Exmark 109-4173 Manual

Page 1 of 5
109-6457 Rev. A
Loose Parts
Note: Use the chart below to verify that all parts have been shipped.
109-4173 Dealer Pack
Part # Description Qty Use
103-1309 Warranty Registration Form 2 Fill out and return to Exmark
103-2106 Key 1 Unit ignition
1-633023
322-3
3256-23
1-805005
1-633349
3296-47
Stud, Fuel Tank
Screw, HH 5/16-18 x 3/4
Washer, 5/16 SAE
Washer, Lock 5/16 Heavy
Spring, Compression
Nut, Nyloc 5/16-18 Thin
2
2
4
2
2
2
Components to install fuel tank
323-6
98-5975
3290-357
Screw, HH 3/8-16 x 1
Washer, Spring Disk 3/8
Nut, Whizlock 3/8-16
4
4
4 Components to install handle assembly
1-806003
1-808280 Hairpin, Cotter Pin, Clevis 5/16 x 1 3 1 Components to install the speed control rod assembly
& to connect the lower end of the speed control linkage
3220-16
322-9
3296-29
Nut, Jam 3/8-24 LH
Screw, HH 5/16-18 x 1 3/4
Nut, Nyloc 5/16-18
2
2
2 Components to install drive lever linkages
1-303335
1-303287 Tie, Cable 7 15/16 (Large) Tie, Cable 5 1/2 (Small) 2 4 For fastening wiring harness to handle assembly
109-4175 Literature Pack
Part # Description Qty Use
------------
------------ Manual, Operator’s Manual, Parts 1 1 Read before operating machine
103-5466 Manual, Engine Operator’s 1 For units with 15HP Kawasaki engines
103-6371 Manual, Engine Operator’s 1 For units with 17HP Kawasaki engines
103-6374 Manual, Engine Operator’s 1 For units with 19HP Kawasaki engines
109-6435 Sheet, Emissions Warranty 1
TURF TRACER HP
SETUP INSTRUCTIONS
For Serial Nos. 670,000 and Highe
r

Page 2 of 5
109-6457 Rev. A
Uncrate Unit
1. Remove tractor and mower deck from their
crates.
Servicing the Battery
The machine is shipped with a filled lead acid
battery.
1. Remove battery cover from machine.
DANGER
POTENTIAL HAZARD
♦Charging the battery may produce explosive
gasses
WHAT CAN HAPPEN
♦Battery gasses can explode causing serious
injury.
HOW TO AVOID THE HAZARD
♦Keep sparks, flames, or cigarettes away from
battery.
♦Ventilate when charging or using battery in an
enclosed space.
♦Make sure venting path of battery is always
open once battery is filled with acid.
2. Check the voltage of the battery with a digital
voltmeter. Locate the voltage reading of the
battery in the table below and charge the battery
for the recommended time interval to bring the
charge up to a full charge of 12.6 volts or greater.
IMPORTANT: Make sure the negative battery
cables are disconnected and the battery charger
used for charging the battery has an output of 16
volts and 7 amps or less to avoid damaging the
battery (see chart below for recommended charger
settings).
Voltage
Reading Percent Charge
Maximum
Charger
Settings
Charging
Interval
12.6 or greater 100% 16 volts /
7 amps No Charging Required
12.4 – 12.6 75 – 100% 16 volts /
7 amps 30 Minutes
12.2 – 12.4 50 – 75% 16 volts /
7 amps 1 Hour
12.0 – 12.2 25 – 50% 14.4 volts /
4 amps 2 Hours
11.7 – 12.0 0 – 25% 14.4 volts /
4 amps 3 Hours
11.7 or less 0% 14.4 volts /
2 amps 6 Hours or More
CAUTION
POTENTIAL HAZARD
♦If the ignition is in the “ON” position there is
potential for sparks and engagement of
components.
WHAT CAN HAPPEN
♦Sparks could cause an explosion or moving
parts could accidentally engage causing
personal injury.
HOW TO AVOID THE HAZARD
♦Be sure ignition switch is in the “OFF” position
before charging the battery.
3. Connect the negative battery cables.
NOTE: If the positive cable is also disconnected,
connect the positive (red) cable to the positive
battery terminal first, then the negative (black)
cable and green/white wire to the negative battery
terminal. Slip insulator boot over the positive
terminal.
NOTE: If time does not permit charging the
battery, or if charging equipment is not available,
connect the negative battery cables and run the
vehicle continuously for 20 to 30 minutes to
sufficiently charge the battery.
Checking Tire Air Pressure
1. Check the air pressure in the drive tires. Proper
inflation for drive tires is 12-16 psi (83-110 kPa).
2. Adjust the tire pressure within 12-16 psi
(83-110 kPa) range to make the tire
circumferences match as closely as possible.
3. The front caster tires are semi-pneumatic. No
adjustment is necessary.
Installing the Fuel Tank
1. Apply retaining adhesive “Fel-Pro ProLock
Retaining I or Retaining II” or “Loctite RC 609 or
680” on the two threaded studs from the bolt bag
and install into the two left holes underneath fuel
tank. Install the fuel tank on top of the fuel tank
support with the studs going through the slots in
the support.
2. Install two 5/16 x 3/4 screws with a 5/16 SAE flat
washer and 5/16 lock washer into the threaded
holes in the right side of the fuel tank. Do not
over tighten.
3. Place a 5/16 SAE flat washer, then a spring,
over each of the studs and fasten with a 5/16
nyloc nut. Tighten 5/16 nyloc nut fully then back
WARNING: Battery posts, terminals, and related
accessories contain lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.

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109-6457 Rev. A
Align Bolt to
Indicator
within 1/16”
Indicator
Turnbuckle
Engine Deck
off a 1/2 turn. This is to allow for normal fuel tank
expansion and contraction with changes in
temperature and fuel levels. Do not over
tighten.
4. Attach the fuel tank hose to the tank fitting and
secure with the clamp provided.
Installing the Handle Assembly
1. Position the lower end of the handle assembly on
the outside of the upper rear section of the fuel
tank and handle support. Install four 3/8-16 x 1
bolts (with four spring disk washers against the
head of each bolt) from the outside in. Secure
using four 3/8 whizlock nuts on the inside of each
handle support and tighten until the spring disk
washers are flat (See Figure 1).
FIGURE 1
Attaching Throttle Cable
1. Route the throttle cable along the right side of the
upper handle, under the fuel tank support, and
position the cable on the left side of the engine.
2. Position the throttle control lever (located on
console) in the full throttle position. You will feel
a detent when the throttle lever is pushed
towards the upper end of the slot.
3. Attach inner wire of the throttle cable to the top
hole in the throttle control lever (See Figure 2).
4. Loosen the clamp, place the cable behind it, and
pull on the cable to move the throttle linkage to
the full throttle position. Tighten the cable clamp
screw.
FIGURE 2
Connecting PTO Engagement
Linkage
1. Loosen jam nut and remove turnbuckle from
lower linkage (See Figure 3).
2. Screw turnbuckle onto both upper and lower
linkages simultaneously. Note that threads on
upper linkage are left hand.
NOTE: Handles have the drive lever linkage on
the inside of the blade engagement lever tab
and the hairpin on the outside.
FIGURE 3
Adjusting PTO Engagement
Linkage
1. With PTO engaged, adjust the linkage length by
loosening the locknut on the turnbuckle and
adjusting the turnbuckle so that the bolt on the
bellcrank and the indicator arm align with each
other within 1/16” (.16 cm) (See Figure 4).
Tighten locknut against turnbuckle.
FIGURE 4
Installing Speed Control Rod
Assembly
1. Install the speed control rod assembly (linkage
with the yoke installed on one end) into the end
of the speed control lever located underneath
the center of the console.
2. Insert the end of the linkage (opposite the yoke)
into the end of the speed control lever from the
right hand side and fasten with a hairpin from
the bolt bag.

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109-6457 Rev. A
Connecting Speed Control Linkage
1. Connect the lower end of the speed control
linkage to the speed control crank located at the
top rear of the fuel tank support. Secure with
clevis pin and hairpin from the bolt bag.
Installing Drive Lever Linkages
1. Position the speed control lever in neutral.
Position the drive levers in neutral and engage
the neutral lock latches.
2. Thread a 3/8-24 LH jam nut, from the bolt bag,
onto the lower end of each drive lever linkage.
Drive lever linkages are shipped with upper ball
joints installed (See Figure 5).
3. Identify the lower ball joints installed on hydro
control arm weldments. Thread lower end of
each drive lever linkage into the lower ball joint
until hole in upper ball joint aligns with hole in
drive lever.
4. Install 5/16-18 x 1 3/4 hex cap screws and 5/16-
18 nyloc nuts from the bolt bag and tighten.
FIGURE 5
Adjusting Drive Lever Linkage
1. Raise rear of machine off of the ground.
CAUTION
POTENTIAL HAZARD
♦Raising the rear of the unit for assembly 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
equivalent support.
2. With rear of machine on jack stands and engine
running at full throttle, disengage the park brake
and 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 6). If
the tire rotates in either direction, the length of
the drive lever link will need to be adjusted.
3. Adjust the linkage length by loosening the jam
nuts at both ends of the linkage and rotating the
linkage in the ball joints. Lengthen the linkage if
the tire is turning in reverse and shorten the
linkage if the tire is creeping forward. Tighten
the jam nuts at both ends. Release and re-
engage the neutral lock latch checking that the
tire stops. Continue this process until the tire is
at a dead stop.
FIGURE 6
4. Make this adjustment for both sides.
Connecting Wire Harness
For recoil start models:
1. Route the long unattached portion of the wiring
harness up the left handle and under the
console. Connect the connector on the end of
the shorter lead to the key switch. Connect the

Page 5 of 5
109-6457 Rev. A
two flag terminals that are in the longer lead to
the OPC switch in any order.
2. Continue routing this lead down the right side of
the handle and connect the connector on the end
to the park brake switch.
3. Fasten the harness to the left hand side of the
handle using two large ties from the bolt bag.
Fasten the harness to the right hand side of the
handle using two small ties from the bolt bag. On
ECS models fasten the harness to the two small
holes in the channel under the console using two
small ties from the bolt bag.
For electric start models:
1. Route the long unattached portion of the wiring
harness up the left handle and under the console.
Connect the two flag terminals to the OPC switch
in any order. Connect the connector to the key
switch.
2. Fasten the harness to the left hand side of the
handle using two large ties from the bolt bag. On
ECS models fasten the leads connecting to the
OPC switch to the small hole in the channel
under the console using a small tie from the bolt
bag.
Positioning the Discharge Chute
1. Loosen the two (2) 5/16 nyloc nuts attaching
discharge chute. Lower the discharge chute into
position. Retighten nyloc nuts until chute is snug
but can pivot freely.
Servicing the Engine
Refer to Engine Owner’s Manual.
Servicing the Hydraulic Oil
The machine is shipped with hydraulic oil in the
reservoir.
1. Run the machine for approximately 15 minutes to
allow any extra air to purge out of the hydraulic
system.
2. Check hydraulic reservoir and if necessary fill
the reservoir to the appropriate level with Mobil 1
15W-50 synthetic motor oil.
3. 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” level shows the level of oil when
it is at 225°F (107°C). The “COLD” level shows
the level of the oil when it is at 75°F (24°C). Fill
to the appropriate level depending upon the
temperature of the oil. For example: If the oil is
about 150°F (65°C), fill to halfway between the
“HOT” and “COLD” levels. If the oil is at room
temperature (about 75°F (24°C)), fill only to the
“COLD” level.
Grease Unit
NOTE: Unit is not greased at the factory.
1. Lubricate fittings with NGLI grade #2 multi-
purpose gun grease.
Refer to the following chart for fitting locations
and initial pumps.
GREASE LUBRICATION CHART
No. 4 (Idler Pivot)
Located Under Engine Deck
No. 5 (Clutch Arm Pivot)
Located Under Engine Deck
2. Lubricate the pivot point on pto lever with a
spray penetrating lubricant.
FITTING
LOCATIONS INITIAL PUMPS
1. Caster Wheel Bearings 12
2. Caster Pivots 2
3. PTO Engagement Bellcrank 1
4. Idler Pivot (Pump Drive) 2
5. Clutch Arm Pivot 1
6. Mower Deck Idler Pivots 2
7. Pump Control Bearings 2