Exmark Turf Ranger FMD524 Operator'S Manual Download Page 42

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ENGINE TROUBLESHOOTING TABLE

PROBLEM

FUEL

IMPROPER

FUEL

DIRT IN

FUEL LINE

DIRTY AIR

FILTER

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

AIR

SCREEN

Will not start

X X X

Hard starting

X X X

Stops suddenly

X X X

Lacks power

X X X X X

Operates erratically

X X X X

Knocks or pings

X X

Skips or misfires

X X

Backfires

X X X

Overheats

X X

High fuel
consumption

X X X

Summary of Contents for Turf Ranger FMD524

Page 1: ...For Turf Tracer Serial Nos 510 000 Higher and FMD524 FMD604 Serial Nos 510 000 Higher Part No 103 9190 ...

Page 2: ...om eyes and skin Never siphon by mouth IMPORTANT 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 0...

Page 3: ...bmitting 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 res...

Page 4: ...wer 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 st...

Page 5: ... 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 12 Assembly 12 15 4 OPERATION INSTRUCTIONS 4 1 Controls 15 17 4 2 Pre Start 17 4 3 Operation Instructions 17 19 4 4 Transporting 20 5 MAINTENANCE ADJUSTMENTS 5 1 Periodic Maintenance 20 29 5 2 Adjustments 30 35 6 WASTE DISPOSAL 6 1 Motor Oil Disposal 35 6 2 Battery Disposal 35 7 TROUBLE SHO...

Page 6: ...perator 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 Ke...

Page 7: ...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 t...

Page 8: ...e 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 ...

Page 9: ...stall 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...

Page 10: ...ocks 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 if mower must be tilted for transportation and when transporting the mower to and fro...

Page 11: ...tive terminal post on the starter 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 afterstarting 1 5 MAINTENANCE AND STORAGE 1 5 1 For engine maintenance follow the engine manufactur...

Page 12: ...ying 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 locking drive levers in neutral and shutting off the engine before performing any work on the hydraulic system 1 6 RIDING ATTACHMENTS Use only Exmark rid...

Page 13: ... PART NO 1 513746 LOCATION Surface of Engine Deck Next to Muffler Type A Anti Scalp Rollers Only See Figure 9 PART NO 1 323540 LOCATION Front of Mower Deck Top Surface For FMD524 FMD604 Units with SN 540 000 Higher PART NO 103 7491 LOCATION On Top Front RH Surface of Mower Deck PART NO 98 5954 LOCATION Under LH RH Center Belt Shields PART NO 103 2242 LOCATION LH Side of Console PART NO 103 2243 LO...

Page 14: ...O 103 4935 LOCATION Left Rear Top Corner of Engine Deck PART NO 1 413214 LOCATION Right Side of Hydro Control Crank Arm PART NO 1 523552 LOCATION On Top of Hydraulic Tank PART NO 103 2239 LOCATION Top of Mower Deck Beneath Center Shield PART NO 103 2432 LOCATION Parking Brake Lever For FMD524 FMD604 Units with SN 410 000 439 999 PART NO 103 1077 LOCATION Front RH Side of Mower Deck ...

Page 15: ...C levers will cause the engine to stop if speed control lever is not in neutral and or PTO is engaged Park brake must be disengaged to move speed control out of neutral or engine will kill 2 5 STEERING CONTROL Fingertip drive control levers provide independent speed control braking and neutral to each drive wheel for moving forward or reverse stopping and power turning 2 6 TRANSMISSION 2 6 1 Two H...

Page 16: ... 1 Overall Width w 52 Deck w 60 Deck Discharge chute down 64 2 163 1 cm 72 2 183 4 cm Discharge chute up 53 4 135 6 cm 61 4 156 0 2 10 2 Overall Length w 52 Deck w 60 Deck 83 4 211 8 cm 83 4 211 8 cm 2 10 3 Curb Weight w 52 Deck w 60 Deck 720 lbs 327 kg 760 lbs 345 kg Weights will vary slightly depending on engine and handle option 2 10 4 Overall Height 45 114 3 cm 2 10 5 Tread Width to outside of...

Page 17: ...nnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart below for recommended charger settings Voltage Reading Percent Charge Maximum Charger Settings Charging Interval 12 6 or greater 100 16 volts 7 amps No Charging Required 12 4 12 6 75 100 16 volts 7 amps 30 Minutes 12 2 12 4 50 75 16 volts 7 amps 1 Hour ...

Page 18: ...ck support pins and by removing the two hairpins and spacers from the rear deck support pins See Figure 1 3 5 3 Install mower deck support frame to tractor engine deck and secure using 8 3 8 16 x 1 1 4 screws 8 disc spring washers and 8 whizlock nuts from bolt bag See Figure 1 NOTE Place spring washer cone side against bolt head cupped side away from head and install to outside of support frame as...

Page 19: ...ler Position the belt into the V groove of the mower deck drive sheave Carefully release the spring loaded idler Install the center belt shield 3 5 7 Adjust cutting height of deck and anti scalp rollers See Adjustment Section 5 2 1 3 6 POSITION DISCHARGE CHUTE Loosen two 2 5 16 nyloc nuts attaching discharge chute Lower the discharge chute into position Retighten nyloc nuts until chute is snug but...

Page 20: ...operator s position When the levers are released the OPC system senses that the operator has moved from the normal operating position and will kill the engine if either the speed control lever is not in the neutral position or the PTO is engaged 4 1 2 Drive Levers Located on each side of the upper handle assembly directly below the handle grips See Figure 3 These levers individually control the sp...

Page 21: ...r engine will kill 4 1 8 Ignition Switch Located on the control console The ignition switch is used to start and stop the engine The ignition switch has three positions Off On and Start Insert key into switch and rotate clockwise to the On position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Operator must have speed control ...

Page 22: ...and cylinder head will require more frequent service See Engine Owner s Manual Do not add oil to gasoline Do Not overfill fuel tank Never fill the fuel tank so that the fuel level rises above a level that is 1 2 below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage 4 2 2 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary inspection an...

Page 23: ...nd rotate them under the drive levers into the neutral lock position See Figure 4 b Release the drive levers CAUTION POTENTIAL HAZARD If the neutral lock latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position WHAT CAN HAPPEN If the drive levers slip into the drive position the unit could lurch forward and cause injury or property damage HOW TO A...

Page 24: ...neutral position Move the neutral lock latches into the neutral lock position and release drive levers Move the speed control lever to the neutral position 4 3 6 PTO Engagement DANGER POTENTIAL HAZARD The rotating blades under the mower deck are dangerous WHAT CAN HAPPEN Blade contact can cause serious injury or kill you HOW TO AVOID THE HAZARD DO NOT put hands or feet under the mower or mower dec...

Page 25: ...opes Do not rely solely on the parking brake to hold the machine on the trailer Be sure that the trailer has all necessary lighting and marking as required by law and use a safety chain 5 MAINTENANCE ADJUSTMENTS WARNING POTENTIAL HAZARD While maintenance or adjustments are being made someone could start the engine WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or othe...

Page 26: ... intake and around the hydraulic pumps can create a fire hazard HOW TO AVOID THE HAZARD Clean all debris from around the engine and hydraulic pumps daily a Stop engine wait for all moving parts to stop and remove key b Clean all debris from engine air intake screen around engine shrouding and around the hydraulic pumps 5 1 3 Clean grass build up under deck Service Interval Daily a Stop engine wait...

Page 27: ...r the deck causing serious injury or property damage HOW TO AVOID THE HAZARD Replace the blade bolt after striking a foreign object Use only Exmark replacement parts PN 103 0862 blade bolt and PN 103 0865 spring disc washer DO NOT lubricate the threads of the bolt or spindle before assembly Torque the blade bolt to 115 120 ft lbs 156 163 N m FIGURE 5 BLADE BOLT INSTALLATION For Serial Nos 540 000 ...

Page 28: ...e Interval Daily a Check starting circuit Starter should crank with Operator Presence Control levers depressed speed control lever in neutral and PTO disengaged Try to start the engine with OPC levers disengaged speed control lever in neutral and PTO disengaged starter MUST NOT crank Try to start with OPC levers depressed speed control lever in any speed but neutral and PTO disengaged starter MUST...

Page 29: ...ips 5 1 8 Change engine oil Service Interval See Engine Owner s Manual NOTE Change oil after first five 5 hours of operation Follow engine manufacturers recommendations for future oil changes a Stop engine wait for all moving parts to stop and remove key b Drain oil while engine is warm from operation c Oil drain valve is located on the right hand side of Kohler engines and the left hand side for ...

Page 30: ...ure 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 Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C fill halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C fill only to the COLD level 5 1 11 Change hydr...

Page 31: ...ion once the charge pump is primed FIGURE 7 CHARGE PUMP LOCATION a Stop engine and wait for all moving parts to stop Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off the ground b Check oil level as stated in Section 5 1 10 c Start engine and move throttle control ahead to full throttle position Move the speed control lever to the middle speed position and...

Page 32: ...manent tire sealant installed 5 1 14 Inspect Belt wear Service Interval 40 hrs a Stop engine wait for all moving parts to stop and remove key b Remove the three mower deck belt shields to check mower primary and secondary belt condition c Look under engine deck to check the pump drive belt condition d Check all idler arms to be sure they pivot freely 5 1 15 Lubrication a Stop engine wait for all m...

Page 33: ...om the outer surface of the spacer nut to the end of the axle inside the nut i Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing h With the open end of the wheel facing up fill the area inside the wheel around the axle full of NGLI grade 1 multi purpose grease i Insert the second bearing and new seal into the wheel j Apply a thread locking adhe...

Page 34: ... the following fasteners a Pump drive sheave setscrews b Square head setscrews on Hydro pump control arms c Shoulder bolts in ends of speed control crank e OPC lever setscrews f Electric clutch retaining bolt g Pump drive idler pivot bolt h Fuel tank bulkhead fitting threads i Thumb latch screw threads on handles j Caster wheel spacer nuts Reference Section 5 1 16 h Cutter housing spindle nut Adhe...

Page 35: ...d a Stop engine and wait for all moving parts to stop b Install hairpin clips in the holes for the desired cutting height See Figure 9 IMPORTANT To maintain correct cutting height and rake check the following for proper adjustment 1 The front and rear hairpins are in the same holes with the proper spacers under the hair pins See Figure 8 2 The tire pressures are set as directed in Section 5 1 13 3...

Page 36: ...itions it may be necessary to position the anti scalp rollers one or two holes higher than described in c to prevent damage to the rollers and or bolt failure See Figure 10 NOTE When anti scalp rollers are placed in these positions reduced deck flotation will result 5 2 2 Pump drive belt tension adjustment No adjustment necessary 5 2 3 Mower deck drive belt No adjustment necessary 5 2 4 Blade driv...

Page 37: ... sure you have not reached the end of the neutral lock latch slot If you have shorten the drive lever linkage If the wheel turns while holding the drive lever in neutral the neutral control linkages need to be adjusted If wheels stop then go to step 7 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 contro...

Page 38: ... wheel rotation to see if further adjustment is necessary be sure the speed control lever is in the neutral position If inconsistent neutral occurs check to be sure both springs are properly tightened on the speed control lever under the console especially the rear pivot spring Repeat above adjustments if necessary 3 Place the speed control lever in neutral Adjust the right side linkage by turning...

Page 39: ...o Pump Spring Tension Setting a For medium or heavy duty drive conditions such as operation with a sulky on steep slopes a higher spring force may be required on the hydro pump control arms to prevent the drive system from stalling b For a heavier drive setting relocate the spring anchor link as shown in Figure 15 The spring anchor links are located under the engine deck on the left and right hand...

Page 40: ...rns WHAT CAN HAPPEN Swallowing electrolyte can be fatal or if it touches skin can cause severe burns HOW TO AVOID THE HAZARD Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do not swallow electrolyte Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal stat...

Page 41: ... are depressed f Check that there is fuel in the tank and that the fuel valve is open g Check that the spark plug wires are properly connected h Check for loose or faulty wiring connections If it is necessary to disconnect wire connectors Do Not pull on the wires i Check for corrosion at all wiring connections Even minor corrosion may cause a faulty connection Clean connector terminals thoroughly ...

Page 42: ...OADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN Will not start X X X X X X Hard starting X X X X X X X Stops suddenly X X X X X X X Lacks power X X X X X X X X Operates erratically X X X X X X X Knocks or pings X X X Skips or misfires X X X X X Backfires X X X X X Overheats X X X X X High fuel consumption X X X X ...

Page 43: ... 38 8 HYDRAULIC SCHEMATIC ...

Page 44: ... 39 9 WIRING DIAGRAM ...

Page 45: ...with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extend...

Page 46: ... 40 SERVICE RECORD Date Description of Work Done Service Done By ...

Page 47: ...L O P E T H IS IS A 1 0 S L O P E TH IS IS A 5 S L O P E ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC EXAMPLE COMPARE SLOPE WITH FOLDED EDGE FOLD ALONG APPROPRIATE LINE T H I S I S A 2 0 S L O P E ...

Page 48: ...ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1997 2005 EXMARK MFG CO INC PART NO 103 9190 INDUSTRIAL PARK BOX 808 402 223 6300 BEATRICE NE 68310 FAX 402 223 ...

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