Exmark Turf Tracer HP TT3615KA Operator's Manual
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Exmark Turf Tracer HP TT3615KA Operator's Manual

Exmark lawn mower operator's manual
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  • Page 2 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.
  • Page 3 UPS, Exmark bills the distributor for parts and shipping charges, where applicable. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the program.
  • Page 4 CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment, and safety instructions for your Exmark mower.

  • Page 5: Table Of Contents

    1. SAFETY ...PAGE 1.1 Safety Alert Symbol ... 1 1.2 Training ... 1 1.3 Preparation... 1-3 1.4 Operation ... 4-6 1.5 Maintenance & Storage ... 6-7 1.6 Riding Attachments ... 7 1.7 Safety Signs ... 7-10 2. SPECIFICATIONS 2.1 Model Number ... 11 2.2 Engine ...

  • Page 6: Safety

    CAUTION: Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. 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.
  • Page 7 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 operator or bystanders. POTENTIAL HAZARD Engine exhaust contains carbon monoxide, which is an odorless deadly poison.
  • Page 8 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.

  • Page 9: Operation

    1.4 OPERATION Although hazard control and accident prevention are partially dependent upon the design and configuration of the equipment, these factors are also dependent upon 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.
  • Page 10 1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of traction and/or control could occur. Mow across slopes with walk behind mowers, never up and down. 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 and sustaining serious injury.

  • Page 11: Maintenance & Storage

    1.4.17 Be aware of the mower discharge direction and do not point it at anyone. 1.4.18 Do NOT operate the mower under the influence of alcohol or drugs. 1.4.19 Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

  • Page 12: Riding Attachments

    1.6 RIDING ATTACHMENTS 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.
  • Page 13 PART NO. 1-303517 LOCATION: Left Side of Rear Surface of Engine Deck 17 HP Kawasaki Electric Start Only PART NO. 1-513747 LOCATION: Battery Cover PART NO. 1-413214 LOCATION: Right Side of Hydro Control Crank Arm PART NO. 103-1077 LOCATION: On Top LH Side of Mower Deck. PART NO.
  • Page 14 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 36” Decks PART NO. 1-413206 LOCATION: Top of Cutter Deck Under Center Belt Shield - 9 - PART NO.
  • Page 15 ECS Handles 15 & 17 HP Kawasaki Manual Start PART NO. 103-1977 LOCATION: Console ECS Handles PART NO. 103-2242 LOCATION: LH Side of Console PART NO. 1-323540 LOCATION: Front of Mower Deck Top Surface ECS Handles PART NO. 103-2243 LOCATION: RH Side of Console - 10 - 48”...

  • Page 16: Specifications

    2. SPECIFICATIONS 2.1 MODEL NUMBER: Serial Nos. 320,000 & Higher: TT3615KA; TT4817KA; TT5217KA; TT3615KAC; 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 or higher. In countries using the research method, it should be a 90 octane minimum.

  • Page 17: Tires

    2.9 TIRES 36” Drive Pneumatic (Air-Filled) Size 16 x 6.50-8 Quantity Tread Turf Master Ply Rating Pressure 14 psi (97 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.

  • Page 18: Torque Requirements

    2.12 TORQUE REQUIREMENTS BOLT LOCATION 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.
  • Page 19 POTENTIAL HAZARD If the ignition is in the “ON” position there is potential for sparks and engagement of components. WHAT CAN HAPPEN Sparks could cause an explosion or moving parts could accidentally engage causing personal injury. HOW TO AVOID THE HAZARD Be sure ignition switch is in the “OFF”...

  • Page 20: Controls

    3.9 Route 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. Attach throttle cable to engine: a) Position the throttle control lever (located on console) ¼” (6mm) from the upper end of the slot.
  • Page 21 3.12 Connect the lower end of the speed control linkage to the speed control crank located at the top rear of the fuel tank support. Secure with clevis pin and hairpin from the bolt bag. 3.13 Install drive lever linkages. For Standard Pistol Grip Handles: Refer to figures 4 and 5.
  • Page 22 DRIVE LEVER LINKAGE INSTALLATION 3.14 Connect wiring harness. For recoil start models: Route the long unattached portion of the wiring harness up the left handle and under the console. Connect the connector on the end of the shorter lead to the keyswitch. Connect the two flag terminals that are in the longer lead to the OPC switch in any order.

  • Page 23: Operation Instructions 4.1 Controls

    4. OPERATION INSTRUCTIONS 4.1 Controls 4.1.1 Operator Presence Control (OPC) Levers: Located on the upper handle 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 system senses that the operator has moved from the normal operating position and will kill the engine if either the speed control lever is not in the neutral position or the blade clutch is engaged.

  • Page 24: Pre-Start

    4.1.7 Throttle Control: Located on the control console’s right side. The throttle is used to control engine speed. Moving the throttle control forward will increase engine speed and moving it to the rear will decrease engine speed. 4.1.8 “Off-Run” Switch (15 & 17 HP Kawasaki Manual Start only): Located on the console.
  • Page 25 DANGER POTENTIAL HAZARD In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN A fire or 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.

  • Page 26: Operation Instructions

    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 section 4.3. 3 OPERATING INSTRUCTIONS 4.3.1 Refer to Engine Owner’s Manual for detailed operating instructions regarding the engine.
  • Page 27 POTENTIAL HAZARD If the neutral lock latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position. WHAT CAN HAPPEN If the drive levers slip into the drive position, the unit could lurch forward and cause injury or property damage. HOW TO AVOID THE HAZARD Be sure the pins protruding through the slots of each neutral lock latch are completely engaged in the rear slot of each latch.

  • Page 28: Transporting

    4.3.6 To Stop: Squeeze drive levers back to the neutral position. Move neutral lock latches into the neutral lock position and release drive levers. Move the speed control lever to the neutral position. 4.3.7 PTO Engagement: POTENTIAL HAZARD The rotating blades under the mower deck are dangerous.

  • Page 29: Maintenance & Adjustments

    5. MAINTENANCE & ADJUSTMENTS 5.1 PERIODIC MAINTENANCE POTENTIAL HAZARD If you leave the key in the ignition switch, someone could start the engine. WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD Remove the key from the ignition switch and pull the wire(s) off the spark plug(s) before you do any maintenance.
  • Page 30 HOW TO AVOID THE HAZARD Replace the blade bolt after striking a foreign object. (Use only Exmark replacement parts PN 103-1026 - blade bolt and PN 1-513208 – spring disc washer). DO NOT lubricate the threads of the bolt or spindle before assembly.
  • Page 31 Check safety interlock system. Service Interval: Daily For your safety, your Exmark mower is equipped with Operator Presence Controls (OPC). When either the mower blades are engaged, or the speed control lever is not in neutral and both hands are removed from the handles, the mower engine MUST stop.
  • Page 32 5.1.7 Change engine oil. Service Interval: See Engine Owner's Manual NOTE: Change oil after first five (5) hours of operation. Follow engine manufacturer’s recommendations for future oil changes. Disengage blade clutch. Stop engine and wait for all moving parts to stop. Remove ignition key or spark plug wire(s).
  • Page 33 Service Interval: After First 250 hrs, then yearly thereafter. Note: Use only Exmark Part No. 513211 for Summer use above 32 F (0 C) or Part No. 523541 for Winter use below 32 F (0 C). Refer to 2.7.2 for filter specifications.
  • Page 34 Thoroughly clean the area around each of the charge pump housings. CHARGE PUMP LOCATION 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.
  • Page 35 Engage PTO lever. 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” (See Figure 12). Refer to section 5.2.2 for adjustment.

  • Page 36: Check Battery Charge

    Stop engine and wait for all moving parts to stop. Remove ignition key or spark plug wire(s). 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.

  • Page 37: Cutting Height/Anti-Scalp Roller Adjustment

    Note: To prevent damage due to freezing, battery should be fully charged before putting away for winter storage. a) 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.
  • Page 38 CUTTING HEIGHT ADJUSTMENT ANTI-SCALP ROLLER BOLT INSTALLATION ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT Adjust anti-scalp rollers For Normal Operating Conditions. Place rollers in one of the positions shown in Figure 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.
  • Page 39 Indicator Align Bolt to Indicator within 1/16” BLADE ENGAGEMENT LINKAGE 5.2.3 PTO Safety Switch: Mounted to a tab on the inside lefthand side of the fuel tank support. Stop engine and wait for all moving parts to stop. Remove ignition key or spark plug wire(s).
  • Page 40 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 drive position as shown in Figure 7 and move the speed control lever to the “mid-speed”...
  • Page 41 neutral, until left wheel stops rotating forward. Turn the rear nut an additional 1/2 turn and tighten the front nut making sure not to put a bind on the linkage. Make sure flat part of linkage is perpendicular to pin part of swivel.

  • Page 42: Waste Disposal

    STANDARD PISTOL GRIP HANDLES DRIVE LEVER AND LATCH IN NEUTRAL POSITION 3. Make this adjustment for both sides. Tracking Adjustment 1. Stop engine and wait for all moving parts to stop. Raise the rear of the machine, remove jack stands and carefully lower the machine to the ground.

  • Page 43: Trouble Shooting

    6.2 BATTERY DISPOSAL POTENTIAL HAZARD Battery electrolyte 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. HOW TO AVOID THE HAZARD Wear safety glasses to shield eyes, and rubber gloves to protect skin and clothing when handling electrolyte.
  • Page 44 NOTE: After carefully checking the above steps, attempt to start the engine. If it does not start, contact your authorized Exmark service 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.

  • Page 45: Wiring Diagram

    8. WIRING DIAGRAMS - 40 -...

  • Page 46: Hydraulic Diagram

    9. HYDRAULIC DIAGRAM - 41 -...

  • Page 47: Warranty

    Exmark and found by us (in the exercise of our reasonable discretion) to be defective in factory material or workmanship.

  • Page 48: Warranty

    Exmark service dealer; (iv) rental of like or similar replacement equipment during the period of any warranty, repair or replacement work; (v) any telephone or telegram charges or travel charges;...
  • Page 49 NOTES - 44 -...
  • Page 50 SERVICE RECORD Date Description of Work Done Service Done By - 45 -...
  • Page 51 ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) - 46 -...

  • Page 52: Grass Catcher

    LINE OF PRODUCTS FOR TURF CARE LAZER Z LAZER Z TURF TRACER METRO VIKING HYDRO GRASS CATCHER ©1997,1998, 1999, 2000, 2001 EXMARK MFG. CO. INC. INDUSTRIAL PARK BOX 808 BEATRICE, NE 68310 ALL RIGHTS RESERVED SEE EXMARK’S COMPLETE ® ® ®...

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