Exmark TURF TRACER X-SERIES, Operator'S Manual

Page 1: ...TURF TRACER X SERIES For Serial Nos 920 000 Higher Part No 4500 699 Rev A ...

Page 2: ...du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manuf...

Page 3: ...lable online at http www exmark com manuals htm 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 They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before l...

Page 4: ... Hydraulic Oil Level 27 Check Tire Pressures 27 Check Condition Of Belts 28 Lubricate Grease Fittings 28 Lubricate Caster Wheel Hubs 28 Remove Engine Shrouds and Clean Cooling Fins 29 Check Spark Plugs 29 Change Hydraulic System Filter 30 Replace Emissions Air Intake Filter 31 Wheel Hub Slotted Nut Torque Specification 31 Thread Locking Adhesives 32 Mobil HTS Grease Or Food Grade Anti seize 32 Cop...

Page 5: ... is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate or service the equipment Local regulations may restrict the age of the operator Only adults and mature ...

Page 6: ... certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plasti...

Page 7: ... checking cleaning or working on the mower After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage parking brake Before refueling Before dumping the grass catcher Before making height adjustments...

Page 8: ...e stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Keep engine and engine area free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Let engine cool before storing and do not store near flame or an...

Page 9: ...on and safety of the machine 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 parts WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with thi...

Page 10: ...n installed make sure current safety signs are visible New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and instruction labe...

Page 11: ...Safety 103 2242 103 2243 103 4935 103 2432 116 0404 11 ...

Page 12: ...Safety 116 4296 EFI Units Only 1 Fast 2 Slow 117 2718 12 ...

Page 13: ...ct with handle grips speed control lever in neutral and PTO disengaged to start engine Release of OPC levers will cause the engine to stop if speed control lever is not in neutral and or PTO is engaged Park brake must be disengaged to move speed control out of neutral or engine will kill Operator Controls Steering Control Fingertip drive control levers provide independent speed control braking and...

Page 14: ...ws for bagging mulching or side discharge Deck Depth 52 inch Deck 5 5 inches 14 0 cm 60 inch Deck 5 5 inches 14 0 cm Cutting Height Adjustment Adjusts from 1 1 2 inches 3 8 cm to 4 1 2 inches 11 4 cm in 1 2 inch 1 3 cm increments Mulching Kit Optional Bagger Optional Dimensions Overall Width 52 inch Deck 60 inch Deck Deflector Up 53 4 inches 135 6 cm 61 4 inches 156 0 cm Deflector Down 64 8 inches...

Page 15: ...oller Whizlock Nut See Figure 9 30 35 ft lb 41 47 N m Engine Mounting Bolts Kohler 15 20 ft lb 20 27 N m Engine Mounting Bolts Kawasaki 17 23 ft lb 23 31 N m Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Hub Slotted Nuts Style A 140 155 ft lb 190 210 N m Wheel Hub Slotted Nuts Style B minimum 100 ft lb 136 N m Clutch Retaining Bolt secured with threadlocker 55 60 ft lb 75 81 N m Wheel Motor Mountin...

Page 16: ...spectively to slow down stop or reverse depending on how far each drive lever is squeezed Squeezing the drive levers beyond the neutral position causes the drive wheels to engage in the reverse direction regardless of the position of the neutral lock latches and the speed control lever Neutral Lock Latches Located on the upper handle assembly on the ends of the handle grips These latches allow the...

Page 17: ...e job sites and when the machine will not be used for a few days Rotate valve 1 4 turn clockwise to shut fuel off Rotate valve 1 4 turn counterclockwise to turn fuel on Drive Wheel Release Valves Located on the left rear corner of the hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be moved by hand without the engine running Wit...

Page 18: ...rter motor Note It is helpful to have the left and right neutral lock latches locked in neutral when starting the engine Refer to Neutral Lock Latches section in Controls Engaging the PTO DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck when the blades are engaged DANGER An uncove...

Page 19: ...ers Slowly and carefully release the drive levers See Figure 5 position 3 To place the drive levers in the reverse position squeeze the drive levers past the neutral position See Figure 5 position 4 Figure 5 1 Drive Lever in neutral position 3 Drive Lever in forward position 2 Drive Lever locked in neutral position 4 Drive Lever in reverse position Driving Forward 1 Release the parking brake 2 Wit...

Page 20: ...n the front support rod hairpins are removed The cutting height of the mower deck is adjusted from 1 1 2 to 4 1 2 inches 3 81 cm to 11 4 cm in 1 2 inch increments 1 Stop the machine and move the drive levers to the neutral locked position 2 Disengage the PTO 3 Engage the park brake 4 Stop the engine remove the key and wait for all moving parts to stop 5 Install hairpin clips in the holes for the d...

Page 21: ...und to minimize gouging and roller wear or damage Figure 8 For cutting heights above 3 5 inches 90 mm use the bottom hole The rollers will still be effective against scalping 1 Anti scalp roller mounting bracket 2 Cutting height For Maximum Deck Flotation place the rollers one hole position lower Rollers should maintain 1 4 inch 6 4 mm clearance to the ground Do Not adjust the rollers to support t...

Page 22: ...out from under the unit when loading and unloading If necessary use assistance when loading Be sure the fuel shut off valve is closed Use a heavy duty trailer to transport the machine Engage neutral lock latches and park brake then block wheels 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...

Page 23: ...ch use or daily Check the engine oil level Check the mower blades Check the safety interlock system Check for loose hardware Every 40 hours Check the hydraulic oil level Check the tire pressures Check the condition of the belts Grease the hydro control arm support bushings Every 80 hours Remove engine shrouds and clean cooling fins Every 100 hours Change the engine oil May need more often under se...

Page 24: ...ng battery should be fully charged before putting away for winter storage Check the voltage of the battery with a digital voltmeter or with the message display If the ignition key is turned to the on position for a few seconds the battery voltage will be displayed in the area where the hours are normally displayed Locate the voltage reading of the battery in the table and charge the battery for th...

Page 25: ...atteries Note Be sure the vent caps are tight and level Place a damp cloth if available over any vent caps on both batteries Be sure the vehicles do not touch and that both electrical systems are off and at the same rated system voltage These instructions are for negative ground systems only 3 Connect the positive cable to the positive terminal of the discharged battery that is wired to the starte...

Page 26: ... shown Check Safety Interlock System Service Interval Before each use or daily 1 Check starting circuit Starter should crank with Operator Presence Control levers depressed speed control lever in neutral and PTO disengaged Try to start the engine with OPC levers disengaged speed control lever in neutral and PTO disengaged starter must not crank Try to start with OPC levers depressed speed control ...

Page 27: ...Engine Oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 2 to 3 4 turn 5 Clean around oil fill cap and remove cap Fill to specified capacity and replace cap 6 Use oil recommended in the Check Engine Oil Level section Do Not overfill Start the engine and check for leaks Stop engine and recheck oil level Chec...

Page 28: ...ting Locations Initial Pumps Number of Places Service Interval 1 Front Caster Wheel Hubs 0 2 Yearly 2 Front Caster Pivots 0 2 Yearly 3 Idler Pivots Mower Deck 1 2 Yearly 4 Idler Pivot Pump Drive 2 1 Yearly 5 Hydro Control Arm Support Bushings 2 2 40 Hours See step 3 for special lubrication instructions on the front caster pivots and the Lubricate Caster Wheel Hubs section for special lubrication i...

Page 29: ...ent 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 If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Reapply thread locking adhesive Remove Engine Shrouds and Clean Cooling Fins Service Interval Every 80 hours 1 Stop engine wait for all movi...

Page 30: ... seal contacts the filter adapter Then tighten the filter an additional 2 3 to 3 4 turn 6 Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely CAUTION Raising the mower for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough supp...

Page 31: ...ousing upward and wait for a steady flow of oil to flow out from under the housing Retighten the capscrews Do this for both pumps Note Hydraulic reservoir can be pressurized up to 5 psi to speed this process 6 If either drive wheel still does not rotate stop and repeat steps 4 and 5 above for the respective pump If wheels rotate slowly the system may prime after additional running Check oil level ...

Page 32: ...head setscrews on Hydro pump control arms Shoulder bolts in ends of speed control crank OPC lever setscrews Electric clutch retaining bolt Pump drive idler pivot bolt Thumb latch screw threads on handles Caster wheel spacer nuts Fuel tank bulkhead fitting nuts 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 cro...

Page 33: ...ould be pointing straight down at the 6 o clock position or slightly forward Adjust the threaded yoke at the bottom of the speed control linkage see Figure 17 until the tabs are positioned correctly Figure 17 Viewed from Left Side of Unit 1 Neutral Safety Switch 3 5 16 inch 7 9 mm 2 Actuating Tab in neutral position 3 Pull the speed control lever back to neutral Check that the neutral safety switc...

Page 34: ...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 18 Turn the rear control linkage adjusting nut counterclockwise until wheel rotates forward Turn the rear nut of left control linkage clockwise 1 4 of a turn at a time stopping to move the speed control forward and back to neutral until left wheel stops rotati...

Page 35: ...re stops Continue this process until the tire is at a dead stop 3 Make this adjustment for both sides 4 Stop engine and wait for all moving parts to stop Raise rear of machine remove jack stands and carefully lower machine to the ground Tracking Adjustment 1 Stop engine and wait for all moving parts to stop 2 Check the drive tire pressures and tire circumferences as stated in Check the Tire Pressu...

Page 36: ...s empty 1 Fill the fuel tank 2 Fuel shutoff valve is closed 2 Open the fuel shutoff valve 3 The throttle and choke are not in the correct position 3 Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the ON position for a cold engine or the OFF position for a warm engine 4 Dirt in fuel filter 4 Replace the fuel filter 5 Dirt water or stale fuel is in the...

Page 37: ...rect 5 Adjust tire pressure in the drive tires 6 Blade spindle bent 6 Contact an Authorized Service Dealer Uneven cutting height 7 Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is approximately one blade thickness 7 Replace blades spindles and or check for damage to mower deck 1 Cutting blade s is are bent or unbalanced 1 Install new cutt...

Page 38: ...Schematics Schematics Electrical Diagram All units except Kohler EFI 38 ...

Page 39: ...Schematics Electrical Diagram Kohler EFI 39 ...

Page 40: ...Schematics Electrical Logic Schematic All units except Kohler EFI 40 ...

Page 41: ...Schematics Electrical Logic Schematic Kohler EFI 41 ...

Page 42: ...Schematics Hydraulic Diagram 42 ...

Page 43: ...r Canada customers may also call 402 223 6375 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities If your product requires warranty service it must be returned to an autho...

Page 44: ...Notes 44 ...

Page 45: ...Service Record Date Description of Work Done Service Done By 45 ...

Page 46: ...46 ...

Page 47: ...se 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 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 47 ...

Page 48: ...DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB Place Model No and Serial No Label Here Included in the Literature Pack or Fill i...