Exmark Turf Tracer HP TT3615KA Operator'S Manual Download Page 18 | Manualshive

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2.12 TORQUE REQUIREMENTS

BOLT LOCATION

TORQUE

Blade Mounting Bolt .................................................... 115-120 ft-lbs.
Cutter Housing Spindle Nut .............................................. 75-80 ft-lbs.
Anti-Scalp Roller Bolts...................................................... 40-45 ft-lbs.
Mower Deck Support/Engine Deck Mount ........................ 30-35 ft-lbs.
Engine Mounting Bolts

15 &17

HP

Kawasaki ........................................ 15-20 ft-lbs.

3. ASSEMBLY INSTRUCTIONS

3.1 UNCRATE UNIT: Remove upper handle assembly, fuel tank, and linkages from the top

of the crate.

3.2 SERVICE BATTERY

:

(Electric start units only)

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.

HOW TO AVOID THE HAZARD

♦

Keep sparks, flames, or cigarettes away from battery.

♦

Ventilate when charging or using battery in an

enclosed space.

♦

Make sure venting path of battery is always open once

battery is filled with acid.

3.2.2 Check the voltage of the battery with a digital voltmeter. Locate the voltage

reading of the battery in the table below and charge the battery for the
recommended time interval to bring the charge up to a full charge of 12.6 volts or
greater.

IMPORTANT:

Make sure the negative battery cables are disconnected and the

battery charger used for charging the battery has an output of 16 volts and 7
amps or less to avoid damaging the battery (see chart below for recommended
charger settings).

Voltage

Reading

Percent

Charge

Maximum

Charger Settings

Charging Interval

12.6 or greater

100%

16 volts/7 amps

No Charging Required

12.4 – 12.6

75 – 100%

16 volts/7 amps

30 Minutes

12.2 – 12.4

50 – 75%

16 volts/7 amps

1 Hour

12.0 – 12.2

25 – 50%

14.4 volts/4 amps

2 Hours

11.7 – 12.0

0 – 25%

14.4 volts/4 amps

3 Hours

11.7 or less

0%

14.4 volts/2 amps

6 Hours or More

WARNING:

Battery posts, terminals, and related accessories contain lead compounds, chemicals known

to the State of California to cause cancer and reproductive harm.

Wash

hands after handling.

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Summary of Contents for Turf Tracer HP TT3615KA

Page 1: ......

Page 2: ... Long term exposure to vapors has caused cancer in laboratory animals WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness HOW TO AVOID THE HAZARD Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass c...

Page 3: ...bmitting 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 res...

Page 4: ...wer maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service st...

Page 5: ...11 2 8 Wheel Drive System 11 2 9 Tires 12 2 10 Deck 12 2 11 Dimensions 12 2 12 Torque Requirements 13 3 ASSEMBLY INSTRUCTIONS 3 1 to 3 21 Assembly 13 17 4 OPERATION INSTRUCTIONS 4 1 Controls 17 19 4 2 Pre Start 19 21 4 3 Operation Instructions 21 23 4 4 Transporting 23 5 MAINTENANCE ADJUSTMENTS 5 1 Periodic Maintenance 24 32 5 2 Adjustments 32 37 6 WASTE DISPOSAL 6 1 Motor Oil Disposal 37 7 TROUBL...

Page 6: ... the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 1 2 4 Avoid mowing while people especially children or pets are nearby Keep in mind that the operator or user is responsibl...

Page 7: ... explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD DO NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only in a well ventilated area or refuel outdoors Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap ...

Page 8: ...ble then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignited by electrical spark...

Page 9: ... muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic a...

Page 10: ...condition 1 4 7 Do Not change the engine governor settings or over speed the engine Operating an engine at excessive speed may increase the hazard of personal injury 1 4 8 Place speed control levers in neutral lock position disengage PTO and engage park brake before starting engine 1 4 9 Start the engine carefully with feet well away from blades 1 4 10 Keep hands feet and clothing away from rotati...

Page 11: ...rformance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage 1 5 4 Keep engine and engine area free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate...

Page 12: ...ACHMENTS 1 6 1 Use only Exmark riding attachments The use of other than Exmark riding attachments may create a hazardous condition resulting in injury 1 7 SAFETY SIGNS 1 7 1 Keep all safety signs legible Remove all grease dirt and debris from safety signs 1 7 2 Safety signs must be replaced if they are missing or illegible 1 7 3 When new components are installed be sure that current safety signs a...

Page 13: ...Housing Next to Muffler and On Center Belt Cover PART NO 1 603845 LOCATION Rear Center of Top Surface of Engine Deck PART NO 1 523522 LOCATION On Top of Hydraulic Tank PART NO 1 413421 LOCATION Left Rear on Top of Engine Deck PART NO 1 413214 LOCATION Right Side of Hydro Control Crank Arm Standard Pistol Grip Handles PART NO 1 303102 LOCATION Upper Handle 17 HP Kawasaki Electric Start Only PART NO...

Page 14: ...er Belt Shield PART NO 103 1798 LOCATION RH Side Console Standard Pistol Grip Handles 15 17 HP Kawasaki Manual Start PART NO 103 1974 LOCATION Console ECS Handles 17 HP Kawasaki Electric Start PART NO 103 1976 LOCATION Console PART NO 103 2103 LOCATION Park Brake Lever ...

Page 15: ...NO 1 323540 LOCATION Front of Mower Deck Top Surface ECS Handles 15 17 HP Kawasaki Manual Start PART NO 103 1977 LOCATION Console PART NO 98 5954 LOCATION Under Mower Deck Belt Shield s ECS Handles PART NO 103 2242 LOCATION LH Side of Console ECS Handles PART NO 103 2243 LOCATION RH Side of Console ...

Page 16: ... must have speed control lever in neutral PTO disengaged and OPC levers depressed for electric start to start engine Release of OPC levers will cause the engine to stop if speed control lever is not in neutral and or PTO is engaged 2 6 STEERING CONTROL Fingertip drive control levers provide independent speed control braking and neutral to each drive wheel for moving forward or reverse stopping and...

Page 17: ...upport frame removable for service 2 10 6 Cutting Height Adjusts in 1 2 63 cm increments from 1 5 3 8 cm to 4 1 2 11 4 cm 2 11 DIMENSIONS 2 11 1 Overall Width 36 48 52 46 25 58 25 62 6 Discharge chute down 117 5 cm 148 0 cm 159 0 cm Discharge chute up 36 1 48 1 53 0 Transport only 91 7 cm 122 2 cm 134 62 cm 2 11 2 Overall Length 36 48 52 77 7 73 7 75 9 Standard Pistol Grip Handles 197 cm 187 cm 19...

Page 18: ... once battery is filled with acid 3 2 2 Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater IMPORTANT Make sure the negative battery cables are disconnected and the battery charger used for charging the battery ...

Page 19: ...s and their proper position 3 6 Apply retaining adhesive Fel Pro ProLock Retaining I or Retaining II or Loctite RC 609 or 680 on the two threaded studs from the bolt bag and install into the two left holes underneath fuel tank Install the fuel tank on top of the fuel tank support with the studs going through the slots in the support Install two 5 16 x 3 4 screws with a 5 16 SAE flat washer and 5 1...

Page 20: ...Fig 3 Loosen jam nut and remove turnbuckle 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 The standard pistol grip handles have the drive lever linkage on the outside of the blade engagement lever tab and the hairpin on the inside ECS handles have the drive lever linkage on...

Page 21: ...tall hairpin 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 NOTE There should NOT be a washer between the neutral lock latch and the hairpin cotter FIGURE 4 STANDARD PISTOL GRIP HANDLES DRIVE LINKAGE SWIVEL FIGURE 5 STANDARD PISTOL GRIP HANDLES DRIVE LEVER LINKAGE TO DRIVE LEVER For ECS ha...

Page 22: ...or to the keyswitch Fasten the harness to the left hand side of the handle using two large ties from the bolt bag On ECS models fasten the leads connecting to the OPC switch to the small hole in the channel under the console using a small tie from the bolt bag 3 15 If machine is shipped without muffler installed install muffler with hardware provided 3 16 SERVICE ENGINE Refer to Engine Owner s Man...

Page 23: ...zing the left hand and or right hand lever causes the left hand and or right hand drive wheel respectively to slow down stop or reverse depending on how far each drive lever is squeezed Squeezing the drive levers beyond the neutral position causes the drive wheels to engage in the reverse direction regardless of the position of the neutral lock latches and the speed control lever 4 1 4 Neutral Loc...

Page 24: ...e is used to shut off the flow of fuel when parking inside a building during transportation to and from the job sites and when the machine will not be used for a few days Rotate valve 1 4 turn clockwise to shut fuel off Rotate valve 1 4 turn counter clockwise to turn fuel on 4 1 12 Drive Wheel Release Valves Located on the top rear corner of the hydrostatic pumps Drive wheel release valves are use...

Page 25: ...ing any source of ignition until fuel vapors have dissipated 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 HOW TO AVOID THE HAZARD Purchase and store gasoline only in an approved container Always place gasoli...

Page 26: ...l recoil rope to start engine For a 17HP Kawasaki Electric start engine OPC levers must be depressed turn ignition switch to the start position Release the switch when the engine starts After the engine starts and warms up gradually push down on the choke control and place the throttle control in the full throttle position IMPORTANT For electric start models do not crank the engine continuously fo...

Page 27: ...s slip into the drive position the unit could lurch forward and cause injury or property damage HOW TO AVOID THE HAZARD Be sure the drive levers are past the roller and securely seated at the bottom of the neutral lock latches To place the drive levers in the drive position slightly squeeze the drive levers while placing thumbs on the outer thumb lobe of the neutral lock latches and push forward m...

Page 28: ...tle to begin mowing See Section 4 1 5 4 3 8 PTO Disengagement Pull upward and back completely on the PTO engagement arm to disengage the blades See Section 4 1 5 4 4 TRANSPORTING WARNING POTENTIAL HAZARD Loading the mower onto a trailer without strong enough or properly supported ramps could be dangerous WHAT CAN HAPPEN The ramps could collapse causing the unit to fall which could cause injury HOW...

Page 29: ...g repairs around the engine area 5 1 1 Check engine oil level Service Interval See Engine Owner s Manual a Make sure mower is on a level surface Stop engine and wait for all moving parts to stop b Check with engine cool c Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick DO NOT screw into place Remove dipstick and check oil level d If the oil level is low add oil as...

Page 30: ... deck discharge chute e Inspect blades and sharpen or replace as required f If blade removal is necessary be careful for the sharp cutting edges of the blades g Re install the blades if they were removed and torque blade bolts to 115 120 ft lbs Be sure the spring disc washer cone is installed toward the bolt head See Figure 8 CAUTION POTENTIAL HAZARD Operating a mower deck with loose or weakened b...

Page 31: ...eed control lever in neutral and electric blade clutch engaged starter MUST NOT crank c Check OPC circuits Clear the area Run engine at one third throttle then with drive levers and neutral lock latches in neutral lock position move the speed control lever out of neutral and release OPC levers engine MUST stop Again run engine at one third throttle move the speed control lever to neutral engage bl...

Page 32: ... as specified in Engine Owners Manual Do not overfill g Start the engine and check for leaks Stop engine and recheck oil levels 5 1 8 Check hydraulic oil level Service Interval 40 hr a Stop engine and wait for all moving parts to stop b Clean area around hydraulic reservoir cap and remove cap Oil level should be to the top of the baffle inside the tank If not add oil WARNING POTENTIAL HAZARD Hydra...

Page 33: ...e top of the main pump as shown in Figure 9 may have lost their prime Refer to Section 5 1 10 h DO NOT change hydraulic system oil except what can be drained when changing filter unless it is felt that oil has been contaminated Changing oil unnecessarily could damage the hydraulic system by introducing contaminates into the system 5 1 10 Hydraulic system air purge procedure Air must be purged from...

Page 34: ...ck tire pressures Service Interval Pneumatic air filled Drive Tires 40 hrs Semi pneumatic Caster Tires No maintenance a Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s Check air pressure in drive tires recommended tire pressure is 12 16 psi b Inflate tires to pressures stated above Measure circumference of each drive tire Adjust tire pressures within the ...

Page 35: ...ngs 12 2 2 2 Daily 2 Caster Pivots 2 2 2 2 Daily 3 PTO Engagement Bellcrank 1 1 1 1 Weekly 4 Idler Pivot Pump Drive 2 1 1 1 Weekly 5 Clutch Arm Pivot 1 1 1 1 Weekly 6 Cutter Deck Idler Pivots 2 1 1 1 Weekly 7 Pump Control Bearings 2 2 2 2 Weekly No 4 Idler Pivot Located Under Engine Deck No 5 Clutch Arm Pivot Located Under Engine Deck No 4 6 Idler Arm Pivots Disassemble and grease once a month und...

Page 36: ... sheave setscrews b Square head setscrews on Hydro pump control arms c OPC lever setscrews d Sheave retaining bolt in end of engine crankshaft e Lower Sheave retaining bolt on clutch arm f Shoulder bolts in ends of speed control crank Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining I or Retaining II are used on the following a OPC lever hubs and cross shaft NOTE Care must ...

Page 37: ...0 25 14 4 volts 4 amps 3 Hours 11 7 or less 0 14 4 volts 2 amps 6 Hours or More 5 2 ADJUSTMENTS 5 2 1 Cutting height and anti scalp roller adjustment WARNING POTENTIAL HAZARD When the two front support rod hairpins are removed from the mower deck the weight of the tractor section may cause the front frame to rise suddenly WHAT CAN HAPPEN If the unit rises suddenly injury may occur HOW TO AVOID THE...

Page 38: ...ad of the bolt and mounting bracket Torque to 40 45 ft lbs or loss of roller may result d When operating in extremely rough conditions it may be necessary to position the anti scalp rollers one or two holes higher than described in c to prevent damage to the rollers and or bolt failure See Figure 11 NOTE When anti scalp rollers are placed in these positions reduced deck flotation will result 5 2 2...

Page 39: ...stment a Adjust Speed Control Linkage and Neutral Safety Switch 1 Stop engine and wait for all moving parts to stop 2 Move the speed control lever located on the console to the full forward position and check the orientation of the tabs on the ends of the speed control crank Figure 14 These tabs should be pointing straight down at the 6 o clock position or slightly forward Adjust the threaded yoke...

Page 40: ... lever is pulled against the neutral spring neutral position Turn the adjusting bolt approximately 1 4 turn clockwise if the wheel is turning in reverse or turn the bolt approximately 1 4 turn counter clockwise if the wheel is turning forward Release the drive lever to the forward drive position and squeeze back into the neutral position Check to see if the wheel stops If not repeat the above adju...

Page 41: ...pring is about 1 between the washers Adjust spring length by turning nut at front of spring d Drive Lever Linkage Adjustment 1 With rear of machine still on jack stands and engine running at full throttle move the speed control lever to the midway position Move the respective drive lever upward until it reaches the neutral position and engage neutral lock latches See Figure 16 If the tire rotates ...

Page 42: ...n Setting a For medium or heavy duty drive conditions such as operation with a sulky on steep slopes a higher spring force may be required on the hydro pump control arms to prevent the drive system from stalling b For a heavier drive setting relocate the spring anchor link to either the medium or heavy duty positions as shown in Figure 17 The spring anchor links are attached to the upper rear corn...

Page 43: ...the knob in 1 4 turn increments until the mower tracks correctly 7 2 MOWER CUTS UNEVENLY a Check the drive tire pressure and tire circumference See 5 1 11 A more uniform cutting height may be obtained with higher tire pressure on rough terrain A lower tire pressure provides more flotation b Check deck support pins Hairpin clips must be in the same hole position on each support pin See Section 5 2 ...

Page 44: ...ice dealer ENGINE TROUBLESHOOTING When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing or adjustment procedures such as valves governor etc Have this work done by your Engine ...

Page 45: ... 40 8 WIRING DIAGRAMS ...

Page 46: ... 41 9 HYDRAULIC DIAGRAM ...

Page 47: ... expense of delivering the mower to the dealer for warranty work nor the expense of returning it back to the owner after repair or replacement Our responsibility in respect to claims is limited to making the required repairs or replacements and no claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower Proof of purchase may be required ...

Page 48: ...charges or travel charges vi loss or damage to person or property other than that covered by the terms of this warranty vii any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty or viii attorney s fees There are no representations or warranties which have been authorized and provided to the buyer of the turf equipment other than as set forth in thi...

Page 49: ... 44 NOTES ...

Page 50: ... 45 SERVICE RECORD Date Description of Work Done Service Done By ...

Page 51: ...L O P E T H IS IS A 1 0 S L O P E T H IS IS A 5 S LO P E ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC EXAMPLE COMPARE SLOPE WITH FOLDED EDGE FOLD ALONG APPROPRIATE LINE T H I S I S A 2 0 S L O P E ...

Page 52: ...SELF STEERING SULKY MICRO MULCH ACCESSORY WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm MFG CO INC 1997 1998 1999 2000 2001 PART NO 103 1773 EXMARK MFG CO INC 402 223 6300 INDUSTRIAL PARK BOX 808 FAX 402 223 5489 BEATRICE NE 68310 ALL RIGHTS RESERVED PRINTED IN U S A ...

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