIGHTS ABOVE 3 5 38 mm 7 TYPE A 3 8 WHIZLOCK TORQUE TO 40 45 fHbs 54 61 Nm USE THE BOTTOM HOLE THE ROLLERS WILL DECK SUPPORTPIN TYPE 3 8 NYLOC TORQUE 30 35 ft bs 41 47 N m STILL BE EFFECTIVE AGAINST SCALPING ANTI SCALP ROLLER ANTI SCALP ROLLER CUTTING HEIGHT INSTALLATION ADJUSTMENT ADJUSTMENT FIGURE 10 5 2 2 5 2 3 5 2 4 5 2 5 ANTI SCALP ROLLER INSTALLATION AND CUTTING HEIGHT ADJUSTMENT d When operating in extremely rough conditions it may be necessary to position the anti scalp rollers on
23. ft lbs 41 47 N m Engine Mounting Bolts o P 15 20 ft lbs 20 27 Wheel Lug 28 tue 90 95 ft lbs 122 129 N m Clutch Retaining Bolt secured with threadlocker 55 60 ft Ibs 75 81 N m sd 3 ASSEMBLY INSTRUCTIONS 3 1 UNCRATE UNIT 3 1 1 Remove tractor and mower deck from crates 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 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 serious injury HOW TO AVOID THE HAZARD Keep sparks flames or cigarettes away from battery Ventilate when charging or using battery in enclosed space Make sure venting path of battery is always open once battery is filled with acid 3 2 2 Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater IMPORTANT Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and
24. 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 002 syst me d allumage par tincelle de v hicule est conforme la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 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 dis
25. valve is used to shut off the flow of fuel when parking inside a building during transportation to and from the job sites and when the machine will not be used for a few days Rotate valve 1 4 turn clockwise to shut fuel off Rotate valve 1 4 turn counter clockwise to turn fuel on 16 4 1 11 4 1 12 4 1 13 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 With a 5 8 wrench turn both valves one turn counter clockwise to release the drive system Turn clockwise to reset the drive system Do Not over tighten Tracking Adjustment Knob Located on the right hand side of the rear of the fuel tank support The knob can be adjusted so that machine will track straight ahead with the drive levers released Park Brake Lever Located on the left side of the unit above the hydraulic tank The brake lever engages the park brake on the drive wheels Pull the lever up and rearward to engage the brake Push the lever forward and down to disengage the brake When parking on a steep slope the wheels must be chocked or blocked in addition to the brake being engaged The unit must be tied down and brake engaged when transporting Park brake must be disengaged to move speed control out of neutral or engine will kill 42 PRE START 4 2 1 4 2 2
26. 10 seconds at a time If the engine does not start allow a 60 second starter cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor NOTE It is helpful to have the left and right neutral lock latches locked in neutral when starting the engine See Controls Section 4 1 3 17 4 3 2 4 3 3 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 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 Drive Lever Neutral Lock Latch Operation To lock the drive levers in neutral lock squeeze the drive levers to the neutral position Do Not squeeze the drive levers all the way back as this will cause the drive wheels to go into full reverse direction See Figure 4 a Place thumbs on the inner lobe of the neutral lock latches and rotate them under the drive levers into the neutral lock position See Figure 4 b Release the drive levers CAUTION POTENTIAL HAZARD If the neutral lock latches not completely engaged the drive levers could unexpectedly slip into the forward drive position
27. Exmark blades blade bushings spring disc washers and blade bolts in the correct positions as shown 5 1 5 Check safety interlock system Service Interval Daily a Check starting circuit Starter should crank with Operator Presence Control levers depressed speed control lever in neutral and PTO disengaged Try to start the engine with OPC levers disengaged speed control lever neutral and PTO disengaged starter MUST NOT crank Try to start with OPC levers depressed speed control lever in any speed but neutral and PTO disengaged starter MUST NOT crank Try to start with OPC levers depressed speed control lever in neutral and PTO engaged starter MUST NOT crank 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 stop Again run engine at one third throttle move the speed control lever to neutral engage PTO and release OPC levers engine MUST stop NOTE Park brake must be disengaged before the speed control lever is moved out of neutral or engine will kill 23 5 1 7 If machine does not pass any of these tests DO NOT operate Contact your authorized EXMARK SERVICE DEALER IMPORTANT It is essential that all Operator Safety Mechanisms be in place and in proper operating condition prior to mowing Check for loose hardware
28. For Turf Tracer Serial Nos 510 000 amp Higher and FMD524 amp FMD604 Serial Nos 510 000 amp Higher AK MFG CO INC OPERATOR S MANUAL TURF CONGRATULATIONS on the purchase of your new Exmark mower This product has been carefully designed and manufactured to give you maximum amount of dependability and years of trouble free operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor If you need to order replacement parts from your dealer always give the model number and serial number of your mower as well as the part number description and quantity of the part needed The Serial No plate of the tractor is located on top of the engine frame on the left hand side of the machine just inside the left wheel The Serial No Plate for the mower deck is located on the rear right hand belt cover support under the front frame For Ease of ordering and reference we suggest that you record the information requested in the following identification table Place Tractor Model No and Serial No Label Here Place Mower Deck Model No and Serial No Label Here Included in Literature Pack Included in Literature Pack or Fill in Below or Fill in Below Tractor Model No Mower Deck Model No Tractor Serial No Mower Deck Serial No Engine Model No and Spec No Code Engine Serial No E No Date P
29. NKAGE 4 5 6 Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground 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 Figure 4 and move the speed control lever to the mid speed position Note The park brake must be disengaged and the OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill Squeeze the respective drive lever until an increased resistance is felt this is where neutral should be For Standard Pistol Grip Models Make sure you have not reached the end of the neutral lock latch slot If you have shorten the drive lever linkage If the wheel turns while holding the drive lever in neutral the neutral control linkages need to be adjusted If wheels stop then go to step 7 DRIVE LEVER LINKAGE SPEED CONTROL LINKAGE ADJUST HERE ROTATE AT APPROXIMATELY 1 4 TURN INCREMENTS ES LOOSEN NUT YOKE FIGURE 12 HYDRO DRIVE LINKAGE ADJUSTMENT Loosen the nut against the neutral control linkage yoke as shown in Figure 12 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
30. 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 step d d Thoroughly clean the area around each of the charge pump housings e prime charge pump loosen two hex socket head capscrews shown in Figure 7 1 1 2 turns only Make sure engine is not running Lift the charge pump housing upward and wait for a steady flow of oil to flow out from under the housing Retighten the capscrews Do this for both pumps Note Hydraulic reservoir can be pressurized up to 5 psi to speed this process 26 5 1 13 5 1 14 5 1 15 f If either drive wheel still does not rotate stop and repeat steps d and e above for the respective pump If wheels rotate slowly the system may prime after additional running Check oil level as stated in Section 5 1 10 0 Allow unit to run several minutes after the charge pumps are primed with drive system in the full speed position Check oil level as stated in Section 5 1 10 h Check hydro drive linkage adjustment as stated in Section 5 2 5 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
31. T 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 hot engine can cause severe burns HOW TO AVOID THE HAZARD Allow the engine to cool completely before service making repairs around the engine area 20 5 1 PERIODIC MAINTENANCE 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 oil off Reinsert the dipstick DO NOT screw into place Remove dipstick and check oil level d Ifthe oil level is low add oil as specified in the Engine Owner s Manual to bring the oil level up to the FULL mark on the dipstick DO NOT OVERFILL IMPORTANT DO NOT operate the engine with oil level below the LOW or ADD mark or over the FULL mark Clean engine air cooling system Service Interval Daily or more often in dry conditions CAUTION POTENTIAL HAZARD Excessive debris can cause the engine and
32. TER CABLES OR ADJUST POST CONNECT AND ALWAYS SHIELD EYES FACE SKIN AND CLOTHING IONS WITHOUT PROPER TRAINING IN EVENT OF AN FROM BATTERY CIGARETTES FLAMES OR SPARKS ACCIDENT FLUSH WITH WATER AND CALL A PHYSICIAN COULD CAUSE BATTERY TO EXPLODE DO NOT CHARGE IMMEDIATELY KEEP OUT OF REACH OF CHILDREN Check air pressure in drive tires recommended pressure is 12 16 psi Measure circumference of each drive tire Adjust tire pressure within 12 16 psi range to try to make tire circumferences match as closely as possible 3 5 MOWER DECK INSTALLATION 3 5 1 3 5 2 3 5 3 NOTE 3 5 4 Release the wheel drive system by opening the drive wheel release valves See Section 4 1 11 Roll the tractor to the mower deck assembly and allow the tractor assembly to tip backward until the rear of the engine deck contacts the ground Remove mower deck support frame from mower deck by removing the two hairpins and spacers from the front deck support pins and by removing the two hairpins and spacers from the rear deck support pins See Figure 1 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 Place spring washer cone side against bolt head cupped side away from head and install to outside of support frame as shown in Figure 1 Install with whizlock nuts to the inside of engine deck Tighten until spring washers are
33. 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 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 36 ENGINE TROUBLESHOOTING TABLE Er pes 2 x X X X ee cee ee x X X X x X X taskspower X X X X X X X X Operateseraticaly X X X X Knocks orpings X Siipsormistres x X X x x ee Overheats E NEN fuel ca consumption 287 8 HYDRAULIC SCHEMATIC G0104 HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE HYDRAULIC TANK HIGH PRESSURE G SS a URE FORWARD HIGH PRESSURE CHARGE PUMP INLET FRONT e CASE DRAIN OF UNIT 38 9 WIRING DIAGRAM ANTONI 23018 HILIMS D Wad 039v9N3 J3Y88 034013 SI HILINS
34. 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 restrictions apply The Exmark Parts Plus Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday Parts Plus service is only available in the 48 contiguous United States UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday The next day air charge plus the Saturday delivery fee will be the responsibility of the purchaser Exmark Mfg will assume no responsibility for Saturday delivery shipments To qualify all Exmark Parts Plus orders must be received by Exmark by 3 00 p m central time Orders must be six 6 line items orless Exclusions from the Exmark Parts Plus Program are Any wholegood or accessory in its entirety engines and engine replacement parts 5 speed Peerless transmissions and 5 speed transaxles hydraulic or hydrostatic wheel motors cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions Due to UPS restrictions aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air Exmar
35. 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 Percent Maximum Reading Charge 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 7596 16 volts 7 amps 1 Hour 12 0 12 2 25 5096 14 4 volts 4 amps 2 Hours 11 7 12 0 0 2596 14 4 volts 4 amps 3 Hours 11 7 or less 096 14 4 volts 2 amps 6 Hours or More 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 and remove Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 15W 50 synthetic motor oil Replace hydraulic reservoir cap and tighten until snug Do not overtighten 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 If the oil is about 150 F 65 C fill halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level
36. ctive equipment such as but not limited to protection for the eyes ears feet and head is recommended CAUTION POTENTIAL HAZARD This machine produces sound levels in excess of 85 dBA at the operator s ear when in operation WHAT CAN HAPPEN Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss HOW TO AVOID THE HAZARD Wear hearing protection when operating this machine 1 3 3 While mowing always wear substantial footwear and long trousers Do not operate equipment when barefoot or when wearing open sandals ed 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 A WARNING POTENTIAL HAZARD Engine exhaust contains carbon monoxide which is an odorless deadly poison WHAT CAN HAPPEN Carbon monoxide kill you HOW TO AVOID THE HAZARD Do run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect DANGER POTENTIAL HAZARD In certain conditions gasoline is extremely flammable 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 smoke while refueling and stay away from an open flame or where gasoline
37. d 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 fuel tank expansion and contraction with changes in temperature and fuel levels 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 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact 29 5 2 ADJUSTMENTS IMPORTANT Disengage PTO shut off engine wait for all moving parts to stop and remove key before servicing cleaning or making adjustments to the unit 5 2 1 Cutting height and anti scalp roller adjustment CAUTION POTENTIAL HAZARD When mower deck is not 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 removed a
38. e or two holes higher than described in c to prevent damage to the rollers and or bolt failure See Figure 10 NOTE When anti scalp rollers are placed in these positions reduced deck flotation will result Pump drive belt tension adjustment No adjustment necessary Mower deck drive belt No adjustment necessary Blade drive belt tension No adjustment necessary 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 control crank See Figure 11 These tabs should be pointing straight down at the 6 o clock position or slightly forward Adjust threaded yoke at the bottom of speed control linkage until tabs are positioned correctly See Figure 11 3 Pull speed control lever back to neutral Check that the neutral safety switch actuating tab has depressed the plunger of the switch so that there is about 5 16 between the tab and the switch See Figure 11 If necessary move the switch fore and aft 31 IN NEUTRAL POSITION 2 816 4 20 ACTUATING NEUTRAL SAFETY SWITCH AS VIEWED FROM LEFT SIDE OF UNIT FIGURE 11 NEUTRAL SAFETY SWITCH ADJUSTMENT b Adjust Neutral Control Linkages 1 HYDRO CONTROL LINKAGE NEUTRAL CONTROL LI
39. e the right hand drive lever to turn right and the left hand drive lever to turn left To make a zero turn squeeze either the left hand or the 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 Squeeze both drive levers into the reverse position For smooth operation of this machine avoid quick jerky movements of the drive levers Move the drive levers smoothly and deliberately To Stop Squeeze drive levers back to the neutral position Move the neutral lock latches into the neutral lock position and release drive levers Move the speed control lever to the neutral position PTO Engagement DANGER POTENTIAL HAZARD The rotating blades under the mower deck are dangerous WHAT CAN HAPPEN Blade contact can cause serious injury or kill you 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 Anuncovered 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 mower with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly
40. ee limbs etc from the mowing area Tall grass can hide obstacles e Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control Use EXTREME caution when backing up LOOK BEHIND YOU Stop the blades when crossing surfaces other than grass if mower must be tilted for transportation and when transporting the mower to and from the area to be mowed 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 Do Not change the engine governor settings or over speed the engine Operating an engine at excessive speed may increase the hazard of personal injury Place speed control lever in neutral lock drive levers in neutral disengage PTO and engage park brake before starting engine Start the engine carefully with feet well away from the blades Keep hands feet and clothing away from rotating parts while the mower is being operated Stop the engine wait for all moving parts to stop and remove plug wire s or key e Before checking cleaning or working on the mower e After striking a foreign object inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages e Whenever you leave the mower 5 1 4 13 1 4 14 1 4 15 1 4 16 1 4 17 1 4 18 1 4 19 1 4 20 1 4 21 Stop the
41. engine and wait for all moving parts to stop e Before removing grass catcher e Before refueling e Before making height adjustments 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 The fuel system is provided with a shut off valve The fuel shut off valve is used to shut off the fuel e When the machine will not be used for a few days e During transport to and from the job e When parking inside a building This mower was designed for one operator only Keep all others away from mower during operation Do NOT mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Be aware of the mower discharge and direct discharge away from others Do NOT operate the mower under the influence of alcohol or drugs Use extra care when approaching blind corners shrubs trees or other objects that may obscure vision If jump starting is required a Connect the positive power cable from the positive post on the booster battery to the positive 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 Disconnect battery cab
42. es and sharpen or replace as required For Serial Nos 510 000 539 999 d Rerinstall the blades if they were removed by placing a block of wood between the front or rear baffles and the blade then torquing the blade bolts to 115 120 ft lbs 156 163 N m Be sure the spring disk washer cone is installed toward the bolt head See Figure 5 CAUTION POTENTIAL HAZARD Operating a mower deck with loose or weakened blade bolts can be dangerous WHAT CAN HAPPEN loose or weakened blade bolt could allow a blade rotating at a high speed to come 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 156 163 N m BLOCK OF WOOD BETWEEN TORQUE TO DO NOT USE WRENCH HERE X FOR BLADE INSTALLATION MAINTAIN PRONTOR REAR BAFFLES 140 145 ft lbs 190 197 N m ON THIS NUT TN CONE TOWARDS BOLT HEAD E TORQUE P3 Ej 115 120 T 156 163 N m Dec Bids FIGURE 5 BLADE BOLT INSTALLATION For Serial Nos 540 000 and Higher d Re install the blades if they were removed in the following order See Figure 6 1 Install bushing through blade
43. flat Position tractor with mower deck support frame in place over the mower deck CAUTION POTENTIAL HAZARD When mower deck is not installed or the two front support rod hairpins are removed the unbalanced weight of the tractor or tractor with mounted mower 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 Align and re install the mower deck support pins into the support frame Install the two spacers and hairpins onto the front support pins and the two hairpins and spacers onto the rear support pins See Figure 1 133 BPDECKSHOW FORREFERENCE ONLY ENGINE DECK 2 ES REAR 1 SUPPORT PIN NUTS TO INSIDE 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 WASHER Lb IDLER BUSHING ima SPACER A Y RIGHT HAND mj HOLE 3 8 16 x 4 1 2 HEX CAPSCREW FIGURE 2 STATIONARY IDLER INSTALLATION 3 5 6 Install the deck drive belt around the clutc
44. fumes may be ignited by spark Refuel only outdoors Store gasoline in an approved container and keep it out of the reach of children fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot Never fill the fuel tank so that the gasoline level rises above a level that is 1 2 below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage If fuel is spilled DO NOT attempt to start the engine Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Do not operate without entire exhaust system in place and in proper working condition DANGER POTENTIAL HAZARD Incertain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN 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 an approved container Always place gasoline containers on the ground away from your vehicle before filling Do fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment fr
45. g to your state and local regulations 6 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 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 replaced or if the unit containing the battery is no longer operating and is being scrapped take the battery to a local certified recycling center If no local recycling is available return the battery to any certified battery reseller 7 TROUBLE SHOOTING 7 1 MOWER TRACKS TO LEFT OR RIGHT a Check the drive tire pressures and tire circumferences See 5 1 13 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 35 7 2 MOWER CUTS UNEVENLY a Check the drive tire pressures and tire circumferences See 5 1 13 A more uniform cutting height may be obtained with higher tire pressure on rough terrain A lower tire pressure provides more flotation Check dec
46. grease zerk and thread plug back in Place cap back on 5 1 16 Lubricate caster wheel hubs Service Interval Once Yearly a Stop engine wait for all moving parts to stop and remove key Remove caster wheel from caster forks x SEAL c Remove seal guards from the wheel hub NN X Pi GUARD d Remove one of the spacer nuts from the A axle assembly in the caster wheel Note that Ve thread locking adhesive has been applied to g SPACER NUT WITH lock the spacer nuts to the axle Remove WRENCH FLATS the axle with the other spacer nut still FIGURE 8 assembled to it from the wheel assembly CASTER WHEEL 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 Ifthe 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 i Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing h With the open end of the wheel facing up fill the area inside the wheel around the axle full of
47. h Refer to belt routing decal Be sure belt is in the clutch drive sheave groove Place the other end of the belt into the V groove of the stationary idler move the spring loaded idler outward and route the belt around the inside of the spring loaded 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 but can pivot freely 3 7 SERVICE ENGINE See Engine Operator s Manual 3 8 SERVICE HYDRAULIC OIL The machine is shipped with hydraulic oil in the reservoir Run the machine for approximately 15 minutes to allow any extra air to purge out of the hydraulic system Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 15W 50 synthetic motor oil Replace hydraulic reservoir cap and tighten until snug Do not overtighten 14 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
48. hite lettering Red background Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION Black lettering Yellow background Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury 1 2 TRAINING 1 22 1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit 1 2 2 Read the instructions carefully Familiarize yourself with the controls and the proper use of the equipment If the operator 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 Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property 1 3 PREPARATION 1 3 1 Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark 1 3 2 The use of personal prote
49. hydraulic system to overheat WHAT CAN HAPPEN 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 Clean grass build up under deck Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Raise deck to the highest position Lift the front of unit and support unit using jack stands or equivalent support CAUTION POTENTIAL HAZARD Raising the mower deck for service maintenance relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support c Clean out any grass build up from underside of deck and in discharge chute 21 5 1 4 Check mower blades Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Lift deck and secure in raised position as stated in Section 5 1 3 C Inspect blad
50. including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense As a condition to this warranty customer shall have read the operator s manual and shall have completed and submitted to Exmark Warranty Company within the prescribed time the Exmark warranty registration General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein Neither Exmark nor Exmark Warranty Company shall have any liability for any other cost loss or damage including but not limited to any incidental or consequential loss or damage In particular we shall have no liability or responsibility for e Expenses related to gasoline oil or lubricants e Travel time overtime after hours time or other extraordinary repair charges or charge relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark service dealer e Rental of like or similar replacement equipment during the period of any warranty repair or replacement work e Any telephone or telegram charges or travel charges e Loss or damage to pe
51. ing shrouds are properly reinstalled Operating the engine without cooling shroud cleanout covers or cooling shrouds will cause engine damage due to overheating 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 Wheel hub slotted nut torque specification When tightening the slotted nut on the wheel motor tapered shaft a Torque the slotted nut to 100 ft Ibs 136 N m b Further tighten the nut until the next set of slots line up with the cross hole in the shaft c Replace cotter pin Note Do not use anti seize compound on the wheel hub Thread locking adhesives such as Loctite 242 or Fel Pro Pro Lock Nut Type are used on the following fasteners a Pump drive sheave setscrews b Square head setscrews on Hydro pump control arms c Shoulder bolts in ends of speed control crank e OPC lever setscrews f Electric clutch retaining bolt g Pump drive idler pivot bolt h Fueltank bulkhead fitting threads Thumb latch screw threads on handles 1 Caster wheel spacer nuts Reference Section 5 1 16 h Cutter housing spindle nut Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining or Retaining Il are used on the following a OPC lever hubs and cross shaft NOTE Care must be use
52. is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing WARNING POTENTIAL HAZARD Operating engine parts especially the muffler become extremely hot WHAT CAN HAPPEN Severe burns can occur on contact Debris such as leaves grass brush etc can catch fire HOW TO AVOID THE HAZARD Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land AWARNING 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 guards shields and safety devices in place and working properly Keep hands feet hair jewelry or clothing away from rotating parts 1 4 1 1 4 2 1 4 3 1 4 4 Give complete undivided attention to the job at hand Mow only in daylight or in good artificial light keeping away from holes and hidden hazards DO NOT operate the mower when children or others are in the area When feasible avoid operating the equipment in wet grass Use EXTREME caution when mowing and or turning on slo
53. k Manufacturing stocks a limited supply of parts for transaxles pumps and wheel motors These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program 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 By following the operating maintenance and safety instructions you will prolong the life of your mower 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 stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance TABLE OF CONTENTS 1
54. k support pins Hairpin clips must be in the same hole position on each support pin See Section 5 2 1 Check deck support alignment and check mounting brackets to be sure all bolts are tight Check blades tip to tip for straightness They should be within 3 16 or one blade width from being in line 7 3 ENGINE WILL NOT START Make sure battery has a full charge Check that the throttle control is midway between slow and fast positions and choke is in position for a cold engine or position for a warm engine Make sure the speed control lever is in the true neutral position See Section 5 2 5 Check that the PTO is disengaged Make sure the OPC levers are depressed Check that there is fuel in the tank and that the fuel valve is open Check that the spark plug wires are properly connected Check for loose or faulty wiring connections If it is necessary to disconnect wire connectors Do Not pull on the wires 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 operator safety mechanisms be connected and in proper operating condition prior to mower use NOTE After carefully checking the above steps attempt to start the engine If it does not start contact your authorized Exmark service dealer ENGINE TROUBLESHOOTING When
55. les the reverse order after starting 1 5 MAINTENANCE AND STORAGE 1 5 1 1 5 2 1 5 3 1 5 4 1 5 5 1 5 6 For engine maintenance follow the engine manufacture s recommendations precisely as stated in the engine manual Disconnect the battery from the negative battery post when the unit will be allowed to sit for more than 30 days without use Allowing batteries to stand for an extended period of time 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 voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage Keep engine and engine area free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Store fuel in a container specifically designed for this purpose in a cool dry place Keep the mower and fuel container in locked storage to prevent children from playing or tampering with them 1 5 7 1 5 8 1 5 9 1 5 10 1 5 11 1 5 12 Gasoline powered equipment or fuel containers should not be stored ina basement or any enclosed area where open pilot lights or heat appliances are present Maximum mowing results and safety can only be achieved if the mower is properly maintainet and ope
56. move all grease dirt and debris from safety signs and instructional labels Safety signs must be replaced if they are missing or illegible When new components are installed be sure that current safety signs are affixed to the replaced components New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower 103 1541 mrajo0nzr4 Engage at 1 2 throttle 6 Disengage idle 6 5 4 3 2 1 Read operator s manual before operating Do NOT operate unless trained to safely operate this machine Do NOT operate without shields guards and safety devices in place and working A DAN R Do NOT carry passengers Clear area of debris before mowing Thrown objects or blade contact can Before leaving operator s position cause serious injury or death ENHANCED CONTROL SYSTEM PART NO 103 2242 LOCATION LH Side of z Lock drive ever in neutral lock position Keep all people and pets out of 2 wi Disengage Shift speed control lever to neutral area wien mowing Engage park brake Avoid blades unless blades and E M
57. ne deck on the left and right hand sides Note In medium or heavy duty positions the drive lever forces at the upper handle will also be increased Medium Heavy Duty Retaining Bolt Standard 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 the engine until the throttle control arm contacts the stop screw Secure cable with cable clamp Tension in throttle lever can be adjusted by adjusting the tightness of the lever pivot bolt which is located under the console See Figure 16 34 LEVER TAB WASHER BELLEVILLE WASHERS BRACKET HEX LOCKNUT FRICTION WASHERS FIGURE 16 THROTTLE TENSION 5 2 8 Electric Clutch Adjustment No adjustment necessary 5 2 9 Park Brake Adjustment a Shut off engine and wait for all moving parts to stop b Disengage the park brake c Remove the hairpin in the park brake linkage Turn the linkage in the yoke until there is 3 16 48 cm to 1 4 64 cm clearance between the park brake tire bars and the tires with the park brake disengaged Re install the hairpin 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 accordin
58. ngines Place pan under machine to catch oil and open valve with a 10 mm wrench Allow oil to drain then close the valve d Replace the oil filter as per Engine Owner s Manual Clean around oil filter and unscrew filter to remove Before reinstalling new filter apply a thin coating of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 2 3 to 3 4 turn e Clean around oil fill cap and remove cap Fill to the specified capacity and replace cap Use oil as specified in Engine Owners Manual Do not overfill f Start the engine and check for leaks Stop engine and recheck oil level 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 voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage 24 5 1 10 5 1 11 Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater IMPORTANT Make sure the negative battery cables are disconnected and the battery charger used for charging the
59. oil For example If the oil is about 150 F 65 C fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level 3 9 GREASE UNIT NOTE UNIT IS NOT GREASED AT THE FACTORY Refer to Maintenance Section 5 1 14 for grease zerk locations and grease amounts 3 10 FAMILIARIZE YOURSELF WITH THE CONTROLS See Controls Section 4 1 3 11 FOLLOW PRE START INSTRUCTIONS See Pre Start Section 4 2 3 12 PERFORM NECESSARY ADJUSTMENTS See Maintenance and Adjustment Section 5 4 OPERATION INSTRUCTIONS 4 1 Controls 4 1 1 Operator Presence Control OPC Levers Located on the upper handle assembly directly above the handle grips See Figure 3 When these levers are depressed the OPC system senses that the operator is in the normal 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 Drive Levers Located on each side of the upper handle assembly directly below the handle grips See Figure 3 These levers individually control the speed and direction of each drive wheel When the speed control lever is moved out of the neutral position and the neutral lock latches are moved into the drive position as shown in Figure 3 and the drive levers are released the d
60. om the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle Ifa 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 A WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignited by electrical sparks or hot engine exhaust components WHAT CAN HAPPEN Explosion and fire may occur resulting in property damage personal injury and or death HOW TO AVOID THE HAZARD Provide adequate ventilation of any enclosed trailer to prevent build up of gasoline vapors especially at floor level Refuel only outdoors never inside an enclosed trailer Be sure all fuel tanks and gasoline storage containers have proper caps installed to prevent spillage and minimize vapor escaping into the trailer Do not place any equipment that is leaking gasoline in an enclosed trailer 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
61. on the top of the main pump as shown in Figure 7 may have lost their prime Refer to Section 5 1 12 h not change hydraulic system oil except what can be drained 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 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 purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump See Figure 7 Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is primed LOOSEN 1 1 2 TURNS ONLY FIGURE 7 CHARGE PUMP LOCATION a Stop engine and wait for all moving parts to stop Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off the ground b Check oil level as stated in Section 5 1 10 c Start engine and move throttle control ahead to full throttle position Move the speed control lever to the middle speed position and place the drive levers in the drive position If either drive wheel does not rotate it is possible to assist the purging of the charge pump by carefully rotating the tire in the forward position
62. pes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes A DANGER POTENTIAL HAZARD Mowing on wet grass or steep slopes can cause sliding and loss of control Loss of control and or loss of operator s footing could result in fall with an arm or leg getting under the mower or engine deck which may result in serious injury or death 99999 HOW TO AVOID THE HAZARD Mow across slopes never up and down Do not mow slopes when grass is wet Do not mow near drop offs or near water Do not mow slopes greater than 20 degrees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes 1 4 5 1 4 6 1 4 7 1 4 8 1 4 9 1 4 10 1 4 11 1 4 12 e See inside the back cover to determine the approximate slope angle of the area to be mowed Progressively greater care is needed as the slope increases e Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope e Be aware that loss of traction may occur going downhill Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine e Remove or mark obstacles such as rocks tr
63. r direction the length of the drive lever linkage will need to be adjusted Adjust the linkage length by loosening the jam nuts at both ends of the linkage and rotating the linkage in the ball joints Lengthen the linkage 33 if the tire is turning in reverse and shorten the linkage if the tire is creeping forward Tighten the jam nuts at both ends Release and re engage the neutral lock checking that the tire stops Continue this process until the tire is at a dead stop FIGURE 14 DRIVE LEVER AND LATCH IN NEUTRAL POSITION 3 Make this adjustment for both sides 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 13 Run the unit and observe the tracking on a level smooth hard surface such as concrete or asphalt 4 the unit tracks to one side or the other turn the quick track knob Turn the knob right to steer right turn the knob left to steer left 5 2 6 Hydro Pump Spring Tension Setting a b For medium or heavy duty drive conditions such as operation with a sulky on steep slopes a higher spring force may be required on the hydro pump control arms to prevent the drive system from stalling For a heavier drive setting relocate the spring anchor link as shown in Figure 15 The spring anchor links are located under the engi
64. rated correctly Check all bolts frequently to maintain proper tightness Keep all guards shields and all safety devices in place and in safe working condition Frequently check for worn or deteriorating components that could create a hazard All replacement parts must be the same as or equivalent to the parts supplied as original equipment A 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 gangrene may result HOW TO AVOID THE HAZARD Make sure all hydraulic fluid hoses and lines are in good condition an all hydraulic connections and fittings are tight before applying 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 riding attachments The use of other than Exmark riding attachments may create a hazardous condition resulting in injury 1 7 SAFETY SIGNS 1 7 1 1 7 2 1 7 3 1 7 4 1 7 5 1 7 6 Keep all safety signs legible Re
65. rive wheels are engaged in the forward direction Squeezing the left hand and or right hand lever causes the left hand and or right hand drive wheel respectively to slow down stop or reverse depending on how far each drive lever is squeezed Squeezing the drive levers beyond the neutral position causes the drive wheels to engage in the reverse direction regardless of the position of the neutral lock latches and the speed control lever Neutral Lock Latches These latches allow the operator to lock the drive levers ina neutral position where the drive wheels are not engaged in either a forward or reverse direction See Figure 3 15 4 1 10 ROTATE DOWNWARD FOR NEUTRAL LOCK POSITION w OPC LEVER NEUTRAL DRIVE LEVER LOCK LATCH IN NEUTRAL POSITION 60005 FIGURE 3 DRIVE LEVER NEUTRAL LOCK LATCH OPERATION 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 operator presence control levers depressed when PTO is engaged or engine will stop Choke Control Located on the control console right hand side Choke is used to aid in starting a cold engine The choke control is pulled out to be in the ON position and pushed in to be in the OFF position DO NOT run a warm engine with choke in the position Throttle Control
66. rson or property other than that covered by the terms of this warranty e claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty e Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower There are no understandings agreements representations or warranties express or implied including but not limited to any regarding the merchantability that product is fit for ordinary use or fitness for use that product is fit for a particular purpose not specified herein respecting the equipment which is the subject of this warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state SERVICE RECORD Date Description of Work Done Service Done By 40 FOLD ALONG APPROPRIATE LINE THIS IS A 5 SLOPE 2 2 ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC 41 SEE EXMARK S COMPLETE LINE OF ACCESSORIES RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS
67. s turning in reverse or turn the bolt approximately 1 4 turn counter clockwise if the wheel is turning forward Release the drive lever to the forward drive position and squeeze back into the neutral position Check to see if the wheel stops If not repeat the above adjustment procedure Make this adjustment on both sides 282 7 After adjustments are made and the wheels stop when the drive lever is in the neutral position tighten the nut against the yokes c Adjust Hydro Control Linkage 1 Place the speed 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 Loosen the front nut on left hydro control link as shown in Figure 12 Turn the rear control linkage adjusting nut counter clockwise until wheel rotates forward Turn the rear nut of left control link clockwise 1 4 of a turn at a time stopping to move the speed control forward and back to neutral until left wheel stops rotating forward Turn the nut an additional 1 2 turn and tighten the front jam nut making sure not to put a bind on the linkage Make sure flat part of linkage is perpendicular to pin part of swivel See Figure 13 YES N LEFT SIDE n SHOWN END VIEW FIGURE
68. to pressures stated above Measure circumference of each drive tire Adjust tire pressures within the above range to try to make tire circumferences match as closely as possible Note Front caster tires have permanent tire sealant installed Inspect Belt wear Service Interval 40 hrs a Stop engine wait for all moving parts to stop and remove key b Remove the three mower deck belt shields to check mower primary and secondary belt condition C Look under engine deck to check the pump drive belt condition d Check all idler arms to be sure they pivot freely Lubrication a Stop engine wait for all moving parts to stop and remove key b Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule LUBRICATION CHART LOCATIONS PUMPS PLACES INTERVAL 3 Idler Pivots Mower Deck 4 Idler Pivot Pump Drive 5 Hydro Control Arm Support Bushings See 5 1 15 Section c for special lubrication instructions on the front caster pivots and Section 5 1 16 for special lubrication instructions on the front caster wheel hubs No 4 Idler Pivot Pump Drive Located Under Engine Deck 27 C Lubricate front caster pivots 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
69. tributor by 1 00 p m local time and requests Exmark Parts Plus shipment of six 6 line items or less 2 Distributor ships part s to dealer or customer as requested by dealer same day overnight UPS Distributor bills dealer for part and freight charges where applicable EXMARK PARTS PLUS 3 If distributor does not have the part s in stock to satisfy Exmark Parts Plus order he contacts Exmark by 3 00 p m central time with an Exmark Parts Plus order of six 6 line items or less 4 If order is received by 3 00 p m central time Exmark ships part s direct to dealer or customer as requested by distributor same day overnight UPS bills the distributor for parts and shipping charges where applicable 5 The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the program 6 Who pays for the part and freight if it fails to arrive overnight in accordance to the program A Under any circumstance the customer does not pay B If the part does not arrive overnight due to 1 The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1 00 p m the dealer pays for the part and freight 2 The Distributor being unable to ship the part the same day or not submitting 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
70. urchased Part No 103 9190 WARNING POTENTIAL HAZARD This product is a piece of power equipment WHAT CAN HAPPEN e Failure to follow safe operating practices can result in serious operator injury or even death HOW TO AVOID THE HAZARD Keep 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 If mower deck becomes clogged stop engine and wait for all moving parts to stop Remove spark plug wire s or remove key before cleaning blockage Keep hands feet and clothing away from power driven parts Keep off mower unless seat platform is provided Keep others off mower WARNING POTENTIAL HAZARD Gasoline is harmful or fatal if swallowed 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 covered land a working spark arrester must be attached to the muffler If not the operator is violating state
71. ving forward or reverse stopping and power turning 2 6 TRANSMISSION 2 6 1 Two Hydro Gear BDP 10A variable displacement piston pumps independently coupled to two high efficiency Parker wheel drive motors 2 6 2 Hydraulic Oil Use Mobil 1 15W 50 Synthetic Motor Oil 2 6 3 Hydraulic Oil Capacity 2 4 qt 2 2 2 6 3 Hydraulic Filter is replaceable cartridge type P N 1 513211 10 microns 18 psi bypass Summer use above 32 F 0 C P N 1 523541 40 microns 18 psi bypass Winter use below 32 F 0 C 2 6 4 Speed Range Forward 0 6 75 mph 10 9 km h Reverse 0 2 25 mph 3 6 km h 2 6 5 Drive wheel release valves allow machine to be moved when the engine is not running 2 7 WHEEL DRIVE SYSTEM Drive wheels are direct coupled to Parker wheel drive motors with 1 0 25 4 mm tapered shaft 10 2 8 TIRES Drive Front Caster 18 5 8 50 8 11 4 0 5 Quantity 2 Tread eee Turf rette Smooth Ply utes 4 Pressure 14 psi 90 kPa 16 psi 152 kPa 2 9 MOWER DECK 2 9 1 Model Numbers FMD604 and FMD524 2 9 2 Cutting Width 60 in 152 4 cm 52 in 132 1 cm 2 9 3 Discharge Right Side 2 9 4 Optional Mulch Kit and Bagger available 2 9 5 Blade Size 60 3 ea 20 50 in 52 1 cm 52 3 ea 18 00 in 45 7 cm 2 9 6 Type of
72. with bushing flange on bottom grass side of blade 2 Install bushing blade combo into spindle 3 Install blade bolt and spring disc washer Be sure the spring disc washer cone is installed towards the bolt head Place a block of wood between front or rear baffles and the blade then torque the blade bolts to 55 60 ft lbs 75 81 N m 22 2 INSTALL BUSHING BLADE PRIOR TO INSTALLING BUSHING IN SPINDLE 2 3 SPLINED BUSHING DO NOT USE WRENCH HERE FOR BLADE INSTALLATION THIS NUT HAS BEEN TORQUED TO 140 145 ftHbs 190 197 N m AND SECURED WITH THREADLOCKER 22 _ CONE TOWARDS BOLT HEAD Nod 7 BLOCK OF WOOD BETWEEN TORQUE TO FRONT OR REAR 55 60 ftlbs BAFFLES amp BLADE 75 81N m 0289 FIGURE 6 BLADE BOLT INSTALLATION IMPORTANT DO NOT use components other than the original blade blade bushing spring disc washer and blade bolt supplied with the unit Failure to use all original components and assembled as shown will increase the risk of a blade bolt becoming loose or weak after striking a foreign object POTENTIAL HAZARD CAUTION Operating a mower deck with loose weakened blade bolts can be dangerous WHAT HAPPEN A loose or weakened blade bolt could allow a blade rotating at a high speed to come out from under the deck causing serious injury or property damage HOW AVOID THE HAZARD Always re install original

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