Exmark Turf Tracer TT20KCC Operator's Manual
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Exmark Turf Tracer TT20KCC Operator's Manual

Exmark Turf Tracer TT20KCC Operator's Manual

Exmark mfg. co. inc. turf tracer 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...
  • 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 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 stations.

  • Page 5: Table Of Contents

    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 - 5 1.5 Maintenance & Storage ...6 1.6 Riding Attachments...7 1.7 Safety Signs ..7-8 2. SPECIFICATIONS 2.1 Model Number ...9 2.2 Engine ...9 2.3 Fuel System...9 2.4 Electrical System ...9...

  • Page 6: Safety

    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 1.4.5 Stop the blades when crossing surfaces other than grass, if mower must be tilted for transportation, and when transporting the mower to and from the area to be mowed. 1.4.6 Never operate the mower with defective guards, shields, or covers. Always have safety shields, guards, switches, and other devices in place and in proper working condition.

  • Page 11: Maintenance & Storage

    1.5 MAINTENANCE AND STORAGE 1.5.1 For engine maintenance, follow the engine manufacture’s recommendations precisely as stated in the engine manual. 1.5.2 Disconnect the battery from the negative battery post when the unit will be allowed to sit for more than 30 days without use. 1.5.3 Allowing batteries to stand for an extended period of time without recharging them will result n reduced performance and service life.

  • Page 12: Riding Attachments

    1.6 RIDING ATTACHMENTS 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 and instructional labels.
  • Page 13 PART NO. 1-323540 LOCATION: Front of Mower Deck Top Surface PART NO. 1-303517 LOCATION: LH Side of Rear Surface of Engine Deck PART NO. 103-1077 LOCATION: On Top Front RH Surface of Mower Deck ECS Handles PART NO. 103-2242 LOCATION: LH Side of Console PART NO.

  • Page 14: Specifications

    2. SPECIFICATIONS 2.1 MODEL NUMBER: Serial Nos. 320,000 & Higher: TT23KCC; TT23KAC; TT20KCC 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 15: Deck

    2.9 MOWER DECK 2.9.1 Model Numbers: Serial Nos. 320,000 and higher: FMD604 and FMD524 NOTE: Turf Tracer units 320,000 and higher can only be used with FM604 and FMD524 units. 2.9.2 Cutting Width: 60 in. (152.4 cm.) 2.9.3 Discharge: Right Side 2.9.4 Optional Mulch Kit and Bagger available.
  • Page 16 3.2.1 Remove battery cover from machine. Disconnect the battery cables (negative (black) cable first) and remove battery. 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.
  • Page 17 3.4 DRIVE WHEELS 3.4.3 Check air pressure in drive tires; recommended pressure is 12-16 psi. Measure circumference of each drive tire. Adjust tire pressure within 12-16 psi range to try to make tire circumferences match as closely as possible. 3.5 MOWER DECK INSTALLATION 3.5.1 Release the wheel drive system by opening the drive wheel release valves (See 4.1.11).
  • Page 18 3.5.5 Mower Deck Stationary Idler Installation: Locate the two holes along the back center section of the deck (See Figure 2) and install the stationary idler and related parts (from bolt bag) in the right hand hole. Be sure the coned end of the disc spring washer is against the head of the bolt.

  • Page 19: Operation Instructions

    4. OPERATION INSTRUCTIONS 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 PTO is engaged.

  • Page 20: Pre-Start

    4.1.8 Ignition Switch: Located on the control console left side. The ignition switch is used to start and stop the engine. The ignition switch has three positions, “Off”, “On” and “Start”. Insert key into switch and rotate clockwise to the “On” position. Rotate clockwise to the next position to engage the starter (key must be held against spring pressure in this position).
  • Page 21 On a cold engine, place the throttle midway between the “Slow” and “Fast” positions and place the choke in the “On” position. On a warm engine, place the throttle lever midway between “Slow” and “Fast” positions and leave the choke in the “Off” position. Turn ignition switch to “Start”...
  • Page 22 DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION 4.3.4 Drive Wheel Engagement/Turning: With drive levers locked in neutral, shift speed control lever to desired forward speed. Slowly squeeze and hold both drive levers in the neutral position and rotate both neutral lock latches from the neutral lock position to the forward position.

  • Page 23: Transporting

    4.4 TRANSPORTING 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 TO AVOID THE HAZARD Use proper ramps that are secured to the truck or trailer.
  • Page 24 5.1.1 Check engine oil level. Service Interval: See Engine Owner's Manual Stop engine, wait for all moving parts to stop and make sure unit is on a level surface. Check with engine cool. Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick.
  • Page 25 HOW TO AVOID THE HAZARD Replace the blade bolt after striking a foreign object. (Use only Exmark replacement parts PN 103-0862 – blade bolt and PN 103-0865 – spring disc washer). DO NOT lubricate the threads of the bolt or spindle before assembly.
  • Page 26 MUST stop. If machine does not pass any of these tests, DO NOT operate. Contact your authorized EXMARK SERVICE DEALER. IMPORTANT: It is essential that all Operator Safety Mechanisms, be in place and in proper operating condition prior to mowing.
  • Page 27 Drain oil while engine is warm from operation. Oil drain valve is located on the right hand side of Kohler engines and the left hand side for Kawasaki engines. Place pan under machine to catch oil and open valve with a 10 mm wrench. Allow oil to drain then close the valve.
  • Page 28 Change hydraulic system filter. Service Interval: After First 250 hrs, then yearly thereafter. Note: Use only Exmark P/N 1-513211 for Summer use above 32 F (0 C) or P/N 1-523541 for Winter use below 32 F (0 C). (Refer to Section 2.6.2 for filter specifications) Place unit on a level surface.
  • Page 29 5.1.11 Hydraulic system air purge procedure. Air must be purged from the hydraulic system when any hydraulic components, including oil filter, are removed or any of the hydraulic lines are disconnected. The critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump.
  • Page 30 Stop engine, wait for all moving parts to stop, and remove key. Check air pressure in tires; recommended tire pressure is: rear, 12-16 psi; front casters, 15-17 psi. Inflate tires to pressures stated above. Measure circumference of each drive tire. Adjust tire pressures within the above range to try to make tire circumferences match as closely as possible.
  • Page 31 Pack the bearings with NGLI grade #2 multi-purpose gun grease. Insert (1) bearing, (1) new seal, and (1) bearing spacer. NOTE: Seals (Exmark PN 103-0063) must be replaced. Insert Caster Spacer. With open end of wheel up, fill area inside wheel around caster spacer with gun grease.

  • Page 32: Adjustments

    Shoulder bolts in ends of speed control crank. OPC lever setscrews. Electric clutch retaining bolt. Pump drive idler pivot bolt. 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: Care must be used not to bond the bearing, next to each OPC hub, to the cross shaft which could cause binding of the OPC levers and...
  • Page 33 LEFT HAND SIDE SHOWN CUTTING HEIGHT ADJUSTMENT ANTI-SCALP ROLLER BOLT INSTALLATION ANTI-SCALP ROLLER ADJUSTMENT CUTTING HEIGHT ADJUSTMENT Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of the positions shown in Figure 8. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize gouging and roller wear or damage.
  • Page 34 5.2.4 Blade drive belt tension: No adjustment necessary. 5.2.5 Hydro Drive Linkage Adjustment: Adjust Speed Control Linkage and Neutral Safety Switch 1. Stop engine and wait for all moving parts to stop. 2. Move speed control lever (located on console) to the full forward position and check orientation of tabs on the ends of the speed control crank (See Figure 9).
  • Page 35 4. Loosen the nut against the neutral control linkage yoke as shown in Figure 10. 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 the wheel is turning forward.
  • Page 36 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 about 1” between washers. Adjust spring length by turning nut at front of spring. Drive Lever Linkage Adjustment 1.

  • Page 37: Waste Disposal

    6. WASTE DISPOSAL 6.1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at a certified recycling center or according to your state and local regulations. 6.2 BATTERY DISPOSAL POTENTIAL HAZARD Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns WHAT CAN HAPPEN...
  • Page 38 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 39: Hydraulic Schematic

    8. HYDRAULIC SCHEMATIC - 34 -...

  • Page 40: Wiring Diagrams

    9. WIRING DIAGRAMS - 35 -...

  • Page 41: Warranty

    Exmark; (vi) repair or replacement arising as a result of any operation from turf equipment that has been altered or modified so as to, in the determination of Exmark or Exmark Warranty Company, adversely affect the operation, performance or durability of the equipment or that has altered, modified or affected the turf equipment so as to change the intended use of the product;...
  • Page 42 REGARDING THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), NOT SPECIFIED HEREIN, RESPECTING THE EQUIPMENT WHICH IS THE SUBJECT OF THIS WARRANTY. This warranty applies to all Exmark turf equipment sold in the United States and Canada and intended to be used for commercial purposes. - 37 -...
  • Page 43 ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) - 38 -...
  • Page 44 MICRO-MULCH The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or ©1997-2001 EXMARK MFG. CO. INC. INDUSTRIAL PARK BOX 808 BEATRICE, NE 68310 ALL RIGHTS RESERVED LAZER Z TURF RANGER ®...

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