Exmark Turf tracer HP Manual

TURFTRACER®HP
SetupInstructions
ForSerialNos.850,000&Higher
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer
extranet.
DealerPack
Part#DescriptionQty.Use
1-633023Stud,FuelTank2
322-3Screw,HH5/16-18x3/4inch2
3256-23Washer,5/16inchSAE4
1-805005Washer,Lock5/16inchHeavy2
1-633349Spring,Compression2
3296-47Nut,Nyloc5/16-18inchThin2
Installingthefueltank.
107-4543Clamp,Tank2
322-10Screw,HH5/16-18x22
3256-3Washer,5/16Std2
104-8300Nut,Nyloc5/16-18Flg2
InstallingtheCAUnitfueltank
323-6Screw,HH3/8-16x1inch4
3290-357Nut,Whizlock3/8-16inch4
98–5975Washer,SpringDisc4
Installingthehandleassembly.
1-806003Hairpin,Cotter2
1-808280Pin,Clevis1Installingthespeedcontrolrod.
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
formandplacethekeysintoliterature
pack.
LiteraturePack
Part#DescriptionQty.Use
—Manual,Operator’s1Readbeforeoperatingthemachine.
—Manual,EngineOperator’s1Readbeforeoperatingthemachine.
UncratingtheUnit
1.Leavingtheunitonthepallet,placetheupperhandle
assemblyandthefueltankattherearofthemachine.
2.Removetheboltbagfromunderthemowerdeck
beltshield.
3.Refertothepartsmanualtohelpyouidentifyand
locatethepartsandtheirproperposition.
©2010—ExmarkMfg.Co.,Inc.
P .O.Box808
Beatrice,NE68310
PartNo.4500-637Rev.A
PrintedintheUSA
AllRightsReserved

InstallingtheFuelTank
1.Applyretainingadhesive“Fel-ProProLockRetaining
IorRetainingII”or“LoctiteRC609or680”onthe
twothreadedstudsfromtheboltbagandinstallinto
thetwoleftholesunderneathfueltank.Installthe
fueltankontopofthefueltanksupportwiththe
studsgoingthroughtheslotsinthesupport.
2.Installtwo5/16x3/4inchscrewswitha5/16inch
SAEatwasherand5/16inchlockwasherintothe
threadedholesintherightsideofthefueltank.Do
Notovertighten.
3.Placea5/16inchSAEatwasher,thenaspring,
overeachofthestudsandfastenwitha5/16inch
nylocnut.Tighten5/16inchnylocnutfullythen
backoffa1/2turn.Thisistoallowfornormal
fueltankexpansionandcontractionwithchangesin
temperatureandfuellevels.Donotovertighten.
4.Attachthefueltankhosetothetankttingand
securewiththeclampprovided.
InstallingtheFuelTank(CAUnits
Only)
1.Installthefueltankontopofthefueltanksupport.
Secureeachsideofthetankwithaclamp,5/16-18x
2screw,washer,and5/16nylocnut.
2.Attachthepurgehosefromthecanistertothetop
ttingofthefueltankasshowninFigure1.
Figure1
1.Attachpurgehosefromcanistertotoptting
3.Attachthefueltankhosetothetankttingand
securewiththeclampprovided.
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.Attachtheinnerwireofthethrottlecabletothe
topholeinthethrottlecontrolleverasshownin
Figure3.
4.Loosentheclamp,installthethrottlecableonthe
bottomsideoftheclamp,andpullonthecableto
movethethrottlelinkagetothefullthrottleposition.
Tightenthecableclampscrew .
2

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.
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.
3

2.Inserttheendofthelinkageoppositetheyoke
intotheendofthespeedcontrolleverlocated
underneaththehandleconsolefromtherighthand
sideandfastenwithahairpinfromtheboltbag.
3.Connectthelowerendofthespeedcontrollinkage
tothespeedcontrolcranklocatedatthetoprearof
thefueltanksupport.Securewithaclevispinand
hairpin.
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.
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
4

eitherdirection,thelengthofthedriveleverlinkwill
needtobeadjusted.
3.Adjustthelinkagelengthbylooseningthejamnuts
atbothendsofthelinkageandrotatingthelinkage
intheballjoints.Lengthenthelinkageifthetireis
turninginreverseandshortenthelinkageifthetire
iscreepingforward.Tightenthejamnutsatboth
ends.Releaseandre-engagetheneutrallocklatch
checkingthatthetirestops.Continuethisprocess
untilthetirenolongerrotates.
Figure7
4.Makethisadjustmentforbothsides.
ConnectingWireHarness
Forrecoilstartmodels:
1.Routethelong,unattachedwiringharnesslead
upthelefthandsideofthehandleandunderthe
console.
2.Connecttheconnectorontheendoftheshorter
leadtothekeyswitch.
3.ConnectthetwoagterminalstotheOPCswitch
inanyorder.
4.Continueroutingthisleaddowntherightsideofthe
handleandconnecttheconnectorontheendtothe
parkbrakeswitch.
5.Fastentheharnesstotheleftsideofhandlewithtwo
largeplastictiesfromtheboltbag.
6.Fastentheharnesstotherighthandsideofthe
handleusingtwosmalltiesfromtheboltbag.
7.Fastentheharnesstothetwosmallholesinthe
channelundertheconsoleusingtwosmalltiesfrom
theboltbag.
Forelectricstartmodels:
1.Routethelong,unattachedwiringharnesslead
upthelefthandsideofthehandleandunderthe
console.
2.ConnectthetwoagterminalstotheOPCswitch
inanyorder.
3.Connecttheconnectortothekeyswitch.
4.Fastentheharnesstotheleftsideofhandlewithtwo
largeplastictiesfromtheboltbag.
5.FastentheleadsconnectingtotheOPCswitchto
thesmallholeinthechannelundertheconsoleusing
asmalltiefromtheboltbag.
ServicingtheBattery
WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
Important:Themachineisshippedwithalled
leadacidbattery.
DANGER
Chargingorjumpstartingthebatterymayproduce
explosivegases.Batterygasescanexplodecausing
seriousinjury.
•Keepsparks,ames,orcigarettesawayfrom
battery.
•Ventilatewhenchargingorusingbatteryinan
enclosedspace.
•Makesureventingpathofbatteryisalwaysopen
oncebatteryislledwithacid.
•Alwaysshieldeyesandfacefrombattery.
5

DANGER
Batteryelectrolytecontainssulfuricacid,whichis
poisonousandcancausesevereburns.Swallowing
electrolytecanbefatalorifittouchesskincan
causesevereburns.
•Wearsafetyglassestoshieldeyes,andrubber
glovestoprotectskinandclothingwhen
handlingelectrolyte.
•DoNotswallowelectrolyte.
•Intheeventofanaccident,ushwithwaterand
calladoctorimmediately.
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
11.7–12.00–25%14.4volts/4
amps
3Hours
11.7orless0%14.4volts/2
amps
6Hoursor
More
CAUTION
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagementof
components.Sparkscouldcauseanexplosion
ormovingpartscouldaccidentallyengage
causingpersonalinjury
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#2multi-purpose
gungrease.RefertothefollowingchartandFigure8
forttinglocationsandinitialpumps.
LubricationChart
Fitting
Locations
Initial
Pumps
Numberof
Places
Service
Interval
1.FrontCaster
WheelBearings
122Daily
2.FrontCaster
Pivots
22Daily
3.PTO
Engagement
Bellcrank
1140hours
4.PumpDrive
IdlerPivot
21Yearly
5.ClutchArm
Pivot
1140hours
6

LubricationChart
Fitting
Locations
Initial
Pumps
Numberof
Places
Service
Interval
6.PumpControl
Bearings
2240hours
7.MowerDeck
IdlerPivots
21Yearly
Number4(PumpDriveIdlerPivot)Locatedunder
theenginedeck.
Number5(ClutchArmPivot)Locatedunderthe
enginedeck.
Figure8
2.LubricatethepivotpointonPTOleverwithaspray
penetratinglubricant.
ServicingtheEngine
RefertoEngineOwner’sManual.
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.
7