Serial Nos. 440,000 & Higher

For Turf Ranger

and

FMD524 & FMD604

Part No. 103-4867

Page 1

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Exmark FMD 604, FMD 524 manual For Turf Ranger Serial Nos. 440,000 & Higher and FMD524 & FMD604

Contents

Serial Nos. 440,000 & Higher For Turf Ranger Serial Nos. 440,000 & Higher and FMD524 & FMD604Page EFFECTIVE DATE September 1 Program EXMARK PARTS PLUS PROGRAMHow the Program Works OPERATORS MANUAL SAFETY TABLE OF CONTENTSSPECIFICATIONS ASSEMBLY INSTRUCTIONS 1.1 SAFETY ALERT SYMBOL 1.SAFETYATTENTION! BECOME ALERT YOUR SAFETY IS INVOLVED 1.2 TRAINING DANGER DANGER 1.4 OPERATION G0083 SAFE ZONE FOR MOWING a 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 starting 1.5 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 Tank 2.1 MODEL NUMBER TR23KC 2.2 ENGINE 2. SPECIFICATIONS2.3 FUEL SYSTEM 2.4 ELECTRICAL SYSTEM 2.8 TIRES 2.10 DIMENSIONS2.9 MOWER DECK 2.11 TORQUE REQUIREMENTS 3.1 Uncrate tractor and mower deck 3.2 SERVICE BATTERY 3. ASSEMBLY INSTRUCTIONSThe machine is shipped with a filled lead acid battery 3.4 INSTALL REAR STEERING WHEEL 3.3 INSTALL SEAT3.5 INSTALL DRIVE WHEELS 3.6 INSTALL HANDLE BAR HARDWARE 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 5.1 PRE-START 5. OPERATION INSTRUCTIONS5.2 MOWING DRIVE WHEEL RELEASE LEVER 5.3 TRANSPORTING 6.1 PERIODIC MAINTENANCE 6. MAINTENANCE & ADJUSTMENTS Clean 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 blades DO NOT USE WRENCH HERE BLADE BOLT INSTALLATION 6.1.7 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 conditions 6.1.10 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 Monthly SERVICE LUBRICATION CHARTCASTER WHEEL ASSEMBLY FITTING LOCATIONS 6.1.16 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 hrs 6.1.20 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 specification 6.2 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 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 7.2 BATTERY DISPOSAL 8. TROUBLE SHOOTING7. WASTE DISPOSAL 7.1 MOTOR OIL DISPOSAL ENGINE TROUBLESHOOTING TABLE ENGINE TROUBLESHOOTINGPROBLEM Engine Deck Wiring Diagram 9. WIRING DIAGRAMSConsole Wiring Diagram 10.Limited Warranty Exmark Turf Equipment Page LAZER Z MICRO-MULCH ACCESSORYLAZER Z HP LAZER Z XP