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Exmark FMD524 - page 1
For Turf Tracer Serial Nos. 510, 000 & Higher and FMD524 & FM D604 Serial Nos. 510, 000 & Higher Part No. 103-9190 ...
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Exmark FMD524 - page 2
WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment . W HAT CAN HAPPEN ♦ Failure to f ollow safe operating practices can result in ser ious operator inj ur y or even death. HOW TO AVO ID T HE HAZARD ♦ Keep all shields, guar ds, and saf ety devices (especially the grass discharge system) in place and in pr oper working cond ...
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Exmark FMD524 - page 3
- i - EXMARK PA RTS PLUS ® PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not have the Exmark part in stock, Exmark w ill 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 "dow n" unit at the time of ...
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Exmark FMD524 - page 4
- ii - CONGRAT ULATIONS on the purchase of your Exmark Mow er . This product has been caref ully designed and m anufact ur ed t o give you a maximum amount of dependability and years of tr ouble- fr ee oper at ion. OPERA TOR'S M ANUA L This manual cont ains assem bly, oper at ing , maint enance, adj ustment, and saf ety instructi ons for your ...
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Exmark FMD524 - page 5
- iii - TA BLE OF CONTENTS 1. SA FETY .............................................................................................PAGE 1.1 Sa f ety A lert Sy mbol ...................................................................................... 1 1.2 Trai ning ................................................................................... ...
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Exmark FMD524 - page 6
- 1 - 1. SA FETY 1.1 SA FETY A LERT SYMBOL This SAFET Y ALERT SYMBOL is used both in this manual and on t he machine to identif y import ant saf et y messages which must be f ollowed to avoid accidents. T his symbol means: A TTENTION! BECOME A LE RT! YOUR SA FETY IS IN VOLVED! The saf ety alert symbol appears above infor m at ion which alerts you t ...
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Exmark FMD524 - page 7
- 2 - 1.3.4 Thoroug hly inspect the area where the equipm ent is to be used and remove all stones, stick s, wires, bones, and other f oreig n obj ects which may damage the equipment or cause per sonal inj ury to the operator or bystanders. WA RNING POTENT IAL HAZARD ♦ Engine exhaust contains carbon m onoxide, which is an odorless deadly poison. W ...
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Exmark FMD524 - page 8
- 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flam m able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g asoline vapors. A f ir e or explosion from g asoline can burn you, others, and cause property damag e. HOW TO AVO ID T HE HAZARD ♦ Purchase and store g asoline only in an approved c ...
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Exmark FMD524 - page 9
- 4 - 1.4 OPERA TION Although hazard control and acci dent prevent ion are partial l y dependent upon t he design and configurat i on of t he equipment, t hese f act ors are al so dependent upon the awareness, concern, prudence, and proper t r ai ni ng of the personnel invol ved in the operation, t r ansport , mai nt enance, and storage of the equi ...
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Exmark FMD524 - page 10
- 5 - DA NGER POTENT IAL HAZARD ♦ Mow ing on wet gr ass or steep slopes can cause sliding and loss of cont r ol. W HAT CAN HAPPEN ♦ Loss of cont r ol and/ or loss of oper at or ’s f ooting could result in a fall with an arm or leg gett ing under t he m ower or engine deck , which may result in ser ious inj ur y or deat h. HOW TO AVO ID T HE H ...
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Exmark FMD524 - page 11
- 6 - 1.4.13 Stop the eng ine and wait f or all moving par t s t o st op: • Before remov ing grass catcher. • Before refueli ng. • Befor e m ak ing heig ht adj ustments. 1.4.14 Befor e st opping the engine, place the throt t le control midw ay between the “slow” and “f ast ” posit ions. Allow the engine to r un a m inim um of 15 secon ...
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Exmark FMD524 - page 12
- 7 - 1.5.7 Gasoline powered equipment or fuel cont ainer s should not be st ored in a basement or any enclosed area where open pilot lig ht s or heat appliances are present. 1.5.8 Max imum mowing result s and saf ety can only be achieved if the mower is proper ly maintaine d and operated corr ect ly. 1.5.9 Check all bolts fr eq uently to maint ain ...
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Exmark FMD524 - page 13
- 8 - PART NO. 103- 1541 LOCATI ON: Console PART NO. 1- 403005 LOCATIO N: LH & RH Front T op Surfac e of Mower Deck PART NO. 1- 303508 LOCATIO N: On Top RH Sur face of Mower Deck PART NO. 1- 303517 LOCATI ON: LH Side of Rear Sur face of Engine Deck PART NO. 1- 513746 LOCAT ION: Surfac e of Engine Deck Next to Muffler Type A Anti-Scalp Rollers O ...
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Exmark FMD524 - page 14
- 9 - PART NO. 1- 403143 LOCATIO N: RH Rear Surf ace of Engine Dec k PART NO. 1- 513747 LO CATI ON: To p Rear of Batter y Cover PART NO. 1- 553049 LOCATIO N: On T op Front LH Surfac e of Mower Deck PART NO. 103- 4935 LOCATIO N: Left Rear T op Corner of Engine Deck PART NO. 1- 413214 LOCATI ON: Right Side of Hydro Control Crank Arm PART NO. 1- 52355 ...
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Exmark FMD524 - page 15
- 10 - 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: TT 23KCC; TT 23KAC; TT 20KCC 2.2 ENGINE 2.2.1 Engine Specif icat ions: See your Engine Owner's Manual. 2.2.2 3600 RPM (No Load). 2.3 FUEL SYSTEM 2.3.1 Capacity: 5.0 g al. ( 18.9 L.) 2.3.2 Type of Fuel: Regular unl eaded gasoline, 87 octane or hig her. In count ries using the r esear ch m et hod, it ...
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Exmark FMD524 - page 16
- 11 - 2.8 TIRES Driv e Front Caster Siz e .......................... 18 x 8 .50-8 ..........................11 x 4.0-5 Quant ity ............................ 2 ........................................ 2 Trea d ........................ Turf Master ........................... Smoo th Pl y Rating ......................... 4 .......................... ...
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Exmark FMD524 - page 17
- 12 - 3. A SSEM BLY INSTRUCTIONS 3.1 UNCRA TE UNIT 3.1.1 Remove tractor and m ower deck f rom cr at es. 3.2 SERVICE BATTERY: The ma chine is ship ped with a filled lead-acid b attery. 3.2.1 Remove battery cover fr om machine. DA NGER POTENT IAL HAZARD ♦ Charging t he bat tery may produce explosive gasses W HAT CAN HAPPEN ♦ Battery gasses can e ...
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Exmark FMD524 - page 18
- 13 - NOTE: If the positive cable is also disconnected, connect the posit i ve (red) cable first , then the neg at ive (black) cable. Slip insulat o r boot over t he posit ive termina l. NOTE: If t ime does not perm it char ging t he bat t ery, or if charging eq uipment is not available, connect the neg ative battery cables and run t he vehicle co ...
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Exmark FMD524 - page 19
- 14 - FIGURE 1 SUPPORT PIN LOCAT I ON 3.5.5 Mow er Deck Stationar y Idler I nst allation: Locate the two holes along t he back center section of the deck and install the stationary idler and r elat ed par ts (f rom bolt bag ) in the rig ht hand hole. See Figure 2. Be sur e t he coned end of the disc spr ing washer is ag ainst t he head of the bolt ...
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Exmark FMD524 - page 20
- 15 - NOTE: T he baff le is labeled “HOT ” and “CO LD” . The oil level varies with the temperat ure of t he oil. The “HO T ” level shows the level of oil when it is at 225°F (107°C). T he “COLD” level shows the level of t he oil when it is at 75° F ( 24° C) . Fill to the appropr iat e level depending upon the tem per at ure of ...
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Exmark FMD524 - page 21
- 16 - FIGURE 3 DRIVE LEVER, NEUTRA L LO CK LA TCH OPERAT I ON 4.1.4 PTO Engag ement : Switch is located on lef t side of control console. The switch must be pulled out to the ” Rotate ” posit ion to engag e the blades. T he switch is pushed in to the “ St op ” position to st op t he blades. O perator m ust have operat or pr esence control ...
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Exmark FMD524 - page 22
- 17 - 4.1.11 Drive W heel Release Valves : Located on the lef t rear cor ner of t he hydrostat ic pumps. Drive wheel release valves are used to release the hydro-st at ic dr ive system to allow the machine to be moved by hand without the engine r unning . W it h a 5/ 8 wrench, t ur n bot h valves one turn count er - clock wise to release the drive ...
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Exmark FMD524 - page 23
- 18 - 4.3.2 Stopping Engine : Lock drive levers in neutral, diseng age PT O, move speed control lever to neut r al, and engag e par k brak e. Move thrott le t o t he “ m idway ” position. Allow engine to r un a m inimum of 15 seconds. Rotate ig nition switch to “Of f ” position. Rem ove k ey to pr event childr en or ot her unauthorized per ...
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Exmark FMD524 - page 24
- 19 - 4.3.4 Drive W heel Eng agem ent / Turning : W ith drive levers locked in “ neut ral”, shif t speed control lever to desir ed f orward speed. Slowly squeeze and hold both drive lev ers in the neut r al posit ion and r otate bot h neutral lock lat ches fr om the neutr al lock position to t he for ward position. DO NOT sq ueeze both drive l ...
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Exmark FMD524 - page 25
- 20 - 4.4 TRA NSPORTING WA RNING POTENT IAL HAZARD ♦ Loading the m ower onto a t r ailer without strong enough or proper ly supported ramps could be dangerous. W HAT CAN HAPPEN ♦ The ram ps could collapse causing the unit t o f all, which could cause injury. HOW TO AVO ID T HE HAZARD ♦ Use proper ramps t hat are secured t o t he t r uck or t ...
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Exmark FMD524 - page 26
- 21 - 5.1 PERIODIC MA INTENA NCE 5.1.1 Check eng ine oil level . Serv ice Interv al: See Engine Ow ner's Manual a) Stop engine, wait f or all moving par t s to stop and m ak e sure unit is on a level surface. b) Check with engine cool. c) Clean area around dipst ick . Remove dipstick and wipe oil off . Reinser t t he dipstick. DO NOT screw in ...
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Exmark FMD524 - page 27
- 22 - 5.1.4 Check mower blades . Servic e Interval: Daily a) St op eng ine, wait for all moving parts t o st op, and remove k ey. b) Lif t deck and secur e in r aised position as stated in Sect ion 5. 1.3. c) Inspect blades and shar pen or r eplace as r eq uired. For Serial Nos. 510, 000 – 539, 999: d) Re- insta ll t he blades ( if they were rem ...
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Exmark FMD524 - page 28
- 23 - FIGURE 6 BLA DE BOLT INST AL LA TION IMPO RTANT : DO NOT use components ot her than the or ig inal blade, blade bushing, spr ing disc washer, and blade bolt supplied with the unit. Failure t o use all original com ponent s and assem bled as shown will increase the risk of a blade bolt becoming loose or weak af ter st riking a f oreig n obj e ...
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Exmark FMD524 - page 29
- 24 - c) If m achine does not pass any of these t est s, DO NOT operate. Contact your authorized EXMARK SERVICE DEALER. IMPORTA NT: It i s essent i al that al l O perator Safety Mechanisms, be i n place and in proper operating condi tion prior to mow i ng. 5.1.6 Check f or loose hardware . Serv ice Interv al: Daily a) St op eng ine, wait for all m ...
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Exmark FMD524 - page 30
- 25 - Check the voltag e of t he battery with a digital voltm eter. Locat e the voltage r eading of t he bat t ery in the table below and charge the bat t ery for t he recommended t ime interval to bring the charg e up t o a full char g e of 12. 6 volts or gr eat er . IMPOR TA NT: Make sure the negat ive batt er y cables are disconnect ed and t he ...
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Exmark FMD524 - page 31
- 26 - f) Raise the rear of the machine up ont o j ack stands hig h enough to r aise t he drive wheels off of the g round. Run machine t o allow any other air t o be purged f rom t he hydraulic system and r echeck the oil level. g) I f either dr ive wheel does not rotat e, one or bot h of t he char g e pumps (located on the t op of the main pum p a ...
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Exmark FMD524 - page 32
- 27 - f) If eit her drive wheel still does not rotate, st op and r epeat steps (d) and ( e) above for the r espect ive pump. I f wheels rotat e slowly, the system may prime af ter addit ional r unning . Check oil level as stat ed in Section 5.1.10. g) Allow unit to r un several minut es af ter t he char g e pumps are “ pr im ed” with drive sys ...
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Exmark FMD524 - page 33
- 28 - c) Lubr icat e f ront cast er pivots once a year. Remove hex plug and cap. T hr ead grease zerk in hole and pump with grease until it oozes out around top bearing. Rem ove g r ease zerk and thread plug back in. Place cap back on. 5.1.16 Lubricat e cast er wheel hubs: Servic e Interval: Once Y early a) St op eng ine, wait f or all moving part ...
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Exmark FMD524 - page 34
- 29 - b) Rem ove cooling shr oud cleanout covers ( Kohler ) or cooling shrouds (Kawasaki) f r om engine and clean cooling fins. Also clean dust , dir t, and oil fr om exter nal sur f aces of engine which can cause improper cooling . c) Make sure cooling shr oud cleanout covers or cooling shrouds ar e pr operly reinstalled. O per ating t he eng ine ...
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Exmark FMD524 - page 35
- 30 - 5.2 A DJUSTMENTS IMPORTA NT: Disengage PTO, shut of f engine, w ai t for all moving parts t o stop, and remove key before servicing, cl eani ng, or making adjustment s t o t he uni t . 5.2.1 Cutting heig ht and anti-scalp r oller adjustm ent . CA UTION POTENT IAL HAZARD ♦ W hen m ower deck is not installed or the t wo f r ont support rod h ...
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Exmark FMD524 - page 36
- 31 - c) Adjust ant i- scalp r ollers f or Normal O perating Condit ions. Place rollers in one of t he posit ions shown in Figure 10. Rollers will maintain 3/ 4 in. (19 mm ) clearance to the g round to m inimize goug ing and roller wear or damage. For Maximum Deck Flot at i on, place r o ller s one hole posit ion lower. Rollers should maintain 1/4 ...
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Exmark FMD524 - page 37
- 32 - FIGURE 11 NEUTRA L SA FETY SWI TCH A DJUSTMENT b) Adjust Neut r al Cont rol Linkag es 1. Raise the rear of the machine up onto j ack stands hig h enoug h to raise the drive wheels off of the g round. 2. Start the eng ine and move the thr ot t le ahead to the f ull throt t le posit ion. Place the neutral lock latches in the “ for ward” po ...
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Exmark FMD524 - page 38
- 33 - 7. Aft er adj ustments ar e m ade and t he wheels stop when the drive lev er is in the neutral posit ion, tight en t he nut against t he yok es. c) Adjust Hydro Contr ol Linkag e: 1. Place the speed control lever in t he “ neut ral” position. T his adjustm ent is again made with rear of machine on jack stands and eng ine r unning at f ul ...
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Exmark FMD524 - page 39
- 34 - if t he t ire is turning in reverse and short en t he linkag e if the t ir e is creeping f orward. Tig hten the jam nuts at both ends. Release and r e- engage t he neutral lock check ing that the tire st ops. Cont inue t his process until the t ir e is at a dead st op. FIGURE 14 DRIVE LEVER A ND LATCH IN NEUTRA L PO SITION 3. Make t his adj ...
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Exmark FMD524 - page 40
- 35 - FIGURE 16 THRO TTLE TE NSI O N 5.2.8 Electric Clutch Adj ustment No adjustment necessar y. 5.2.9 Park Br ak e Adjustm ent : a) Shut off eng ine and wait for all m oving par t s to stop. b) Disengage the park br ak e. c) Rem ove the hair pin in t he park br ak e linkag e. T ur n t he linkag e in t he yoke until there is 3/ 16” ( .48 cm) t o ...
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Exmark FMD524 - page 41
- 36 - 7.2 MOWER CU TS UNEVENLY . a) Check t he dr ive tire pr essur es and tire circum f erences. See 5. 1.13. A mor e unifor m cut t ing height m ay be obtained with higher tire pressur e on rough t er r ain. A lower tire pressure provides mor e f lotation. b) Check deck support pins. Hair pin clips m ust be in the same hole position on each supp ...
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Exmark FMD524 - page 42
- 37 - ENGINE TROUBLESHOOTING TA BLE PROBLEM NO FUEL IMPROPER FUEL DIRT IN FUEL LI NE DIRTY AIR FILTER FAU LTY SPARK PLUG ENGINE OVERLOADED 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 ...
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Exmark FMD524 - page 43
- 38 - 8. HYDRA ULIC SCHEM A TIC ...
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Exmark FMD524 - page 44
- 39 - 9. WIRING DIA GRAM ...
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Exmark FMD524 - page 45
- 40 - 10. 2-Year Limited Warranty Exmark Tu rf Equipment (For units pur chased on or af ter October 1, 2004) Conditions and Products Covered Exmark M fg. Co. Inc. and its affiliate, Exmark W arranty Company, pursuant to an agreement betw een them, jointly warrant on the terms and conditions herein, that w e will repair, replace or adjust any part ...
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Exmark FMD524 - page 46
- 40 - SERVICE RECORD Date Descripti on of Work Done Service Done By ...
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Exmark FMD524 - page 47
- 41 - T H I S I S A 1 5 ° S L O P E T H I S I S A 1 0 ° S L O P E T H I S I S A 5 ° S L O P E ALIGN THIS EDGE WITH A VERTICAL SURF ACE (TREE, BUILDI NG , FENC E POST , POLE ETC. ) EXAMPLE: COMP ARE SLOPE WITH FOLDED EDGE. FOLD ALONG APP ROPRIA TE LINE T HI S I S A 2 0 ° S L O P E ...
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Exmark FMD524 - page 48
® M FG . CO. IN C. SEE EXMA RK’S COMPLETE LINE OF A CCESSORIES RIDING A CCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT K IT MICRO-MULCH SY ST EM ROLL OVER PROTECT ION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONT AINER TURF STRIPER ULTRA VAC COLLECT ION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WA LK BEHIND A CC ...
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