Exmark TURF TRACER S-SERIES Operator's Manual
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Exmark TURF TRACER S-SERIES Operator's Manual

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TURF TRACER
®
S-SERIES
For Serial Nos.
920,000 & Higher
Part No. 4500-696 Rev. B

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Summary of Contents for Exmark TURF TRACER S-SERIES

  • Page 1 TURF TRACER ® S-SERIES For Serial Nos. 920,000 & Higher Part No. 4500-696 Rev. B...
  • 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.

  • Page 3: Introduction

    All Exmark parts are thoroughly tested and inspected before leaving the factory, however, attention is required on your part if you are to obtain the fullest measure of satisfaction and performance.

  • Page 4: Table Of Contents

    Contents Tracking Adjustment ........36 Hydro Pump Spring Tension Setting ....36 PTO Safety Switch ........37 Introduction ............3 Cleaning ............37 Safety ..............5 Clean Engine and Exhaust System Safety Alert Symbol ......... 5 Area ............37 Safe Operating Practices ........5 Remove Engine Shrouds and Clean Cooling Safety and Instructional Decals .....

  • Page 5: Safety

    The owner is responsible for training the users. Institute in effect at the time of production. • Never let children or untrained people operate Exmark designed and tested this lawn mower to offer or service the equipment. Local regulations may reasonably safe service; however, failure to comply restrict the age of the operator.
  • Page 6 Safety DANGER DANGER In certain conditions gasoline is extremely In certain conditions during fueling, static flammable and vapors are explosive. electricity can be released causing a spark which can ignite gasoline vapors. A fire or A fire or explosion from gasoline can burn explosion from gasoline can burn you and you, others, and cause property damage.
  • Page 7 Safety Operation damage and make repairs before restarting and operating the mower). WARNING – Before clearing blockages. Operating engine parts, especially the muffler, – Whenever you leave the mower. become extremely hot. Severe burns can occur • Stop engine, wait for all moving parts to stop, and on contact and debris, such as leaves, grass, engage parking brake: brush, etc.

  • Page 8: Maintenance And Storage

    Safety • Keep engine and engine area free from DANGER accumulation of grass, leaves, excessive grease Operating on wet grass or steep slopes can or oil, and other debris which can accumulate cause sliding and loss of control. Loss of control in these areas.
  • Page 9 Failure to use original Exmark parts could cause serious injury or death. Replace all parts including, but not limited to, tires, belts, and blades with original Exmark...

  • Page 10: Safety And Instructional Decals

    Exmark equipment dealer or labels. distributor or from Exmark Mfg. Co. Inc. • Replace all worn, damaged, or missing safety • Safety signs may be affixed by peeling off the signs.
  • Page 11 Safety 1-413327 48 inch and 52 inch Decks Only 103-1798 1-413421 1-553049 103-1976 20 HP Kawasaki Electric Start 98-5954...
  • Page 12 Safety 103-1977 16 HP and 18 HP Kawasaki Manual Start 103–2242 103-2076 103–2243 103-2103 103-4935...
  • Page 13 Safety 109-3148 116-0404 117–2718...

  • Page 14: Specifications

    Fuel System high efficiency Parker/Ross wheel drive motors. • Capacity: 5.0 gal. (18.9 L) • Hydraulic Oil: Use Exmark Premium Hydro Oil. • Type of Fuel: Regular unleaded gasoline, 87 • Hydraulic Oil Capacity: 2.4 qt. (2.2 L) octane or higher; containing no more than 10% methanol or ethanol.

  • Page 15: Dimensions

    Specifications Dimensions Tires & Wheels Drive Front Caster Overall Width: Pneumatic Semi- (Air-Filled) Pneumatic 36 inch 48 inch 52 inch Deck Deck Deck Quantity Deflector 36.1 inches 48.1 inches 53.0 inches Turf Master Smooth Tread (91.7 cm) (122.2 cm) (134.6 cm) Size 16 x 6.50–8 9 x 3.50-4...

  • Page 16: Torque Requirements

    Product Overview Torque Requirements Product Overview Bolt Location Torque Cutter Housing Spindle 140-145 ft-lb (190-197 N-m) Blade Mounting Bolt 55-60 ft-lb (75-81 N-m) (lubricate with anti-seize) 30-35 ft-lb (41-47 N-m) Engine Deck/Mower Deck Support Mount Bolts Anti-Scalp Roller Nyloc 30-35 ft-lb (41-47 N-m) Nut See Figure 9 Anti-Scalp Roller Whizlock 30-35 ft-lb (41-47 N-m)

  • Page 17: Operation

    Operation Operation as shown in Figure 4, and the drive levers are released, the drive wheels are engaged in the forward direction. Note: Determine the left and right sides of the Squeezing the left hand and/or right hand lever machine from the normal operating position. causes the left hand and/or right hand drive wheel respectively to slow down, stop, or reverse, depending on how far each drive lever is “squeezed”.

  • Page 18: Park Brake Lever

    Operation Park Brake Lever transportation to and from the job sites, and when the machine will not be used for a few days. Located on the left side of the unit above the hydraulic tank. Rotate valve 1/4 turn clockwise to shut fuel off. Rotate valve 1/4 turn counterclockwise to turn fuel The brake lever engages the park brake on the drive wheels.

  • Page 19: Pre-Start

    Operation Pre-Start B. Start engine. Refer to the following guidelines for further starting suggestions. Fill fuel tank on level ground. For best results use • To engage pump drive (disengage cold start only clean, fresh regular grade unleaded gasoline with kit): an octane rating of 87 or higher.

  • Page 20: Driving The Machine

    Operation PTO Engagement 6. Place the throttle midway between the “SLOW” and “FAST” positions. DANGER 7. Allow the engine to run for a minimum of 15 seconds, then turn the ignition switch to the The rotating blades under the mower deck are “OFF”...
  • Page 21 Operation Driving in Reverse To move rearward in a straight line, squeeze drive levers into the reverse position. To turn left or right, squeeze the right hand drive lever to turn left and the left hand drive lever to turn right. To make a “zero turn”, squeeze either the left hand or the right hand drive lever back into the reverse position while the opposite drive lever is in a forward...

  • Page 22: Adjusting The Anti-Scalp Rollers

    Operation Adjusting the Anti-Scalp Rollers It is recommended to change the anti-scalp roller position when the height of cut has changed. 1. Stop the machine and move the drive levers to the neutral lock position. 2. Disengage the PTO. 3. Engage the park brake. 4.

  • Page 23: Transporting

    Operation Figure 9 1. Spring disc washer 3. 3/8 nyloc-torque to 30-35 (cone towards nut ) ft-lb (41-47 N-m) 2. Front right anti-scalp 4. 3/8-16 whizlock nut bracket shown torque to 30-35 ft-lb (41-47 N-m) Transporting Transporting a Unit WARNING Loading the mower onto a trailer without strong enough or properly supported ramps could be dangerous.

  • Page 24: Maintenance

    Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING WARNING While maintenance or adjustments are being The engine can become very hot. Touching a hot made, someone could start the engine. engine can cause severe burns.

  • Page 25: Periodic Maintenance

    “FULL” cables are disconnected and the battery charger mark on the dipstick. Exmark 4-Cycle Premium used for charging the battery has an output of Engine Oil is recommended; refer to the Engine 16 volts and 7 amps or less to avoid damaging Owner’s manual for an acceptable alternative.
  • Page 26 Maintenance Recommended Jump WARNING Starting Procedure (Electric Batteries contain acid and produce explosive gases. Start Units Only) • Shield the eyes and face from the batteries Service Interval: As required at all times. 1. Check the weak battery for terminal corrosion •...

  • Page 27: Check Mower Blades

    (grass) side of blade. 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...

  • Page 28: Check Safety Interlock System

    3. Discharge deflector 6. Assembled view Note: If machine does not pass any of these tests, do not operate. Contact your authorized EXMARK 3. Hook the bent end of the rod around the front SERVICE DEALER. discharge deflector bracket to retain it from Important: It is essential that operator safety sliding out.

  • Page 29: Change Engine Oil

    2. Clean area around hydraulic reservoir cap and for additional information.) remove cap. Oil level should be to the top of the baffle inside the tank. If not, add oil. Use Exmark Every 200 hours/Yearly Premium Hydro Oil. Replace hydraulic reservoir (whichever comes cap and tighten until snug.

  • Page 30: Check Spark Plugs

    Yearly using Mobil 1 15W50) Deck Idler Pivots Note: Use only Exmark Part No. 109-4180 for Summer use above 32°F (0°C) or P/N 1-523541 for Winter use 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.
  • Page 31 Maintenance Exmark Premium Hydro Oil is recommended. The critical area for purging air from the hydraulic Refer to the chart for an acceptable alternative: system is between the oil reservoir and each charge pump located on the top of each variable...

  • Page 32: Replace Emissions Air Intake Filter

    Maintenance 4. Thoroughly clean the area around each of the charge pump housings. 5. To “prime” charge pump, loosen two hex socket head capscrews (shown in Figure 14) 1 1/2 turns only. Make sure engine is not running. Lift the charge pump housing upward and wait for Figure 15 a steady flow of oil to flow out from under the 1.

  • Page 33: Inspect Pto Clutching Belt Tension

    Maintenance Inspect PTO Clutching Belt • Sheave retaining bolt in end of engine crankshaft. Tension • Fuel tank bulkhead fitting threads Adhesives such as “Loctite RC/609 or RC/680” or Service Interval: After the first 2 hours “Fel-Pro Pro-Lock Retaining I or Retaining II” are Check every 2 hours used on the following: for the first 8 hours of...

  • Page 34: Adjustments

    Maintenance Adjustments Adjust the threaded yoke at the bottom of the speed control linkage (see Figure 18) until the Note: Disengage PTO, shut off engine, wait for tabs are positioned correctly. all moving parts to stop, engage parking brake, and remove key before servicing, cleaning, or making any adjustments to the unit.

  • Page 35: Adjust Hydro Control Linkages

    Maintenance disengaged whenever speed control levers are moved out of the neutral position. Note: The neutral lock latches should be “unlocked” and in the forward position. 2. Loosen the front nut on left hydro control linkage as shown in Figure 19. Turn the rear control linkage adjusting nut counterclockwise until wheel rotates forward.

  • Page 36: Tracking Adjustment

    Maintenance Tracking Adjustment to neutral. Recheck the drive wheel rotation to see if further adjustment is necessary. 1. Stop engine and wait for all moving parts to stop. 4. The spring that keeps tension on the knob 2. Check the drive tire pressures and tire should normally not need adjustment.

  • Page 37: Pto Safety Switch

    Maintenance PTO Safety Switch Cleaning Mounted to a tab on the inside left side of the fuel Clean Engine and Exhaust tank support. System Area 1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove ignition key or Service Interval: Before each use or daily spark plug wire(s).

  • Page 38: Clean Debris From Machine

    Maintenance Clean Debris From Machine If a battery is being replaced or if the unit containing the battery is no longer operating and is being Service Interval: Before each use or daily scrapped, take the battery to a local certified recycling center.

  • Page 39: Troubleshooting

    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.
  • Page 40 Troubleshooting Problem Possible Cause Corrective Action Engine overheats 1. Engine load is excessive 1. Reduce the ground speed. 2. Oil level in the crankcase is low. 2. Add oil to the crankcase. 3. Cooling fins and air passages for the 3.

  • Page 41: Schematics

    Schematics Schematics Electrical Diagram...
  • Page 42 Schematics Electrical Diagram...
  • Page 43 Schematics Hydraulic Diagram...
  • Page 44 No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower. All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement All implied warranties of merchantability (that the parts.

  • Page 45: Service Record

    Service Record Date: Description of Work Done: Service Done By:...
  • Page 47 Figure 23 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 20 degrees. Use 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.
  • Page 48 SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID-MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM (ROPS) DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT...

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