Instruction/ maintenance manual of the product FMD604 Exmark
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For Turf Tracer Serial Nos. 440,000 & Higher and FMD524 & FMD604 Serial Nos. 440,000 & Higher Part No. 103-4869.
WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HO W TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system) in place and in proper working condition.
- i - 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.
- ii - 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.
- iii - TABLE OF CONTENTS 1. SAFETY ............................................................................................. PAGE 1.1 Safety Alert Symbol ...................................................................................... 1 1.2 Training .
- 1 - 1. SAFETY 1.1 SAFETY ALERT SY MBOL This SAFETY ALERT SYMBOL is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents.
- 2 - 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. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison.
- 3 - DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite gasoline vapors. A fire or explosion from gasoline can burn you, others, and cause property damage.
- 4 - 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.
- 5 - DANGER POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can cause sliding and loss of control. WHAT CAN HAPPEN ♦ Loss of control and/or loss of operator’s footing could result in a fall with an arm or leg getting under the mower or engine deck, which may result in serious injury or death.
- 6 - 1.4.13 Stop the engine and wait for all moving parts to stop: • Before removing grass catcher. • Before refueling. • Before making height adjustments. 1.4.14 Before stopp ing the engine, place the throttle control midway between the “slow” and “fast” positions.
- 7 - 1.5.7 Gasoline powered equipment or fuel containers sho uld not be stored in a basement or any enclosed area where open pilot lights or heat appliances are present. 1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly.
- 8 - Decals for ECS Handle units only: Decals for Pistol Grip Handle units only: Decals for all units: PART NO. 103-1541 LOCATION: Console PART NO. 1-303508 LOCATION: On Top RH Surface of Mower Deck PART NO. 1-303517 LOCATION: LH Side of Rear Surface of Engine Deck PART NO.
- 9 - PART NO. 1-403005 LOCATION: LH & RH Front Top Surface of Mower Deck PART NO. 1-403143 LOCATION: RH Rear Surface of Engine Deck PART NO. 1-513747 LOCATION: Top Rear of Battery Cover PART NO. 1-513746 LOCATION: Surface of Engine Deck Next to Muffler PART NO.
- 10 - 2. SPECIFICATIONS 2.1 MODEL NUMBER: TT23KCC; TT23KAC; TT20KC 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 Type of Fuel: Regular unleaded gasoline, 87 octane or higher.
- 11 - 2.6.5 Drive wheel release valves allow machine to be moved when the engine is not running 2.7 WHEEL DRIVE SYS TEM: Drive wheels are direct coupled to Parker wheel drive motors with 1.0" (25.4 mm) tapered shaft. 2.8 TIRES Drive Front Caster Size .
- 12 - 3. ASSEMBLY INSTRUCTIONS 3.1 UNCRATE UNIT 3.1.1 Remove tractor and mower deck from crates. 3.2 SERVICE BATTERY : The machine is shipped with a filled lead-acid battery.
- 13 - 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.
- 14 - 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.
- 15 - 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).
- 16 - STANDARD PISTOL GRIP HANDLES ECS HANDLES FIGURE 3 DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION 4.1.4 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.
- 17 - 4.1.11 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. W ith a 5/8 wrench, turn both valves one turn counter-clockwise to release the drive system.
- 18 - 4.3.2 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.
- 19 - CAUTION POTENTIAL HAZARD ♦ If the neutral lock latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position. WHAT CAN HAPPEN ♦ If the drive levers slip into the drive position the unit could lurch forward and cause injury or property damage.
- 20 - 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: S queeze both drive levers into the reverse position. For smooth operation of this machine, avoid qu ick, jerky movements of the drive levers.
- 21 - 4.4 TRANSPORTING 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.
- 22 - 5.1 PERIODIC MAINTE NANCE 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.
- 23 - d) Clean out any grass build-up from underside of deck and in deck discharge chute. e) Inspect blades and sharpen or replace as required. f) If blade removal is necessary, be careful of the sharp cutting edges of the blades.
- 24 - Try to start with OPC levers depressed , speed control lever in neutral and PTO engaged - starter MUST NOT crank. b) Check OPC circuits. Clear the area.
- 25 - f) Start the engine and check for leaks. Stop engine and recheck oil level. 5.1.8 Check the battery charge . Allowing the batteries to stand for an extended period without recharging them will result in reduced performance and service life.
- 26 - IMPORTANT: Before re-installing new filter, fill it completely with Mobil 1 15 W-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.
- 27 - 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 s tep (d).
- 28 - ∗ See 5.1.14 Section c) for special lubrication instructions on the front caster pivots and Section 5.1.15 for special lubrication instructions on the front caster wheel hubs. No. 4 (Idler Pivot (Pump Drive)) Located Under Engine Deck No. 3 & 4 (Idler Pivots) Disassemble and grease once a month under a “No Load” condition.
- 29 - l) Re-install the sea l 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.
- 30 - NOTE: Care must be used not 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.
- 31 - FIGURE 9 CUTTING HEIGHT ADJUSTMENT FIGURE 10 ANTI-SCALP ROLLER BOLT INSTALLATION ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT c) Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of the positions shown in Figure 10.
- 32 - 5.2.4 Blade drive belt tension : No adjustment necessary. 5.2.5 Hydro Drive Linkage Adjustment : a) Adjust Speed Control Linkage and Neutral Safety Switch 1.
- 33 - FIGURE 12 HYDRO DRIVE LINKAGE ADJUSTMENT 4. Loosen the nut against the neutral control linkage yoke as shown in Figure 12. 5. Adjust the neutral control linkage until the respective drive wheel stops when the lever is pulled against the neutral spring (neutral position).
- 34 - 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.
- 35 - e) 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 5.1.12. 3. Run the unit and o bserve the tracking on a level, smooth, hard surface such as concrete or asphalt.
- 36 - 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 according to your state and local regulations.
- 37 - h) Check for loose or faulty wiring connections. If it is nec essary to disconnect wire connectors, Do Not pull on the wires. i) Check for corrosion at all wiring connections. Even minor corrosion may cause a faulty connection. Clean connector terminals thoroughly, apply dielectric grease and reconnect.
- 38 - 8. HYDRAULIC SCHEMATIC.
- 39 - 9. WIRING DIAGRAMS.
- 40 - 10. Limited Warranty Exmark Turf Equipment Conditions and Products Covered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warran.
- 41 - SERVICE RECORD Date Description of Work Done Service Done By.
- 42 - T H I S I S A 1 5 ° S L O P E T H I S I S A 1 0 ° S L O P E T H I S I S A 5 ° S L O P E ALIGN THIS EDGE WITH A VERTICAL SUR FACE (TREE, BUILDING, FENCE POS T , POLE ETC.
® M FG. CO. INC. SEE EXM ARK’S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z ® LAZER Z ® CT LAZER Z ® HP LAZER Z ® XP TURF RANGER ® VIKING HYDRO TURF TRACER ® TURF TRACER ® HP METRO ® MET.
An important point after buying a device Exmark FMD604 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Exmark FMD604 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Exmark FMD604 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Exmark FMD604 you will learn all the available features of the product, as well as information on its operation. The information that you get Exmark FMD604 will certainly help you make a decision on the purchase.
If you already are a holder of Exmark FMD604, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Exmark FMD604.
However, one of the most important roles played by the user manual is to help in solving problems with Exmark FMD604. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Exmark FMD604 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
