Exmark FMD 604 Assembly Instructions, Uncrate tractor and mower deck 3.2 SERVICE BATTERY, Danger

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3.ASSEMBLY INSTRUCTIONS

3.ASSEMBLY INSTRUCTIONS

3.1Uncrate tractor and mower deck.

3.2SERVICE BATTERY:

WARNING: Battery posts, terminals, and related accessories contain lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

The machine is shipped with a filled lead acid battery.

3.2.1Remove 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 an enclosed space.

Make sure venting path of battery is always open once battery is filled with acid.

3.2.2Check 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 7 amps or less to avoid damaging the battery (see chart below for recommended charger settings).

Voltage

Percent

Maximum

 

Charging Interval

Reading

Charge

Charger Settings

 

 

 

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

– 50%

14.4 volts/4 amps

2

Hours

11.7 – 12.0

0 – 25%

14.4 volts/4 amps

3

Hours

11.7 or less

0%

14.4 volts/2 amps

6

Hours or More

CAUTION

POTENTIAL HAZARD

If the 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

Be sure ignition switch is in the “OFF” position before charging the battery.

3.2.3Connect the negative battery cables.

NOTE: If the positive cable is also disconnected, connect the positive (red) cable to the positive terminal on the battery first, then connect the negative

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Contents Serial Nos. 440,000 & Higher For Turf Ranger Serial Nos. 440,000 & Higher and FMD524 & FMD604Page How the Program Works EXMARK PARTS PLUS PROGRAMEFFECTIVE DATE September 1 Program OPERATORS MANUAL SAFETY TABLE OF CONTENTSSPECIFICATIONS ASSEMBLY INSTRUCTIONS1.1 SAFETY ALERT SYMBOL 1.SAFETYATTENTION! BECOME ALERT YOUR SAFETY IS INVOLVED 1.2 TRAININGDANGER DANGER 1.4 OPERATION G0083 SAFE ZONE FOR MOWINGa Before refueling b Before making height adjustments a Before checking, cleaning, or working on the mowerc When parking inside a building c Disconnect battery cables in the reverse order after starting1.5 MAINTENANCE AND STORAGE 1.6 SAFETY SIGNS LOCATION Under Belt Shields PART NO. 103-2248 LOCATION Steering ConsoleLOCATION LH & RH Front Top Surface of Mower Deck LOCATION On Intake Screen Below Fuel Tank2.1 MODEL NUMBER TR23KC 2.2 ENGINE 2. SPECIFICATIONS2.3 FUEL SYSTEM 2.4 ELECTRICAL SYSTEM2.8 TIRES 2.10 DIMENSIONS2.9 MOWER DECK 2.11 TORQUE REQUIREMENTSThe machine is shipped with a filled lead acid battery 3. ASSEMBLY INSTRUCTIONS3.1 Uncrate tractor and mower deck 3.2 SERVICE BATTERY 3.4 INSTALL REAR STEERING WHEEL 3.3 INSTALL SEAT3.5 INSTALL DRIVE WHEELS 3.6 INSTALL HANDLE BARHARDWARE AND SUPPORT PIN LOCATION FOR DECK SUPPORT FRAME 3.9 POSITION DISCHARGE CHUTE 4. CONTROLSIDLER PULLEY KIT AND LOCATION NOTE Do Not tow machine or transmission damage may result 5.1 PRE-START 5. OPERATION INSTRUCTIONS5.2 MOWING DRIVE WHEEL RELEASE LEVER5.3 TRANSPORTING 6.1 PERIODIC MAINTENANCE 6. MAINTENANCE & ADJUSTMENTSClean all debris from around the engine and transmission daily 6.1.2 Clean engine air cooling system6.1.3 Clean transmission cooling compartment Service Interval Daily 6.1.4 Clean grass build-up under mower deck and check mower bladesDO NOT USE WRENCH HERE BLADE BOLT INSTALLATION6.1.7 Service air cleaner Service Interval 50 hrs 6.1.6 Check for loose hardware Service Interval Dailyb Loosen retaining clips and remove air cleaner compartment cover More often under severe conditions6.1.10 Check tire pressures Service Interval 40 hrs 6.1.9 Check hydraulic oil level Service Interval 40 hrsb Inflate tires to pressures specified in Section 2.8 Specifications 6.1.11 Check battery charge Service Interval MonthlySERVICE LUBRICATION CHARTCASTER WHEEL ASSEMBLY FITTING LOCATIONS6.1.16 Change fuel filter Service Interval As Required 6.1.15 Remove engine shrouds and clean cooling fins6.1.17 Lubrication of steering yoke pivot Service Interval Monthly 6.1.18 Check spark plugs Service Interval 160 hrs6.1.20 Inspect Electric clutch gap Service Interval 250 hrs 6.1.19.2 Change hydraulic oil Service Interval YearlyRefer to Section 6.2.12 for inspection and adjustment procedures 6.1.22 Wheel hub, slotted nut torque specification6.2 ADJUSTMENTS ANTI-SCALP ROLLER BOLT INSTALLATION ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENTTorque to 40-45 ft-lbs. 54-61 N-m, or loss of roller may result 6.2.3 Mower deck drive belt No adjustment necessaryPage BRAKE CONTROL LINK AND SPRING ADJUSTMENT NEUTRAL CENTERING DEVICE ADJUSTMENTPARKING BRAKE QUADRANT ADJUSTMENT PARKING BRAKE NEUTRAL LOCKOUT ADJUSTMENT ELECTRIC CLUTCH ADJUSTMENT MOTION CONTROL LINKAGE ADJUSTMENTSEAT SWITCH ADJUSTMENT Armrest Adjustment Tab Rotate ¼ Turn ARMREST ADJUSTMENTTHROTTLE TENSION 7.2 BATTERY DISPOSAL 8. TROUBLE SHOOTING7. WASTE DISPOSAL 7.1 MOTOR OIL DISPOSALPROBLEM ENGINE TROUBLESHOOTINGENGINE TROUBLESHOOTING TABLE Console Wiring Diagram 9. WIRING DIAGRAMSEngine Deck Wiring Diagram 10.Limited Warranty Exmark Turf Equipment Page LAZER Z MICRO-MULCH ACCESSORYLAZER Z HP LAZER Z XP