Exmark FR604 User manual

Brand: Exmark

Model: FR604

Type: User manual

This manual is also suitable for

FR524/FR604/

FR724

ForSerialNos.

720,000&Higher

PartNo.4500-230Rev.A

Exmarkreservestherighttomakechangesor

addimprovementstoitsproductsatanytime

withoutincurringanyobligationtomakesuch

changestoproductsmanufacturedpreviously.

Exmark,oritsdistributorsanddealers,accept

noresponsibilityforvariationswhichmaybe

evidentintheactualspecicationsofitsproducts

andthestatementsanddescriptionscontained

inthispublication.

IndustrialParkBox808

Beatrice,NE68310

Contactusatwww.Exmark.com.

PrintedintheUSA.

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour

ExmarkCuttingDeck.Thisproducthasbeen

carefullydesignedandmanufacturedtogiveyou

amaximumamountofdependabilityandyearsof

trouble-freeoperation.

Thismanualcontainsoperating,maintenance,

adjustment,andsafetyinstructionsforyourExmark

mower.

BEFOREOPERATINGYOURMOWER,

CAREFULLYREADTHISMANUALINITS

ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety

instructions,youwillprolongthelifeofyourmower,

maintainitsmaximumefciency,andpromotesafe

operation.

Ifadditionalinformationisneeded,orshouldyou

requiretrainedmechanicservice,contactyour

authorizedExmarkequipmentdealerordistributor.

AllExmarkequipmentdealersanddistributorsare

keptinformedofthelatestmethodsofservicing

andareequippedtoprovidepromptandefcient

serviceintheeldorattheirservicestations.They

carryamplestockofservicepartsorcansecurethem

promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected

beforeleavingthefactory,however,attentionis

requiredonyourpartifyouaretoobtainthefullest

measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,

oradditionalinformation,contactanAuthorized

ServiceDealerorExmarkCustomerServiceandhave

themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial

numbersontheproduct.Writethenumbersinthe

spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.......................7

Specications.........................................................9

ModelNumbers..............................................9

Systems...........................................................9

Dimensions.....................................................9

TorqueRequirements....................................10

Setup....................................................................11

AssembleDecktoFrontRunner.....................11

DeckRemoval...............................................13

ProductOverview................................................14

Operation.............................................................14

DeckRaisingandLowering...........................14

Maintenance.........................................................17

RecommendedMaintenanceSchedule(s)...........17

PeriodicMaintenance.......................................17

CheckMowerBlades.....................................17

CheckforLooseHardware............................18

CheckTirePressures.....................................18

ChangeGearboxOil......................................18

LubricateGreaseFittings...............................19

ThreadLockingAdhesives.............................19

Adjustments.....................................................20

DeckLeveling...............................................20

CasterPivotBearingsPre-load

Adjustment...............................................20

Cleaning...........................................................21

CleanGrassBuild-UpUnderDeck................21

Troubleshooting...................................................22

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin

thismanualandonthemachinetoidentifyimportant

safetymessageswhichmustbefollowedtoavoid

accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation

whichalertsyoutounsafeactionsorsituations

andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if

notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground.

Indicatesapotentiallyhazardoussituationwhich,if

notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Yellowbackground.

Indicatesapotentiallyhazardoussituationwhich,if

notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight

information.Importantcallsattentiontospecial

mechanicalinformationandNoteemphasizes

generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadthetractorandcuttingdeckOperator’s

Manualsandothertrainingmaterial.Ifthe

operator(s)ormechanic(s)cannotreadEnglish

itistheowner’sresponsibilitytoexplainthis

materialtothem.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.

Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate

orservicetheequipment.Localregulationsmay

restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible

foraccidentsorinjuriesoccurringtohimselfor

herself,otherpeopleorproperty.

Preparation

•DoNotmodifytheFrontRunnercuttingdeck.

•OnlyuseonmachinesapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,

substantialfootwear,longtrousers,andhearing

protection.DoNotoperatewhenbarefootor

whenwearingopensandals.

CAUTION

Thismachineproducessoundlevelsin

excessof85dBAattheoperator’searand

cancausehearinglossthroughextended

periodsofexposure.

Wearhearingprotectionwhenoperatingthis

machine.

•Inspecttheareawheretheequipmentistobe

usedandremoveallrocks,toys,sticks,wires,

bones,andotherforeignobjectswhichcanbe

thrownbythemachineandmaycausepersonal

injurytotheoperatororbystanders.

Operation

•Operateonlyindaylightorgoodarticiallight,

keepingawayfromholesandhiddenhazards.

•Neverfoldthedeckwithbladesrunning.

•Stopengine,waitforallmovingpartstostop,

removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor

damageandmakerepairsbeforerestarting

andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

Safety

WARNING

Hands,feet,hair,clothing,oraccessoriescan

becomeentangledinrotatingparts.Contact

withtherotatingpartscancausetraumatic

amputationorseverelacerations.

•DoNotoperatethemachinewithout

guards,shields,andsafetydevicesin

placeandworkingproperly.

•Keephands,feet,hair,jewelry,orclothing

awayfromrotatingparts.

•Stoptheblades,slowdown,andusecautionwhen

crossingsurfacesotherthangrassandwhen

transportingthemowertoandfromtheareato

bemowed.

•Bealert,slowdownandusecautionwhenmaking

turns.Lookbehindandtothesidebefore

changingdirections.

MaintenanceandStorage

•DisengagePTO,setparkingbrake,stopengine

andremovekeyordisconnectsparkplugwire.

Waitforallmovementtostopbeforeadjusting,

cleaningorrepairing.

•Usecarewhencheckingblades.Wraptheblade(s)

orweargloves,andusecautionwhenservicing

them.Onlyreplaceblades.Neverstraightenor

weldthem.

•Keepallguards,shieldsandallsafetydevicesin

placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper

tightness.

•Frequentlycheckforwornordeteriorating

componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas

orequivalenttothepartssuppliedasoriginal

equipment.

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,

dirtanddebrisfromsafetysignsandinstructional

labels.

•Replaceallworn,damaged,ormissingsafety

signs.

•Whenreplacementcomponentsareinstalled,be

surethatcurrentsafetysignsareafxedtothe

replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,

makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom

yourauthorizedExmarkequipmentdealeror

distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe

backingtoexposetheadhesivesurface.Apply

onlytoaclean,drysurface.Smoothtoremove

anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns

andinstructionlabels.Theyarecriticaltothesafe

operationofyourExmarkcommercialmower.

1-303508

1-403005

1-633922

1-643222

98–5954

Safety

103-8425

109-2354

109-2359

109-2376

109-2993

109-3148

Specications

ModelNumbers

SerialNos:720,000andHigher

FR524;FR604;FR724

Systems

Tires&Wheels

FrontCaster

Type

Semi-Pneumatic

Quantity

Tread

Smooth

Size9x3.50–4

CuttingDeck

•ModelNumbers:

–FR524

–FR604

–FR724

•CuttingWidth:

–52inchDeck:52inch(132cm)

–60inchDeck:60inch(152cm)

–72inchDeck:72inch(183cm)

•Discharge:Side

•BladeSize:(3ea.)

–52inchDeck:18.00inches(45.7cm)

–60inchDeck:20.50inches(52.1cm)

–72inchDeck:24.50inches(62.2cm)

•DeckDrive:

–Shaftdrivetogearboxatrearofdeck.

–Beltdrivefromgearboxtobladespindles.

•Deck:

Fulloatingdeckisattachedtoout-frontsupport

frame.Sixanti-scalprollersprovidemaximum

turfprotection.Deckdesignallowsforbagging,

mulching,orsidedischarge.

•DeckDepth:

–52inchDeck:51/2inches(14cm)

–60inchDeck:51/2inches(14cm)

–72inchDeck:51/2inches(14cm)

•CuttingHeightAdjustment:

Adjustsfrom1inch(2.5cm)to5inches(12.7cm)

innitelyvariable

•MulchingKit:Optional

Dimensions

OverallWidth:

52inch

Deck

60inch

Deck

72inch

Deck

Deector

Down

64.6inches

(164.1cm)

72.7inches

(184.7cm)

84.4inches

(214.4cm)

Deector

53.9inches

(136.9cm)

61.4inches

(156.0cm)

73.3inches

(186.2cm)

OverallLength:

52inchDeck60inchDeck72inchDeck

42.5inches

(108.0cm)

42.3inches

(107.4cm)

45.5inches

(115.6cm)

OverallHeight:

52inchDeck60inchDeck72inchDeck

18.0inches

(45.7cm)

18.0inches

(45.7cm)

18.0inches

(45.7cm)

Specications

CurbWeight:

52inchDeck60inchDeck72inchDeck

393lb(178kg)434lb(197kg)514lb(233kg)

TorqueRequirements

BoltLocation

Torque

BladeMountingBolt

(lubricatewithanti-seize)

55-60ft-lb(75-81N-m)

GearboxMountingBolts16-18ft-lb(22-24N-m)

DriveShaftSetScrew

18ft-lb(24N-m)

DriveShaftPinchBolt

44ft-lb(60N-m)

CutterHousingSpindle

Nut

140-145ft-lb

(190-197N-m)

Anti-ScalpRollerNyloc

NutSeeFigure12

30-35ft-lb(41-47N-m)

Anti-ScalpRollerWhizlock

NutSeeFigure12

30-35ft-lb(41-47N-m)

Setup

WARNING

OperatingaFrontRunnertractorwithoutan

approvedExmarkfrontmountattachment

increasesthepossibilityofforwardtipover.

Tip-overcouldcauseseriousinjuryordeath.

WhenoperatingaFrontRunnertractor

withoutanapprovedExmarkfrontmount

attachment,observethefollowing:

•Limitoperationtominimumrequiredto

installadifferentfrontmountattachment.

•Minimizespeedanduseextremecaution.

•Onlyoperateonaatlevelsurface.

•DoNotoperateupordownatrailerramp.

•Avoidsuddenaccelerationordeceleration.

AssembleDeckto

FrontRunner

Important:DoNottransportFrontrunner

tractorwithoutandapprovedExmarkfront

mountattachment.

1.Stoptheengine,waitforallmovingpartstostop,

engagetheparkingbrake,andremovethekey.

2.Rotatethefoldlocklever,locatedonthedeck,in

theunlockedposition(Figure3).

Figure3

1.Foldlocklevershownintheunlockedposition

3.Onthetractor,removethetworetainingpins

onhitchlatchessothelatchescanactuatefreely.

Raisetheoorpanandlockinuprightposition

(Figure4).

Figure4

1.Removetheretainingpinsfrombothhitchlatches

2.Floorpanshownlockedintheuprightposition

4.Alignthefrontframeofthemowerdecktothe

Frontrunnertractorhitch.

5.Manuallyliftuponthehitchtogetthebarsonthe

frontframestartedintothereceiversofthehitch.

6.Pushthefrontframetowardsthetractoruntilthe

twohitchlatchesseatintothe“secure”position.

Setup

7.Insertthehitchlatchretainingpinsintothehitch

pinlock.Thedeckisnowlockedontothetractor.

8.Reinstallthekeyandturntheswitchtothe“run”

position.DoNotstarttheengine.

9.Alignthecylinderrodendtothetopholeofthe

oatlinkbracketandinsertthepinasshownin

Figure5.Insertthecotterhairpintolockthe

cylinderpinintoplace.

Figure5

1.Floatlinkbracket

3.Cylinder

2.Cylinderpin

4.Besuregreasezerkis

pointedupward

WARNING

Incorrectlyraisingorloweringamowerdeck

canbedangerous.Adroppedmowerdeck

canresultinaseriousinjuryorproperty

damage.

•Alwaysraiseandlowerdeckonat,dry

ground,freeofanyobstructions.

•Alwaysmakesurethedeckissecurely

latchedinthe“up”or“down”position.

10.Retractthecylindertofoldthedeckupward.

Attachtheweighttransferchains.Itisvery

importantnottotwistthechains.Lockthe

chainsontothepinbyinsertingthecotterhairpin

(Figure6).

Figure6

1.Retainingpin

3.Weighttransferchains

2.Cotterhairpin

WARNING

Operatingthemowerdeckintheraised

servicepositioncanbedangerous.Engaging

thePTOwithadeckintheraisedposition

canresultinaseriousinjuryorproperty

damage.

Alwayslowerandlockmowerdeckinthe

operationpositionbeforeengagingthePTO.

11.Extendthecylinderfullyuntilthecasterwheels

contactthegroundandthedeckisinthefully

raisedposition.Thefoldlockleversshouldhave

resetandsnappedintothe“locked”position.

Lowertheoorpan.

Figure7

1.Floorpan

2.Rotatefoldlockleverto

uprightposition.

Setup

WARNING

Operatingmowerwithoutfoldlocklevers

securelylatchedcanresultinthemower

deckfoldingupunexpectedlyandcancause

seriousinjury.

Alwaysoperatemowerwiththefoldlock

leverssecurelylatched.

12.Connectthedriveshaftbypushingbackthe

springloadedcollar.Alignandcouplethedrive

shafttothesplineddriveshaftandreleasethe

collar(Figure8).

Figure8

Viewedfrombelowthemachine

1.Pushspringloadedcollartowardsdeck

DeckRemoval

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Disconnectthedriveshaftbypullingbackonthe

springloadedcollarandpullingawayfromthe

splinedshaft(seeFigure8).Laythedriveshaft

ontheground.

3.Insertkeyandturntothe“run”position.Do

Notstarttheengine.

4.Extendthecylinderuntilthefoldlocklatches

areunloaded,andthenrotatethemtowardthe

tractor.

5.Retractthecylinderandpartiallyfoldthedeck

justtothepointwheretheweighttransferchains

goslack.

6.Pulloutthehairpinsandchainpinsfromthe

clevisbracket.Placethepinandcotterhairpinon

thechainandsetaside.

7.Lowerthedeckbyextendingthecylinderuntilthe

deckfoldsdown.Thecastertiresshouldtouch

theground.

8.Theoatlinkbracketswillstarttorotateforward

andatthispoint,thecylindercanbedetachedat

therodendbypullingthepinoutofthebracket.

Liftthecylinderoutofthewayandpositionthe

rodendsothatitrestsonthebuckleoftheheight

indicatorbracket.

9.Removethehitchlatchpinsfromthehitch

brackets.Raisethehitchlatchabovetheholeand

insertpin.Thetopofthehitchlatchshouldrest

underthepin(seeFigure9).

Figure9

1.Floorpanlockedin

uprightposition

3.Hitchlatchesin“up”

position

2.Hitchlatchpins

10.Standinfrontofthedeckandpulltheunitaway

fromthetractororbackthetractorawayfrom

thedeck.

Important:DoNottransportFrontRunner

tractorwithoutanapprovedExmarkfrontmount

attachment.

Operation

ProductOverview

Figure10

1.Foldlocklever

3.Casterwheel

2.Anti-scalprollers

Operation

DeckRaisingandLowering

SettingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted

from1to5inches(2.5cmto12.7cm)innitely

variable.

1.Thekeymustbeinthe“run”positiontosetthe

cutheight.

2.Extendorretractcylinderuntilthecuttingheight

indicatorpointstothedesiredcutheight.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller

position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethemotioncontrol

leversoutwardtotheneutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall

movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe

anti-scalprollersbyremovingthewhizlocknut

andthespringdiscwasher.

6.Placetherollersinoneofthepositionsshown

(Figure11).Rollerswillmaintain3/4inch(19

mm)clearancetothegroundtominimizegouging

androllerwearordamage.

Figure11

Forcuttingheightsabove3.5inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller

mountingbracket

2.Cuttingheight

Operation

ForMaximumDeckFlotation,placetherollers

oneholepositionlower.Rollersshouldmaintain

1/4inch(6.4mm)clearancetotheground.Do

Notadjusttherollerstosupportthedeck.

7.Besurethewhizlocknutsareinstalledwiththe

springdiscwasherbetweentheangeofthenut

andthemountingbracket(seeFigure12).

8.Torquethe3/8-16whizlocknutto30-35ft-lb

(41-47N-m)(Figure12).

9.Ifthe3/8nylocnuthasbeenremoved,re-install

andtorqueitto30–35ft-lb(41-47N-m)

(Figure12).

Figure12

1.Springdiscwasher

(conetowardsnut)

3.3/8nyloc-torqueto30-35

ft-lb(41-47N-m)

2.Frontrightanti-scalp

bracketshown

4.3/8-16whizlocknut

torqueto30-35ft-lb

(41-47N-m)

RaisingtheMowerDeckintoService

Position

1.Stopengine,waitforallmovingpartstostop,

engageparkingbrake,andturnkeyto“run”

position.DoNotstarttheengine.

WARNING

Incorrectlyraisingorloweringamowerdeck

canbedangerous.Adroppedmowerdeck

canresultinaseriousinjuryorproperty

damage.

•Alwaysraiseandlowerdeckonat,dry

ground,freeofanyobstructions.

•Alwaysmakesurethedeckissecurely

latchedinthe“up”or“down”position.

2.Fullyextendthecylindertounloadthefoldlock

levers.

3.Rotatethefoldlocklevers,locatedoneachside

ofthedeck,totheunlockedposition(Figure3).

4.Retractthecylinderandthedeckwillfoldto

approximately50degrees.

WARNING

Operatingthemowerdeckintheraised

servicepositioncanbedangerous.Engaging

thePTOwithadeckintheraisedposition

canresultinaseriousinjuryorproperty

damage.

Alwayslowerandlockmowerdeckinthe

operationpositionbeforeengagingthePTO.

RaisingtheMowerDeckintothe

StoragePosition

1.Stopengine,waitforallmovingpartstostop,

engageparkingbrake,andturnkeyto“run”

position.DoNotstarttheengine.

2.Flipuptheoorpanandremovefullfoldpin.

Retractthecylindertoalignholesinoatlink

bracketwithholesinfrontframe.(Deckwillbe

atornearlowestheight.)Insertintothebottom

holeoftheoatlinkbracket(seeFigure13).

Lowertheoorpan.

Operation

Figure13

1.Removethehairpinand

fullfoldpin

4.Hairpin

2.Floatlinkbrackets

5.Fullfoldpin

3.Insertpinhere

WARNING

Foldingthemowerdeckwiththeoorpanin

lockedpositionmaybedangerous.Hooks

willnotautomaticallydropintheslotsonthe

frontcover.

Makesuretheoorpanisnotlockedinthe

uprightposition.

3.Fullyretractcylinder.Thedeckwillfoldtoan

approximate70degreeangle.

WARNING

Drivingthemowerdeckinthefoldedservice

positioncanbedangerous.Themowercan

tipforward.

Alwayslowerandlockmowerdeckinthe

operationpositionbeforedriving.

LoweringtheMowerDecktothe

OperatingPosition

1.Makecertainthatyouandanyobserversareclear

ofthedeck.

2.Raisetheoorpantothelockedpositionas

showninFigure13.

3.Extendthecylinderuntilthefrontcasterwheels

justtouchtheground.

4.Ifthefullfoldpinwasusedwhenthedeckwas

folded,removeitfromtheoatlinkandplaceit

inthestoragelocationundertheoorpan.

5.Fullyextendthecylinderuntilitstops.Conrm

thatthelatchesareinthelockedposition.

6.Retractthecylinderuntilthedecklowerstothe

desiredcutheightreadingshownontheheight

indicatorbar.

WARNING

Operatingmowerwithoutlockinglatches

securelylatchedcanresultinthemowerdeck

foldingupunexpectedly.Themowerdeck

foldingupunexpectedlycancauseserious

injury.

Alwaysoperatemowerwithlockinglatches

securelylatched.

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing

made,someonecouldstarttheengine.

Accidentalstartingoftheenginecould

seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch,

engageparkingbrake,andpullthewire(s)

offthesparkplug(s)beforeyoudoany

maintenance.Alsopushthewire(s)aside

soitdoesnotaccidentallycontactthespark

plug(s).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst50hours

•Changeoilinallthreegearboxhousings.Addoilasneededuntillevelwithoildrainplug.

Beforeeachuseordaily

•Checkthemowerblades.

•Checkforloosehardware.

•Greasethefrontcasterwheelhub.

•Cleanthegrassbuild-upfromunderthedeck.

Every40hours

•Checktheconditionofthebelts.

•Greasethedriveshaft.

•Greasetheheightadjustmentshaftbearings.

Every100hours

•Changeoilinallthreegearboxhousings.Addoilasneededuntillevelwithoildrainplug.

•Greasethedeckip-up.

Yearly

•Greasethefrontcasterpivots.

•Greasethedeckdrivebeltidlerarm.

PeriodicMaintenance

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Inspectbladesandsharpenorreplaceasrequired.

3.Reinstalltheblades(iftheywereremoved)inthe

followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure14

1.Installbushinginbladepriortoinstallingbushingin

spindle.

Maintenance

B.Installbushing/bladeassemblyintospindle.

Figure15

1.Usewrenchherefor

bladeinstallation.This

nuthasbeentorquedto

90–110ft-lb(122–149

N-m)

2.Torqueto55-60ft-lb

(75-81N-m)Apply

lubricanttothreads

asneededtoprevent

seizing.Copper-based

anti-seizepreferable.

Greaseacceptable

substitute.

C.Applylubricanttothreadsofbladeboltas

neededtopreventseizing.Copper-based

anti-seizepreferable.Greaseacceptable

substitute.Installbladeboltngertight.Place

wrenchonthetopspindlenutthentorquethe

bladeboltsto55-60ft-lb(75-81N-m).

WARNING

Incorrectinstallationofthebladeor

componentsusedtoretainthebladecan

bedangerous.Failuretousealloriginal

componentsandassembledasshowncould

allowabladeorbladecomponenttobe

thrownoutfromunderthedeckresultingin

seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades,

bladebushings,andbladeboltsasshown.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware

oranyotherpossibleproblem.Tightenhardware

orcorrecttheproblembeforeoperating.

CheckTirePressures

ServiceInterval:Every40hours

Thefrontcastertiresaresemi-pneumaticandDo

Notneedtobeinated.

ChangeGearboxOil

ServiceInterval:Aftertherst50hours

Every100hoursthereafter

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.Placeunitonalevelsurface.

3.Removethegearboxanddriveshaftassembly

fromthemowerdeck.Retainhardwareforre-use.

4.Removetheoildrainplugonthesideofthe

gearboxsectionanddrainoil(Figure16).

Figure16

1.Oildrain/llplug

5.Reinstallthegearboxanddriveshaftassemblyto

themowerdeck.

6.FillgearboxwithMobilSHC(synthetic)75W-90

gearlubeoiluntillevelwithoildrain/llplug.

Note:Mowerdeckshouldremainleveltothe

groundwhenllinggearboxwithoil.DoNotll

gearboxwithdeckraisedintheserviceposition.

7.ApplyaTeonpipesealanttotheoilplugand

re-installintothegearbox.

Maintenance

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

2.LubricatettingswithNGLIgrade#2

multi-purposegungrease.

Refertothefollowingchartforttinglocations

andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.Front

Caster

WheelHub

128Hours

2.Drive

Shaft

340Hours

3.Height

Adjustment

Shaft

Bearings

440Hours

4.Deck

Flip-Up

100Hours

5.Front

Caster

Pivots

*Yearly

6.Deck

DriveBelt

IdlerArm

Yearly

*Seestep3forspeciallubricationinstructionson

thefrontcasterpivots.

3.Lubricatecasterpivotsonceayear.Removehex

plugandcap.Threadgreasezerkinholeand

pumpwithgreaseuntilitoozesoutaroundtop

bearing.Removegreasezerkandthreadplugback

in.Placecapbackon.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242”

or“Fel-Pro,Pro-LockNutType”areusedonthe

followingfasteners:

•Spindletopnut.

•Driveshaftsetscrewatthegearbox.

•Largenutsattheendsofthedeckliftlinks.

•Setscrewsonthegearboxsheave.

Maintenance

Adjustments

Note:DisengagePTO,shutoffengine,waitfor

allmovingpartstostop,engageparkingbrake,and

removekeybeforeservicing,cleaning,ormakingany

adjustmentstotheunit.

DeckLeveling

1.Positionmoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and

removekey.Engageparkingbrake.

3.Checktirepressureindrivetires.

ForUnitsEquippedWithTurfTires:Thedrive

tiresshouldbeinatedto13psi(90kpa).

ForUnitsEquippedWithBar-LugTires:The

drivetiresshouldbeinatedto9psi(62kpa).

4.Fullyextendthecylindertoraisethedeckashigh

asitwillgo(thisisalsothetransportposition).

Notethepositionofthecutheightindicator.

Adjusttheindicatorifnecessarysothatthe

indicatorispointingtothe5inchcutheightmark

(seeFigure17).

Figure17

1.Cutheightindicator

2.Adjustindicatorusing

thesescrews

5.Lowerthedecktothe4inchcutheightposition

andremoveignitionkey.Orienttheblades

longitudinallywithrespecttothemachine.Stand

awoodenblockapproximately5inchestallnext

tothefrontbladetipofthecenterblade;markthe

locationofthebladetipontheblock.Removethe

blockandmeasureheightontheblock,itshould

be4inches.Repeatthisprocessfortherearblade

tipofboththeleftandrightblades,thoseshould

measure41/4inchestogivetherecommended

1/4inchpositiverake(seeFigure18).

Figure18

1.41/4inches

2.4inches

6.Ifadjustmentsarenecessary,foursockethead

5/16-18x1-1/4inchscrewshavebeenprovided

intheliteraturebag.Installthesescrewsintothe

deckliftarmsuntiltheytouchthehexheaddeck

chainscrews.Loosenthetopchainscrewsin

slotsinthedeckliftarms(seeFigure19).Turn

thesocketheadscrewstomovethedeckchain

screwsupanddowntocorrectthecutheights

measuredabove.Tightenthechainboltsinthe

deckliftarmsmakingsuretheydon’tmovewhile

tightening.

Figure19

1.Socketheadscrew

3.Adjustscrewandlocknut

2.Deckliftarms

CasterPivotBearings

Pre-loadAdjustment

Removedustcapfromcasterandtightennylocnut

untilwashersareat.Backthenylocoff1/4ofa

turntoproperlysetthepre-loadonthebearings.

Note:Ifdisassembled,makesurethespringwashers

arereinstalledasshowninFigure20.

Page is loading ...

Exmark FR604 User manual

Brand: Exmark

Model: FR604

Type: User manual

This manual is also suitable for

Download PDF

report

Exmark FR604 User manual

This manual is also suitable for

Exmark FR604 User manual

Related papers

Other documents