Exmark Turf Ranger FMD524, Turf Ranger FMD604 Operator's Manual
For Turf Ranger
Serial Nos. 440,000 & Higher
and
FMD524 & FMD604
Serial Nos. 440,000 & Higher
Part No. 103-4867
WARNING
POTENTIAL HAZARD
♦ This product is a piece of power equipment.
WHAT CAN HAPPEN
♦ Failure to follow safe operating practices 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 condition.
♦ Stop engine and wait for all moving parts to stop. Remove spark
plug wire(s) or remove key before adjusting, servicing, or
performing maintenance.
♦ If mower deck becomes clogged, stop engine and wait for all
moving parts to stop. Remove spark plug wire(s) or remove key
before cleaning blockage.
♦ Keep hands, feet, and clothing away from power driven parts.
♦ Keep off mower unless seat platform is provided.
♦ Keep others off mower.
WARNING
POTENTIAL HAZARD
♦ Gasoline is harmful or fatal 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.
When the mower is used or operated on any California forest, brush or grass covered land, a working
spark arrester must be attached to the muffler. If not, the operator is violating state law, Section 4442
Public Resource Code. To acquire a spark arrester 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 conforme 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 Manual with your unit. Should this engine Owner’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 changes to products manufactured previously. Exmark, or its
distributors and dealers, accept no responsibility for variations which may be evident in the actual
specifications of its products and the statements and descriptions contained in this publication.
IMPORTANT
i
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
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.
2. Distributor ships part(s) to dealer or customer, as
requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus
central time, with an Exmark Parts Plus order of six (6) line items or less.
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by
distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.
order, he contacts Exmark by 3:00 p.m.,
5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in
accordance to the program.
6. Who pays for the part and freight if it fails to arrive overnight in accordance to the program?
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:
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.
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
Exmark pays for the part and freight.
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
pays for the part.
The following restrictions apply -- The Exmark Parts Plus Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available
only 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
Program are:
Any wholegood or accessory in its 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.
ii
CONGRATULATIONS on the purchase of your Exmark Mower. This product has been
carefully designed and manufactured to give you a maximum amount of dependability and
years of trouble-free operation.
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 life
of your mower, maintain its maximum efficiency, and promote safe operation.
If additional information is needed, or should you require trained mechanic service,
contact your authorized Exmark equipment dealer or distributor.
All Exmark equipment dealers and distributors are kept informed of the latest methods
of servicing and are equipped to provide prompt and efficient service in the field or at their
service stations. They carry ample stock of service parts or can secure them promptly for you
from the factory.
All Exmark parts are thoroughly tested and inspected before leaving the factory,
however, attention is required on your part if you are to obtain the fullest measure of
satisfaction and performance.
iii
TABLE OF CONTENTS
1. SAFETY PAGE
1.1 Safety Alert Symbol...................................................................................... 1
1.2 Training........................................................................................................ 1
1.3 Preparation ...............................................................................................1-3
1.4 Operation..................................................................................................4-6
1.5 Maintenance & Storage................................................................................7
1.6 Safety Signs..............................................................................................8-9
2. SPECIFICATIONS
2.1 Model Number............................................................................................ 10
2.2 Engine........................................................................................................ 10
2.3 Fuel System............................................................................................... 10
2.4 Electrical System........................................................................................ 10
2.5 Operator Controls....................................................................................... 10
2.6 Seat ........................................................................................................... 10
2.7 Hydrostatic Ground Drive System .............................................................. 10
2.8 Tires........................................................................................................... 11
2.9 Deck........................................................................................................... 11
2.10 Dimensions ............................................................................................... 11
2.11 Torque Requirements ............................................................................... 11
3. ASSEMBLY INSTRUCTIONS
3.1 to 3.8 Assembly..................................................................................... 12-15
4. CONTROLS .............................................................................................. 15-17
5. OPERATION INSTRUCTIONS
5.1 Pre-Start..................................................................................................... 17
5.2 Mowing.................................................................................................. 17-18
5.3 Transporting.......................................................................................... 18-19
6. MAINTENANCE & ADJUSTMENTS
6.1 Periodic Maintenance............................................................................ 19-27
6.2 Adjustments.......................................................................................... 27-33
7. WASTE DISPOSAL
7.1 Motor Oil Disposal...................................................................................... 34
7.2 Battery Disposal......................................................................................... 34
8. TROUBLE SHOOTING
8.1 Mower Cuts Unevenly ................................................................................ 34
8.2 Engine Will Not Start............................................................................. 34-35
9. WIRING DIAGRAMS..................................................................................... 36
10. WARRANTY................................................................................................. 37
iv
1.SAFETY
1.1 SAFETY ALERT SYMBOL
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:
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. Indicates an imminently hazardous
situation which, if not avoided, WILL result in death or serious injury.
WARNING: Black lettering / Orange background. Indicates a potentially hazardous
situation which, if not avoided, COULD result in death 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. Familiarize yourself with the controls and the
proper use of the equipment. If the operator(s) or mechanic(s) can not read
English, it is the owner’s responsibility to explain this material to 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.
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
1.3 PREPARATION
1.3.1 Evaluate the terrain to determine what accessories and attachments 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)
protection for the eyes, ears, feet, and head is recommended.
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.
- 1 -
1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all
stones, sticks, wires, bones, and other foreign objects, which may damage the
equipment or cause personal injury to the operator or bystanders.
1.3.5 Always set the park brake before starting the engine.
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 flammable
and highly explosive.
WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can burn you, others,
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 may 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 starting 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 that 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 until fuel vapors have
dissipated.
♦ Do not operate without the entire exhaust system in
place and in proper working condition.
- 2 -
DANGER
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable
and highly explosive.
WHAT CAN HAPPEN
♦ A static charge can ignite gasoline 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 filling.
♦ Do not fill gasoline containers inside a vehicle or on a
truck or trailer bed because interior carpets or plastic
truck bed liners may insulate the container and slow
the loss of any static charge.
♦ When practical, remove gas-powered equipment from
the truck or trailer and refuel 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 property
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 storage 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 partially dependent upon the
design and configuration of the equipment, these factors are also dependent
upon the awareness, concern, prudence, and proper training of the personnel
involved in the operation, transport, maintenance, and storage of the equipment.
It is essential that all Operator Safety Mechanisms be connected and in operating
condition prior to use for mowing.
WARNING
POTENTIAL HAZARD
♦ Operating engine parts, especially the muffler, become
extremely hot.
WHAT CAN HAPPEN
♦ Severe burns can occur on contact.
♦ Debris, such as leaves, grass, brush, etc. can catch fire.
HOW TO AVOID THE HAZARD
♦ Allow engine parts, especially the muffler, to cool before
touching.
♦ Remove accumulated debris from muffler and engine area.
♦ Install and maintain in working order a spark arrester before
using equipment on forest-covered, grass-covered, or
brush-covered unimproved land.
WARNING
POTENTIAL HAZARD
♦ Hands, feet, hair, clothing, or accessories can become
entangled in rotating parts.
WHAT CAN HAPPEN
♦ Contact with rotating parts can cause traumatic amputation
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, jewelry, or clothing away from
rotating parts.
1.4.1 Give complete, undivided attention to the job at hand.
1.4.2 Mow only in daylight or good artificial light, keeping away from holes and
hidden hazards. NEVER carry passengers. DO NOT operate the mower
when children or others are in the area.
1.4.3 When feasible, avoid operating the equipment in wet grass.
1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of traction
and/or tip-over could occur. The operator is responsible for safe operation on
slopes.
- 4 -
DANGER
G0083
POTENTIAL HAZARD
♦ Mowing on wet grass or steep slopes can cause sliding and
loss of control.
WHAT CAN HAPPEN
♦ Wheels dropping over edges, ditches, steep banks, or
water can cause rollovers, which may result in serious
injury, death or drowning.
HOW TO AVOID THE HAZARD
♦ Mow up and down slopes.
♦ Do not mow slopes when grass is wet.
♦ Do not mow near drop-offs or near water.
♦ Do not mow slopes greater than 15 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.
• Use a walk behind mower and\or a hand trimmer near drop-offs, ditches,
steep banks or water. This area can be dangerous, see Figure 1.
Figure 1
SAFE ZONE FOR MOWING
• Progressively greater care is needed as the slope increases.
• Always avoid sudden starts and turns.
• Be aware that loss of traction may occur going downhill. Weight transfer to
the front wheels may cause rear wheel to lift off ground cause loss of
steering.
• Watch for ditches, holes, rocks, dips, and rises that change the operating
angle, as rough terrain could overturn the machine.
• Remove or mark obstacles such as rocks, tree limbs, 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 BEHIND YOU!
1.4.6 Stop the blades when crossing surfaces other than grass and when
transporting the mower to and from the area to be mowed.
- 5 -
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
working condition.
1.4.8 Do Not change the engine governor settings or overspeed the engine. Operating
an engine at excessive speed may increase the hazard of personal injury.
1.4.9 Disengage PTO 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 parts while the mower is
being operated.
1.4.12 Stop the engine, wait for all moving parts to stop, and remove key:
a) Before checking, cleaning, or working on the mower.
b) After striking a foreign object (inspect the mower for damage and
make repairs before restarting and operating the mower).
c) Before clearing blockages.
d) Whenever you leave the mower.
1.4.13 Stop the engine and wait for all moving parts to stop:
a) Before refueling.
b) Before making height adjustments.
c) Before dumping the grass catcher.
1.4.14 Before stopping the engine, place the throttle control midway between the
“slow” and “fast” positions. Allow the engine to run a minimum of 15 seconds,
then stop the engine.
1.4.15 The fuel system is provided with a shut-off valve. The fuel shut-off valve is
used to shut off the fuel when:
a) The machine will not be used for a few days.
b) During transport to and from the job.
c) When parking inside a building.
1.4.16 This mower was designed for one operator only. Keep all others away from
mower during operation.
1.4.17 Do Not mow with the discharge deflector raised, removed or altered unless
there is a grass collection system or mulch kit in place and working properly.
1.4.18 Be aware of the mower discharge and direct discharge away from others.
1.4.19 Do NOT operate the mower under the influence of alcohol or drugs.
1.4.20 Use care when approaching blind corners, shrubs, trees, other objects that
may obscure vision.
1.4.21 If jump starting is required:
a) Connect the positive (+) power cable from the positive post on the
booster battery to the positive terminal post on the starter solenoid switch
(this post has the positive battery cable attached to it).
b) Connect the negative or ground cable (-) to the negative post on the battery
to any engine deck ground, preferably the engine block as far away from
the battery as possible.
c) Disconnect battery cables in the reverse order after starting.
- 6 -
1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maintenance, follow the engine manufacturer’s recommendations
precisely as stated in the engine manual.
1.5.2 Disconnect the battery cable form the 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 service life. To preserve optimum
battery performance and life, recharge batteries in storage when the open
circuit voltage drops to 12.4 volts.
NOTE: To prevent damage due to freezing, battery 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 fire.
1.5.5 Store fuel in a container specifically designed for this purpose 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.
1.5.7 Gasoline powered equipment or fuel containers should not be stored in a
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 maintained and operated correctly.
1.5.9 Check all bolts frequently 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 equivalent to the parts supplied
as original equipment.
WARNING
POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure can penetrate
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 may 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 find
hydraulic leaks.
♦ Safely relieve all pressure in the hydraulic system by
letting the foot pedal return to neutral and shutting off
the engine before performing any work on the
hydraulic system.
- 7 -
1.6 SAFETY SIGNS
1.6.1 Keep all safety signs legible. Remove all grease, dirt, and debris from safety
signs and instructional labels.
1.6.2 Safety signs must be replaced if they are missing or illegible.
1.6.3 When new components are installed, be sure that current safety signs are
affixed to the replaced components.
1.6.4 New safety signs may be obtained from your authorized Exmark equipment
dealer or distributor or from Exmark Mfg. Co. Inc.
1.6.5 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.
1.6.6 Familiarize yourself with the following safety signs and instruction labels. They
are critical to the safe operation of your Exmark commercial mower.
PART NO. 1-553049
LOCATION: On Top Front LH
Surface of Mower Deck
PART NO. 1-543624
LOCATION: Front Right
Foot Support
PART NO. 1-553040
LOCATION: Top Surface of Hydraulic
Reservoir
PART NO. 1-513747
LOCATION: Top Front of Battery Cover
PART NO. 1-513746
LOCATION: Surface of Engine
Deck Next to Muffler
PART NO. 103-1077
LOCATION: Front RH Side of
PART NO. 103-2432
LOCATION: Left Side of
Brake Lever
Mower Deck
FMD524 & FMD604 units only
PART NO. 103-2239
LOCATION: Top of Mower Deck
Beneath Center Shield
PART NO. 1-303508
LOCATION: On Top RH Surface
of Mower Deck
- 8 -
PART NO. 98-5954
LOCATION: Under Belt Shields
PART NO. 1-403005
LOCATION: LH & RH Front Top
Surface of Mower Deck
PART NO. 1-543620
LOCATION: On Intake Screen Below Fuel Tank
PART NO. 1-323540
LOCATION: Front of Mower Deck, Top Surface
PART NO. 103-2248
LOCATION: Steering Console
PART NO. 1-543896
LOCATION: Under Engine Deck on
Wood Blocks for Shipping
- 9 -
Loading...