Exmark FR604 User's Manual
Contents
1. 2 37 32151 103 ERINO E int rH pete 4 18 109 2205 Wid Lock Lever LH 1 38 32151 29 Ring 1 19 109 2206 Wid Lock Lever 1 39 1 806005 Hairpin 1 20 109 2760 Arm Switch 1 40 109 0045 Pin Cylinder 1 Exmark red touch up paint spray paint P N 1 850337 6 oz liquid bottle P N 103 9140 WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 202608 4 N 4 ANTI SCALP ROLLER ADJUSTMENT FOR NORMAL OPERATING CONDITIONS PLACE ROLLERS IN POSITIONS SHOWN FOR 3 4 19 mm GROUND CLEARANCE CUTTING HEIGHT INCHES mm 20 51 8 06 38 IFOR MAXIMUM FLOTATION ROLLERS MAY BE POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM JOF 1 4 6 4 mm GROUND CLEARANCE NEVER POSITION THE ROLLERS TO SUPPORT THE MOWER DECK CES M 7 10 DECAL GROUP 2 BELT ROUTING BLADE BELT 1 643052 72 1 633127 60 1 633366 52 1 643222 DANGER avoid set or death Avoid blades unless engine and blades are stopped To avoid serious injury or death Pick up objects2. 1 7 32120 10 Ring Retaining 2 109 5404 Shield Belt RH 727 1 8 1 602913 01 Wild Baffle Discharge 1 36 32128 20 Nut Whizlock 5 16 18 6 9 1 603805 Sheave 1 37 3296 39 Nut Nyloc 3 8 16 3 10 109 2796 Sheave Flat 2 38 109 2393 Shield Belt 52 2 11 1 633366 Belt Blade Drive 52 39 109 4383 Asm Deck W Decals 52 1 1 633127 Belt Blade Drive 60 109 5393 Asm Deck W Decals 60 1 643052 Belt Blade Drive 72 109 5406 Asm Deck W Decals 72 12 109 2985 Strip Seal 2 2 40 3290 357 Nut Whizlock 3 8 16 2 13 103 3900 Spacer 4 41 3256 4 Washer 3 8 2 14 1 633456 Bushing ldler sess 2 42 1 633922 Decal Anti Scalp ssss 1 15 103 2916 Guard Top ssl 43 109 2354 Decal Crushing Hazard 16 103 3330 Spring 1 44 109 2359 Decal Deck 1
3. 1 373034 Washer 2 1 21 323 34 Screw HH 3 8 16 x 5 8 2 2 1 523157 Washer sisiane tee Rees at 3 22 323 4 Screw HH 3 8 16 x 3 4 1 3 1 633441 Swivel Deck Mount 4 23 323 9 Screw HH 3 8 16 x 1 3 4 1 4 98 5975 Washer Spring Disk 3 8 1 24 3217 11 Nut Hex 5 8 11 4 5 103 8316 Spring Torsion 1 25 32151 48 6 6 103 9699 01 Wid Decklift 1 26 3230 8 7 103 9708 01 Wid Decklift 1 27 3253 5 8 103 9710 Rod Decklift 2 28 3256 23 9 103 9714 Spacer Spring Anchor 2 29 3256 29 10 105 1210 2 30 3256 4 11 107 0075 Bushing s 31 3256 69 12 109 3013 01 Plate Cylinder Mount 1 32 3274 18 13 109 3014 01 Plate Cylinder 1 33 3290 500 Screw PPH 10 24 x 5 8 2 14 109 0047 Pin Decklift Stop 34 3296 2 15 109 0340 01 Arm Deck 35 3296 29 16 109 1896 Arm Height Indicator 1 36 3296 39 17 109 2065 Tube Decklift Rod
4. 2 1 643292 Sheave Split Steel 60 amp 72 1 27 109 0938 01 Bracket Discharge Chute 1 6 13296 39 Nut 3 8 16 3 28 1109 2738 Chute Discharge 1 7 1 805005 Washer Lock 5 16 Heavy 4 29 109 2965 Roller Full 2 8 13 2840 Key Machine 1 4 x 1 4 x 1 1 4 2 30 322 3 Screw HH 5 16 18 x 3 4 4 9 198 5975 Washer Spring Disc 3 8 6 31 322 5 Screw HH 5 16 18 x 1 2 10 99 2842 Spacer Wheel 32 109 2767 Asm Driveshaft 1 11 32128 37 Nut Whizlock 7 16 14 330 1 803022 Setscrew 5 16 18 x 5 8 2 12 1103 1898 Screw HH 7 16 20 x 1 5 8 SP 6 34 327 12 Screw HH 5 8 11 x 4 3 4 2 13 3296 53 Nut Nyloc 5 8 11 2 35 109 4492 Washer Special 1 14 1103 4051 Kit 6 36 103 9792 Asm Chain 2 15 1100 4576 Seal 1 1 2 X 1 X 1 4 PT 37 3230 22 Bolt Carriage 5 16 18 x 1 Sp 3 16 1100 4575 Seal 2 1 1 4 1 380 3247 4 Setscrew HSH 3 8 16 5 8 1 17 109 4449 Driveshaft Fr Splined Half 1 39 3
5. 256 82 ELEME m 3 18 109 4448 Asm Driveshaft Tube W Decal 1 40 3290 357 Nut Whizlock 3 8 16 6 19 323 9 Screw 3 8 16 x 1 3 4 3 41 3296 29 Nut Nyloc 5 16 18 5 20 109 4941 Guard 1 42 109 6207 Asm Wheel 2 21 103 7959 Seal DOX oe tci that betae aen 1 43 242 50 N t etae eet e eee eee 8 Exmark red touch up paint spray paint P N 1 850337 6 oz liquid bottle P N 103 9140 Use Pro Lock Nut Type P N 1 840022 5ml tube on setscrews items 33 and 38 SPINDLE ASSEMBLY 13 Torque to e 140 145 ft Ibs 14 Apply lubricant to threads as needed to prevent seizing Copper based 42 Torque to anti seize preferable 55 60 ft lbs Grease is an acceptable substitute Item Part No Description Qty Item Part No Description Qty 1e 3217 46 Nut Hex 3 4 16 3 14 103 6402 Blade Notched 52 3 2 103 1330 Guard Bearing 3 103 6387 Blade Low Lift 52 3 3 103 2535 Spacer Guard Bottom 3 103 6382 Blade Solid 52 3 4 103 2794 Shea
6. 323 8 Screw HH 3 8 16 x 1 1 2 2 10 63 8410 Washer PE 29 325 20 Screw HH 1 2 13 x 6 Ps 11 103 3898 Flat Strut 30 3296 45 Nut Hex 1 2519 re 12 103 3899 Flat Strut 2 31 103 2171 Kit Tire amp Wheel Asm W Spacer 2 13 103 3900 Spacer Strut 4 32 3256 24 Washer 3 8 14 3296 39 Nut 3 8 16 52 amp 60 5 33 3256 26 Washer 1 2 SAE 3296 39 Nut 3 8 16 72 11 34 109 4574 Asm Front Frame W Decal FR524 1 15 103 4882 Cap Grease 2 109 4575 Asm Front Frame W Decal FR604 1 16 103 9712 01 Wd Caster 2 109 5408 Asm Front Frame W Decal FR724 1 17 109 2379 Asm Front Cover W Decal 1 35 109 4455 01 Strut Deck 724 1 18 3296 51 Nut Nyloc 3 4 10 2 36 323 16 Screw 3 8 16 x 4 2 19 32120 47 Ring Retaining 2 37 323 9 Screw HH 3 8 16 x 1 3 4 2 Exmark red touch up paint spray paint P N 1 850337 6 oz liquid bottle P N 103 9140 FRONT FRAME GROUP cont Item Part No Description Qty Item Part No Description Qty 1
7. 7 103 3504 Bearing 2 46 109 3148 Decal Bolt 1 18 98 5961 Screw 3 8 16 x 4 8 1 47 1 643222 Decal Belt Routing 1 19 103 3505 Seal Double 1 48 109 2376 Decal Crushing 1 20 103 3506 Seal Single 1 49 103 8425 Decal Driveline 1 21 103 5677 RE 1 50 103 1145 Decal Ultracut 52 1 22 103 5693 Asm Deck 1 1 103 1146 Decal Ultracut 60 1 23 63 8410 Washer inde eee 4 103 1147 Decal Ultracut 72 1 24 105 7699 Strip Seal 3 2 51 1 403005 Danger 2 25 106 7159 inest 2 52 1 303508 Decal Discharge Warning 1 27 302 40 Zerk 90 1 4 28 1 53 98 5954 Decal Danger 3 28 322 2 Screw HH 5 16 18 x 5 8 5 54 109 4382 Asm Deck Complete 52 29 322 6 Screw HH 5 16 18 x 1 1 4 ze 109 4380 Asm Deck Complete 60 30 323 12 Screw HH 3 8 16
8. Decal Crushing Hazard 1 14 103 1147 Decal Ultracut 72 1 7 98 5954 Decal Missing 3 15 109 2114 Decal FrontRunner 1 8 109 3148 Decal Bolt 1 109 3062 Decal Kit 10 SERVICE RECORD Date Description of Work Done Service Done By SEE EXMARK S COMPLETE LINE OF ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM ROLL OVER PROTECTION SYSTEM 5 DECK LIFT ASSIST KIT SNOW BLADE HITCH KIT SUN SHADE LAZERLOCKER TRASH CONTAINER LIGHT KIT TURF STRIPER MICRO MULCH SYSTEM ULTRA VAC COLLECTION SYSTEM OPERATOR CONTROLLED DISCHARGE ULTRA VAC QUICK DISPOSAL SYSTEM CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM ROLL OVER PROTECTION SYSTEM ROPS WEATHER CAB ROTARY BROOM WALK BEHIND ACCESSORIES GRASS CATCHER TURF STRIPER LAZERLOCKER STANDON MICRO MULCH SYSTEM Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Date Purchased Model No Serial No 2005 2008 Exmark Mfg Co Inc Part No 4500 231 Rev A Industrial Park Box 808 402 223 6300 Ik Beatrice NE 68310 Fax 402 223 5489 allt All Right
9. FR524 FR604 FR7 24 For Serial Nos 720 000 amp Higher Part No 4500 231 Rev A OVERNIGHT FREE 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 Some restrictions apply See your participating Exmark Dealer for details WARNING READ OPERATOR S MANUAL BEFORE OPERATING OR SERVICING EXMARK EQUIPMENT TABLE OF CONTENTS Description Page Decal Groupe and ak SSR um 9 DECK Ra n EDEN 4 5 Front Frame Group sciatis nte RE ru o urere ans 6 7 Gearbox Components 8 FR524 FR604 FR724 GROUP Item Part No Description Qty Item Part No Description Qty 1 1 303334 Washer Spring Disc 5 16 1 31 3234 11 Screw HH FLG 3 8 16 1 1 2 323 20 Screw 3 8 16 x 3 1 4 2 32 3256 24 Washer 3 8 3 3 1 322110 Belt 1 33 3256 3 Washer 5 16 4 1 323385 Knob 3 Prong 4 34 109 2392 Shield Belt LH 60 5 1 373034 anes 2 109 5405 Shield Belt LH 72 6 98 5975 Washer Spring Disc 3 8 3 35 109 2391 Shield Belt RH 60
10. cro Mulch accessory for proper mulching Mulch kit P N MK524Q 52 MK604Q 60 and MK724 O Kit includes items 1 5 6 8 12 amp 13 Apply Mobil HTS grease P N 103 5217 1 5 oz packet a food grade anti seize between the spindles amp bearings and spindles amp sheaves and under top bearing guard DO NOT use a copper or nickel based anti seize Use Pro Lock Nut Type P N 1 840022 5ml tube on nut Item 13 7 FRONT FRAME GROUP Item Part No Description Qty Item Part No Description Qty 1 1 513547 Spacer Front 2 20 109 0636 Chain Weight Transfer 2 2 1 513658 Bumper zie teenie 6 21 109 2993 Decal Cutting Height 1 3 1 513809 Bearing Roller 22 109 2114 Decal FrontRunner 1 4 1 513810 Bushing Flanged 23 283 40 Pin Clevis 1 2 x 1 3 4 2 5 1 543509 Cone Bearing Tapered Roller 24 302 19 Zerk 1 4 28 4 6 1 543511 Seal Grease 25 302 61 Zerk 45 1 4 28 2 7 1 633508 Washer Spring Disc 26 323 12 Screw HH 3 8 16 x 2 1 2 1 8 1 806005 Hairpin Cotter 27 323 13 Screw HH 3 8 16 x 2 3 4 2 9 1 811010 Plug anse n SN oet et sete Reuter 28
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12. that could be thrown the blades Do NOT mow when people and pets are in the area 1092359 Lubricate Blade Bolt threads with copper based antiseize or grease and torque to 55 60 ft lbs 75 81 N m 1023148 12 14 N UN KEEP HANDS and FEET AWAY ROTATING DRIVELINE Can cause ry or death pla attach both ends of the dri WARNING CRUSHING HAZARD Can cause serious injury or death Floorpan hooks must be in slots in front cover when folding deck or is raised service position Read operator s manual for complete procedure 109 2375 WARNING CRUSHING HAZARD Can cause serious injury d cet 8 when adjusting or folding de Item Part No Description Qty Item Part No Description Qty 1 1 303508 Decal Discharge Warning 1 9 109 2354 Decal Crushing Hazard 2 2 1 643222 Decal Belt Routing 1 10 103 1146 Decal Ultracut 60 1 3 103 8425 Decal 2 11 109 2993 Decal Deck Height 1 4 1 633922 Decal 1 12 103 1145 Decal Ultracut 52 1 5 109 2359 Decal Deck Warning 1 13 1 403005 Decal Danger eene 2 6 109 2376
13. ve Blade Drive 52 amp 60 3 103 6397 Blade Extreme 52 3 103 2795 Sheave Blade Drive 72 3 103 6392 Blade Mulching 52 3 5 103 2802 Washer Spring Disc 3 4 3 103 6403 Blade Notched 60 3 6 103 2982 Key Machine 1 4 x 3 16 x 3 4 3 103 6388 Blade Low Lift 60 704 103 9086 Kit Spindle 103 6383 Blade Solid 60 8 103 3037 Bushing Splined 103 6398 Blade Extreme 60 9 3296 39 Nut 3 8 16 21 103 6393 Blade Mulching 60 3 10 103 8280 Asm Cutter 3 103 6404 Blade Notched 72 3 11 323 8 Screw HH 3 8 16 x 1 1 2 60 amp 72 18 103 6389 Blade Low Lift 72 3 323 7 Screw HH 3 8 16 x 1 1 4 52 103 6384 Blade Solid 72 3 12 109 5958 Screw HH 1 2 20 x 2 103 6399 Blade Extreme 72 3 13 103 9076 Asm Cutter Housing Complete 52 amp 60 3 103 6394 Blade Mulching 72 3 103 9074 Asm Cutter Housing Complete 72 3 Requires installation of Mi
14. x 2 1 2 3 109 5419 Asm Deck Complete 72 Kit also includes items 2 amp 37 Exmark red touch up paint spray paint P N 1 850337 6 oz liquid bottle P N 103 9140 Complete deck assembly includes all items from pages 4 amp 6 except drive shaft assembly drive shaft assembly hardware deck chain and deck chain hardware on page 5 FR524 FR604 FR724 DECK GROUP e fe 8 3E i G Ie eg o amp SA A R N _ V EL Ev 72 INCH DEC 52 INCH DECK FR524 FR604 FR724 DECK GROUPS cont 42 43 Torque to 90 95 ft lbs Item Part No Description Qty Item Part No Description Qty 1 1109 6658 Nut 3 8 16 Flg 6 22 32151 29 Ring 1 2 109 2148 Asm Discharge 1 23 103 8425 Decal Driveline 1 3 3 603299 Roller Anti Scalp 6 24 103 9859 Chain Decklift Front 2 4 1 633447 Chain Deck 2 25 103 9861 Shackle Front Chain 2 5 1109 2714 Sheave Split Steel 52 1 26 1103 9863 Bushing Shackle
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