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Troubleshooting

Troubleshooting

Important:

It is essential that all operator safety mechanisms be connected and in proper operating

condition prior to mower use.

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 of adjustments procedures (such as valves, governor, etc.). Have
this work done by your

Engine Service Dealer

.

Note:

When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.

Problem

Possible Cause

Corrective Action

1. PTO is engaged.

1. Disengage the PTO.

2. Speed control lever is are not in neutral

lock position.

2. Ensure the speed control lever is in the

neutral lock position.

3. OPC levers are released.

3. Depress OPC levers.

4. Battery does not have a full charge.

4. Charge the battery. See

Check

Battery Charge

and

Recommended

Jump Starting Procedure

sections in

Maintenance.

5. Electrical connections are corroded, loose

or faulty.

5. Check the electrical connections for

good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.

6. Fuse is blown.

6. Replace the blown fuse.

Starter does not crank (Electric Start Units).

7. Relay or switch is defective.

7. Contact an Authorized Service Dealer.

1. Engine oil level is low.

1. Check and add oil if necessary.

2. LPG tank is overfilled.

2. Take tank to an approved LPG provider

to bleed off some fuel.

3. LPG tank is not an Exmark approved

vapor tank.

3. Remove tank and replace with an Exmark

approved LPG vapor tank.

4. Engine is flooded.

4. Shut off fuel valve. Let unit set for 15-30

minutes. With the valve still off and the
throttle in the “SLOW” position, start the
unit. Once the engine attempts to start,
slowly open the fuel valve.

5. Oil pressure switch or fuel shut-off

solenoid malfunction.

5. Contact an Authorized Service Dealer.

6. Connection to the LPG tank is loose.

6. Hand-tighten connector to tank.

7. LPG fuel tank is empty or very low.

7. Replace the LPG fuel tank.

8. Fuel valve is closed.

8. Slowly open the fuel valve.

9. Fuel valve opened to fast.

9. Open the fuel valve slowly to equalize

pressure in the tank(s).

10. LPG tank is not installed properly.

10. Reinstall the LPG tank.

11. LPG tank components or hoses are dirty

or damaged.

11. Replace LPG tank components or hoses.

12. The throttle is not in the correct position.

12. Be sure the throttle control is in the

“SLOW” position.

13. Air cleaner is dirty.

13. Clean or replace the air cleaner element.

14. Electrical connections are corroded, loose

or faulty.

14. Check the electrical connections for

good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.

15. Relay or switch is defective.

15. Contact an Authorized Service Dealer.

Engine will not start, starts hard, or fails to
keep running.

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Содержание TURF TRACER TTS600PKAE483

Страница 1: ...TURF TRACER S SERIES LP For Serial Nos 312 000 000 Higher Part No 4501 049 Rev A ...

Страница 2: ... manufacturer 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 publica...

Страница 3: ...e available online at http www exmark com 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 stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving...

Страница 4: ...ition Of Belts 31 Lubricate Grease Fittings 31 Check Spark Plugs 32 Check LPG Tank 32 Check LPG Fuel Delivery System 32 Change Hydraulic System Filter 33 Wheel Hub Slotted Nut Torque Specification 35 Inspect PTO Clutching Belt Tension 35 Thread Locking Adhesives 35 Mobil HTS Grease Or Food Grade Anti seize 35 Copper Based Anti seize 35 Dielectric Grease 36 Adjustments 36 Deck Leveling 36 Pump Driv...

Страница 5: ... is stored in a tank under pressure Before the liquid leaves the tank it is converted into a vapor Since LPG is stored as both liquid and gas it may leak from joints or connections that are not sealed properly LPG becomes flammable when it is mixed with air The LPG information in this Operator s manual is provided only as a guide Consult the NFPA 58 Liquefied Petroleum Gas Code 2008 Edition for ad...

Страница 6: ...osion from LPG fuel can burn you others and cause property damage Never smoke around tank s and stay away from an open flame or where fumes may be ignited by a spark Extinguish all sources of spark or flame when approaching LPG tanks or mowers The hazard increases for enclosed trailers or storage locations where vapor leakage may occur and collect LPG is heavier than air and may accumulate in low ...

Страница 7: ... contact occurs with vapors or liquid Check that the operator s presence controls safety switches and shields are attached and functioning properly Do Not operate unless they are functioning properly Inspection It is very important to check the LPG tank and components for wear or leaks Important Never check for leaks using an open flame Important Never use bare hands when checking the fitting or v...

Страница 8: ... a trained and qualified LPG tank provider for more details Do Not fill the LPG tank if it is beyond the requalification period Do Not fill damaged or rusted LPG tanks Operation WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before...

Страница 9: ...GER Operating on wet grass or steep slopes can cause sliding and loss of control Loss of control and or loss of operator s footing could result in a fall with an arm or leg getting under the mower or engine deck which may result in serious injury death or drowning Mow across slopes never up and down Do Not mow slopes when grass is wet Do Not mow near drop offs or near water Do Not mow slopes great...

Страница 10: ...cking blades Wrap the blade s or wear gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep hands and feet away from moving parts If possible Do Not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clo...

Страница 11: ...ted into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result If equipped make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic...

Страница 12: ... been installed make sure current safety signs are visible New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and instruction ...

Страница 13: ...Safety 1 553049 98 5954 103 1798 103 1976 103 2076 103 2103 103 2242 13 ...

Страница 14: ...Safety 103 2243 103 4935 109 3148 109 9870 109 9875 116 0404 14 ...

Страница 15: ...Safety 117 2718 109 9906 15 ...

Страница 16: ...lift type liquid withdrawal tank will result in icing or freezing of the LPG regulator and prevent the engine from operating This may also result in permanent fuel system damage and the release of highly flammable propane liquid or vapor Electrical System Charging System Flywheel Alternator Charging Capacity 15 amps Battery Type BCI Group U1 235 amps 0 F Battery Voltage 12 Volt Polarity Negative G...

Страница 17: ... Size 16 x 7 50 8 9 x 3 50 4 Ply Rating 4 Pressure 14 psi 97 kPa Cutting Deck Cutting Width 47 25 inches 120 0 cm Discharge Side Blade Size 16 25 inches 41 3 cm Quantity 3 Deck Drive Manual engagement of belt with over center lock Blade belt tension is adjustable via turnbuckle Deck Mounting Full floating deck is attached to out front support frame removable for service Deck Depth 48 inch Deck 5 0...

Страница 18: ...Scalp Roller Nyloc Nut See Figure 9 30 35 ft lb 41 47 N m Anti Scalp Roller Whizlock Nut See Figure 9 30 35 ft lb 41 47 N m Engine Mounting Bolts 15 20 ft lb 20 27 N m Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Hub Slotted Nut 140 155 ft lb 190 210 N m Wheel Motor Mounting Bolts 30 35 ft lb 41 47 N m Muffler Guard Mounting Bolts 30 35 ft lb 41 47 N m Product Overview Figure 3 1 Park Brake Lever ...

Страница 19: ...vely 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 Neutral Lock Latches Located on the upper handle assembly on the ends of the handle grips These latches allow the opera...

Страница 20: ... to release the drive system Turn clockwise to reset the drive system Do Not overtighten Tracking Adjustment Knob Located on the right hand side of the rear of the fuel tank support The knob can be adjusted so that machine will track straight ahead with the drive levers released PTO Engagement Located on the left side of the upper handle To engage the blades push the lever forward or away from the...

Страница 21: ...s soon as the engine starts Important Do Not crank the engine continuously for more than ten 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 Note It is helpful to have the left and right neutral lock latches locked in neutral when starting the engine Refer to Neutra...

Страница 22: ...on the outer thumb lobe of the neutral lock latches or the index finger on the front lobe and rotate them from under the drive levers Slowly and carefully release the drive levers See Figure 5 position 3 To place the drive levers in the reverse position squeeze the drive levers past the neutral position See Figure 5 position 4 Figure 5 1 Drive Lever in neutral position 3 Drive Lever in forward pos...

Страница 23: ...port rod hairpins are removed The cutting height of the mower deck is adjusted from 1 1 2 to 4 1 2 inches 3 81 cm to 11 4 cm in 1 2 inch increments 1 Stop the machine and move the drive levers to the neutral locked position 2 Disengage the PTO 3 Engage the park brake 4 Stop the engine remove the key and wait for all moving parts to stop 5 Install hairpin clips in the holes for the desired cutting ...

Страница 24: ...nst scalping 1 Anti scalp roller mounting bracket 2 Cutting height 7 Torque the 3 8 16 whizlock nut to 30 35 ft lb 41 47 N m Figure 9 8 If the 3 8 nyloc nut has been removed reinstall and torque to 30 35 ft lb 41 47 N m Figure 9 Figure 9 1 Spring disc washer cone towards nut 3 3 8 nyloc torque to 30 35 ft lb 41 47 N m 2 Front right anti scalp bracket shown 4 3 8 16 whizlock nut torque to 30 35 ft ...

Страница 25: ...ace of a vehicle Do Not transport leaking fuel tanks Trailers must have appropriate markings to transport LPG Follow NFPA 58 and state and local regulations for transporting LPG Use a heavy duty trailer to transport the machine Engage neutral lock latches and park brake then block wheels Securely fasten the machine to the trailer with straps chains cables or ropes Do Not rely solely on the parking...

Страница 26: ...l hub slotted torque specification After the first 250 hours Change the hydraulic filter Before each use or daily Check the engine oil level Check the mower blades Check the safety interlock system Check for loose hardware Grease the caster wheel bearings Grease caster pivots Check the LPG tank and components Clean the engine and exhaust system area Clean the grass and debris build up from the mac...

Страница 27: ... of California to cause cancer and reproductive harm Wash hands after handling Allowing batteries to stand for an extended period of time without recharging 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 4 volts Note To prevent damage due to freezing battery should be ...

Страница 28: ...plosive gases Shield the eyes and face from the batteries at all times Do Not lean over the batteries Note Be sure the vent caps are tight and level Place a damp cloth if available over any vent caps on both batteries Be sure the vehicles do not touch and that both electrical systems are off and at the same rated system voltage These instructions are for negative ground systems only 3 Connect the ...

Страница 29: ... components used to retain the blade can be dangerous Failure to use all original components and assembled as shown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death Always install the original Exmark blades blade bushings and blade bolts as shown Replacing the Discharge Deflector Service Interval As required DANGER An uncover...

Страница 30: ...l Units Check OPC circuits Clear the area Disengage the park brake 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 PTO and release OPC levers engine must stop Note Park bra...

Страница 31: ...emium Hydro Oil Replace hydraulic reservoir cap and tighten until snug Do Not overtighten Note The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If t...

Страница 32: ...efore each use or daily Check the LPG tank and components for wear or leaks Follow all the inspection checks as specified in the Inspection section in Safety Check LPG Fuel Delivery System Service Interval Every 40 hours Check the entire LPG fuel delivery system for damage or deterioration Follow all the inspection checks as specified in the Inspection section in Safety Change LPG Tank Service Int...

Страница 33: ...se below 32 F 0 C Refer to Transmission section in Specifications for filter specifications 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system 3 Unscrew filter to remove and allow oil to drain from reservoir Important Before reinstalling new filter fill it with...

Страница 34: ...vers in the drive position If either drive wheel does not rotate it is possible to assist the purging of the charge pump by carefully rotating the tire in the forward position 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...

Страница 35: ...rews Square head setscrews on hydro pump control arms OPC lever setscrews Lower sheave retaining bolt on clutch arm Shoulder bolts in ends of speed control crank Sheave retaining bolt in end of engine crankshaft Fuel tank bulkhead fitting threads Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining I or Retaining II are used on the following OPC lever hubs and cross shaft Note ...

Страница 36: ...Park Brake Adjustment 1 Shut off engine and wait for all moving parts to stop 2 Disengage the park brake 3 Remove the hairpin in the park brake linkage Turn the linkage in the yoke until there is 3 16 inch 4 8 mm to 1 4 inch 6 4 mm clearance between the park brake tire bars and the tires with the park brake disengaged Re install the hairpin Hydro Drive Linkage Adjustment Adjust Speed Control Linka...

Страница 37: ... the drive lever in neutral the neutral control linkages need to be adjusted If the wheel stops then go to step 7 Figure 18 Viewed from Left Side of Unit 1 Neutral Control Linkage 5 Speed Control Linkage 2 Hydro Control Linkage 6 Adjust here rotate at approximately 1 4 turn increments and re check 3 Drive Lever Linkage 7 Loosen nut 4 Speed Control Crank 8 Yoke 4 Loosen the nut against the neutral ...

Страница 38: ...t above adjustments if necessary 3 Place the speed control lever in neutral Adjust the right side linkage by turning the quick track knob counterclockwise 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 Th...

Страница 39: ...g relocate the spring anchor link as shown in Figure 13 The spring anchor links are located under the engine deck on the left and right hand sides Note In medium or heavy duty positions the drive lever forces at the upper handle will also be increased Figure 21 1 Heavy duty 3 Standard 2 Medium duty 4 Retaining bolt PTO Safety Switch Mounted to a tab on the inside left side of the fuel tank support...

Страница 40: ...p engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean off any oil debris or grass build up on the machine and cutting deck especially under deck belt shields around the fuel tank around engine and exhaust area Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake...

Страница 41: ...eplaced or if the unit containing the battery is no longer operating and is being scrapped take the battery to a local certified recycling center If no local recycling is available return the battery to any certified battery reseller 41 ...

Страница 42: ...7 Contact an Authorized Service Dealer 1 Engine oil level is low 1 Check and add oil if necessary 2 LPG tank is overfilled 2 Take tank to an approved LPG provider to bleed off some fuel 3 LPG tank is not an Exmark approved vapor tank 3 Remove tank and replace with an Exmark approved LPG vapor tank 4 Engine is flooded 4 Shut off fuel valve Let unit set for 15 30 minutes With the valve still off and...

Страница 43: ... tracks correctly Mower pulls left or right with levers fully forward 2 Tire pressure in drive tires not correct 2 Adjust tire pressure in the drive tires 1 Bypass valve is not closed tight 1 Tighten the bypass valve 2 Drive or pump belt is worn loose or broken 2 Change the belt Machine does not drive 3 Drive or pump belt is off a pulley 3 Change the belt 1 Blade s not sharp 1 Sharpen the blade s ...

Страница 44: ... belt and check adjusting shafts and belt guides for correct position 3 Deck belt is worn loose or broken 3 Install new deck belt 4 Deck belt is off pulley 4 Install deck pulley and check the idler pulley idler arm and spring for correct position and function 5 Broken or missing idler spring 5 Replace the spring Blades do not rotate 6 PTO clutch does not engage 6 Contact an Authorized Service Deal...

Страница 45: ...Schematics Schematics Electrical Diagram 45 ...

Страница 46: ...Schematics Hydraulic Diagram 46 ...

Страница 47: ...r Canada customers may also call 402 223 6375 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities If your product requires warranty service it must be returned to an autho...

Страница 48: ...Notes 48 ...

Страница 49: ...Service Record Date Description of Work Done Service Done By 49 ...

Страница 50: ...50 ...

Страница 51: ...se the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 20 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 51 ...

Страница 52: ...DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB Place Model No and Serial No Label Here Included in the Literature Pack or Fill i...

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