Exmark Turf Tracer HP Operator's Manual
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Exmark Turf Tracer HP 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 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.
  • 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 ....................3-4 1.5 Maintenance & Storage ................4-5 1.6 Riding Attachments ..................5 1.7 Safety Signs ....................6-9 2. SPECIFICATIONS 2.1 Model Number....................

  • Page 6: Safety

    RESULT IN PERSONAL INJURY 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.
  • Page 7 WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison. WHAT CAN HAPPEN ♦ Carbon monoxide can kill you and is also known to the State of California to cause birth defects. HOW TO AVOID THE HAZARD ♦...

  • Page 8: Operation

    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 ♦...

  • Page 9: Maintenance & Storage

    1.4.5 Stop the blades when crossing surfaces other than grass; 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 10: Riding Attachments

    ♦ Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system. 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. - 5 -...

  • Page 11: Safety Signs

    When new components are installed, be sure that current safety signs are affixed to the replaced components. 1.7.4 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg. Co. Inc. 1.7.5 Safety signs may be affixed by peeling off the backing to expose the adhesive surface.
  • Page 12 Serial Nos. 160,000 & Higher: 14 HP Kawasaki & 15 HP Kohler 14 HP Kawasaki & 15 HP Kohler Serial Nos. 160,000-189,999: 17 HP Kawasaki & 16 HP B&S PART NO. 323689 PART NO. 413440 LOCATION: RH Side of Console LOCATION: Console PART NO.
  • Page 13 36” Decks PART NO. 303508 PART NO. 413206 LOCATION: Right Front of Mower LOCATION: Top of Cutter Deck Deck Top Surface Under Center Belt Shield 48” & 52” Decks PART NO. 413327 LOCATION: Top Center of Cutter Deck Under Center Belt Shield PART NO.

  • Page 14: Specifications

    15 & 17 HP Kawasaki PART NO. 323691 LOCATION: RH Side Console Serial Nos. 190,000 & Higher 15 & 17 HP Kawasaki (Manual Start) PART NO. 413446 LOCATION: Console 2. SPECIFICATIONS 2.1 MODEL NUMBER: Serial Nos. 160,000-189,999: TT4816BV; TT5216BV; Serial Nos. 160,000-219,999: TT3615KC; TT3614KA; TT4814KA Serial Nos.

  • Page 15: Transmission

    2.7 TRANSMISSION: Twin Hydrostatic Drive 2.7.1 Two Hydro Gear BDP-10L series variable displacement efficiency pumps independently coupled to two high effeciency Parker/Ross wheel drive motors. 2.7.2 Hydraulic Filter is replaceable cartridge type. P/N 513211: 10 microns, 18 psi bypass (Summer use above 32° F) P/N 523541: 40 microns, 18 psi bypass (Winter use below 32°...

  • Page 16: Dimensions

    2.11 DIMENSIONS 2.11.1 Overall Width: 36” 48” 52” Discharge chute down 46.25” 58.25” 62.6” (117.5 cm) (148.0 cm) (159.0 cm) Discharge chute up 36.1” 48.1” 53.0” (Transport only) (91.7 cm) (122.2 cm) (134.62 cm) 2.11.2 Overall Length: 36” 48” 52” Overall Length 77.7”...
  • Page 17 Attach the fuel tank hose to the tank fitting and secure with the clamp provided. Make sure that fuel hose is not between engine and throttle plate on engine. Position the lower end of the handle assembly on the outside of the upper rear section of the fuel tank &...
  • Page 18 FIG 3 14 HP KAWASAKI SPEED CONTROL (THROTTLE CABLE HOOK-UP) Choke Link Control Plate Lever Control Alignment Holes Clamp Control Cable Choke Adjusting Screw FIG 4 15 & 17 HP KAWASAKI SPEED CONTROL (THROTTLE CABLE HOOK-UP) c) Pull cable upward for 14 HP Kawasaki and Kohler units (pull the cable to the right when facing the control plate on the 15 &...
  • Page 19 For 15 & 17 HP Kawasaki engines: There is not a “STOP” position. The engine will continue to run when the throttle control is moved past the rear detent. Turn the ignition switch to the “off” position to stop the engine. For B&S Vanguard Engines: a) Position the throttle control lever (on console) 1/8"...
  • Page 20 3.10 Install the speed control rod assembly (linkage with the yoke installed on one end) into the end of the speed control lever located underneath the center of the console. Insert the end of the linkage (opposite the yoke) into the end of the speed control lever from the right hand side and fasten with a hairpin from the bolt bag.
  • Page 21 DANGER 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 ♦...

  • Page 22: Controls

    Place battery back on battery stand. Connect battery cables - positive (red) 3.17.7 cable first, then the negative (black) cable. Slip insulator boot over the positive terminal. Place cover over battery. Secure with battery hold downs. DO NOT overtighten. NOTE: If time does not permit charging the battery, or if charging equipment is not available, follow steps 3.17.1 through 3.17.4 and install as described in 3.17.7.
  • Page 23 4.1.4 Neutral Lock Latch: Located directly above the drive levers. These latches allow the operator to lock the drive levers in a "neutral" position where neither of the drive wheels are engaged in either a forward or reverse direction (See Figure 8).

  • Page 24: Pre-Start

    Rotate valve 1/4 turn clockwise to shut fuel off. Rotate valve 1/4 turn counter- clockwise to turn fuel on. 4.1.11 Drive Wheel Release Valves:Located on the top rear corner of the hydrostatic pumps. Drive wheel release valves are use to release the hydro-static drive system to allow the machine to be moved by hand without the engine running.
  • Page 25 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 ♦...
  • Page 26 To engage pump drive (unhook cold start kit) a) Pull chain straight out from the side of the unit until the split ring can be removed from the bolt. SLOWLY release tension on chain. For Kohler and Kawasaki engines: On a cold engine, place the throttle in the full forward “Choke” position. For a 15 &...
  • Page 27 CAUTION POTENTIAL HAZARD ♦ If the nuetral 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.

  • Page 28: Transporting

    Be sure that all persons are clear of mower deck and discharge area before engaging the blades. Set throttle to “midway” position. Push the blade engagement arm forward and down to engage blades. Accelerate to full throttle to begin mowing (See Section 4.1.5). 4.3.8 Blade Disengagement: Pull upward and back completely on the blade engagement arm to disengage the blades (See Section 4.1.5).
  • Page 29 WARNING POTENTIAL HAZARD ♦ The engine can become very hot. WHAT CAN HAPPEN ♦ Touching a hot engine can cause severe burns. HOW TO AVOID THE HAZARD ♦ Allow the engine to cool completely before service or making repairs around the engine area. 5.1.1 Check engine oil level.
  • 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 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 31 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. 5.1.5 Check for loose hardware.
  • Page 32 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 33 5.1.10 Hydraulic system air purge procedure. Air must be purged from the hydraulic system when any hydraulic components, including the 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 34 Allow unit to run several minutes after the charge pumps are “primed” with drive system in the full speed position. Check oil level as stated in Section 5.1.8. Check hydro drive linkage adjustment as stated in Section 5.2.6. 5.1.11 Check tire pressures. Service Interval: 40 hrs.
  • Page 35 GREASE LUBRICATION CHART FITTING INITIAL QUANTITY SERVICE LOCATIONS PUMPS 36” 48” 52” INTERVAL 1. Caster Wheel Bearings Daily 2. Caster Pivots Daily 3. Blade Engagement Bellcrank Weekly 4. Idler Pivot (Pump Drive) Weekly 5. Clutch Arm Pivot Weekly 6. Cutter Deck Idler Pivots Weekly 7.
  • Page 36 5.1.19 Wheel hub - slotted nut torque specification. When tightening the slotted nut on the wheel motor tapered shaft: Torque the slotted nut to 100 ft. lbs. Further tighten the nut until the next set of slots line up with the cross hole in the shaft.

  • Page 37: Adjustments

    5.2 ADJUSTMENTS 5.2.1 Cutting height and anti-scalp roller adjustment. WARNING POTENTIAL HAZARD ♦ When the two front support rod hairpins are removed from the mower deck, the weight of the tractor section may cause the front frame to rise suddenly WHAT CAN HAPPEN ♦...
  • Page 38 With blade drive 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”. See Figure 12. 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 drive position as shown in Figure 8 and move the speed control lever to the “mid-speed”...
  • Page 40 2. Loosen the front nut on left hydro control linkage as shown in Figure 14. Turn the rear control linkage adjusting nut counter-clockwise until wheel rotates forward. Turn the rear nut of left control link clockwise 1/4 of a turn at a time, stopping to move the speed control forward and back to neutral, until left wheel stops rotating forward.

  • Page 41: Trouble Shooting

    FIG. 16 DRIVE LEVER AND LATCH IN NEUTRAL POSITION 3. Replace the hairpin back into each clevis pin. 4. 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 42: Mower Cuts Unevenly

    IMPORTANT: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. 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.
  • Page 43 ENGINE TROUBLESHOOTING TABLE FAULTY BLOCKED INCORRECT DIRTY IMPROPER DIRT IN DIRTY AIR ENGINE PROBLEM SPARK FUEL FUEL FUEL FUEL LINE FILTER OVERLOADED PLUG FILTER LEVEL SCREEN Will not start Hard starting Stops suddenly Lacks power Operates erratically Knocks or pings Skips or misfires Backfires Overheats...

  • Page 44: Wiring Diagram

    8. WIRING DIAGRAMS - 39 -...
  • Page 45 15 & 17 HP KAWASAKI - 40 -...

  • Page 46: Hydraulic Diagram

    8. HYDRAULIC DIAGRAM - 41 -...

  • Page 47: 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 48: Warranty

    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. - 43 -...
  • 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

    The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. ©1997,1998 EXMARK MFG. CO. INC. PART NO. 850660 Rev. B INDUSTRIAL PARK BOX 808 (402) 223-6300 BEATRICE, NE 68310...

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