For Turf Ranger Serial Nos. 440,000 & Higher and FMD524 & FMD604 Serial Nos. 440,000 & Higher

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1 For Turf Ranger Serial Nos. 440,000 & Higher and FMD524 & FMD604 Serial Nos. 440,000 & Higher Part No

2 EXMARK PARTS PLUS PROGRAM EFFECTIVE DATE: September 1, 1995 Program If your Exmark dealer does not have the Exmark part in stock, Exmark will 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 "down" unit at the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus shipment of six (6) line items or less. 2. Distributor ships part(s) to dealer or customer, as requested by dealer, same day, overnight UPS Distributor bills dealer for part and freight charges where applicable. 3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus order, he contacts Exmark by 3:00 p.m., central time, with an Exmark Parts Plus order of six (6) line items or less. 4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by distributor, same day, overnight UPS Exmark bills the distributor for parts and shipping charges, where applicable. 5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the program. 6. Who pays for the part and freight if it fails to arrive overnight in accordance to the program? A. Under any circumstance the customer does not pay. B. If the part does not arrive overnight due to: 1. The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1:00 p.m., the dealer pays for the part and freight. 2. The Distributor being unable to ship the part the same day or not submitting 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 restrictions apply -- The Exmark Parts Plus Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus orders must be received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions. Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air. Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program. -1-

3 READ OPERATOR S MANUAL BEFORE OPERATING OR SERVICING EXMARK EQUIPMENT. TABLE OF CONTENTS Description Page 52 and 60 Deck Support FMD524 and FMD Mower Deck FMD Mower Deck FMD Axles and Hydraulics... 8 Decals Electrical Diagram Electrical Group Engine Deck Group Motion Controls Parking Brake Rider Frame and Steering Seat assembly and Lift Actuator

4 52 DECK GROUP FMD524 Item Part No. Description Qty. Item Part No. Description Qty Capscrew, 5/8-18 x 2 3/4, Gr Chute, Discharge Capscrew, 3/8-16 x Washer, Disc Spring 3/ Nut, Whizlock 3/ Capscrew, 3/8-16 x 1 1/ Nut, HH 3/4-16 Heavy Washer, Spring Disc Sheave, Blade Drive Spacer, Guard Bottom Spindle, Outer Blade (Short) Washer, Pivot Spindle, Center Blade (Long) Key, 1/4 x 3/16 x 3/ Sheave, Mower Drive Guard, Bearing Top Housing W/Bearings Capscrew, 5/16-18 x 3/ Cover, Deck Belt, Blade Drive Capscrew, 3/8-16 x Housing, Cutter Complete (Center) Housing, Cutter Complete (Outer) Spacer, Tube Spacer Washer, Blade Bolt Hvy Capscrew, 3/8-16 x 1 3/ Spacer Spacer Bolt, Tap 5/16-18 x 3 1/ Bushing Washer, 5/16 Flat Capscrew, 3/8-16 x 2 1/ Nut, Hex 3/ Idler Idler Deck, W/ Decals Capscrew, 5/16-18 x Nut, Nyloc 5/ Capscrew, 5/16-18 x 5/ Pulley, V-Idler Nut, Whizlock 5/ Roll Pin, 1/4 x 1-1/ Link Assy Spring, Extension Pulley, Idler Screw, Whizlock 3/8-16 x Nut, Nyloc 3/ Washer, 3/ Bearing, Pivot Idler Arm Assy W/Bearings Bushing, Idler Pivot Idler Arm, W/ Bearings Deck Drive Zerk, 1/4-28 (90 ) Complete Deck Assembly Link, Rear Deck Support Balljoint Roller, Anti Scalp Capscrew, 3/8-16 x 4 Gr Bushing, Roller Bracket, Spring Anchor Capscrew, 3/8-16 x 3-1/2 Gr Spring, Extension Baffle Rod, Deck Support Washer, 3/8 SAE Flat Blade, Notched Blade, Solid Blade, Low Lift Blade, Mulching Hairpin, Cotter Spacer...2 Exmark red touch up spray paint - P/N Apply Mobil HTS grease (P/N oz packet) (or a food-grade anti-sieze) between the spindles & bearings and spindles & sheaves and under top bearing guard. DO NOT use a copper or nickel based anti-sieze. Complete cutter housings also include items #1 & #25. Link assembly nominal length is 6.89 (or approx. 6 7/8 ) between center of ball joint & center of furthest hole. See diagram on next page. Initially adjust both links to this dimension, then adjust to where both links are equally supporting rear of mower deck by lengthening one link and shortening th other by an equal amount. Kit includes antiscalp roller, bushing, & mounting hardware. Requires installation of Micro-Mulch accessory for proper mulching. Mulch kit P/N MK

5 52 DECK GROUP FMD524-4-

6 60 DECK GROUP FMD604 Item Part No. Description Qty. Item Part No. Description Qty Capscrew, 5/8-18 x 2 3/4, Gr Capscrew, 5/16-18 x Capscrew, 3/8-16 x Washer, Disc Spring 3/ Nut, Whizlock 3/ Capscrew, 3/8-16 x 1 1/ Nut, HH 3/4-16 Heavy Washer, Spring Disc Sheave, Blade Drive Spacer, Guard Bottom Spindle, Outer Blade (Short) Washer, Pivot Spindle, Center Blade (Long) Key, 1/4 x 3/16 x 3/ Sheave, Mower Drive Guard, Bearing Top Housing W/Bearings Capscrew, 5/16-18 x 3/ Link Assy Belt, Blade Drive Capscrew, 3/8-16 x Housing, Cutter Complete (Center) Housing, Cutter Complete (Outer) Spacer, Tube Spacer Washer, Blade Bolt Hvy Capscrew, 3/8-16 x 1 3/ Spacer Spacer Bolt, Tap 5/16-18 x 3 1/ Bushing Washer, 5/16 Flat Capscrew, 3/8-16 x 2 1/ Nut, Hex 3/ Idler Idler Deck, W/ Decals Chute, Discharge Nut, Nyloc 5/ Capscrew, 5/16-18 x 5/ Pulley, V-Idler Nut, Whizlock 5/ Shield, Belt RH Shield, Belt LH Spring, Extension Pulley, Idler Screw, Whizlock 3/8-16 x Nut, Nyloc 3/ Washer, 3/ Bearing, Pivot Idler Arm Assy W/Bearings Bushing, Idler Pivot Idler Arm, W/ Brngs Deck Drive Zerk, 1/4-28 (90 ) Complete Deck Assy Link, Rear Deck Support Balljoint Roller, Anti Scalp Capscrew, 3/8-16 x 4 Gr Bushing, Roller Bracket, Spring Anchor Capscrew, 3/8-16 x 3 1/2 Gr Spring, Extension Baffle Rod, Deck Support Washer, 3/8 SAE Flat Blade, Notched Blade, Solid Blade, Low Lift Blade, Mulching Hairpin, Cotter Spacer Roll Pin, 1/4 X 1-1/2 2 Exmark red touch up spray paint - P/N Apply Mobil HTS grease (P/N oz packet) (or a food-grade anti-sieze) between the spindles & bearings and spindles & sheaves and under top bearing guard. DO NOT use a copper or nickel based anti-sieze. Complete cutter housings also include items #1 & #25. Link assembly nominal length is 6.89 (or approx. 6 7/8 ) between center of ball joint & center of furthest hole. See diagram on next page. Initially adjust both links to this dimension, then adjust to where both links are equally supporting rear of mower deck by lengthening one link and shortening th other by an equal amount. Kit includes antiscalp roller, bushing, & mounting hardware. Requires installation of Micro-Mulch accessory for proper mulching. Mulch kit P/N MK

7 60 DECK GROUP FMD604-6-

8 52 and 60 DECK SUPPORT FMD524 and FMD604 Item Part No. Description Qty. Item Part No. Description Qty Support, Deck ( ) (52 ) Capscrew, 1/2-13 x Support, Deck ( ) (60 ) Guard Capscrew, 3/8-16 x 1 1/ Washer, Disc Spring 3/ Nut, Whizlock 3/ Cap, Grease Nut, Nyloc 3/ Washer, Spring Disk Bearing, Cone Tapered Roller Bearing, Cup Tapered Roller Plug Bushing, Deck Support Ring, Retaining (External) Seal, Grease Fork, Caster...2 Exmark red touch up spray paint - P/N Use Pro-Lock, Nut Type (P/N ,.5ml tube) on spacer nut, Item #17. Includes frame weldment plus items #5, #9, #10, #11, #12 and # Spacer, Nut Seal, Caster Bearing, Cone Tire, 11 x Ply Axle, Caster Nut, Nyloc 1/2-13 Thin Asm, Wheel & Tire With Axle Shield, Belt ( ) W/Decal (52 ) Shield, Belt ( ) W/Decal (60 ) Knob, 3 Prong Washer, Belt Cover Mounting

9 AXLE and HYDRAULICS Item Part No. Description Qty. Item Part No. Description Qty Hub, Wheel W/Studs Pin, Guide Stud, 1/ Screw, Whizlock 3/8-16 x 3/ Bearing, Pillow Base Pro-Lock,Nut Type (.5cc Tube) Use On Setscrews In Bearings Clamp, Collar (1 ) Capscrew, 3/8-16 x 3/ Washer, Disc Spring 3/ Stabilizer, Axle (Upper) Stabilizer, (Axle Lower) Nut, Whizlock 3/ Washer, 3/8 Std. Flat Capscrew, 1/4-20 x 1-1/ Lockwasher, 1/4 Hvy Spring Washer, Pulley Retainer Fan, 7" OD/10 Blade Spacer, Fan Rollpin, 7/32 x 7/ Pulley, Cast Iron Elbow, O-Ring Hose Clamp Hose, 16.5 Push Lok Hose, 8.0 Push Lok...1 Exmark black touch up spray paint - Gloss black. Exmark red touch up spray paint - P/N Not Illustrated. Apply antisieze compound to bore Screw,10-32x1/2 Thrd Cttng Breather, Filler & Cap Capscrew, 5/16-18 x 3/ Tank, Hydraulic Oil Eye, Hyd Tank Elbow, Suction Strainer Key, Woodruff 1 x 1/ Tire, 20 x Rim Tire And Wheel Assy Nut, Wheel 1/ Nut, Slotted 3/ Pin, Cotter, 9/64 x 1-1/ Transaxle Series Elbow, Ring Bolt, 3/8-16x2-3/4 Carriage Pro-Lock,Nut Type(.5cctube) Use On Threads Key, Woodruff 3/8 x 5/ Nut, Whizlock 5/ Element, Oil Filter...1

10 ENGINE DECK GROUP Item Part No. Description Qty. Item Part No. Description Qty Fuel Line, Plastic Tie, Large Fuel Line, Valve, Fuel Line Fitting, Fuel Bulkhead W/Screen O-Ring Capscrew, 5/16-18 x 1-3/ Asm, Fuel Tank Clamp, Gas Line Strap, Fuel Tank Screw, 1/4-20 x 2-1/ Gas Tank Pad Cap, Fuel Tank Screen, Air Intake Nut, Retainer 1/ Screw, Thumb 1/4-20 x 3/ Capscrew, 3/8-16 x 3/ Nut, Flange 3/ Capscrew, 3/8-16 x Pulley, Idler 5 3/4 OD Cross Member Bushing, Idler Mount, Battery Nut, Whizlock 5/ Capscrew, 5/16-18 x 3/ Bolt, Hold Down Capscrew, 3/8-16 x 2-1/ Wingnut, Nyloc 1/ Grommet, Fuel Line Grommet Spacer, Grommet Washer Capscrew, 5/16-18 x Spacer Strap, Clutch Grommet Washer, Lock 5/ Cover, Batt ( ) W/Decal Key, 1/4 x 1/4 x Pulley, Engine Clutch, Elec W/Ties(Warner) Bushing, Clutch Keeper Washer, Spring Disc 7/ Capscrew, 7/16-20 x Belt, Deck Drive (60" Deck) Belt, Deck Drive (52" Deck) Spacer Grip (Drive Lever) Washer, Pivot Bolt, Carriage 5/16-18 x1-1/ Bolt, Carriage 3/8-16x1-3/ Spring Nut, Nyloc 5/ Bushing, Steel Bushing, Bronze Arm, Hyd Drive Idler Strut, Adjustment Spacer Nut, Nyloc 3/ Pulley, Idler (Steel) Washer, 3/8 SAE Belt, A (Transmission Drive) Plate, Skid Capscrew, 1/2-13 x 1 1/ Washer, 1/ Nut, 1/ Spacer, Crankshaft Valve, Oil Drain Deck, Engine ( ) W/ Tank Pads & Decals Kohler Part No Fuel Filter Washer, 5/ Washer, Disc Spring 5/ Capscrew, 5/16-18 x 1-1/4...1 Exmark black touch up spray paint - Gloss black. Exmark red touch up spray paint - P/N Use Pro-Lock, Nut Type (P/N ,.5ml tube) on clutch bolt and on bulkhead fuel tank fitting nut. Use Teflon Pipe Sealant or equivalent on threads. Fuel tank assembly includes bulkhead fitting. Kohler Replacement Parts List (Refer to Engine Owner s Manual) Description Kohler P/N Air Filter Element Outer S Air Filter Element Inner S -9-

11 ENGINE DECK GROUP -10-

12 MOTION CONTROLS Item Part No. Description Qty. Item Part No. Description Qty Bolt, Carriage 5/16-18 x Bushing Nut, 5/ Arm, Transaxle Washer, Pulley Retainer Washer, Lock 1/4 Hvy Spring Capscrew, 1/4-20 x 1-1/ Linkage, Motion Control Ball joint Rod, End Pro-Lock, Nut Type (.5ml Tube) Use On Both Rod Ends Bushing, Spring Guide Centering Spring Wldmnt Rod, End Nut, Nyloc 5/ Washer, 5/16 Stnd. Flat Nut, Jam 5/16-24 (RH) Idler Linkage S/A Linkage, Idler Bearing, Control...2 Exmark black touch up spray paint - Gloss black. Not Illustrated Capscrew, 5/16-18 x 2-1/ Pin, Clevis 5/16 x Pin, Cotter 3/32 x 1/ Yoke, Adjustable Capscrew, 5/16-18 x 1-1/ Nut, 5/ Housing, Override Rod, Link Key, Woodruff #3, 1/8 x 1/ Spring Assy, Pedal (Center) Spring, Pedal (Override) Screw, Socket HD 5/16x3/4 Shld Nut, Nyloc 1/ Capscrew, 5/16-24 x Ball Joint Capscrew, 5/16-18 x 1-1/ Spacer Nut, Whizlock 5/

13 PARKING BRAKE Item Part No. Description Qty. Item Part No. Description Qty Capscrew, 5/16-18 x 2-1/ Bolt, Whizlock 5/16-18 x 3/ Nut, Whizlock, 5/ Pro-Lock Nut Type (.5ml Tube) Link, Brake Pin, Clevis 5/16 x 3/ Pin, Cotter 1/8 x 3/ Arm, Butterfly Control Roll Pin, 7/32 x 7/ Pivot Wldmt, Brake Lever Support, Transmission (LH) Support, Transmission (RH) Lever,Brake ( )... W/ Grip & Decal Grip (Adjustment Lever) Trigger, Brake Washer, 5/ E Ring Spring, Brake Handle Pushnut, 5/ Bearing Control Butterfly Quadrant, Brake Washer, Disc 5/ Capscrew, 5/16-18 x 3/4...9 Exmark red touch up spray paint - P/N Not Illustrated. Use On Bolt Threads Linkage, Brake Nut, Jam 3/8-24 Pltd Washer, 3/ Spring, Brake Protect Pin, Trunion Capscrew, 5/16-18 x Flange Mntg (Side) Spring, 3 x 1/ Link, Connector # Jackshaft, Brake Mount, Jackshaft Bearing Arm, Brake Control Pin, Clevis, 5/16 x Clamp, Hose Pin, Clevis 3/32 x 1/ Clamp Spacer Spring, Dump Valve Rollpin 1/4 x Capscrew, 5/16-18 x 1 1/

14 RIDER FRAME and STEERING Item Part No. Description Qty. Item Part No. Description Qty Frame, Rider ( ) W/Pads, Bracket, Pivot(LH)...1 Decal, Bsgs, And Brg Cups Bearing Cone, Tapered Roller Seal, Grease Zerk, 1/4-28 (Straight) Washer, 3/4 SAE Pin, Cotter 5/32 x 1 1/ Nut, Slotted 3/ Cap, Grease Grommet Washer, 5/ Capscrew, 3/8-16 x 1 1/ Washer, 3/8 Disc Spring Nut, Flange 3/ Washer, 6" Caster Pivot Handle Bar Grip, Handle Bar Console ( ) W/ Decals Cover, Console Steering Post Screw, x 1/ Capscrew, 3/8-16 x 3/ Bushing, 6" Caster Flange Sleeve, 6" Caster Roll Pin, 1/4 x 1-1/ Pedal, Ft ( ) W/ Pad Pad, Reverse Control Pedal Pad, Forward Control Pedal Nut, Whizlock 5/ Bracket, Pivot (RH)...1 Exmark black touch up spray paint - Gloss black. Exmark red touch up spray paint - P/N Not Illustrated Capscrew, 5/16-18 x Tire, 18 x Capscrew, 1/4-20 x 5/ Rollpin, 1/4 x 1 1/ Washer, 1/ Bearing, DU l Shaft, Foot Pedal Lever, Foot Pedal Pad, Rider Anti-Skid (R) Pad, Rider Anti-Skid (L) Shaft, Steering Link, Connector # Eyebolt, 5/ Chain, #40-29 Pitch Chain, #40-33 Pitch Link Nut, Jam 5/ Capscrew, 3/8-16 x Stop, Actuator Mount, Steering Wheel Nut, Torque 5/ Capscrew, 5/8-11 x 10 1/ Bushing, Wheel Spacer, Wheel (Short) Bearing Cup Rim Tire/Whl Assy, 18.0 x U-Clip, #

15 RIDER FRAME and STEERING -14-

16 SEAT ASSY. and LIFT ACTUATOR Item Part No. Description Qty. Item Part No. Description Qty Seat Complete W/Armrests Screw, 7/16-20 x Washer, 5/16 SAE Seat Track, Adjustable (6 ) Rail, Seat (LH) Rail, Seat (RH) Base Rail, Seat Seat Rail Wldmnt Cushion, Seat Cushion, Back Rest Pad, Arm Rest (RH) Bushing, Spring Guide Spring Screw, 1/2-13 x 3 1/ Washer, 1/ Strut, Adjustment Spacer Flatwasher, 3/8 Std Nut, Whizlock 5/ Nut, Nyloc 1/ Pivot Wldmnt, Actuator Screw, 1/2-13 x 1 1/ Screw, 3/8-16 x Actuator, Linear Spring, Compression...1 Exmark black touch up spray paint - Gloss black. Exmark red touch up spray paint - P/N Includes armrests, armrest adjuster hardware and seat back decal Screw, 7/16-20 x Nut, Flange 3/ Nut, Nyloc 7/ Tap Bolt, 5/16-18 x 2 1/ Washer, 5/ Washer, Lock 1/ Nut, Nyloc 1/ Washer, 7/ Bumper, Rubber Nut, Nyloc Spring, Seat (TR) Guard, Actuator Spacer, Track Nut, 5/ Screw, 5/16-18 x 3/ Pad, Arm Rest (LH) Screw, 5/16-18 x 3/4 CR Seat Frame Tab, Armrest Adjustment Screw, 5/ /2...2

17 DECALS Item Part No. Description Qty. Item Part No. Description Qty Decal, Console Decal, Exmark Decal, Battery Decal, Brake Lever Decal, Danger Decal, Muffler Decal, Mower Deck Decal, Hydraulic Tank Decal, Bolt Torque Decal, Ultracut Decal, Roller Mounting Decal, Turf Ranger Decal, Foot Pedal Decal, Ultracut Decal, Discharge Warning Decal, Belt Routing Decal, Intake Decal, Exmark logo Decal, Missing Cover Decal Kit Complete

18 ELECTRICAL GROUP Item Part No. Description Qty. Item Part No. Description Qty Battery, 12 Volt Hose, Battery Manifold (23 ) Capscrew, 1/4-20 x 3/ Clip, 1/2 Loom Nut, Whizlock 5/ Harness, Wiring (Rider) Nut, Ignition Switch, Seat Safety Cable, Ground ( - ) Bolt, Carriage x 3/ Cable, Starter Meter, Engine Hours Insulator, Solenoid (Pos. +) Module, Safety Interlock Washer, Disc Spring 5/ Switch, PTO Harness, Wiring Flatwasher, 1/ Nut, Whizlock 1/ Boot, Toggle Switch Capscrew, 1/4-20 x 5/ Switch, Toggle DPDT Switch, 12 Volt Solenoid Ignition Switch W/Keys Fuse, Blade 20 AMP Key, Exmark Logo Harness, Wiring (Engine) Ignition Key Plastic Tie, (Small) Grommet Cable, Throttle Fuse, Blade 30 AMP Cable, Choke Nut, 5/8-32 (Seat Switch) Plastic Tie, (Large) Insulator, Battery Positive Bracket, Safety Switch Insulator, Battery Negative Switch, Neutral Lockout Clip, 9/16 Loom Knob, Red Ball Capscrew, 5/16-18 x 1-3/ Screw, x 5/8 Flathead Connector, Packard 2-Way Nut, Nyloc Plate, Tapped Grommet...1 NOTE: Apply dielectric grease to all electrical connectors. -17-

19 ELECTRICAL GROUP -18-

20 ELECTRICAL DIAGRAM Engine Deck Wiring Diagram NOTE: All connectors are viewed from the wire input side of the connector. Console Wiring Diagram NOTE: All connectors are viewed from the wire input side of the connector. -19-

21 NOTES -20-

22 NOTES -21-

23 SERVICE RECORD Date Description of Work Done Service Done By -22-

24 SEE EXMARK S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z LAZER Z HP LAZER Z XP LAZER Z CT TURF RANGER VIKING HYDRO TURF TRACER TURF TRACER HP METRO METRO HP ULTRA VAC ULTRA VAC QDS GRASS CATCHER MICRO-MULCH ACCESSORY SELF STEERING SULKY EXMARK MFG. CO. INC. INDUSTRIAL PARK BOX 808 BEATRICE, NE ALL RIGHTS RESERVED PART NO (402) FAX (402) PRINTED IN U.S.A. MFG. CO.

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