POTENTIAL HAZARD
♦ This product is a piece of power equipment.
WHAT CAN HAPPEN
♦ Failure to follow safe operating pr actices can result in serious
operator injury or even death.
HOW TO AVOID THE HAZARD
♦ Keep all shields, guards, and safety devices (especially the grass
discharge system) in place and in proper working condit ion.
♦ Stop engine and wait for all moving parts to stop. Remove spark
plug wire(s) or remove key before adjust ing, servicing, or
performing maint enance.
♦ If mower deck becomes clogged, stop engine and wait for all
moving parts to stop. Remove spark plug wire(s) or r em ove k ey
before cleaning blockage.
♦ Keep hands, feet, and clothing away from power driven parts .
♦ Keep off mower unless seat platf o r m is pr ovided.
♦ Keep others off mower.
WARNING
POTENTIAL HAZARD
♦ Gasoline is harmful or f at a l if swallowed. Long-term exposure to
vapors has caused cancer in laboratory animals.
WHAT CAN HAPPEN
♦ Failure to use caution may cause serious injury or illness.
HOW TO AVOID THE HAZARD
♦ Avoid prolonged breathing of vapors.
♦ Keep face away from nozzle and gas tank/container opening.
♦ Keep away from eyes and skin.
♦ Never siphon by mouth.
IMPORTANT
When the mower is used or oper ated on any California forest, brush or grass covered land, a working
spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442
Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.
This spark ignition system complies with Canadian ICES-002
Ce système d’allumage par ètincelle de vèhicule est conform e à la norme NMB-002 du Canada
The enclosed Engine Owner’s Manual is supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and the California Emission Control Regulation
of emission systems, maintenance and warranty.
Keep this engine Owner’s M anual with your unit. Should this engi ne O wner’s Manual
become damaged or illegible, replace immediately. Replacements may be ordered
through the engine manufacturer.
Exmark reserves the right to make changes or add improvements to its products at any time
without incurring any obligation to make such chang es to products manufactured previously.
Exmark, or its distributors and dealer s, accept no responsibility for variations which may be
evident in the actual specifications of its pr oducts and the statements and descriptions
contained in this publication.
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. If dealer does not have part in stock for a "down" unit at
2. Distributor ships part(s) to dealer or customer, as
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by
5. The customer pays for the part
6. Who pays for the part
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
The following restrictions apply
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is only available
in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United
States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the
Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday
delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by 3:00 p.m., central time. Orders
must be six (6) line items or less. Exclusions from the Exmark Parts Plus
entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or
hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight
restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or
Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered
for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus
®
shipment of six (6) line items or less.
requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.
®
order, he contacts Exmark by 3:00 p.m.,
central time, with an Exmark Parts Plus
®
order of six (6) line items or less.
distributor, same day, overnight UPS Exmark bills the distributor for parts and shipping charges, where applicable.
and freight if it is shipped under the Exmark Parts Plus® and if it arrives in
accordance to the program.
and freight if it fails to arrive overnight in accordance to the program?
1. The dealer not submitting the Exmark Parts Plus
®
order to his Exmark distributor by 1:00 p.m., the dealer
pays for the part and freight.
®
order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
Exmark pays for the part and freight.
pays for the part.
-- The Exmark Parts Plus® Program is available only through participating Exmark
®
Program are: Any wholegood or accessory in its
- i -
CONGRATULATIONS on the purchase of your Exmark Mower. This product has been
carefully designed and manufactur ed to give you a maximum amount of dependability and
years of trouble-free oper at ion.
OPERATOR'S MANUAL
This manual contains assembly, operating, maintenance, adjustment, and safety
instructions for your Exmark mower.
BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
By following the operating, maintenance, and safety instructions, you will prolong the lif e
of your mower, maintain its maximum ef ficiency, and promote safe operation.
If additional information is needed, or should you require trained mechanic ser vice,
contact your authorized Exmark equipment dealer or distributor.
All Exmark equipment dealers and dist r ibut or s ar e kept informed of the latest methods
of servicing and are equipped to provide prompt and efficient service in the f ield or at their
service stations. They carry ample stock of ser vice parts or can secur e t hem promptly for you
from the factor y.
All Exmark parts are thoroughly tested and inspected before leaving the factory,
however, attention is required on your part if you are t o obt ain the fullest measure of
satisfaction and performance.
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. This
symbol means:
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
The safety alert symbol appears above information which alerts you to unsafe actions or
situations and will be followed by the word DANGER, WARNING, or CAUTION.
DANGER: White lettering / Red background. I ndicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injur y.
WARNING: Black lettering / O r ange background. Indicates a pot ent ially hazardous
situation which, if not avoided, COULD result in deat h or serious injury.
CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous
situation which, if not avoided, MAY result in minor or moderate injury.
1.2 TRAINING
1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to
all who operate this unit.
1.2.2 Read the instructions carefully. Familiar ize yourself with the cont r ols and t he
proper use of the equipment. If the operator(s) or m echanic(s) can not read
English, it is the owner’s responsibility to explain this mater ial t o them.
1.2.3 Do not allow operation of this machine by untrained personnel. Never allow
children, teenagers, or people unfamiliar with these instructions to use the mower.
Local regulations may restrict the age of the operator.
1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind
that the operator or user is responsible for accidents or hazards occurring to other
people or their property.
1.3 PREPARATION
1.3.1 Evaluate the terrain to determine what accessories and attachm ents are needed to
properly and safely perform the job. Only use accessories and attachments
approved by Exmark.
1.3.2 The use of personal protective equipment, such as (but not limited to) pr ot ection
for the eyes, ears, feet , and head is r ecom mended.
CAUTION
POTENTIAL HAZARD
♦ This machine produces sound levels in excess of 85
dBA at the operator’s ear when in operation.
WHAT CAN HAPPEN
♦ Exposure to sound levels of 85 dBA or above for
extended periods of time can cause hearing loss.
HOW TO AVOID THE HAZARD
♦ Wear hearing protection when operating this machine.
1.3.3 While mowing, always wear substantial footwear and long trousers. Do not
operate equipment when barefoot or when wearing open sandals.
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1.3.4 Thoroughly inspect the area where the equipment is t o be used and r emove all
stones, sticks, wires, bones, and other foreign objects which may damage the
equipment or cause personal injury to the operat or or bystander s.
WARNING
POTENTIAL HAZARD
♦ Engine exhaust contains carbon monoxide, which is
an odorless deadly poison.
WHAT CAN HAPPEN
♦ Carbon monoxide can kill you.
HOW TO AVOID THE HAZARD
♦ Do not run engine indoors or in a small confined area
where dangerous carbon monoxide fumes can collect.
DANGER
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flamm able
and highly explosive.
WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can bur n you, ot hers,
and cause property damage.
HOW TO AVOID THE HAZARD
♦DO NOT smoke while refueling , and stay away from
an open flame or where gasoline fumes m ay be ignited
by spark.
♦ Refuel only outdoors.
♦ Store gasoline in an approved container and keep it
out of the reach of children.
♦ Add fuel before start ing the engine. Never remove the
cap of the fuel tank or add fuel when engine is running
or when the engine is hot.
♦ Never fill the fuel tank so t hat the gasoline level rises
above a level that is 1/2” below the bottom of the filler
neck to allow for gasoline expansion and prevent fuel
spillage.
♦ If fuel is spilled, DO NOT attempt to start the engine.
Move away from the area of the spill and avoid
creating any source of ignition unt il fuel vapors have
dissipated.
♦ Do not operate without entire exhaust system in place
and in proper working condition.
- 2 -
DANGER
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flamm able
and highly explosive.
WHAT CAN HAPPEN
♦ A static charge can ignite g asoline vapors. A fire or
explosion from gasoline can burn you, others, and
cause property damage.
HOW TO AVOID THE HAZARD
♦ Purchase and store gasoline only in an approved
container.
♦ Always place gasoline containers on the ground away
from your vehicle before f illing.
♦ Do not fill gasoline containers inside a vehicle or on a
truck or trailer bed because interior car pet s or plastic
truck bed liners may insulate the container and slow
the loss of any static charge.
♦ When practical, r emove gas-powered equipment from
the truck or trailer and r efuel the equipment with its
wheels on the ground.
♦ If this is not possible, then refuel such equipment on a
truck or trailer from a portable container, rather than
from a gasoline dispenser nozzle.
♦ If a gasoline dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete.
WARNING
POTENTIAL HAZARD
♦ Gasoline vapor can collect inside enclosed trailers and
may be ignited by electrical sparks or hot
engine/exhaust components.
WHAT CAN HAPPEN
♦ Explosion and fire may occur, resulting in proper t y
damage, personal injury, and/or death.
HOW TO AVOID THE HAZARD
♦ Provide adequate ventilation of any enclosed trailer to
prevent build up of gasoline vapors, especially at floor
level.
♦ Refuel only outdoors, never inside an enclosed trailer.
♦ Be sure all fuel tanks and gasoline st or age containers
have proper caps installed to prevent spillage and
minimize vapor escaping into the trailer.
♦ Do not place any equipment that is leaking gasoline in
an enclosed trailer.
- 3 -
1.4 OPERATION
Although hazard control and accident prevention are parti al l y dependent upon the
design and configuration of the equipment, these factors are also dependent upon
the awareness, concern, prudence, and proper training of t he personnel i nvolved in
the operation, transport, maintenance, and st orage of t he equipment. It is essential
that all Operator Safety Mechanisms be connect ed and i n operat i ng condition prior
to use for mowing.
POTENTIAL HAZARD
♦ Operating engine parts, especially the m uffler, become
extremely hot.
WHAT CAN HAPPEN
♦ Severe burns can occur on contact.
♦ Debris, such as leaves, grass, brush, etc. can cat ch fire.
HOW TO AVOID THE HAZARD
♦ Allow engine parts, especially the muff ler , to cool before
touching.
♦ Remove accumulated debris from muffler and engine area.
♦ Install and maintain in working order a spar k arrester before
using equipment on forest - covered, grass-covered, or
brush-covered unimproved land.
WARNING
WARNING
POTENTIAL HAZARD
♦ Hands, feet, hair, clothing, or accessories can become
entangled in rotating part s.
WHAT CAN HAPPEN
♦ Contact with rotating parts can cause traum at ic am putation
or severe lacerations.
HOW TO AVOID THE HAZARD
♦ Do not operate the machine without guards, shields, and
safety devices in place and working properly.
♦ Keep hands, feet, hair, je welry, or clot hing away from
rotating parts.
1.4.1 Give complete, undivided attention to the job at hand.
1.4.2 Mow only in daylight or in good artif icial light, keeping away from holes and hidden
hazards. DO NOT operate the mower when children or others are in the area.
1.4.3 When f easible, avoid operating the equipment in wet grass.
1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tr action
and/or tip-over could occur. The operator is r esponsible for safe operation on
slopes.
- 4 -
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.
HOW TO AVOID THE HAZARD
♦ Mow across slopes, never up and down.
♦ Do not mow slopes when grass is wet.
♦ Do not mow near drop-offs or near water.
♦ Do not mow slopes greater than 20 degrees.
♦ Reduce speed and use extreme caution on slopes.
♦ Avoid sudden turns or rapid speed changes.
• See inside the back cover to determine the approximate slope angle of the
area to be mowed.
• Progressively greater care is needed as the slope increases.
• Always avoid sudden starting or stopping on a slope. If tires lose traction,
disengage the blades and proceed slowly off the slope.
• Be aware that loss of traction may occur going downhill. Weight transfer to
the front wheels may cause drive wheels to slip and cause loss of braking
and steering.
• Watch for ditches, holes, rocks, dips, and r ises t hat change the operating
angle, as rough terrain could overtur n the machine.
• Remove or mark obstacles such as rocks, t r ee lim bs, etc. from the mowing
area. Tall grass can hide obstacles.
• Use extreme care with grass catchers or attachments. These can change the
stability of the machine and cause loss of control.
1.4.5 Use EXTREME caution when backing up. LOOK BEHI ND YO U!!
1.4.6 Stop the blades when crossing surfaces other than grass, if mower must be tilted
for transportation, and when transpor t ing the mower to and from the area to be
mowed.
1.4.7 Never operate the mower with defective guards, shields, or covers. Always have
safety shields, guards, switches, and other devices in place and in proper work ing
condition.
1.4.8 Do Not change the engine governor set t ings or over speed the engine. Operating
an engine at excessive speed may increase the hazard of personal injury.
1.4.9 Place speed control lever in neutral, lock drive levers in neutra l, disengage PTO,
and engage park brake before starting engine.
1.4.10 Start the engine carefully with feet well away from the blades.
1.4.11 Keep hands, feet, and clothing away from rotating part s while the mower is being
operated.
1.4.12 Stop the engine, wait for all moving parts to stop, and r em ove plug wire(s) or key:
• Before checking, cleaning or work ing on the mower.
• After striking a foreign object (inspect the m ower for damage and make
repairs before restart ing and operating the mower).
• Before clearing blockages.
• Whenever you leave the mower.
- 5 -
1.4.13 Stop the engine and wait f or all moving parts to stop:
• Before removing grass catcher.
• Before refueling.
• Before making heig ht adjustments.
1.4.14 Before stopping the engine, place the throttle cont r ol midway between the “slow”
and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds, then stop
the engine.
1.4.15 The fuel system is pr ovided with a shut-off valve. The fuel shut-off valve is used
to shut off the fuel:
• When the machine will not be used for a few days.
• During transport to and f r om the job.
• When parking inside a building.
1.4.16 This mower was designed fo r one oper at or only. Keep all others away from
mower during operation.
1.4.17 Do NOT mow with the discharge deflector raised, r em oved or altered unless
there is a grass collection system or mulch k it in place and work ing properly.
1.4.18 Be aware of the mower discharge and direct discharge away from ot her s.
1.4.19 Do NOT operate the mower under the influence of alcohol or drugs.
1.4.20 Use extra care when approaching blind corners, shrubs, trees, or ot her objects
that may obscure vision.
1.4.21 If jump star ting is required:
a) Connect the positive (+) power cable from t he positive post on the booster
battery to the positive terminal post on the star ter solenoid switch (this post
has the positive battery cable attached to it).
b) Connect the negative or ground cable (-) from the negative post on the
booster battery to the engine block as far away from the battery as
possible.
c) Disconnect battery cables in the reverse order after starting.
1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maintenance, follow the engine m anufacture’s recommendations
precisely as stated in the engine manual.
1.5.2 Disconnect the battery from t he negative battery post when the unit will be
allowed to sit for more than 30 days without use.
1.5.3 Allowing batteries to stand for an extended period of time without recharging
them will result in reduced performance and ser vice life. To preserve optimum
battery performance and lif e, recharge batteries in storage when the open circuit
voltage drops to 12.4 volts.
Note: To prevent damage due to freezing, bat t er y should be fully charged before
putting away for winter storage.
1.5.4 Keep engine and engine area free from accumulation of grass, leaves, excessive
grease or oil, and other debris which can accumulate in these areas. These
materials can become combustible and may result in a fir e.
1.5.5 Store f uel in a container specifically designed for t his pur pose in a cool, dry place.
1.5.6 Keep the mower and fuel container in locked storage to prevent children from
playing or tampering with them.
- 6 -
1.5.7 Gasoline powered equipment or fuel containers should not be stored in a
d
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 maintaine
and operated correctly.
1.5.9 Check all bolts freq uently to maintain proper tightness.
1.5.10 Keep all guards, shields, and all safety devices in place and in safe working
condition.
1.5.11 Frequently check for worn or deteriorating components that could create a hazard.
1.5.12 All replacement parts must be the same as or eq uivalent t o the parts supplied as
original equipment.
WARNING
POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure can penetrat e
skin and cause injury.
WHAT CAN HAPPEN
♦ Fluid accidentally injected into the skin must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangrene ma y result .
HOW TO AVOID THE HAZARD
♦ Make sure all hydraulic fluid hoses and lines are in
good condition an all hydraulic connections and fittings
are tight before applying pressure to hydraulic system.
♦ Keep body and hands away from pinhole leaks or
nozzles that eject high pressure hydraulic fluid.
♦ Use cardboard or paper, not your hands, to f ind
hydraulic leaks.
♦ Safely relieve all pressure in the hydraulic system by
locking drive levers in neutral and shutting off the
engine before perfor ming any work on the hydraulic
system.
1.6 RIDING ATTACHMENTS
Use only Exmark riding attachments. The use of other than Exmark riding at tachments
may create a hazardous condition resulting in injury.
1.7 SAFETY SIGNS
1.7.1 Keep all safety signs legible. Remove all gr ease, dirt, and debris from safety
signs and instructional labels.
1.7.2 Safety sign s m ust be replaced if they are missing or illegible.
1.7.3 When new components are installed, be sur e that current safety signs are
affixed to the replaced components.
1.7.4 New safety signs may be obtained from your authorized Exmark equipment
dealer or distributor or fr om Exmar k Mfg. Co. Inc.
1.7.5 Safety signs may be affixed by peeling off the backing to expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.
1.7.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They
are critical to the safe operation of your Exmark commercial mower.
- 7 -
PART NO. 103-1541
LOCATION: Console
PART NO. 1-303517
LOCATION: LH Side of Rear Surface of
Engine Deck
For FMD524 & FMD604 Units with SN 540,000 & Higher
PART NO. 103-7491
LOCATION: On Top Front RH Surface of Mower Deck
PART NO. 1-303508
LOCATION: On Top RH Surface
of Mower Deck
PART NO. 1-513746
LOCATION: Surface of Engine
PART NO. 98-5954
LOCATION: Under LH, RH & Center Belt Shields
- 8 -
PART NO. 103-2242
LOCATION: LH Side of
Console
PART NO. 103-2243
LOCATION: RH Side of
Console
Type A Anti-Scalp Rollers Only – See Figure 9
PART NO. 1-323540
LOCATION: Front of Mower
Deck Top Surface
Deck Next to Muffler
PART NO. 1-403005
LOCATION: LH & RH Front Top
Surface of Mower Deck
p
PART NO. 1-403143
LOCATION: RH Rear Surface of Engine Deck
PART NO. 1-513747
LOCATION: To
Rear of Battery Cover
PART NO. 1-553049
LOCATION: On Top Front LH Surface of
Mower Deck
PART NO. 103-2239
LOCATION: Top of Mower Deck Beneath Center Shield
PART NO. 1-413214
LOCATION: Right Side of Hydro
Control Crank Arm
PART NO. 103-2432
LOCATION: Parking Brake
PART NO. 103-4935
LOCATION: Left Rear Top Corner
PART NO. 1-523552
LOCATION: On Top of
Lever
of Engine Deck
Hydraulic Tank
For FMD524 & FMD604 Units with SN 410,000 – 439,999
PART NO. 103-1077
LOCATION:
- 9 -
Front RH Side of Mower Deck
2. SPECIFICATIONS
2.1 MODEL NUMBER:
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 g asoline, 87 octane or higher. In countries
2.3.3 Fuel Filter: Replaceable in- line
2.3.4 Fuel Shut-Off Valve: 1/4 turn
2.4 ELECTRICAL SYSTEM:
2.4.1 Charging System: Flywheel Alternator
2.4.2 Charging Capacity: 15 amp
2.4.3 Battery Type: BCI Group U1 235 amps at O° F
2.4.4 Battery Voltage: 12 Volt; Polarity, negative ground.
2.4.5 Fuses: blade type, 20 amp to char ging circuit; 20 amp to electric clutch.
2.4.6 Safety Int er lock System: Operator must have OPC (Operator Presence Control)
Park brake must be diseng aged to move speed control out of neutral or engine
TT23KCC; TT23KAC; TT20KCC
using the research method, it should be a 90 oct ane minimum.
levers held in contact with handle grips, speed control lever in neutral, and PTO
disengaged to start eng ine. Release of OPC levers will cause the engine to stop
if speed control lever is not in neutral and/or PTO is engaged.
will kill.
2.5 STEERING CONTROL:
Fingertip drive control levers provide independent speed control, braking and neut ral
to each drive wheel for moving forward or reverse, st opping, and power turning.
2.6 TRANSMISSION:
2.6.1 Two Hydro Gear BDP-10A variable displacement piston pumps independently
coupled to two high efficiency Parker wheel drive motor s .
2.6.2 Hydraulic Oil: Use Mobil 1 15W-50 Synthet ic Motor O il.
2.6.3 Hydraulic Oil Capacity: 2.4 qt. (2. 2 L.)
2.6.3 Hydraulic Filter is replaceable cartridge type.
P/N 1-513211: 10 microns, 18 psi bypass (Summer use above 32°P/N 1-523541: 40 microns, 18 psi bypass (Winter use below 32° F (0° C))