Exmark TURF TRACER S-SERIES Operators Manual

TURFTRACER®S-SERIES
SetupInstructions
ForSerialNos.313,000,000&Higher
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer
extranet.
DealerPack
Part#DescriptionQty.Use
107-4543Clamp,Tank2
322-10Screw,HH5/16-18x22
3256-3Washer,5/16Std2
104-8300Nut,Nyloc5/16-18Flg2
Installingthefueltank.
323-6Screw,HH3/8-16x1inch4
3290-357Nut,Whizlock3/8-16inch4
98–5975Washer,SpringDisc4
Installingthehandleassembly.
1-806003Hairpin,Cotter1
3272-5Pin,Cotter3/32x1/2inch1
1-808280Pin,Clevis1
Installingthespeedcontrolrod.
322-9Screw,HH5/16-18x13/4inch2
3296-29Nut,Nyloc5/16-18inch2
3220-16Nut,Jam3/8-24inchLH2
Installingthewheeldrivelinkages.
1-303335Tie,Cable2
1-303287Tie,Cable4Connectingwireharness.
103-2106Key,ExmarkLogo1
1-603511Key,Standard1
Fillouttheonlinewarrantyregistration
formandplacekeysintoliterature
pack.
LiteraturePack
Manual,Operator's
Manual,EngineOperator's
UncratingtheUnit
1.Leavingtheunitonthepallet,placetheupperhandle
assemblyandthefueltankattherearofthemachine.
2.Removetheboltbagfromunderthemowerdeck
beltshield.
3.Refertothepartsmanualtohelpyouidentifyand
locatethepartsandtheirproperposition.
InstallingtheFuelTank
1.Installthefueltankontopofthefueltanksupport.
Secureeachsideofthetankwithaclamp,5/16-18x
2inchscrew ,washer,and5/16inchnylocnut.
2.Attachthefuelsupplyhosetothebottomtanktting
andsecurewiththeclampprovided.
3.Attachthepurgehosefromtheteeontheengine
(canisteronCAunits)tothetopttingofthefuel
tankasshowninFigure1.Pressthehoseintothe
slotonthetanktoretainit.
©2012—ExmarkMfg.Co.,Inc.
P .O.Box808
Beatrice,NE68310
PartNo.4501-436Rev.A
PrintedintheUSA
AllRightsReserved

Figure1
1.Attachpurgehosetotoptting
InstallingtheHandleAssembly
1.Positionthelowerendofthehandleassemblyon
theoutsideoftheupperrearsectionofthefueltank
andhandlesupport.
2.Installfour3/8-16x1inchbolts,fourspringdisk
washersfromtheoutsidein.Secureusingfour
3/8-16whizlocknutsontheinsideofeachhandle
supportandtightenuntilthespringdiskwashersare
at(Figure2).
Note:Besuretheconeofthespringdiskwasheris
againsttheheadofthebolt.
Figure2
1.Frontoftheunit3.Upperhandle
2.Upperhandlemounting
tab
AttachingtheThrottleCable
1.Routethethrottlecablealongtherightsideofthe
upperhandle,underthefueltanksupport,and
positionthecableontheleftsideoftheengine.
2.Positionthethrottlecontrollever(locatedonthe
console)inthefullthrottleposition.Youwillfeela
detentwhenthethrottleleverispushedtowardsthe
upperendoftheslot.
3.Attachtheinnerwireofthethrottlecabletothetop
holeinthethrottlecontrolleverasshowninFigure3.
4.Loosentheclamp,installthethrottlecableonthe
bottomsideoftheclamp,andpullonthecableto
movethethrottlelinkagetothefullthrottleposition.
Tightenthecableclampscrew .
Figure3
1.Throttlecontrollever3.Clamp
2.Throttlecable—Located
onbottomsideofclamp.
4.Chokecable
InstallthePTOEngagement
Linkage
1.Loosenthejamnutandremovetheturnbucklefrom
thelowerlinkage(Figure4).
2.Screwtheturnbuckleontoboththeupperandthe
lowerlinkagessimultaneously.Notethatthreadson
upperlinkagearelefthand.
Note:Thehandleshavethedriveleverlinkageon
theinsideofthebladeengagementlevertabandthe
hairpinontheoutside.
2

Figure4
1.LowerPTOengagementlinkage
2.Jamnut
3.Turnbuckle
4.UpperPTOengagementlinkage
3.WiththePTOengaged,adjustthelinkagelength
bylooseningthelocknutontheturnbuckleand
adjustingtheturnbucklesothattheboltonthe
bellcrankandtheindicatorarmalignwitheach
otherwithin1/16inch(1.6mm)(Figure5).Tighten
locknutagainstturnbuckle.
Figure5
1.Enginedeck3.Alignbolttoindicator
within1/16inch(1.6mm)
2.Indicator4.Turnbuckle
InstallingtheSpeedControlRod
1.Locatethespeedcontrolrodassemblywithayoke
atoneend.
2.Inserttheendofthelinkageoppositetheyokeinto
theendofthespeedcontrolleverlocatedunderneath
thehandleconsolefromtherighthandsideand
fastenwithahairpinfromtheboltbag.
3.Connectthelowerendofthespeedcontrollinkage
tothespeedcontrolcranklocatedatthetoprearof
thefueltanksupport.Securewithaclevispinand
3/32x1/2inchcotterpin.
InstallingtheWheelDrive
Linkages
1.Positionthespeedcontrolleverinneutral.
2.Positionthedriveleversinneutralandengagethe
neutrallocklatches(Figure6).
3.Threada3/8-24inchLHjamnut,fromtheboltbag,
ontothelowerendofeachdriveleverlinkage.
4.Identifythelowerballjointsinstalledonthehydro
controlarmweldments.Threadthelowerendof
eachdriveleverlinkageintothelowerballjointuntil
theholeinupperballjointalignswithholeindrive
lever.
5.Installa5/16-18x13/4inchhexcapscrewand
a5/8-18inchnylocnutoneachsideandtighten.
Thiswillgiveanapproximatesettingfordrivelever
linkages.
3

Figure6
RightHandSideofUnitShown
1.Driveleverlinkage
2.5/16-18inchnylocnut
3.Speedcontrolleverinneutral
4.Driveleversinneutral
5.5/16-18x13/4inchhexcapscrew
6.3/8-24inchLHjamnut
7.Hydrocontrolarmweldment
8.Lowerballjoint
AdjustingtheDriveLeverLinkages
1.Raisetherearofmachineoffoftheground.
CAUTION
Raisingtherearoftheunitforassemblyrelying
solelyonmechanicalorhydraulicjackscouldbe
dangerous.Themechanicalorhydraulicjacks
maynotbeenoughsupportormaymalfunction
allowingtheunittofall,whichcouldcause
injury.
DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstandsor
equivalentsupport.
2.Withtherearofmachineonjackstandsandengine
runningatfullthrottle,disengagetheparkbrake
andmovethespeedcontrollevertothemidway
position.Movetherespectivedriveleverupward
untilitreachestheneutralpositionandengagethe
neutrallocklatches(Figure7).Ifthetirerotatesin
eitherdirection,thelengthofthedriveleverlinkwill
needtobeadjusted.
3.Adjustthelinkagelengthbylooseningthejamnuts
atbothendsofthelinkageandrotatingthelinkage
intheballjoints.Lengthenthelinkageifthetireis
turninginreverseandshortenthelinkageifthetire
iscreepingforward.Tightenthejamnutsatboth
ends.Releaseandre-engagetheneutrallocklatch
checkingthatthetirestops.Continuethisprocess
untilthetirenolongerrotates.
Figure7
4.Makethisadjustmentforbothsides.
ConnectingWireHarness
1.Routethelong,unattachedwiringharnessleadupthe
lefthandsideofthehandleandundertheconsole.
2.ConnectthetwoagterminalstotheOPCswitch
inanyorder.
3.Connecttheconnectortothekeyswitch.
4.Fastentheharnesstotheleftsideofhandlewithtwo
largeplastictiesfromtheboltbag.
5.FastentheleadsconnectingtotheOPCswitchto
thesmallholeinthechannelundertheconsoleusing
asmalltiefromtheboltbag.
4

ServicingtheBattery
WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
Important:Themachineisshippedwithalled
leadacidbattery.
DANGER
Chargingthebatterymayproduceexplosivegasses.
Batterygassescanexplodecausingseriousinjury.
•Keepsparks,ames,orcigarettesawayfrom
battery.
•Ventilatewhenchargingorusingbatteryinan
enclosedspace.
•Makesureventingpathofbatteryisalwaysopen
oncebatteryislledwithacid.
1.Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebattery
inthetablebelowandchargethebatteryforthe
recommendedtimeintervaltobringthechargeup
toafullchargeof12.6voltsorgreater.
Important:Makesurethenegativebattery
cableisdisconnectedandthebatterycharger
usedforchargingthebatteryhasanoutputof
16voltsand7ampsorlesstoavoiddamaging
thebattery(seechartbelowforrecommended
chargersettings).
Voltage
Reading
Percent
Charge
Maximum
Charger
Settings
Charging
Interval
12.6or
greater
100%16volts/7
amps
NoCharging
Required
12.4–12.675–100%16volts/7
amps
30Minutes
12.2–12.450–75%16volts/7
amps
1Hour
12.0–12.225–50%14.4volts/4
amps
2Hours
Voltage
Reading
Percent
Charge
Maximum
Charger
Settings
Charging
Interval
11.7–12.00–25%14.4volts/4
amps
3Hours
11.7orless0%14.4volts/2
amps
6Hoursor
More
CAUTION
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagementof
components.Sparkscouldcauseanexplosionor
movingpartscouldaccidentallyengagecausing
personalinjury.
Besureignitionswitchisinthe“OFF”position
beforechargingthebattery.
2.Connectthenegativebatterycable.
Note:Ifthepositivecableisalsodisconnected,
connectthepositive(red)cabletothepositive
batteryterminalrst,thenthenegative(black)cable
tothenegativebatteryterminal.Slipinsulatorboot
overthepositiveterminal.
Note:Iftimedoesnotpermitchargingthebattery,
orifchargingequipmentisnotavailable,connect
thenegativebatterycableandrunthevehicle
continuouslyfor20to30minutestosufciently
chargethebattery.
CheckingTirePressure
1.Checkthetirepressureinthedrivetires.Proper
inationfordrivetiresis12-16psi(83-110kPa).
2.Adjustthetirepressurewithin12-16psi(83-110
kPa)rangetomakethetirecircumferencesmatchas
closelyaspossible.
GreasingtheUnit
Note:Theunitisnotgreasedatthefactory.
1.LubricatettingswithNGLIgrade#2
multi-purposegungrease.Refertothefollowing
chartandFigure8forttinglocationsandinitial
pumps.
LubricationChart
Fitting
Locations
Initial
Pumps
Numberof
Places
Service
Interval
1.FrontCaster
WheelBearings
122Daily
2.FrontCaster
Pivots
22Daily
5

LubricationChart
Fitting
Locations
Initial
Pumps
Numberof
Places
Service
Interval
3.PTO
Engagement
Bellcrank
1140hours
4.PumpDrive
IdlerPivot
21Yearly
5.ClutchArm
Pivot
1140hours
6.PumpControl
Bearings
2240hours
7.MowerDeck
IdlerPivots
21Yearly
Number4(PumpDriveIdlerPivot)Locatedunder
theenginedeck.
Number5(ClutchArmPivot)Locatedunderthe
enginedeck.
Figure8
2.LubricatethepivotpointonPTOleverwithaspray
penetratinglubricant.
ServicingtheEngine
Theengineisshippedwithoil;checkoillevelandif
necessarylltotheappropriatelevel.Exmark4-Cycle
PremiumEngineOilisrecommended.Refertothe
EngineOwner’sManualforanacceptablealternative.
ServicingtheHydraulicOil
Themachineisshippedwithhydraulicoilinthe
reservoir.
1.Runthemachineforapproximately15minutesto
allowanyextraairtopurgeoutofthehydraulic
system.
2.Checkhydraulicreservoirandifnecessaryllthe
reservoirtotheappropriatelevelwithExmark
PremiumHydrooil.
3.Replacehydraulicreservoircapandtightenuntil
snug.DoNotovertighten.
Note:Thebafeislabeled“HOT”and“COLD”.
Theoillevelvarieswiththetemperatureoftheoil.
The“HOT”levelshowsthelevelofoilwhenitisat
225°F(107°C).The“COLD”levelshowsthelevelof
theoilwhenitisat75°F(24°C).Filltotheappropriate
leveldependinguponthetemperatureoftheoil.For
example:Iftheoilisabout150°F(65°C).Filltohalfway
betweenthe“HOT”and“COLD”levels.Iftheoilisat
roomtemperature(about75°F(24°C)),llonlytothe
“COLD”level.
FillingOuttheProduct
Registration
Fillouttheonlinewarrantyregistrationformandplace
keysintoliteraturepack.
6