Exmark FMD604 - Manuals

- 1 - 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. Thissymbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol appears above i...

- 2 - 1.3.4 Thoroughly inspect the area where the equipment is to be used and remove allstones, sticks, wires, bones, and other foreign objects which may damage theequipment or cause personal injury to the operator or bystanders. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, wh...

- 5 - 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 orengine deck, which may result in serious injury or death....

- 6 - 1.4.13 Stop the engine and wait for all moving parts to stop: • Before removing grass catcher. • Before refueling. • Before making height adjustments. 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...

- 7 - 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 arepresent. 1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly. 1.5.9 Chec...

- 11 - 2.6.5 Drive wheel release valves allow machine to be moved when the engine is notrunning 2.7 WHEEL DRIVE SYSTEM: Drive wheels are direct coupled to Parker wheel drive motors with 1.0" (25.4mm) tapered shaft. 2.8 TIRES Drive Front Caster Size .......................... 18 x 8.50-8 ...........

- 12 - 3. ASSEMBLY INSTRUCTIONS 3.1 UNCRATE UNIT 3.1.1 Remove tractor and mower deck from crates. 3.2 SERVICE BATTERY: The machine is shipped with a filled lead-acid battery. 3.2.1 Remove battery cover from machine. DANGER POTENTIAL HAZARD ♦ Charging the battery may produce explosive gasses WHAT CAN...

- 13 - NOTE: If the positive cable is also disconnected, connect the positive (red) cable first , then the negative (black) cable. Slip insulator boot over the positive terminal. NOTE: If time does not permit charging the battery, or if charging equipment is not available, connect the negative batte...

- 14 - FIGURE 1 SUPPORT PIN LOCATION 3.5.5 Mower Deck Stationary Idler Installation: Locate the two holes along the back center section of the deck and install thestationary idler and related parts (from bolt bag) in the right hand hole. SeeFigure 2. Be sure the coned end of the disc spring washer i...

- 15 - NOTE: The baffle is labeled “HOT” and “COLD”. The oil level varies with thetemperature of the oil. The “HOT” level shows the level of oil when it is at 225°F(107°C). The “COLD” level shows the level of the oil when it is at 75°F (24°C). Fillto the appropriate level depending upon the temperat...

- 17 - 4.1.11 Drive Wheel Release Valves: Located on the left rear corner of the hydrostaticpumps. Drive wheel release valves are used to release the hydro-static drivesystem to allow the machine to be moved by hand without the engine running. With a 5/8 wrench, turn both valves one turn counter-clo...

- 18 - 4.3.2 Stopping Engine: Lock drive levers in neutral, disengage PTO, move speedcontrol lever to neutral, and engage park brake. Move throttle to the “midway”position. Allow engine to run a minimum of 15 seconds. Rotate ignition switchto “Off” position. Remove key to prevent children or other u...

- 19 - CAUTION POTENTIAL HAZARD ♦ If the neutral lock latches are not completely engaged the drive levers could unexpectedly slip into theforward drive position. WHAT CAN HAPPEN ♦ If the drive levers slip into the drive position the unit could lurch forward and cause injury or propertydamage. HOW TO...

- 20 - right hand drive lever back into the reverse position while the opposite drive leveris in a forward position at an equal but opposite speed. For reverse: S queeze both drive levers into the reverse position. For smooth operation of this machine, avoid quick, jerky movements of the drivelevers...

- 22 - 5.1 PERIODIC MAINTENANCE 5.1.1 Check engine oil level. Service Interval: See Engine Owner's Manual a) Stop engine, wait for all moving parts to stop and make sure unit is on alevel surface. b) Check with engine cool. c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert th...

- 23 - d) Clean out any grass build-up from underside of deck and in deck dischargechute. e) Inspect blades and sharpen or replace as required. f) If blade removal is necessary, be careful of the sharp cutting edges of theblades. g) Re-install the blades (if they were removed) by placing a block of ...

- 25 - f) Start the engine and check for leaks. Stop engine and recheck oil level. 5.1.8 Check the battery charge. Allowing the batteries to stand for an extended period without recharging them willresult in reduced performance and service life. To preserve optimum batteryperformance and life, recha...

- 26 - IMPORTANT: Before re-installing new filter, fill it completely with Mobil 1 15W-50 and apply a thin coat of oil on the surface of the rubber seal. Turnfilter clockwise until rubber seal contacts the filter adapter. Do not tightenyet. d) Fill reservoir as stated in Section 5.1.9. e) Loosen fil...

- 27 - NOTE: It is necessary to lightly touch the charge pump cap with your hand to check the pump temperature. If the cap is too hot to touch, turn offengine. The pumps may be damaged if the pump becomes too hot. If either drive wheel still does not rotate continue with step (d). d) Thoroughly clea...

- 28 - ∗ See 5.1.14 Section c) for special lubrication instructions on the front caster pivots and Section 5.1.15 for special lubrication instructions on the front caster wheel hubs. No. 4 (Idler Pivot (Pump Drive))Located Under Engine Deck No. 3 & 4 (Idler Pivots)Disassemble and grease once amo...

- 30 - NOTE: Care must be used not to bond the bearing, next to each OPC hub, to the cross shaft which could cause binding of the OPC leversand erratic operation. b) Fuel tank studs where studs are inserted into tank. NOTE: When installing the nuts onto the fuel tank studs, fully tighten thenyloc nu...

- 32 - 5.2.4 Blade drive belt tension: No adjustment necessary. 5.2.5 Hydro Drive Linkage Adjustment: a) Adjust Speed Control Linkage and Neutral Safety Switch 1. Stop engine and wait for all moving parts to stop. 2. Move speed control lever (located on console) to the full forward position and chec...

- 33 - FIGURE 12 HYDRO DRIVE LINKAGE ADJUSTMENT 4. Loosen the nut against the neutral control linkage yoke as shown in Figure 12. 5. Adjust the neutral control linkage until the respective drive wheel stops when the lever is pulled against the neutral spring (neutral position).Turn the adjusting bol...

- 34 - Recheck the left drive wheel rotation to see if further adjustment isnecessary - be sure the speed control lever is in the neutral position. If inconsistent neutral occurs, check to be sure both springs areproperly tightened on the speed control lever under the console -especially the rear pi...

- 37 - h) Check for loose or faulty wiring connections. If it is necessary to disconnect wireconnectors, Do Not pull on the wires. i) Check for corrosion at all wiring connections. Even minor corrosion may cause afaulty connection. Clean connector terminals thoroughly, apply dielectric greaseand rec...

- 41 - SERVICE RECORD Date Description of Work Done Service Done By

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