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

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For Turf Tracer
Serial Nos. 600,000 & Higher
And
FMD524 & FMD604
Serial Nos. 510,000 & Higher
Part No. 109-0625 Rev. B

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Summary of Contents for Exmark Turf Tracer

  • Page 1 For Turf Tracer Serial Nos. 600,000 & Higher FMD524 & FMD604 Serial Nos. 510,000 & Higher Part No. 109-0625 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. Exmark, or its...
  • 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 ....................4-6 1.5 Maintenance & Storage ................6-7 1.6 Riding Attachments ..................7 1.7 Safety Signs ..................... 7-9 2. SPECIFICATIONS 2.1 Model Number....................

  • 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. WARNING POTENTIAL HAZARD ♦...
  • 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 ♦...

  • 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 DANGER POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can cause sliding and loss of control. WHAT CAN HAPPEN ♦ 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, which may result in serious injury or death.

  • Page 11: Maintenance & Storage

    1.4.13 Stop the engine and wait for all moving parts to stop: • Before removing grass catcher. • Before refueling. • Before making height adjustments. 1.4.14 Before stopping the engine, place the throttle control midway between the “slow” and “fast” positions. Allow the engine to run a minimum of 15 seconds, then stop the engine.

  • 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.
  • Page 13 Turf Tracer Decals: PART NO. 103-2242 LOCATION: LH Side of Console PART NO. 103-1541 LOCATION: Console PART NO. 103-2243 LOCATION: RH Side of Console PART NO. 1-513746 LOCATION: Surface of Engine Deck Next to Muffler PART NO. 1-303517 LOCATION: LH Side of Rear Surface of Engine Deck PART NO.
  • Page 14 FMD524 and FMD604 Decals: PART NO. 1-553049 LOCATION: On Top Front LH Surface of PART NO. 1-403005 Mower Deck LOCATION: LH & RH Front Top Surface of Mower Deck PART NO. 98-5954 PART NO. 103-7491 LOCATION: Under LH, RH & LOCATION: On Top Front RH Center Belt Shields Surface of Mower Deck...

  • Page 15: Specifications

    2. SPECIFICATIONS 2.1 MODEL NUMBER: TT23KCE; TT23KAE; TT20KCE 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 16: Tires

    2.8 TIRES Drive Front Caster Pneumatic (Air-Filled) Pneumatic (Air-Filled) Semi-Pnuematic All Serial Nos. SN 599,999 & lower SN 600,000 & higher Size 18 x 8.50-8 11 x 4.0-5 11 x 4.0x5 Quantity Tread Turf Master Smooth Smooth Ply Rating Pressure 14 psi (90 kPa) 16 psi (152 kPa) 2.9 MOWER DECK...

  • Page 17: Operation Instructions 3.1 Controls

    3. OPERATION INSTRUCTIONS 3.1 Controls 3.1.1 Operator Presence Control (OPC) Levers: Located on the upper handle assembly directly above the handle grips. See Figure 3. When these levers are depressed, the OPC system senses that the operator is in the normal operator's position.

  • Page 18: Pre-Start

    3.1.7 Speed Control Lever: Located in middle of control console, it controls the maximum forward speed and is infinitely variable from neutral 0 mph to 6.75 mph. Park brake must be disengaged to move speed control out of neutral or engine will kill.

  • Page 19: Operation Instructions

    3.2.2 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary inspection and maintenance steps. 3.2.3 Make sure you understand the controls, their locations, their functions, and their safety requirements. OPERATING INSTRUCTIONS 3.3.1 Starting Engine: Open fuel valve. Operator must have Operator Presence Control (OPC) levers depressed, the PTO disengaged and speed control lever in neutral.
  • Page 20 To place the drive levers in the “forward” position, slightly squeeze the drive levers while placing thumbs on the outer thumb lobe of the neutral lock latches (or the index finger on the front lobe) and rotate them from under the drive levers.

  • Page 21: Transporting

    3.3.6 PTO Engagement: DANGER POTENTIAL HAZARD ♦ The rotating blades under the mower deck are dangerous. WHAT CAN HAPPEN ♦ Blade contact can cause serious injury or kill you. HOW TO AVOID THE HAZARD ♦ DO NOT put hands or feet under the mower or mower deck when the PTO is engaged.

  • Page 22: Maintenance & Adjustments

    Securely fasten the machine to the trailer with straps, chains, cables, or ropes. Do not rely solely on the parking brake to hold the machine on the trailer. Be sure that the trailer has all necessary lighting and marking as required by law and use a safety chain.
  • Page 23 4.1.2 Clean engine air cooling system. Service Interval: Daily or more often in dry conditions. CAUTION POTENTIAL HAZARD ♦ Excessive debris can cause the engine and hydraulic system to overheat. WHAT CAN HAPPEN ♦ Excessive debris around the engine cooling air intake and around the hydraulic pumps can create a fire hazard.
  • Page 24 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 25 HOW TO AVOID THE HAZARD ♦ Always re-install original Exmark blades, blade bushings, spring disc washers, and blade bolts in the correct positions as shown.
  • Page 26 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 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 28 Fill reservoir as stated in Section 4.1.10. Loosen filter 1/2 turn and allow a small amount of oil to leak from the oil filter (this allows air to be purged from the oil filter and supply hose from the hydraulic reservoir). Turn filter clockwise until rubber seal contacts the filter adapter.
  • Page 29 To “prime” charge pump, loosen two hex socket head capscrews (shown in Figure 7) 1-1/2 turns only. Make sure engine is not running. Lift the charge pump housing upward and wait for a steady flow of oil to flow out from under the housing.
  • Page 30 Pack the bearings with a NGLI grade #1 multi-purpose grease. Insert (1) bearing, (1) new seal into the wheel. NOTE: Seals (Exmark PN 103-0063) must be replaced. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to (1) spacer nut and thread onto the axle with the wrench flats facing outward.
  • Page 31 Re-install the seal guards over the wheel hub and insert wheel into caster fork. Re-install caster bolt and tighten nut fully. IMPORTANT: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play.

  • Page 32: Adjustments

    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 erratic operation. Fuel tank studs where studs are inserted into tank. NOTE: When installing the nuts onto the fuel tank studs, fully tighten the nyloc nut and back off 1/2 turn.
  • Page 33 LEFT HAND SIDE SHOWN FIGURE 6 CUTTING HEIGHT ADJUSTMENT Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of the positions shown in Figure 10. 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 34 4.2.2 Pump drive belt tension adjustment: No adjustment necessary. 4.2.3 Mower deck drive belt: No adjustment necessary. 4.2.4 Blade drive belt tension: No adjustment necessary. 4.2.5 Hydro Drive Linkage Adjustment: Adjust Speed Control Linkage and Neutral Safety Switch 1. Stop engine and wait for all moving parts to stop. 2.
  • Page 35 FIGURE 9 HYDRO DRIVE LINKAGE ADJUSTMENT 4. Loosen the nut against the neutral control linkage yoke as shown in Figure 9. 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 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. If inconsistent neutral occurs, check to be sure both springs are properly tightened on the speed control lever under the console - especially the rear pivot spring.

  • Page 37: Waste Disposal

    4.2.6 Hydro Pump Spring Tension Setting For medium or heavy duty drive conditions such as operation with a sulky on steep slopes, a higher spring force may be required on the hydro pump control arms to prevent the drive system from stalling. For a heavier drive setting, relocate the spring anchor link as shown in Figure 12.

  • Page 38: Battery Disposal

    5.2 BATTERY DISPOSAL 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 39 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 40: Hydraulic Schematic

    7. HYDRAULIC SCHEMATIC - 35 -...

  • Page 41: Wiring Diagram

    8. WIRING DIAGRAM - 36 -...

  • Page 42: Warranty

    This warranty extends only to replace or adjust any part manufactured by Exmark and found turf equipment operated under normal conditions. You by us (in the exercise of our reasonable discretion) to be...

  • Page 43: Evaporative Emission Control Warranty

    If any such part fails during the period of warranty coverage, it must be repaired or replaced by Exmark Manufacturing Company. Any such part repaired or replaced under the warranty must be warranted for a time not less than the remaining warranty period.
  • Page 44 NOTES - 39 -...
  • Page 45 NOTES - 40 -...
  • Page 46 SERVICE RECORD Date Description of Work Done Service Done By - 41 -...
  • Page 47 ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) - 42 -...
  • Page 48 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. ©1997-2005 EXMARK MFG. CO. INC. PART NO. 109-0625 Rev. B INDUSTRIAL PARK BOX 808 (402) 223-6300 BEATRICE, NE 68310 FAX (402) 223-5489 ®...

This manual is also suitable for:

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