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

Exmark mower operator's manual
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See also: Operator's Manual
For Serial Nos.
440,000 & Higher
Part No. 103-4871

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Summary of Contents for Exmark Turf Tracer HP

  • Page 1 For Serial Nos. 440,000 & Higher Part No. 103-4871...
  • Page 2 Replacements may be ordered through the engine 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 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 ...3-6 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 ...11 2.3 Fuel System ...11 2.4 Electrical System ...11 2.5 Safety Interlock System ...11 2.6 Steering/Brake Control...11 2.7 Transmission ...11...

  • Page 6: Safety

    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: Operation

    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 POTENTIAL HAZARD Operating engine parts, especially the muffler, become extremely hot. WHAT CAN HAPPEN Severe burns can occur on contact. Debris, such as leaves, grass, brush, etc. can catch fire. HOW TO AVOID THE HAZARD Allow engine parts, especially the muffler, to cool before touching.
  • Page 10 See inside the back cover to determine the approximate slope angle of the area to be mowed. Progressively greater care is needed as the slope increases. Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope. Be aware that loss of traction may occur going downhill.

  • Page 11: Maintenance & Storage

    1.4.16 This mower was designed for one operator only. Keep all others away from mower during operation. 1.4.17 Do Not mow with the grass deflector raised, removed, or altered unless there is a grass collection system or a mulch kit in place and working properly. 1.4.18 Be aware of the mower discharge direction and direct discharge away from others.

  • 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. 1-403005 LOCATION: RH & LH Corners of Mower Deck 36” Decks PART NO. 1-413206 LOCATION: Top of Cutter Deck Under Center Belt Shield PART NO. 1-413421 LOCATION: Left Rear on Top of Engine Deck 17 HP Kawasaki Electric Start Only PART NO.
  • Page 14 PART NO. 103-1077 LOCATION: On Top LH Side of Mower Deck. PART NO. 98-5954 LOCATION: Under Mower Deck Belt Shield(s) 17 HP Kawasaki Electric Start PART NO. 103-1976 LOCATION: Console PART NO. 103-1798 LOCATION: RH Side Console PART NO. 103-4935 LOCATION: Rear Center of Top Surface of Engine Deck - 9 -...
  • Page 15 15 & 17 HP Kawasaki Manual Start PART NO. 103-1977 LOCATION: Console PART NO. 103-2242 LOCATION: LH Side of Console PART NO. 103-2243 LOCATION: RH Side of Console - 10 -...

  • Page 16: Specifications

    2. SPECIFICATIONS 2.1 MODEL NUMBER: Serial Nos. 440,000 & Higher: TT3615KAC; TT4817KAC; TT5217KAC; TT4817KAEC; 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: Deck

    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.
  • Page 18 3.2 Service Battery 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. The machine is shipped with a filled lead acid battery. 3.2.1 Remove battery cover from the machine.
  • Page 19 NOTE: If the positive cable is also disconnected, connect the positive (red) cable to the positive terminal on the battery first, then connect the negative (black) cable to the negative terminal on the battery. Reinstall battery cover. NOTE: If time does not permit charging the battery, or if charging equipment is not available, connect the negative battery cables and run the vehicle continuously for 20 to 30 minutes to sufficiently charge the battery.
  • Page 20 (THROTTLE CABLE HOOK-UP) 3.10 Connect the PTO engagement linkage (See 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.
  • Page 21 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. 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.

  • Page 22: Operation Instructions 4.1 Controls

    3.19 Follow pre-start instructions as outlined in Section 4.2. NOTE: After starting the engine and engaging the hydro drive, if either of the drive wheels acts sluggish or will not rotate at all, stop engine and refer to Section 5.1.10 on the Hydraulic System Air Purge procedure. 3.20 Perform any needed adjustments as outlined in the Adjustment Section.
  • Page 23 4.1.6 PTO Engagement: Located on the left side of the upper handle. To engage the blades, push the lever forward, or away from the operator, until the linkage locks over-center. To disengage the blades, pull the lever to the rear, or towards the operator.

  • Page 24: Pre-Start

    4.1.14 Cold Start Kit: (Manual start units only) Located on the right hand side of engine deck, below the hydro control shield. The cold start kit is used to ease the starting of the unit in cold weather or when the unit has not been operated for a period of time.
  • Page 25 IMPORTANT: For electric start models, do not crank the engine continuously for more than ten (10) 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. On a warm engine, place the throttle control midway between the “Slow”...
  • Page 26 DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION 4.3.5 Drive Wheel Engagement/Turning: With drive levers locked in “neutral”, shift speed control lever to desired forward speed. Note: The park brake must be disengaged before the speed control lever is moved out of neutral or the engine will kill. Slowly squeeze and hold both drive levers in the neutral position and move both neutral lock latches from the neutral lock position.

  • Page 27: Transporting

    POTENTIAL HAZARD An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also, contact with the blade could occur. WHAT CAN HAPPEN Thrown objects or blade contact can cause serious injury or death. HOW TO AVOID THE HAZARD Never operate the mower with the discharge deflector raised, removed, or altered unless there is a grass collection system or mulch kit in place and working...

  • Page 28: Maintenance & Adjustments

    5. MAINTENANCE & ADJUSTMENTS POTENTIAL HAZARD While maintenance or adjustments are being made, 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/or pull the wire(s) off the spark plug(s) before you do any maintenance.
  • Page 29 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 30 Check safety interlock system. Service Interval: Daily For your safety, your Exmark mower is equipped with Operator Presence Controls (OPC). When either the PTO is engaged, or the speed control lever is not in neutral and both hands are removed from the handles, the mower engine MUST stop.
  • Page 31 Service Interval: After First 250 hrs, then yearly thereafter. Note: Use only Exmark Part No. 1-513211 for Summer use above 32 F (0 C) or Part No. 1-523541 for Winter use below 32 F (0 C). Refer to 2.7.2 for filter specifications.
  • Page 32 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. Fill reservoir as stated in Section 5.1.8.
  • Page 33 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 34 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” (.16 cm) (See Figure 13).
  • Page 35 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 36: Adjustments

    5.1.24 Check battery charge: (Electric start units only) Service Interval: Monthly 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.
  • Page 37 NOTE: All (4) pins must equally support the weight of the deck. Adjustment in the length of the rear deck support assemblies may be necessary. If one side is longer than 6.89” (17.5 cm), than the opposite side must be shorter by the same amount. CUTTING HEIGHT ADJUSTMENT ANTI-SCALP ROLLER BOLT INSTALLATION ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT...
  • Page 38 With PTO engaged, adjust the linkage length by loosening the locknut on the turnbuckle and adjusting the turnbuckle so that the bolt on the bellcrank and the indicator arm align with each other within 1/16” (.16 cm). See Figure 11. Tighten locknut against turnbuckle. Indicator Align Bolt to Indicator...
  • Page 39 Adjust Neutral Control Linkages 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 “forward”...
  • Page 40 FIGURE 14 HYDRO CONTROL LINK/SWIVEL ADJUSTMENT After adjusting the left hydro control linkage, move the speed control lever to the mid-speed position and then back to the neutral position. Recheck the left drive wheel rotation to see if further adjustment is necessary - be sure the speed control lever is in the neutral position.

  • Page 41: Waste Disposal

    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. (Check the drive tire pressure and tire circumference. (See 5.1.11.) 2.

  • Page 42: Battery Disposal

    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 43 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 44: Wiring Diagram

    8. WIRING DIAGRAMS - 39 -...

  • Page 45: Hydraulic Diagram

    9. HYDRAULIC DIAGRAM - 40 -...

  • Page 46: Warranty

    (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship. This warranty applies to Exmark turf equipment sold in the US or Canada. This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer.
  • Page 47 ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) - 42 -...
  • Page 48 LINE OF PRODUCTS FOR TURF CARE LAZER Z LAZER Z TURF RANGER TURF TRACER METRO ULTRA VAC GRASS CATCHER ©1997-2003 EXMARK MFG. CO. INC. INDUSTRIAL PARK BOX 808 BEATRICE, NE 68310 ALL RIGHTS RESERVED SEE EXMARK’S COMPLETE ® ® ® ®...

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