Exmark TT20KCC manual

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WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment. W HAT CAN HAPPEN ♦ Failure to f ollow safe operating pr act ices can result in serious operator inj ur y or even death. HOW TO AVO ID THE HAZARD ♦ Keep all shields, guar ds, and saf ety devices (especially the grass discharge system) in place and in pr oper working condi[...]

- 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 a[...]

- ii - CONGRAT ULATIONS on the purchase of your Exmark Mow er . T his product has been caref ully designed and m anufactur ed t o give you a maximum amount of dependabilit y and years of tr ouble- free oper at ion. OPERA TOR'S M ANUA L This manual cont ains assem bly, oper at ing , maintenance, adj ust ment, and saf ety instructi ons for your [...]

- iii - TA BLE OF CONTENTS 1. SA FETY ............................................................................................. PA GE 1.1 Sa f ety Alert Sy mbol ...................................................................................... 1 1.2 Trai ning ..................................................................................[...]

- 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 m achine t o identif y impor t ant saf ety message s which must be f ollowed to avoid accidents. This symbol means: A TTENTION! BECOME A LERT! YOUR SA FETY IS INVOLVED ! The saf ety alert symbol appears above inform at ion which alerts you to[...]

- 2 - 1.3.4 Thoroug hly inspect t he ar ea where the equipment is t o be used and r em ove all stones, stick s, wires, bones, and other f oreign obj ect s which may damage the equipment or cause per sonal inj ury to the operator or bystander s. WA RNING POTENT IAL HAZARD ♦ Engine exhaust contains carbon m onoxide, which is an odorless deadly pois[...]

- 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions gasoline is extremely f lamm able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g a soline vapors. A f ire or explosion from g asoline can burn you, others, and cause property damag e. HOW TO AVO ID THE HAZARD ♦ Purchase and store g asoline only in an approved con[...]

- 4 - 1.4 OPERA TION Although hazard control and acci dent prevent ion are partiall y dependent upon t he design and configurat i on of t he equipment, these f act ors are al so dependent upon the awareness, concern, prudence, and proper t r ai ni ng of the personnel involved in t he operat i on, t ransport, maintenance, and storage of the equipmen[...]

- 5 - 1.4.5 Stop the blades when crossing surf aces other than g rass, if m ower must be tilted f or transport ation, and when transporting t he m ower to and from t he area to be mowed. 1.4.6 N ever oper at e t he m ower w it h def ective guards, shields, or covers. Always have safety shields, g uar ds, switches, and ot her devices in place and in[...]

- 6 - 1.5 MAINTENA NCE A ND S TORAGE 1.5.1 For engine m aint enance, follow the engine m anuf acture’s r ecom m endat ions precisely as stated in the eng ine manual. 1.5.2 Disconnect the batt ery from t he negative batter y post when the unit will be allowed to sit for m or e t han 30 days w ithout use. 1.5.3 Allowing batteries to stand f or an e[...]

- 7 - 1.6 RIDING ATTA CHMENTS Use only Exmark riding attachments. T he use of other than Exmark riding attachments may create a hazardous condition result ing in injury. 1.7 SA FETY SIGNS 1.7.1 Keep all safet y sig ns leg ible. Remove all grease, dir t , and debris f r om safet y signs and instr uct ional labels. 1.7.2 Safet y signs m ust be replac[...]

- 8 - PART NO. 1- 303508 LOCATIO N: On Top RH Surf ace of Mower Deck PART NO. 1- 303517 LOCATI ON: LH Side of Rear Surf ace of Engine Deck PART NO. 1- 513747 LO CATI ON: To p Rear of Batter y Cover PART NO. 1- 513746 LOCAT ION: Surfac e of Engine Deck Next to Muffler PART NO. 1- 303293 LOCATI ON: Top Surf ace of Fuel Tank PART NO. 1- 553049 LOCATIO[...]

- 9 - 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: Serial Nos. 320,000 & Hig her: T T 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 unleaded g asoline, 87 octane or hig her . In countrie[...]

- 10 - 2.9 MOW ER DECK 2.9.1 M odel Numbers: Serial Nos. 320,000 and higher : FMD604 and FM D524 NOTE: Tur f Tr acer unit s 320, 000 and hig her can only be used with FM 604 and FMD524 units. 2.9.2 Cutting W idth: 60 in. ( 152. 4 cm . ) 52 in. (132.1 cm . ) 2.9.3 Discharg e: Right Side 2.9.4 Opt ional Mulch Kit and Bag g er available. 2.9.5 Blade S[...]

- 11 - 3.2.1 Remove battery cover fr om m achine. Disconnect the batt ery cables (negative (black) cable f irst) and r em ove batt er y. DA NGER POTENT IAL HAZARD ♦ Charging t he bat tery may produce explosive gasses W HAT CAN HAPPEN ♦ Battery gasses can explode causing ser ious inj ur y. HOW TO AVO ID THE HAZARD ♦ Keep sparks, f lames, or ci[...]

- 12 - 3.4 DRIVE WHEELS 3.4.3 Check air pressur e in dr ive tires; recommended pr essur e is 12- 16 psi. Measure circumfer ence of each drive tire. Adj ust t ire pressure within 12-16 psi range t o t r y to m ak e tire circumf erences mat ch as closely as possible. 3.5 MOWE R DE CK INSTA LLA TION 3.5.1 Release the wheel drive system by opening the [...]

- 13 - 3.5.5 Mow er Deck Stationary Idler I nstallation: Locate the two holes along t he back center section of the deck ( See Fig ure 2) and install the stat ionary idler and related part s ( from bolt bag ) in the rig ht hand hole. Be sure the coned end of the disc spring washer is against the head of the bolt. T ighten hardware. FIGURE 2 ST AT I[...]

- 14 - 4. OPERA TION INSTRUCTIONS 4.1 Controls 4.1.1 Operator Pr esence Control (OPC) Levers: Locat ed on t he upper handle assembly directly above the handle grips. When these l evers are depressed, the OPC system senses that t he operat or i s i n t he normal operat or's position. When t he l evers are rel eased, the OPC system senses that t[...]

- 15 - 4.1.8 Ignit ion Switch: Located on the contr ol console lef t side. T he ignition switch is used to start and st op the engine. T he ignition switch has three posit ions, “ O ff ”, “On” and “ St ar t ”. Insert k ey into switch and rotate clock wise to the “ O n” position. Rotate clock wise to the next posit ion t o engage t h[...]

- 16 - On a cold engine, place t he t hrottle midway between the “Slow” and “Fast” positions and place the chok e in t he “On” position. On a warm engine, place the throt t le lever midway bet ween “Slow” and “Fast” posit ions and leave the choke in the “ O ff ” position. Turn ig nition switch to “Start ” posit ion. Rele[...]

- 17 - FIGURE 4 DRIVE LEVER, NEUTRA L LO CK LA TCH OPERAT I O N 4.3.4 Drive W heel Engag ement/T urning: W ith drive levers lock ed in neut ral, shif t speed control lever to desir ed f orward speed. Slowly squeeze and hold both drive levers in the neutral posit ion and r otate both neut r a l lock latches fr om t he neutral lock posit ion to the f[...]

- 18 - 4.4 TRA NSPORTING WA RNING POTENT IAL HAZARD ♦ Loading the m ower onto a t r ailer without strong enough or pr oper ly supported r amps could be dangerous. W HAT CAN HAPPEN ♦ The ram ps could collapse causing the unit to f all, which could cause injury. HOW TO AVO ID THE HAZARD ♦ Use proper ramps t hat are secured to t he t r uck or tr[...]

- 19 - 5.1.1 Check eng ine oil level. Serv ice Interv al: See Engine Ow ner's Manual a) Stop eng ine, wait for all m oving par t s t o st op and make sure unit is on a level surface. b) Check with eng ine cool. c) Clean area around dipstick . Remove dipstick and wipe oil off . Reinsert t he dipstick. DO NOT screw into place. Remove dipstick an[...]

- 20 - d) Clean out any gr ass build- up f rom underside of deck and in deck discharge chute. e) Inspect blades and sharpen or r eplace as r eq uired. f) If blade r em oval is necessary, be caref ul f or t he shar p cutting edg es of the blades. g) Re-install the blades ( if they were removed) by placing a block of wood between the fr ont or r ear [...]

- 21 - Try to sta rt with OPC levers depressed , speed control lever in neut ral and PTO engaged - st arter MUST NOT crank. b) Check OPC cir c uit s . Clear t he area. Run engine at one-third th r ot t le, then, with drive levers and neutral lock latches in neutral loc k position , move the speed control lever out of neutral and r elease O PC lever[...]

- 22 - c) Drain oil while engine is warm f rom operat ion. d) Oil dr ain valve is located on the rig ht hand side of Kohler engines and the left hand side f or Kawasaki engines. Place pan under m achine t o catch oil and open valve w ith a 10 m m wrench. Allow oil to drain then close the valve . e) Replace the oil f ilter as per Eng ine Owner'[...]

- 23 - WA RNING POTENT IAL HAZARD ♦ Hydraulic fluid escaping under pr essur e can penet rate skin and cause injur y. W HAT CAN HAPPEN ♦ Fluid accidentally injected into t he skin must be surgically removed within a few hours by a doctor fam iliar with t his f orm of injury or g angrene may result . HOW TO AVO ID THE HAZARD ♦ Make sure all hyd[...]

- 24 - CHARGE PUMP CA P LOOSEN 1-1/2 TURNS ONL Y 5.1.11 Hydraulic system air purg e pr ocedur e. Air must be pur g ed from t he hydraulic system when any hydraulic components, including oil f ilter, are r emoved or any of the hydraulic lines are disconnect ed. The crit ical ar ea f or purg ing air fr om the hydraulic system is between the oil reser[...]

- 25 - a) Stop eng ine, wait for all m oving parts to st op, and remove key. Check air pressure in tires; r ecommended tire pressur e is: r ear, 12-16 psi; f ront casters, 15- 17 psi. b) Inf late tires to pressur es st at ed above. Measure circumf erence of each drive tire. Adjust t ire pressures within the above range to t r y to make tire circumf[...]

- 26 - b) Disassemble the cast er wheels, pry out seals, and inspect bearing s f or wear or damage and replace if necessary. c) Pack the bear ing s with NGLI gr ade #2 m ult i- purpose gun g r ease. d) Insert (1) bearing , ( 1) new seal, and (1) bearing spacer. NOTE : Seals (Exmark PN 103-0063) must be r eplaced. e) Insert Cast er Spacer. f) W ith [...]

- 27 - c) Shoulder bolts in ends of speed control crank . e) OPC lever setscrews. f) El ectric clutch retain ing bolt. g) Pump dr ive idler pivot bolt . Adhesives such as “Loctite RC/609 or RC/ 680” or “ Fel- Pro Pro-Lock Ret aining I or Retaining II” ar e used on t he f ollowing: a) O PC lever hubs and cross-shaft NOTE: Care must be used n[...]

- 28 - FIGURE 7 CUTTING HEIGHT A DJUSTMENT FIGURE 8 A NTI-SCALP ROLLER BOLT INSTA LLA TION A NTI-SCALP ROLLER A DJUSTMENT CUTTING HEIGHT A DJUSTMENT b) Adjust ant i-scalp rollers f or Norm al O per ating Conditions. Place r ollers in one of t he posit ions shown in Figure 8. Rollers will maintain 3/ 4 in. (19 mm) clear ance t o t he ground to m ini[...]

- 29 - 5.2.4 Blade drive belt tension: No adjustment necessar y. 5.2.5 Hydro Drive Linkage Adj ustment: a) Adjust Speed Cont r ol Link age and Neutr a l Saf ety Switch 1. Stop engine and wait f or all moving part s t o stop. 2. Mov e speed control lever (located on console) t o the full f orward position and check or ient at ion of tabs on t he end[...]

- 30 - 4. Loosen the nut ag ainst the neutral contr ol linkage yok e as shown in Figure 10. 5. Adjust t he neut r al control link ag e until the respect ive drive wheel stops when the lever is pulled against the neut ral spring (neut ral position). T urn the adjust ing bolt approximately 1/4 t ur n clockwise if the wheel is turning in r evers e or [...]

- 31 - 4. The spring that k eeps tension on the k nob should nor m ally not need adjustment . However, if adjust m ent is needed, adjust to where lengt h of spr ing is about 1” between washers. Adjust spring leng th by turning nut at front of spring. d) Drive Lever Linkage Adj ustment 1. W ith r ear of machine still on j ack stands and engine r u[...]

- 32 - 6. WA STE DISPOSAL 6.1 MOTOR OIL DISPOSA L Engine oil and hydraulic oil are both pollut ant s to the environment. Dispose of used oil at a certif ied recycling center or accor ding to your stat e and local r eg ulations. 6.2 BATTERY DISPOSA L DA NGER POTENT IAL HAZARD ♦ Battery electr olyte cont ains sulf uric acid, which is poisonous and [...]

- 33 - g) Check for loose or f aulty wiring connections. If it is necessary to disconnect wire connectors, Do Not pull on the wires. h) Check for cor r osion at all wiring connections. Even minor corrosion may cause a fault y connection. Clean connect or t erminals thoroug hly, apply dielectric grease and reconnect . IMPORTA NT: It i s essential th[...]

- 34 - 8. HYDRA ULIC SCHEM A TIC[...]

- 35 - 9. WIRING DIA GRAMS[...]

- 36 - 10. WA RRANTY Limited Warranty Exmark Commercial Turf Equipment Exmark Mfg . Co. Inc. and it s aff iliate, Exmark W arrant y Company, pursuant to an agr eement between them, joint ly w ar r ant on t he terms and conditions her ein, t hat we w ill repair, r eplace or adjust any part m anuf actured by Exmark and f ound by us (in the exercise o[...]

- 37 - As a condition to this warrant y, cust om er shall have read t he oper at or's manual and shall have completed and ret ur ned to Exmark W arrant y Company, within the prescr ibed t ime, the Exmark wa rranty registrati on. The sole liability of Exmark and Exmark W arr ant y Company with respect t o t his warranty shall be repair and repl[...]

- 38 - 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 , POL E 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[...]

® M FG . CO. IN C. SEE EXMARK’S CO MPLETE 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 WA RN ING The engine ex haust from this produc t contains chem icals known to t[...]