Exmark FR524, FR724, FR604 User Manual

FR524/FR604/

FR724

ForSerialNos.
720,000&Higher

PartNo.4500-230Rev.A

Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.

©2005–2008—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310

Contactusatwww.Exmark.com.

2

PrintedintheUSA.

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkCuttingDeck.Thisproducthasbeen
carefullydesignedandmanufacturedtogiveyou
amaximumamountofdependabilityandyearsof
trouble-freeoperation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.

Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready .

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

3

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.......................7

Specications.........................................................9

ModelNumbers..............................................9

Systems...........................................................9

Dimensions.....................................................9

TorqueRequirements....................................10

Setup....................................................................11

AssembleDecktoFrontRunner.....................11

DeckRemoval...............................................13

ProductOverview................................................14

Operation.............................................................14

DeckRaisingandLowering...........................14

Maintenance.........................................................17

RecommendedMaintenanceSchedule(s)...........17

PeriodicMaintenance.......................................17

CheckMowerBlades.....................................17

CheckforLooseHardware............................18

CheckTirePressures.....................................18

ChangeGearboxOil......................................18

LubricateGreaseFittings...............................19

ThreadLockingAdhesives.............................19

Adjustments.....................................................20

DeckLeveling...............................................20

CasterPivotBearingsPre-load

Adjustment...............................................20

Cleaning...........................................................21

CleanGrassBuild-UpUnderDeck................21

Troubleshooting...................................................22

4

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.

•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.

Preparation

•DoNotmodifytheFrontRunnercuttingdeck.

•OnlyuseonmachinesapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.

CAUTION

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadthetractorandcuttingdeckOperator’s
Manualsandothertrainingmaterial.Ifthe
operator(s)ormechanic(s)cannotreadEnglish
itistheowner’sresponsibilitytoexplainthis
materialtothem.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

Operation

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

•Neverfoldthedeckwithbladesrunning.

•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

5

Safety

WARNING

Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.

•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.

MaintenanceandStorage

•DisengagePTO ,setparkingbrake,stopengine
andremovekeyordisconnectsparkplugwire.
Waitforallmovementtostopbeforeadjusting,
cleaningorrepairing.

•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplaceblades.Neverstraightenor
weldthem.

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

6

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

Safety

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

1-303508

1-633922

1-403005

1-643222

98–5954

7

Safety

103-8425

109-2376

109-2354

109-2359

109-2993

109-3148

8

Specications

ModelNumbers

SerialNos:720,000andHigher

FR524;FR604;FR724

Specications

Systems

Tires&Wheels

FrontCaster

Type

Quantity

Tread

Size9x3.50–4

CuttingDeck

•ModelNumbers:

–FR524

–FR604

–FR724

•CuttingWidth:

–52inchDeck:52inch(132cm)

–60inchDeck:60inch(152cm)

–72inchDeck:72inch(183cm)

•Discharge:Side

•BladeSize:(3ea.)

–52inchDeck:18.00inches(45.7cm)

Semi-Pneumatic

2

Smooth

•Deck:

Fulloatingdeckisattachedtoout-frontsupport
frame.Sixanti-scalprollersprovidemaximum
turfprotection.Deckdesignallowsforbagging,
mulching,orsidedischarge.

•DeckDepth:

–52inchDeck:51/2inches(14cm)

–60inchDeck:51/2inches(14cm)

–72inchDeck:51/2inches(14cm)

•CuttingHeightAdjustment:

Adjustsfrom1inch(2.5cm)to5inches(12.7cm)
innitelyvariable

•MulchingKit:Optional

Dimensions

OverallWidth:

52inch
Deck

Deector
Down

Deector
Up

64.6inches
(164.1cm)

53.9inches
(136.9cm)

60inch
Deck

72.7inches
(184.7cm)

61.4inches
(156.0cm)

72inch
Deck

84.4inches
(214.4cm)

73.3inches
(186.2cm)

–60inchDeck:20.50inches(52.1cm)

–72inchDeck:24.50inches(62.2cm)

•DeckDrive:

–Shaftdrivetogearboxatrearofdeck.

–Beltdrivefromgearboxtobladespindles.

OverallLength:

52inchDeck60inchDeck72inchDeck

42.5inches
(108.0cm)

42.3inches
(107.4cm)

OverallHeight:

52inchDeck60inchDeck72inchDeck

18.0inches
(45.7cm)

9

18.0inches
(45.7cm)

45.5inches
(115.6cm)

18.0inches
(45.7cm)