Exmark Turf tracer, Operator'S Manual

Page 1: ...For Turf Tracer Serial Nos 600 000 Higher And FMD524 FMD604 Serial Nos 510 000 Higher Part No 109 0625 Rev B ...

Page 2: ...om eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES 0...

Page 3: ...bmitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 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 The following res...

Page 4: ...wer maintain its maximum efficiency and promote safe operation 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 st...

Page 5: ...m 10 2 8 Tires 11 2 9 Deck 11 2 10 Dimensions 11 2 11 Torque Requirements 11 3 OPERATION INSTRUCTIONS 3 1 Controls 12 13 3 2 Pre Start 13 14 3 3 Operation Instructions 14 16 3 4 Transporting 16 17 4 MAINTENANCE ADJUSTMENTS 4 1 Periodic Maintenance 17 27 4 2 Adjustments 27 32 5 WASTE DISPOSAL 5 1 Motor Oil Disposal 32 5 2 Battery Disposal 33 6 TROUBLE SHOOTING 6 1 Mower Tracks Left or Right 33 6 2 ...

Page 6: ...perator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 1 2 4 Avoid mowing while people especially children or pets are nearby Ke...

Page 7: ...can burn you others and cause property damage HOW TO AVOID THE HAZARD DO NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only outdoors Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when t...

Page 8: ...e then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignited by electrical sparks ...

Page 9: ...stall and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without...

Page 10: ...ocks tree limbs etc from the mowing area Tall grass can hide obstacles Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control 1 4 5 Use EXTREME caution when backing up LOOK BEHIND YOU 1 4 6 Stop the blades when crossing surfaces other than grass if mower must be tilted for transportation and when transporting the mower to and fro...

Page 11: ...tive terminal post on the starter solenoid switch this post has the positive battery cable attached to it b Connect the negative or ground cable from the negative post on the booster battery to the engine block as far away from the battery as possible c Disconnect battery cables in the reverse order afterstarting 1 5 MAINTENANCE AND STORAGE 1 5 1 For engine maintenance follow the engine manufactur...

Page 12: ...ying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by locking drive levers in neutral and shutting off the engine before performing any work on the hydraulic system 1 6 RIDING ATTACHMENTS Use only Exmark rid...

Page 13: ... PART NO 1 513747 LOCATION Top Rear of Battery Cover PART NO 1 513746 LOCATION Surface of Engine Deck Next to Muffler PART NO 103 4935 LOCATION Left Rear Top Corner of Engine Deck PART NO 1 413214 LOCATION Right Side of Hydro Control Crank Arm PART NO 103 2242 LOCATION LH Side of Console PART NO 103 2243 LOCATION RH Side of Console PART NO 103 2432 LOCATION Parking Brake Lever ...

Page 14: ...RH Surface of Mower Deck PART NO 1 553049 LOCATION On Top Front LH Surface of Mower Deck PART NO 1 523552 LOCATION On Top of Hydraulic Tank PART NO 103 2239 LOCATION Top of Mower Deck Beneath Center Shield PART NO 103 7491 LOCATION On Top Front RH Surface of Mower Deck PART NO 98 5954 LOCATION Under LH RH Center Belt Shields ...

Page 15: ...C 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 2 5 STEERING CONTROL Fingertip drive control levers provide independent speed control braking and neutral to each drive wheel for moving forward or reverse stopping and power turning 2 6 TRANSMISSION 2 6 1 Two H...

Page 16: ...ed to out front support frame removable for service 2 10 DIMENSIONS 2 10 1 Overall Width w 52 Deck w 60 Deck Discharge chute down 64 2 163 1 cm 72 2 183 4 cm Discharge chute up 53 4 135 6 cm 61 4 156 0 2 10 2 Overall Length w 52 Deck w 60 Deck 83 4 211 8 cm 83 4 211 8 cm 2 10 3 Curb Weight w 52 Deck w 60 Deck 720 lbs 327 kg 760 lbs 345 kg Weights will vary slightly depending on engine 2 10 4 Overa...

Page 17: ...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 3 1 3 Neutral Lock Latches These latches allow the operator to lock the drive levers in a neutral position where the drive wheels are not engaged in either a forward ...

Page 18: ...otate valve 1 4 turn counter clockwise to turn fuel on 3 1 11 Drive Wheel Release Valves Located on the left rear corner of the hydrostatic pumps Drive wheel release valves are used to release the hydro static drive system to allow the machine to be moved by hand without the engine running With a 5 8 wrench turn both valves one turn counter clockwise to release the drive system Turn clockwise to r...

Page 19: ...l when starting the engine See Controls Section 3 1 3 3 3 2 Stopping Engine Lock drive levers in neutral disengage PTO move speed control lever to neutral and engage park brake Move throttle to the midway position Allow engine to run a minimum of 15 seconds Rotate ignition switch to Off position Remove key to prevent children or other unauthorized persons from starting engine Close fuel shut off v...

Page 20: ... the forward position DO NOT squeeze both drive levers all the way back This will cause the drive wheels to engage in the reverse direction For straight ahead motion Smoothly release both drive levers to engage drive wheels For turning Squeeze the right hand drive lever to turn right and the left hand drive lever to turn left To make a zero turn squeeze either the left hand or the right hand drive...

Page 21: ...ages the cutting blades Be sure that all persons are clear of mower deck and discharge area before engaging the PTO Set throttle to midway position The switch must be pulled out to the Rotate position to engage the blades Accelerate to full throttle to begin mowing 3 3 7 PTO Disengagement Push in on the switch to the Stop position to stop the blades 3 4 TRANSPORTING WARNING POTENTIAL HAZARD Loadin...

Page 22: ...identally contact the spark plug s 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 4 1 PERIODIC MAINTENANCE 4 1 1 Check engine oil level Service Interval See Engine Owner s Manual a Stop engine wait for all moving p...

Page 23: ...TION POTENTIAL HAZARD Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or...

Page 24: ...efore assembly Torque the blade bolt to 115 120 ft lbs 156 163 N m FIGURE 5 BLADE BOLT INSTALLATION Serial Nos 510 000 539 999 For Serial Nos 540 000 and Higher d Re install the blades if they were removed in the following order See Figure 6 1 Install bushing through blade with bushing flange on bottom grass side of blade 2 Install bushing blade combo into spindle 3 Install blade bolt and spring d...

Page 25: ... correct positions as shown 4 1 5 Check safety interlock system Service Interval Daily a 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 ...

Page 26: ... air to clean paper element or inner element f Reinstall elements Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips 4 1 8 Change engine oil Service Interval See Engine Owner s Manual NOTE Change oil after first five 5 hours of operation Follow engine manufacturers recommendations for future oil changes a Stop engine wait for all moving parts to...

Page 27: ...ait for all moving parts to stop b Clean area around hydraulic reservoir cap and remove cap c Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 15W 50 synthetic motor oil Replace hydraulic reservoir cap and tighten until snug Do not overtighten NOTE The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT leve...

Page 28: ...lic components including 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 See Figure 4 Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is primed FIGURE 4 CHARG...

Page 29: ...e circumferences match as closely as possible c For Serial Nos 599 999 and lower Check the tire pressure in the pneumatic front caster tires Adjust the tire pressure to 16 psi 110 kPa Note Front caster tires have permanent tire sealant installed For Serial Nos 600 000 and higher The front caster tires are semi pneumatic No adjustment is necessary 4 1 14 Inspect Belt wear Service Interval 40 hrs a ...

Page 30: ... 1 multi purpose grease g Insert 1 bearing 1 new seal into the wheel NOTE Seals Exmark PN 103 0063 must be replaced h 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 Do not thread spacer nut all of the way onto the end of the axle Leave approximately 1 8 3 mm from the...

Page 31: ...ers or cooling shrouds will cause engine damage due to overheating 4 1 19 Change fuel filter Service Interval As Required a A fuel filter is installed in the fuel line between the fuel tank and the engine Replace when necessary For Kohler engines use Kohler P N 2405002 For Kawasaki engines use Kawasaki P N 49019 7001 4 1 20 Wheel hub slotted nut torque specification When tightening the slotted nut...

Page 32: ...ot installed or the two front support rod hairpins are removed the unbalanced weight of the tractor or tractor with mounted mower deck support frame may cause the front of the unit to rise suddenly WHAT CAN HAPPEN If the unit rises suddenly injury may occur HOW TO AVOID THE HAZARD Securely hold down the front end of the unit when the mower deck is not installed or front support rod hairpins are re...

Page 33: ... of anti scalp roller assemblies are available See Figure 7 to determine which assembly has been installed on the unit Torque hardware as specified or loss of roller may result Type A Torque the 3 8 whizlock nut to 40 45 ft lbs 54 61 N m Type B Torque the 3 8 nyloc nut to 30 35 ft lbs 41 47 N m Torque the 3 8 24x2 Gr 8 hex capscrew to 50 55 ft lbs 68 75 N m FIGURE 7 ANTI SCALP ROLLER INSTALLATION ...

Page 34: ... between the tab and the switch See Figure 8 If necessary move the switch fore and aft FIGURE 8 NEUTRAL SAFETY SWITCH ADJUSTMENT b 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 positi...

Page 35: ...ut against the yokes c Adjust Hydro Control Linkage 1 Place the speed control lever in the neutral position This adjustment is again made with rear of machine on jack stands and engine running at full throttle OPC levers will have to be held down whenever speed control lever is moved out of neutral position Note The neutral lock latches should still be unlocked and in the forward position 2 Loosen...

Page 36: ... 1 With rear of machine still on jack stands and engine running at full throttle move the speed control lever to the midway position Move the respective drive lever upward until it reaches the neutral position and engage neutral lock latches See Figure 11 If the tire rotates in either direction the length of the drive lever linkage will need to be adjusted 2 Adjust the linkage length by loosening ...

Page 37: ...slot Pull on cable assembly at lower end where it attaches to the engine until the throttle control arm contacts the stop screw Secure cable with cable clamp b Tension in throttle lever can be adjusted by adjusting the tightness of the lever pivot bolt which is located under the console See Figure 13 FIGURE 13 THROTTLE TENSION 4 2 8 Electric Clutch Adjustment No adjustment necessary 4 2 9 Park Bra...

Page 38: ...rn the knob in 1 4 turn increments until the mower tracks correctly 6 2 MOWER CUTS UNEVENLY a Check the drive tire pressures and tire circumferences See Section 4 1 13 A more uniform cutting height may be obtained with higher tire pressure on rough terrain A lower tire pressure provides more flotation b Check deck support pins Hairpin clips must be in the same hole position on each support pin See...

Page 39: ...lems could be caused by an empty fuel tank The following tables list some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing or adjustment procedures such as valves governor etc Have this work done by your Engine Service Dealer ENGINE TROUBLESHOOTING TABLE PROBLEM NO FUEL IMPROPER FUEL DIRT IN FUEL LINE DIRTY AIR FILTER FAULTY...

Page 40: ... 35 7 HYDRAULIC SCHEMATIC ...

Page 41: ... 36 8 WIRING DIAGRAM ...

Page 42: ...sfied 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 The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty ...

Page 43: ...t as required maintenance in the written instructions must be warranted for the warranty period of two years 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 B Any warranted part that is scheduled...

Page 44: ... 39 NOTES ...

Page 45: ... 40 NOTES ...

Page 46: ... 41 SERVICE RECORD Date Description of Work Done Service Done By ...

Page 47: ...L O P E T H IS IS A 1 0 S L O P E TH IS IS A 5 S L O P E ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC EXAMPLE COMPARE SLOPE WITH FOLDED EDGE FOLD ALONG APPROPRIATE LINE T H I S I S A 2 0 S L O P E ...

Page 48: ...AC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER STANDON WARNING 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 4...