Page 2 - IMPORTANT
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 p...
Page 4 - CONGRATULATIONS; on the purchase of your Exmark Mower. This product has been; BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS; contact your authorized Exmark equipment dealer or distributor.
- 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 andyears of trouble-free operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment, and safety ins...
Page 5 - TABLE OF CONTENTS; ASSEMBLY INSTRUCTIONS
- iii - TABLE OF CONTENTS 1. SAFETY ............................................................................................. PAGE 1.1 Safety Alert Symbol ...................................................................................... 11.2 Training ...........................................
Page 6 - CAUTION
- 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 in...
Page 7 - DO NOT
- 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...
Page 9 - EXTREME
- 4 - 1.4 OPERATION Although hazard control and accident prevention are partially dependent upon thedesign and configuration of the equipment, these factors are also dependentupon the awareness, concern, prudence, and proper training of the personnelinvolved in the operation, transport, maintenance,...
Page 11 - MAINTENANCE AND STORAGE; WARNING
- 6 - 1.5 MAINTENANCE AND STORAGE 1.5.1 For engine maintenance, follow the engine manufacture’s recommendations precisely as stated in the engine manual. 1.5.2 Disconnect the battery from the negative battery post when the unit will beallowed to sit for more than 30 days without use. 1.5.3 Allowing ...
Page 12 - RIDING ATTACHMENTS; Use only; Exmark; may create a hazardous condition resulting in injury.
- 7 - 1.6 RIDING ATTACHMENTS Use only Exmark riding attachments. The use of other than Exmark riding attachments may create a hazardous condition resulting in injury. 1.7 SAFETY SIGNS 1.7.1 Keep all safety signs legible. Remove all grease, dirt, and debris from safetysigns and instructional labels. ...
Page 15 - TORQUE REQUIREMENTS; ASSEMBLY INSTRUCTIONS; The machine is shipped with a wet battery.; Wash hands after handling.
- 10 - 2.9 MOWER DECK 2.9.1 Model Numbers: Serial Nos. 320,000 and higher: FMD604 and FMD524 NOTE: Turf Tracer units 320,000 and higher can only be used with FM604 and FMD524 units. 2.9.2 Cutting Width: 60 in. (152.4 cm.) 52 in. (132.1 cm.) 2.9.3 Discharge: Right Side 2.9.4 Optional Mulch Kit and Ba...
Page 16 - cable first
- 11 - 3.2.1 Remove battery cover from machine. Disconnect the battery cables (negative(black) cable first) and remove battery. DANGER POTENTIAL HAZARD ♦ Charging the battery may produce explosive gasses WHAT CAN HAPPEN ♦ Battery gasses can explode causing serious injury. HOW TO AVOID THE HAZARD ♦ K...
Page 17 - MOWER DECK INSTALLATION; FIGURE 1
- 12 - 3.4 DRIVE WHEELS 3.4.3 Check air pressure in drive tires; recommended pressure is 12-16 psi.Measure circumference of each drive tire. Adjust tire pressure within 12-16 psirange to try to make tire circumferences match as closely as possible. 3.5 MOWER DECK INSTALLATION 3.5.1 Release the wheel...
Page 18 - Mower Deck Stationary Idler Installation:; FIGURE 2; Carefully; SERVICE HYDRAULIC OIL; NOTE: UNIT IS NOT GREASED AT THE FACTORY.; FAMILIARIZE YOURSELF WITH THE CONTROLS.; See Maintenance and Adjustment Section 5.; HEX CAPSCREW
- 13 - 3.5.5 Mower Deck Stationary Idler Installation: Locate the two holes along the back center section of the deck (See Figure 2)and install the stationary idler and related parts (from bolt bag) in the right handhole. Be sure the coned end of the disc spring washer is against the head ofthe bolt...
Page 19 - OPERATION INSTRUCTIONS; Controls
- 14 - 4. OPERATION INSTRUCTIONS 4.1 Controls 4.1.1 Operator Presence Control (OPC) Levers: Located on the upper handleassembly directly above the handle grips. When these levers are depressed, the OPC system senses that the operator is in the normal operator'sposition. When the levers are released,...
Page 21 - IMPORTANT: Do not crank the engine continuously for more than ten; “neutral lock”; “forward”
- 16 - On a cold engine, place the throttle midway between the “Slow” and “Fast”positions and place the choke in the “On” position. On a warm engine, placethe throttle lever midway between “Slow” and “Fast” positions and leave thechoke in the “Off” position. Turn ignition switch to “Start” position....
Page 22 - For straight ahead motion: S
- 17 - FIGURE 4 DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION 4.3.4 Drive Wheel Engagement/Turning: With drive levers locked in neutral, shiftspeed control lever to desired forward speed. Slowly squeeze and hold bothdrive levers in the neutral position and rotate both neutral lock latches from the neutr...
Page 23 - PERIODIC MAINTENANCE
- 18 - 4.4 TRANSPORTING WARNING POTENTIAL HAZARD ♦ Loading the mower onto a trailer without strong enough or properly supported ramps could bedangerous. WHAT CAN HAPPEN ♦ The ramps could collapse causing the unit to fall, which could cause injury. HOW TO AVOID THE HAZARD ♦ Use proper ramps that are ...
Page 24 - See Engine Owner's Manual; operate the engine with oil level below the; Daily
- 19 - 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 thedipstick. DO NOT screw i...
Page 25 - FIGURE 5
- 20 - d) Clean out any grass build-up from underside of deck and in deckdischarge chute. e) Inspect blades and sharpen or replace as required. f) If blade removal is necessary, be careful for the sharp cutting edges ofthe blades. g) Re-install the blades (if they were removed) by placing a block of...
Page 28 - After First 250 hrs, then yearly thereafter.; Do not; Changing
- 23 - 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 doctorfamiliar with this form of injury or gangrene may result. HOW TO AVOID T...
Page 29 - FIGURE 6; If either drive wheel still does not rotate continue with step (d).
- 24 - CHARGE PUMP CAP LOOSEN 1-1/2TURNS ONLY 5.1.11 Hydraulic system air purge procedure.Air must be purged from the hydraulic system when any hydraulic components,including oil filter, are removed or any of the hydraulic lines are disconnected. The critical area for purging air from the hydraulic ...
Page 30 - Note: Front caster tires have permanent tire sealant installed.; LUBRICATION CHART; Service Interval: Once Yearly
- 25 - a) Stop engine, wait for all moving parts to stop, and remove key. Check airpressure in tires; recommended tire pressure is: rear, 12-16 psi; frontcasters, 15-17 psi. b) Inflate tires to pressures stated above. Measure circumference of eachdrive tire. Adjust tire pressures within the above ra...
Page 32 - Care must be used; not; to bond the bearing, next to each OPC
- 27 - c) Shoulder bolts in ends of speed control crank. e) OPC lever setscrews. f) Electric clutch retaining bolt. g) Pump drive idler pivot bolt. Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pro Pro-Lock RetainingI or Retaining II” are used on the following: a) OPC lever hubs and cross-sha...
Page 35 - Note: The neutral lock latches should still be “unlocked” and in the; left
- 30 - 4. Loosen the nut against the neutral control linkage yoke as shown in Figure 10. 5. Adjust the neutral control linkage until the respective drive wheel stops when the lever is pulled against the neutral spring (neutralposition). Turn the adjusting bolt approximately 1/4 turn clockwise ifthe ...
Page 36 - neutral; HYDRO PUMP SPRING TENSION SETTING
- 31 - 4. The spring that keeps tension on the knob should normally not need adjustment. However, if adjustment is needed, adjust to where lengthof spring is about 1” between washers. Adjust spring length byturning nut at front of spring. d) Drive Lever Linkage Adjustment1. With rear of machine stil...
Page 37 - DANGER
- 32 - 6. WASTE DISPOSAL 6.1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment. Dispose of usedoil at a certified recycling center or according to your state and local regulations. 6.2 BATTERY DISPOSAL DANGER POTENTIAL HAZARD ♦ Battery electrolyte contains sulfur...
Page 38 - ENGINE TROUBLESHOOTING; PROBLEM
- 33 - g) Check for loose or faulty wiring connections. If it is necessary to disconnectwire connectors, Do Not pull on the wires. h) Check for corrosion at all wiring connections. Even minor corrosion may causea faulty connection. Clean connector terminals thoroughly, apply dielectricgrease and rec...
Page 39 - HYDRAULIC SCHEMATIC
Page 43 - IS
- 38 - T H IS IS A 1 5 ° S L O P E T H IS IS A 1 0 ° S L O P E T H IS IS A 5 ° S L O P E ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) EXAMPL E : CO MP A R E SLOPE W ITH FOLDED EDGE. FOLD AL ONG APP R OPRI A T E L INE T HI S IS A 2 0 ° S L O P E
Page 44 - INDUSTRIAL PARK BOX 808
® MFG. CO. INC. SEE EXMARK’S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z ® LAZER Z ® HP LAZER Z ® XP TURF RANGER ® TURF TRACER ® TURF TRACER ® HP METRO ® METRO ® HP VIKING HYDRO ULTRA VAC ™ GRASS CATCHER SELF STEERING SULKY MICRO-MULCH ™ ACCESSORY WARNING The engine exhaust from this product con...
