Exmark Turf Tracer HP manual

For Serial Nos. 440,00 0 & Higher Part No. 103 - 4871[...]

ii WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HO W TO AVOID THE HAZARD ♦ Keep all shields, guards and sa fety devices (especially the grass discharge system) in place and in proper working condition. ?[...]

iii 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 reque[...]

iv CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of depe ndability and years of trouble - free operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERA[...]

v TABLE OF CONTENTS 1. SAFETY ............................................................................................ PAGE 1.1 Safety Alert Symbol ................................................................................... 1 1.2 Training ...................................................................................................[...]

- 1 - 1. SAFETY 1.1 SAFETY ALERT SYM BOL This SAFETY ALERT SYMBOL is used both in this manual and on the machine to identify im portant safety messages which must be followed to avoid accidents. This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol appears above information which alerts you to unsafe actions o[...]

- 2 - 1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones and other foreign objects which may damage the equipment or cause personal injury to the o perator or bystanders. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison. WHAT CAN HAP[...]

- 3 - DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite gasoline vapors. A fire or explosion from gasoline can burn you, others, and cause property damage. HO W TO AVOID THE HAZARD ♦ Purchase and store gasoline only in an approved container. ♦ A[...]

- 4 - WARN ING POTENTIAL HAZARD ♦ Operating engine parts, especially the muffler, become extremely hot. WHAT CAN HAPPEN ♦ Severe burns can occur on contact. ♦ Debris, such as leaves, grass, brush, etc. can catch fire. HO W TO AVOID THE HAZARD ♦ Allow engine parts, especial ly the muffler, to cool before touching. ♦ Remove accumulated debr[...]

- 5 - • See inside the back cover to determine the approximate slope angle of the area to be mowed. • Progressively greater care is needed as the slope increases. • Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope. • Be aware that loss of traction may occur go[...]

- 6 - 1.4.1 6 This mower was designed for one operator only. Keep all others away fr om mower during operation. 1.4.17 Do Not mow with the grass deflector raised, removed, or altered unless there is a grass collection system or a mulch kit in place and working properly. 1.4.1 8 Be aware of the mower discharge direction and direct discharge away fro[...]

- 7 - WARNING POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure can penetrate skin and cause injury. WHAT CAN HAPPEN ♦ Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. HO W TO AVOID THE HAZARD ♦ Make sure all hydraulic fluid h[...]

- 8 - PART NO. 1 - 403143 LOCATI ON: Right Side of Rear Surface of Engine Deck PART NO. 1 - 553049 LOCATION: Front of Mower Deck Top Surface PART NO. 1 - 403005 LOCATION: RH & LH Corners of Mower Deck PART NO. 1 - 513746 LOCATION: On Engine Blower Housing Next to Muffler and On Center Belt Cover 36” Decks PART NO. 1 - 413206 LOCATION: Top of [...]

- 9 - PART NO. 1 03 - 4935 LOCATION: Rear Center of Top Surface of Engine Deck PART NO. 103 - 1798 LOCATION: RH Side Console PART NO. 103 - 1077 LOCATION: On Top LH Side of Mower Deck. 17 HP Kawasaki Electric Start PART NO. 103 - 1976 LOCATION: Console PART NO. 103 - 2103 LOCATION: Park Brake Lever PART NO. 98 - 5954 LOCATION: Under Mower Deck Belt[...]

- 10 - 15 & 17 HP Kawasaki Manual Start PART NO. 103 - 1977 LOCATION: Console PART NO. 103 - 2242 LOCATION: LH Side of Console PART NO. 103 - 2243 LOCATION: RH Side of Console[...]

- 11 - 2. SPECIFICATIONS 2.1 MODEL NUMBER: Seri al Nos. 440 ,000 & Higher: TT3615KA C ; TT4817KA C ; TT5217KAC; TT4817KAEC; TT5217KAEC 2.2 ENGINE 2.2.1 Engine Specifications: See your Engine Owner's Manual. 2.2.2 3600 RPM (No Load). 2.3 FUEL SYSTEM 2.3.1 Capacity: 5.0 gal.(18.9 L.) 2.3.2 Type of Fuel : Regular unleaded gasoline, 87 octane [...]

- 12 - 2.10 DECK 2.10.1 Cutting W idth: Model 36 in. ........................................ 35.25 in. (89.5 cm) Model 48 in. ........................................ 47.25 in. (120.0 cm) Model 52 in. ........................................ 52.00 in. (132.1 cm) 2.10.2 Discharge: Right Side 2.10.3 Blade Size: Model 36 in. .............. 18.00 in. [...]

- 13 - 3.2 Service Battery : The machine is shipped with a filled lead acid battery. 3.2.1 Remove battery cover from the machine. DANGER POTENTIAL HAZARD ♦ Charging the battery may produce explosive gasses WHAT CAN HAPPEN ♦ Battery gasses can explode causing serious injury. HO W TO AVOID THE HAZARD ♦ Keep sparks, flames, or cigarettes away fr[...]

- 14 - NOTE: If the positive cable is also disconnected, connect the positive (red) cable to the positive terminal on the battery first , then connect the negative (black) cable to the negati ve terminal on the battery. Reinstall battery cover. NOTE: If time does not permit charging the battery, or if charging equipment is not available, connect th[...]

- 15 - FIGURE 2 SPEED CONTROL (THROTTLE CABLE HOOK - UP) 3.10 Connect the PTO engagement linkage (See Fig. 3). Loosen jam nut and remove turnbuc kle from lower linkage. Screw turnbuckle onto both upper and lower linkages simultaneously. Note that threads on upper linkage are left hand. See 5.2.2 for linkage adjustment. Note: H andles have the drive[...]

- 16 - This will give an approximate setting for drive lever linkages; you will need to refer to Section 5.2.6 step d to complete the drive lever linkage adjustment. FIGURE 4 ECS HANDLES DRIVE LEVER LINKAGE INSTALLATION 3.14 Connect wiring har ness. For recoil start models: Route the long unattached portion of the wiring harness up the left handle [...]

- 17 - 3.19 Follow pre - start instructions as outlined in Section 4.2. NOTE: After starting the engine and engaging the hydro drive, if eith er of the drive wheels acts sluggish or will not rotate at all, stop engine and refer to Section 5.1.10 on the Hydraulic System Air Purge procedure. 3.20 Perform any needed adjustments as outlined in the Adju[...]

- 18 - 4.1.6 PTO Engagement : Located on the left side of the upper handle. To engage the blades, push the lever forward, or away from the operator, until the linkage locks over - center. To disengage the blades, pull the lever to the rear, or towards the operator. For manual start engines: The park brake must be disengaged before the PTO is engage[...]

- 19 - 4.1.14 Cold Start Kit : (Manual start units only) Located on the right hand side of engine deck, below the hydro control shield. The cold start kit is used to ease the starting of the unit in cold weather or when the unit has not been operated for a period of time. The cold s tart kit moves the idler pulley away from the pump belt releasing [...]

- 20 - IMPORTANT : For electric start models, do not crank the engine continuously for more than ten (10) seconds at a time. If the engine does not start, allow a 60 second starter cool - down period between starting attempts. Failure to follow these guidelines can burn out the starter motor. On a warm engine, place the throttle control midway betw[...]

- 21 - FIGURE 6 DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION 4.3.5 Drive Wheel Engagement/Turning : With drive levers locked in “neutral”, shift speed control lever to desired forward speed. Note: The park brake must be disengaged before the speed control lever is moved out of neutr al or the engine will kill. Slowly squeeze and hold both drive le[...]

- 22 - DANGER POTENTIAL HAZARD ♦ An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s d irection. Also, contact with the blade could occur. WHAT CAN HAPPEN ♦ Thrown objects or blade contact can cause serious injury or death. HO W TO AVOID THE HAZARD ♦ Never operate the mower with the discharge def[...]

- 23 - 5. MAINTENANCE & ADJ USTMENTS WARNING POTENTIAL HAZARD ♦ While maintenance or adjustments are being made, someone could start the engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could ser iously injure you or other bystanders. HO W TO AVOID THE HAZARD ♦ Remove the key from the ignition switch and/or pull the wire(s) off[...]

- 24 - CAUTION POTENTIAL HAZARD ♦ Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enough support or may m al function al lowing the unit to fall, which could cause injury. HO W TO AVOID THE HAZARD ♦ DO NOT rely [...]

- 25 - FIGURE 7 BLADE BOLT INSTALLATION 5.1.4 Check s afety interlock system . Service Interval: Daily a) For your safety, your Exmark mower is equipped with Operator Presence Controls (OPC). When either the PTO is engaged, or the speed control lever is not in neutral and both hands are removed from the handl es, the mower engine MUST stop. b) For [...]

- 26 - 5.1.6 Service pre - cleaner element and air cleaner . Service Interval: See Engine Owner's Manual a) Stop engine and wait for all moving parts to stop. Remove key or spark plug wire(s). b) See engine owner’s manual for cleaning instructions. 5.1.7 Change engine oil . Service Interval: See Engine Owner's Manual NOTE: Change oil af[...]

- 27 - IMPORTANT : Before re - installing new filter, fill it completely with Mobil 1 15W - 50 and apply a thin coat of oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts th e filter adapter. Do not tighten yet. d) Fill reservoir as stated in Section 5.1.8. e) Loosen filter 1/2 turn and allow a small amount of o[...]

- 28 - FIGURE 8 CHARGE PUMP LOCATION e) To “prime ” charge pump, loosen two hex socket head capscrews (shown in Figure 11) 1 - 1/2 turns only. Make sure engine is not running . Lift charge pump housing upward and wait for a steady flow of oil to flow out from under housing. Retighten capscrews . Do this f or both pumps. Note: Hydraulic reservoi[...]

- 29 - b) Engage PTO leve r. c) Look through the round hole in the left rear corner of the engine deck to inspect blade clutching belt tension. Bolt on blade engagement linkage bellcrank and indicator arm should align within 1/16” (.16 cm) (See Figure 13). Refer to section 5.2. 2 for adjustment. 5.1.14 Lubrication Service Interval: Refer to Chart[...]

- 30 - a) Stop engine and wait for all moving parts to stop. Remove ignition key or sp ark plug wire(s). b) Remove cooling shrouds from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine, which can cause improper cooling. c) Make sure cooling shrouds are properly reinstalled. Operating the engine without [...]

- 31 - 5.1.24 Check battery charge : (Electric start units only) Service Interval: Monthly Allowing batteries to stand for an extended period of time without recha rging them will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries in storage when the open circuit voltage drops to 12.[...]

- 32 - NOTE: All (4) pins must equally suppor t the weight of the deck. Adjustment in the length of the rear deck support assemblies may be necessary. If one side is longer than 6.89” (17.5 cm), than the opposite side must be shorter by the same amount. FIGURE 9 CUTTING HEIGHT AD JUSTMENT FIGURE 1 0 ANTI - SCALP ROLLER BOLT IN STALLATION ANTI - S[...]

- 33 - b) W ith PTO engaged, adjust the linkage length by loosening the locknut on the turn buckle and adjusting the turnbuckle so that the bolt on the bellcrank and the indicator arm align with each other within 1/16” (.16 cm). See Figure 1 1 . Tighten locknut against turnbuckle. FIGURE 1 1 BLADE ENGAGEMENT LINKAGE 5.2.3 PTO Safety Swit ch : Mou[...]

- 34 - b) Adjust Neutral Co ntrol Linkages 1. Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground. 2. Start the engine and move the throttle ahead to the full throttle position. Place the neutral lock latches in the “ forw ard ” position as shown in Figure 6 and move the speed control lever [...]

- 35 - FIGURE 1 4 HYDRO CONTROL LINK/SWIVEL ADJUSTMENT After adjusting the left hydro control linkage, move the speed control lever to the mid - speed position and then back to the neutral position. Recheck the left drive wheel rotation to see if further adjustment is necessary - be sure the speed control lever is in the neutral position. If incons[...]

- 36 - 3. Make this adjustment for both sides. e) Tracking Adjustment 1. Stop engine and wait for all moving parts to stop. Raise the rear of the machine, rem ove jack stands and carefully lower the machine to the ground. (Check the drive tire pressure and tire circumference. ( See 5.1.11.) 2. Run the unit and observe the tracking on a level, smoot[...]

- 37 - 6.2 BATTERY DISPOSAL DANGER POTENTIAL HAZARD ♦ Battery elect rolyte contains sulfuric acid, which is poisonous and can cause severe burns WHAT CAN HAPPEN ♦ Swallowing electrolyte can be fatal or if it touches skin can cause severe burns. HO W TO AVOID THE HAZARD ♦ Wear safety glasses to shield eyes, and rubber gloves t o protect skin a[...]

- 38 - g) Check that there is fuel in the tank and that the fuel valve is open. h) Check that the spark plug wire(s) are properly connected. i) Check for loose or faulty wiring connections. If it is necessary to disconnect wire connectors, Do Not pull on the wires while disconnecting. j) Check for corrosion at all wiring connections. Even minor cor[...]

- 39 - 8. WIRING DIAGRAMS[...]

- 40 - 9. HYDRAULIC DIAGRAM[...]

- 41 - 10. Limited Warranty Exmark Turf Equipme nt Conditions and Products Covered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part manufactured by Exmark and found by us (in the exercise of our [...]

- 42 - 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 SURFACE (TREE, BUILDING, FENCE POS T , POLE ETC.) EX A M P L E : C O M P AR E S L O PE W I T H F O L D E D E D G E . F O L D A L O N G A PP R O P R I A T E L I N E T H I S I S A 2 0 ° S L O P E[...]

SEE EXM ARK’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 SELF STEERING SULKY MICRO - M ULCH ™ ACCESSORY WARNING The engine exhaust from this product contains chemicals [...]