Exmark Turf tracer HP Operator'S Manual Download | Manualshive

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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.

HOW TO AVOID THE HAZARD

♦

Keep all shields, guards and safety devices (especially the grass

discharge system) in place and in proper working condition.

♦

Stop engine and wait for all moving parts to stop. Remove spark

plug wire(s) or remove key before adjusting, servicing, or
performing maintenance.

♦

If mower deck becomes clogged, stop engine and remove spark

plug wire(s) or remove key and wait for all moving parts to stop
before cleaning blockage.

♦

Keep hands, feet and clothing away from power driven parts.

♦

Keep off mower unless seat platform is provided.

♦

Keep others off mower.

WARNING

POTENTIAL HAZARD

♦

Gasoline is harmful or fatal if swallowed. 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 covered land, a working
spark arrester must be attached to the muffler. If not, the operator is violating state law, Section 442
Public Resource Code. To acquire a spark arrester for your unit, see your Engine Service Dealer.

Exmark reserves the right to make changes or add improvements to its products at any time without incurring any
obligation to make such changes to products manufactured previously. Exmark, or its distributors and dealers,
accept no responsibility for variations which may be evident in the actual specifications of its products and the
statements and descriptions contained in this publication.

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Summary of Contents for Turf tracer HP

Page 1: ......

Page 2: ...wed 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 gras...

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: ...2 7 Transmission 10 2 8 Wheel Drive System 10 2 9 Tires 10 2 10 Deck 10 2 11 Dimensions 11 2 12 Torque Requirements 11 3 ASSEMBLY INSTRUCTIONS 3 1 to 3 21 Assembly 11 17 4 OPERATION INSTRUCTIONS 4 1 Controls 17 19 4 2 Pre Start 19 20 4 3 Operation Instructions 20 23 4 4 Transporting 23 5 MAINTENANCE ADJUSTMENTS 5 1 Periodic Maintenance 23 31 5 2 Adjustments 32 36 6 TROUBLE SHOOTING 6 1 Mower Tacks...

Page 6: ...URY IF PROPER PRECAUTIONS ARE NOT TAKEN 1 2 TRAINING 1 2 1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit 1 2 2 Read the instructions carefully Familiarize yourself with the controls and the proper use of the equipment 1 2 3 Never allow children teenagers or people unfamiliar with these instructions to use the mower 1 2 4 Avoid mowing while...

Page 7: ...O 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 of the fuel tank or add fuel when engine is running or when the engine is ho...

Page 8: ...pon the awareness concern prudence and proper training of the personnel involved in the operation transport maintenance and storage of the equipment It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing 1 4 1 Give complete undivided attention to the job at hand 1 4 2 Mow only in daylight or good artificial light Do Not operate the mower...

Page 9: ...wer Before removing the grass catcher Before refueling Before making height adjustments 1 4 13 Before stopping the engine return the throttle control to the idle position for 30 seconds to allow the engine to cool down 1 4 14 The fuel system is provided with a shut off valve The fuel shut off valve is used to shut off the fuel when The machine will not be used for a few days During transport to an...

Page 10: ...tly 1 5 8 Check all bolts frequently to maintain proper tightness 1 5 9 Keep all guards shields and all safety devices in place and in safe working condition 1 5 10 Frequently check for worn or deteriorating components that could create a hazard 1 5 11 All replacement parts must be the same as or equivalent to the parts supplied as original equipment WARNING POTENTIAL HAZARD Hydraulic fluid escapi...

Page 11: ...ly to a clean dry surface Smooth to remove any air bubbles 1 7 6 Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower PART NO 403143 LOCATION Right Side of Rear Surface of Engine Deck PART NO 303517 LOCATION Left Side of Rear Surface of Engine Deck PART NO 513746 LOCATION On Engine Blower Housing Next to...

Page 12: ...4 HP Kawasaki 15 HP Kohler PART NO 323689 LOCATION RH Side of Console PART NO 553049 LOCATION Front of Mower Deck Top Surface PART NO 403005 LOCATION RH LH Corners of Mower Deck 16 HP Briggs Stratton PART NO 543631 LOCATION RH Side of Console PART NO 303293 LOCATION On Top RH Side of Fuel Tank PART NO 523522 LOCATION On Top of Hydraulic Tank ...

Page 13: ...27 LOCATION Top Center of Cutter Deck Under Center Belt Shield PART NO 323540 LOCATION Front of Mower Deck Top Surface PART NO 603845 LOCATION Rear Center of Top Surface of Engine Deck Serial No s 220 000 Higher 17HP Kawasaki Electric Start PART NO 413536 LOCATION Console Serial No s 220 000 Higher 17 HP Kawasaki Electric Start PART NO 513747 LOCATION Battery Cover ...

Page 14: ...TEM Electric start units only 2 4 1 Charging System Flywheel Alternator 2 4 2 Charging Capacity 15 amps 2 4 3 Battery Type BCI Group U1 2 4 4 Battery Voltage 12 Volt Polarity negative ground 2 4 5 Fuses Two 20 amp blade type 2 5 SAFETY INTERLOCK SYSTEM Operator must have transmission in neutral blade clutch disengaged and OPC levers depressed for electric start to start engine Release of OPC lever...

Page 15: ... tapered shaft 2 9 TIRES Drive Front Caster Size 16 x 6 50 8 9 x 3 50 4 Quantity 2 2 Tread Turf Saver Turf Master Smooth Ply Rating 4 4 Pressure 14 psi 97 kPa 22 psi 152 kPa 2 10 DECK 2 10 1 Cutting Width 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 45 7 cm Qty 2 Model 48 in 16 25 in 41 3...

Page 16: ... Uncrate unit and remove upper handle assembly fuel tank and linkages from the top of the crate 3 2 Remove and open the bolt bag 3 3 Loosen the 5 16 hardware at the two 2 discharge chute hinge points so that the deflector is snug but can be moved up and down freely 3 4 Refer to Parts Manual to help you identify and locate parts and their proper position 3 5 Apply retaining adhesive Fel Pro ProLock...

Page 17: ...the throttle cable along the right side of the upper handle under the fuel tank support and position the cable on the left side of the engine Kaw Kohler or to the right side of engine B S Attach throttle cable to engine For Kohler and Kawasaki engines with positive detents in throttle cable for the full throttle and idle positions a Position the throttle control lever on console in the full thrott...

Page 18: ...le control is moved to the full throttle position Choke must be completely closed when throttle lever is moved to the full forward CHOKE position e This step needs to be done after the unit has been assembled and the engine has been started Refer to Section 4 Operation Instructions For Kohler and 14 HP Kawasaki engines Check the engine STOP position by moving throttle control fully to the rear Not...

Page 19: ...re to the appropriate throttle control lever on the engine Loosen the cable clamp on the engine place the cable behind it and pull up on the cable to move the throttle linkage to the full throttle position Tighten the cable clamp screw On Kaw and Kohler engines secure fuel line to throttle control cable with a wire tie approximately 2 ahead of filter to keep fuel line away from hydraulic lines to ...

Page 20: ...There should NOT be a washer between the neutral lock latch and the hairpin cotter FIG 7 DRIVE LEVER LINKAGE TO DRIVE LEVER 3 13 Route the long unattached wiring harness lead up the left hand side of the handle and connect the two terminals in any order to the operator presence control switch terminals underneath the control console On 15 17 HP Kawasaki models plug harness into back of key switch ...

Page 21: ...ttery 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 17 3 Fill cells with battery grade sulfuric acid 1 265 specific gravity to halfway between top of separators and bottom of vent well 3 17 4 Let battery stand for 1 2 hour after filling If battery acid level has fallen refill to level above plates 3...

Page 22: ...ystem Air Purge procedure 3 21 Perform any needed adjustments as outlined in the Adjustment Section 4 OPERATION INSTRUCTIONS 4 1 Controls 4 1 1 Operator Presence Control OPC Levers Located on the upperhandle assembly directly above the handle grips When these levers are depressed the OPC system senses that the operator is in the normal operator s position When the levers are released the OPC syste...

Page 23: ... increase engine speed and moving it to the rear will decrease engine speed All Kohler and 14 HP Kawasaki units are equipped with throttle kill as a standard feature Moving the throttle to the full rear Stop position will shut off the engine 15 17 HP Kawasaki B S units use a key switch to shut off engine 4 1 8 Off Run Switch 15 17 HP Kawasaki Manual Start 16 HP B S only Located on the console Seri...

Page 24: ...h regular grade unleaded gasoline with an octane rating of 87 or higher Regular grade leaded gasoline may also be used however combustion chamber and cylinder head will require more frequent service See Engine Owner s Manual Do not add oil to gasoline Never fill the fuel tank so that the fuel level rises above a level that is 1 2 below the bottom of the filler neck to allow for fuel expansion and ...

Page 25: ... 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 4 2 2 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary inspection and maintenance steps 4 2 3 Familiarize yourself with the controls and operation of unit See Controls section 4 1 and Operating Instructions s...

Page 26: ...cold engine place the throttle in the full forward position and pull the choke control on the engine fully outward to the engaged position Pull recoil rope to start engine With a cold engine gradually return choke to the disengaged position after the engine starts and warms up On a warm engine place the throttle control midway between the Slow and Fast positions DO NOT choke B S when warm NOTE It ...

Page 27: ... drive levers all the way back this will cause the drive wheels to be engaged in the reverse direction For straight ahead motion smoothly release both drive levers to engage drive wheels Squeeze the right hand drive lever to turn right and the left hand drive lever to turn left To make a zero turn squeeze either the left hand or the right hand drive lever back into the reverse position while the o...

Page 28: ...d to the truck or trailer Keep feet and legs out from under the unit when loading and unloading If necessary use assistance when loading Use a heavy duty trailer to transport the machine Engage neutral lock latches and block wheels Securely fasten the machine to the trailer with straps chains cables or ropes Use a safety chain and be sure that the trailer has all necessary lighting and marking as ...

Page 29: ...ring the oil level up to the F mark on the dipstick DO NOT OVERFILL IMPORTANT DO NOT operate the engine with oil level below the L mark or over the F mark 5 1 2 Clean engine air cooling system Service Interval See Engine Owner s Manual a Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s b Clean all debris from engine air intake screen and from around engine...

Page 30: ...ol lever is not in neutral and both hands are removed from the handles the mower engine MUST stop b For Electric Start Units Only Check starting circuit Starter should crank with Operator Presence Control levers depressed speed control lever in neutral and electric blade clutch disengaged Try to start the engine with OPC levers disengaged speed control lever in neutral and electric blade clutch di...

Page 31: ...p Remove ignition key or spark plug wire s c Drain oil while engine is warm from operation d Remove the oil drain plug from the right hand side of the engine For electric start units the oil drain plug is located on the left hand side of the engine Allow oil to drain then replace drain plug e Replace the oil filter as per Engine Owner s Manual Clean around oil filter and unscrew filter to remove B...

Page 32: ...mportant that no dirt or contamination enters the hydraulic system c Unscrew filter to remove and allow oil to drain from reservoir 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 the filter adapter Do not tighten yet d Fill reservoir as stated in Section...

Page 33: ... does not rotate it is possible to assist the purging of the charge pump by carefully rotating the tire in the forward direction NOTE It is necessary to lightly touch the charge pump cap with your hand to check the pump temperature If the cap is too hot to touch turn off engine The pumps may be damaged if the pump becomes too hot If either drive wheel still does not rotate continue with step d d T...

Page 34: ...or spark plug wire s b Remove deck support belt shield to check mower deck drive belt condition c Look under engine deck to check the pump drive and clutching belt condition d Check all idler arms to be sure they pivot freely Disassemble clean and grease pivot bushings if necessary 5 1 13 Inspect Blade Clutching Belt Tension Service Interval Check every 2 hrs for first 8 hrs operation then check e...

Page 35: ... spark plugs Service Interval 160 hrs a Stop engine and wait for all moving parts to stop b Remove spark plugs check condition and adjust plug gap or replace with new plugs See Engine Owner s Manual 5 1 16 Remove engine shrouds and clean cooling fins Service Interval See Engine Owner s Manual a Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s b Remove cool...

Page 36: ... not to bond the bearing next to each OPC hub to the cross shaft which could cause binding of the OPC levers and erratic operation 5 1 21 An anti seize compound is used on the following locations a Between engine crankshaft and pump and blade drive sheaves b On clutch arm assembly between bearings and shaft and between lower sheave and shaft c Between pump shafts and sheaves d Between the cutter h...

Page 37: ...ons shown in Fig 11 Rollers will maintain 3 4 in 19 mm clearance to the ground to minimize gouging and roller wear or damage For Maximum Deck Flotation place rollers one hole position lower Rollers should maintain 1 4 in 6 4 mm minimum clearance to ground Do Not adjust rollers to support the deck Be sure roller bolts and nuts are installed with the spring disc washer between head of the bolt and m...

Page 38: ...elt No adjustment necessary 5 2 5 Pump Drive Belt Tension Adjustment No adjustment necessary 5 2 6 Hydro Drive Linkage Adjustment 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 F...

Page 39: ... LINKAGE ADJUSTMENT 4 Loosen the nut against the neutral control linkage yoke as shown in Figure 14 5 Adjust the neutral control linkage until the respective drive wheel stops when the 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 th...

Page 40: ... clockwise until the tire begins to rotate forward Begin to retighten the knob clockwise about 1 4 turn at a time stopping to move the speed control forward and back to neutral Recheck the drive wheel rotation to see if further adjustment is necessary 4 The spring that keeps tension on the knob should normally not need adjustment However if adjustment is needed adjust to where length of spring is ...

Page 41: ...rive 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 corner of the hydro drive shields on the l...

Page 42: ...C levers are depressed Electric start only f Check that there is fuel in the tank and that the fuel valve is open g Check that the spark plug wire s are properly connected h Check for loose or faulty wiring connections If it is necessary to disconnect wire connectors Do Not pull on the wires while disconnecting i Check for corrosion at all wiring connections Even minor corrosion may cause a faulty...

Page 43: ...OADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN Will not start X X X X X X Hard starting X X X X X X X Stops suddenly X X X X X X X Lacks power X X X X X X X X Operates erratically X X X X X X X Knocks or pings X X X Skips or misfires X X X X X Backfires X X X X X Overheats X X X X X High fuel consumption X X X X ...

Page 44: ... 39 8 WIRING DIAGRAMS ...

Page 45: ... 40 15 17 HP KAWASAKI ...

Page 46: ... 41 8 HYDRAULIC DIAGRAM ...

Page 47: ...se 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 by the...

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 I S 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 EXMARK MFG CO INC PART NO 850660 Rev B INDUSTRIAL PARK BOX 808 402 223 6300 BEATRICE NE 68310 FAX 402 223 5489 ALL RIGHTS RESERVED PRINTED IN U S A ...

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