Exmark FMD 524, FMD 604 manual Engine Troubleshooting Table, Problem

Page 40

NOTE: After carefully checking the above steps, attempt to start the engine. If it does not start, contact your authorized Exmark service dealer.

IMPORTANT: It is essential that all Operator Safety Mechanisms be connected and in proper operating conditions prior to the use of the mower.

ENGINE TROUBLESHOOTING

When a problem occurs, do not overlook the simple causes. For example, starting problems could be caused by an empty fuel tank.

The following tables list some common causes of troubles. Do not attempt to service or replace major items or any items that call for special timing or adjustment procedures (governor, valves, etc.). Have this work done by your Engine Service Dealer.

ENGINE TROUBLESHOOTING TABLE

PROBLEM

NO

IMPROPER

DIRT IN

DIRTY AIR

FAULTY

ENGINE

BLOCKED

INCORRECT

DIRTY

SPARK

FUEL

OIL

AIR

FUEL

FUEL

FUEL LINE

FILTER

OVERLOADED

 

 

 

 

 

 

 

 

 

 

 

PLUG

 

FILTER

LEVEL

SCREEN

Will not start

X

 

X

X

X

X

X

 

 

Hard starting

X

X

X

X

X

X

X

 

 

Stops suddenly

X

 

X

X

 

X

X

X

X

Lacks power

 

X

X

X

X

X

X

X

X

Operates erratically

 

X

X

X

X

X

X

 

X

Knocks or pings

 

X

 

 

 

X

 

 

X

Skips or misfires

 

X

X

X

X

 

 

 

X

Backfires

 

 

X

X

X

X

 

 

X

Overheats

 

 

X

X

 

X

 

X

X

High fuel consumption

 

 

 

X

X

X

 

 

X

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Image 40
Contents For Turf Ranger Serial Nos. 440,000 & Higher and FMD524 & FMD604 Serial Nos. 440,000 & HigherPage EFFECTIVE DATE September 1 Program EXMARK PARTS PLUS PROGRAMHow the Program Works OPERATORS MANUAL TABLE OF CONTENTS SAFETYSPECIFICATIONS ASSEMBLY INSTRUCTIONS1.SAFETY 1.1 SAFETY ALERT SYMBOLATTENTION! BECOME ALERT YOUR SAFETY IS INVOLVED 1.2 TRAININGDANGER DANGER 1.4 OPERATION SAFE ZONE FOR MOWING G0083a Before checking, cleaning, or working on the mower a Before refueling b Before making height adjustmentsc When parking inside a building c Disconnect battery cables in the reverse order after starting1.5 MAINTENANCE AND STORAGE 1.6 SAFETY SIGNS PART NO. 103-2248 LOCATION Steering Console LOCATION Under Belt ShieldsLOCATION LH & RH Front Top Surface of Mower Deck LOCATION On Intake Screen Below Fuel Tank2. SPECIFICATIONS 2.1 MODEL NUMBER TR23KC 2.2 ENGINE2.3 FUEL SYSTEM 2.4 ELECTRICAL SYSTEM2.10 DIMENSIONS 2.8 TIRES2.9 MOWER DECK 2.11 TORQUE REQUIREMENTS3.1 Uncrate tractor and mower deck 3.2 SERVICE BATTERY 3. ASSEMBLY INSTRUCTIONSThe machine is shipped with a filled lead acid battery 3.3 INSTALL SEAT 3.4 INSTALL REAR STEERING WHEEL3.5 INSTALL DRIVE WHEELS 3.6 INSTALL HANDLE BARHARDWARE AND SUPPORT PIN LOCATION FOR DECK SUPPORT FRAME IDLER PULLEY KIT AND LOCATION 4. CONTROLS3.9 POSITION DISCHARGE CHUTE NOTE Do Not tow machine or transmission damage may result 5. OPERATION INSTRUCTIONS 5.1 PRE-START5.2 MOWING DRIVE WHEEL RELEASE LEVER5.3 TRANSPORTING 6. MAINTENANCE & ADJUSTMENTS 6.1 PERIODIC MAINTENANCE6.1.2 Clean engine air cooling system Clean all debris from around the engine and transmission daily6.1.3 Clean transmission cooling compartment Service Interval Daily 6.1.4 Clean grass build-up under mower deck and check mower bladesBLADE BOLT INSTALLATION DO NOT USE WRENCH HERE6.1.6 Check for loose hardware Service Interval Daily 6.1.7 Service air cleaner Service Interval 50 hrsb Loosen retaining clips and remove air cleaner compartment cover More often under severe conditions6.1.9 Check hydraulic oil level Service Interval 40 hrs 6.1.10 Check tire pressures Service Interval 40 hrsb Inflate tires to pressures specified in Section 2.8 Specifications 6.1.11 Check battery charge Service Interval MonthlyLUBRICATION CHART SERVICECASTER WHEEL ASSEMBLY FITTING LOCATIONS6.1.15 Remove engine shrouds and clean cooling fins 6.1.16 Change fuel filter Service Interval As Required6.1.17 Lubrication of steering yoke pivot Service Interval Monthly 6.1.18 Check spark plugs Service Interval 160 hrs6.1.19.2 Change hydraulic oil Service Interval Yearly 6.1.20 Inspect Electric clutch gap Service Interval 250 hrsRefer to Section 6.2.12 for inspection and adjustment procedures 6.1.22 Wheel hub, slotted nut torque specification6.2 ADJUSTMENTS CUTTING HEIGHT ADJUSTMENT ANTI-SCALP ROLLER BOLT INSTALLATION ANTI-SCALP ROLLER ANDTorque 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 PARKING BRAKE QUADRANT ADJUSTMENT NEUTRAL CENTERING DEVICE ADJUSTMENTBRAKE CONTROL LINK AND SPRING ADJUSTMENT PARKING BRAKE NEUTRAL LOCKOUT ADJUSTMENT SEAT SWITCH ADJUSTMENT MOTION CONTROL LINKAGE ADJUSTMENTELECTRIC CLUTCH ADJUSTMENT THROTTLE TENSION ARMREST ADJUSTMENTArmrest Adjustment Tab Rotate ¼ Turn 8. TROUBLE SHOOTING 7.2 BATTERY DISPOSAL7. WASTE DISPOSAL 7.1 MOTOR OIL DISPOSALENGINE TROUBLESHOOTING TABLE ENGINE TROUBLESHOOTINGPROBLEM Engine Deck Wiring Diagram 9. WIRING DIAGRAMSConsole Wiring Diagram 10.Limited Warranty Exmark Turf Equipment Page MICRO-MULCH ACCESSORY LAZER ZLAZER Z HP LAZER Z XP