For Turf Tracer Serial Nos. 510,000 & Higher and FMD524 & FMD604 Serial Nos. 510,000 & Higher Part No.
WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system) in place and in proper working condition. ♦ Stop engine and wait for all moving parts to stop. Remove spark plug wire(s) or remove key before adjusting, servicing, or performing maintenance.
EXMARK PARTS PLUS® PROGRAM EFFECTIVE DATE: September 1, 1995 Program If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!! How the Program Works 1. If dealer does not have part in stock for a "down" unit at the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus® shipment of six (6) line items or less. 2.
CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
TABLE OF CONTENTS 1. SAFETY .............................................................................................PAGE 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Safety Alert Symbol...................................................................................... 1 Training ........................................................................................................ 1 Preparation................................................................................................ 1-3 Operation ...........
1. SAFETY 1.1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents. This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER, WARNING, or CAUTION. DANGER: White lettering / Red background.
1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison. WHAT CAN HAPPEN ♦ Carbon monoxide can kill you. HOW TO AVOID THE HAZARD ♦ Do not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect.
DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite gasoline vapors. A fire or explosion from gasoline can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD ♦ Purchase and store gasoline only in an approved container. ♦ Always place gasoline containers on the ground away from your vehicle before filling.
1.4 OPERATION Although hazard control and accident prevention are partially dependent upon the design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the equipment. It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing.
DANGER POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can cause sliding and loss of control. WHAT CAN HAPPEN ♦ Loss of control and/or loss of operator’s footing could result in a fall with an arm or leg getting under the mower or engine deck, which may result in serious injury or death. HOW TO AVOID THE HAZARD ♦ Mow across slopes, never up and down. ♦ Do not mow slopes when grass is wet. ♦ Do not mow near drop-offs or near water. ♦ Do not mow slopes greater than 20 degrees.
1.4.13 Stop the engine and wait for all moving parts to stop: • Before removing grass catcher. • Before refueling. • Before making height adjustments. 1.4.14 Before stopping the engine, place the throttle control midway between the “slow” and “fast” positions. Allow the engine to run a minimum of 15 seconds, then stop the engine. 1.4.15 The fuel system is provided with a shut-off valve. The fuel shut-off valve is used to shut off the fuel: • When the machine will not be used for a few days.
1.5.7 Gasoline powered equipment or fuel containers should not be stored in a basement or any enclosed area where open pilot lights or heat appliances are present. 1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly. 1.5.9 Check all bolts frequently to maintain proper tightness. 1.5.10 Keep all guards, shields, and all safety devices in place and in safe working condition. 1.5.
PART NO. 103-2242 LOCATION: LH Side of Console PART NO. 103-1541 LOCATION: Console PART NO. 103-2243 LOCATION: RH Side of Console PART NO. 1-303517 LOCATION: LH Side of Rear Surface of Engine Deck For FMD524 & FMD604 Units with SN 540,000 & Higher PART NO. 103-7491 LOCATION: On Top Front RH Surface of Mower Deck PART NO. 1-303508 LOCATION: On Top RH Surface of Mower Deck Type A Anti-Scalp Rollers Only – See Figure 9 PART NO. 1-323540 LOCATION: Front of Mower Deck Top Surface PART NO.
PART NO. 1-413214 LOCATION: Right Side of Hydro Control Crank Arm PART NO. 1-403143 LOCATION: RH Rear Surface of Engine Deck PART NO. 1-513747 LOCATION: Top Rear of Battery Cover PART NO. 103-2432 LOCATION: Parking Brake Lever PART NO. 103-4935 LOCATION: Left Rear Top Corner of Engine Deck PART NO. 1-553049 LOCATION: On Top Front LH Surface of Mower Deck PART NO. 103-2239 LOCATION: Top of Mower Deck Beneath Center Shield For FMD524 & FMD604 Units with SN 410,000 – 439,999 PART NO.
2. SPECIFICATIONS 2.1 MODEL NUMBER: TT23KCC; TT23KAC; TT20KCC 2.2 ENGINE 2.2.1 Engine Specifications: See your Engine Owner's Manual. 2.2.2 3600 RPM (No Load). 2.3 FUEL SYSTEM 2.3.1 2.3.2 2.3.3 2.3.4 Capacity: 5.0 gal. (18.9 L.) Type of Fuel: Regular unleaded gasoline, 87 octane or higher. In countries using the research method, it should be a 90 octane minimum. Fuel Filter: Replaceable in-line Fuel Shut-Off Valve: 1/4 turn 2.4 ELECTRICAL SYSTEM: 2.4.1 Charging System: Flywheel Alternator 2.4.
2.8 TIRES Drive Front Caster Size .......................... 18 x 8.50-8 ..........................11 x 4.0-5 Quantity ............................ 2 ........................................ 2 Tread ........................ Turf Master ........................... Smooth Ply Rating ......................... 4 ........................................ 4 Pressure ................ 14 psi (90 kPa) ................. 16 psi (152 kPa) 2.9 MOWER DECK 2.9.1 2.9.2 2.9.3 2.9.4 2.9.5 2.9.6 2.9.7 2.9.8 2.9.
3. ASSEMBLY INSTRUCTIONS 3.1 UNCRATE UNIT 3.1.1 Remove tractor and mower deck from crates. 3.2 SERVICE BATTERY: WARNING: Battery posts, terminals, and related accessories contain lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash The machine is shipped with a filled lead-acid battery. 3.2.1 Remove battery cover from machine.
NOTE: If the positive cable is also disconnected, connect the positive (red) cable first, then the negative (black) cable. 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. 3.4 DRIVE WHEELS 3.4.1 Check air pressure in drive tires; recommended pressure is 12-16 psi.
FIGURE 1 SUPPORT PIN LOCATION 3.5.5 Mower Deck Stationary Idler Installation: Locate the two holes along the back center section of the deck and install the stationary idler and related parts (from bolt bag) in the right hand hole. See Figure 2. Be sure the coned end of the disc spring washer is against the head of the bolt. Tighten hardware. 3/8-16 x 4 1/2 HEX CAPSCREW 3.5.6 3.5.7 FIGURE 2 STATIONARY IDLER INSTALLATION Install the deck drive belt around the clutch. Refer to belt routing decal.
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. 3.
FIGURE 3 DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION 4.1.4 PTO Engagement: Switch is located on left side of control console. The switch must be pulled out to the ”Rotate” position to engage the blades. The switch is pushed in to the “Stop” position to stop the blades. Operator must have operator presence control levers depressed when PTO is engaged or engine will stop. 4.1.5 Choke Control: Located on the control console right hand side. Choke is used to aid in starting a cold engine.
4.1.11 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 reset the drive system. Do Not over tighten. 4.1.12 Tracking Adjustment Knob: Located on the right-hand side of the rear of the fuel tank support.
4.3.2 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 valve when machine will not be used for a few days, when transporting, and when the unit is parked inside a building. 4.3.
4.3.4 Drive Wheel Engagement/Turning: With drive levers locked in “neutral”, shift speed control lever to desired forward speed. Slowly squeeze and hold both drive levers in the neutral position and rotate both neutral lock latches from the neutral lock position to 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.
4.4 TRANSPORTING WARNING POTENTIAL HAZARD ♦ Loading the mower onto a trailer without strong enough or properly supported ramps could be dangerous. WHAT CAN HAPPEN ♦ The ramps could collapse causing the unit to fall, which could cause injury. HOW TO AVOID THE HAZARD ♦ Use proper ramps that are secured to the truck or trailer. ♦ Keep feet and legs out from under the unit when loading and unloading. ♦ If necessary, use assistance when loading. Be sure the fuel shut-off valve is closed.
5.1 PERIODIC MAINTENANCE 5.1.1 Check engine oil level. Service Interval: See Engine Owner's Manual a) Stop engine, wait for all moving parts to stop and make sure unit is on a level surface. b) Check with engine cool. c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick. DO NOT screw into place. Remove dipstick and check oil level.
5.1.4 Check mower blades. Service Interval: Daily a) Stop engine, wait for all moving parts to stop, and remove key. b) Lift deck and secure in raised position as stated in Section 5.1.3. c) Inspect blades and sharpen or replace as required. For Serial Nos. 510,000 – 539,999: d) Re-install the blades (if they were removed) by placing a block of wood between the front or rear baffles and the blade then torquing the blade bolts to 115-120 ft. lbs. (156-163 N-m).
FIGURE 6 BLADE BOLT INSTALLATION IMPORTANT: DO NOT use components other than the original blade, blade bushing, spring disc washer, and blade bolt supplied with the unit. Failure to use all original components and assembled as shown will increase the risk of a blade bolt becoming loose or weak after striking a foreign object. CAUTION POTENTIAL HAZARD ♦ Operating a mower deck with loose or weakened blade bolts can be dangerous.
c) If machine does not pass any of these tests, DO NOT operate. Contact your authorized EXMARK SERVICE DEALER. IMPORTANT: It is essential that all Operator Safety Mechanisms, be in place and in proper operating condition prior to mowing. 5.1.6 Check for loose hardware. Service Interval: Daily 5.1.7 a) Stop engine, wait for all moving parts to stop, and remove key. b) Visually inspect machine for any loose hardware or any other possible problem.
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 12.
f) Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground. Run machine to allow any other air to be purged from the hydraulic system and recheck the oil level. g) If either drive wheel does not rotate, one or both of the charge pumps (located on the top of the main pump as shown in Figure 7) may have lost their “prime”. Refer to Section 5.1.12.
f) 5.1.13 5.1.14 5.1.15 If either drive wheel still does not rotate, stop and repeat steps (d) and (e) above for the respective pump. If wheels rotate slowly, the system may prime after additional running. Check oil level as stated in Section 5.1.10. g) Allow unit to run several minutes after the charge pumps are “primed” with drive system in the full speed position. Check oil level as stated in Section 5.1.10. h) Check hydro drive linkage adjustment as stated in Section 5.2.5. Check tire pressures.
c) Lubricate front caster pivots once a year. Remove hex plug and cap. Thread grease zerk in hole and pump with grease until it oozes out around top bearing. Remove grease zerk and thread plug back in. Place cap back on. 5.1.16 Lubricate caster wheel hubs: Service Interval: Once Yearly a) b) c) d) e) f) g) h) i) h) i) Stop engine, wait for all moving parts to stop, and remove key. Remove caster wheel from caster forks. Remove seal guards from the wheel hub.
5.1.19 b) Remove cooling shroud cleanout covers (Kohler) or cooling shrouds (Kawasaki) from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine which can cause improper cooling. c) Make sure cooling shroud cleanout covers or cooling shrouds are properly reinstalled. Operating the engine without cooling shroud cleanout covers or cooling shrouds will cause engine damage due to overheating. Change fuel filter.
5.2 ADJUSTMENTS IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop, and remove key before servicing, cleaning, or making adjustments to the unit. 5.2.1 Cutting height and anti-scalp roller adjustment. CAUTION POTENTIAL HAZARD ♦ When mower deck is not 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.
c) 5.2.2 5.2.3 5.2.4 5.2.5 Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of the positions shown in Figure 10. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize gouging and roller wear or damage. For Maximum Deck Flotation, place rollers one hole position lower. Rollers should maintain 1/4 in. (6.4 mm) clearance to ground. Do Not adjust rollers to support the deck.
b) FIGURE 11 NEUTRAL SAFETY SWITCH ADJUSTMENT 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” position as shown in Figure 4 and move the speed control lever to the “mid-speed” position.
c) 7. After adjustments are made and the wheels stop when the drive lever is in the neutral position, tighten the nut against the yokes. 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.
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 reengage the neutral lock checking that the tire stops. Continue this process until the tire is at a dead stop. FIGURE 14 DRIVE LEVER AND LATCH IN NEUTRAL POSITION e) 5.2.6 5.2.7 3. Make this adjustment for both sides. Tracking Adjustment 1. Stop engine and wait for all moving parts to stop.
5.2.8 5.2.9 FIGURE 16 THROTTLE TENSION Electric Clutch Adjustment No adjustment necessary. Park Brake Adjustment: a) Shut off engine and wait for all moving parts to stop. b) Disengage the park brake. c) Remove the hairpin in the park brake linkage. Turn the linkage in the yoke until there is 3/16” (.48 cm) to 1/4” (.64 cm) clearance between the park brake tire bars and the tires with the park brake disengaged. Re-install the hairpin. 6. WASTE DISPOSAL 6.
7.2 MOWER CUTS UNEVENLY. a) Check the drive tire pressures and tire circumferences. See 5.1.13. 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 Section 5.2.1. c) Check deck support alignment and check mounting brackets to be sure all bolts are tight. d) Check blades tip to tip for straightness.
ENGINE TROUBLESHOOTING TABLE PROBLEM NO FUEL Will not start X Hard starting X Stops suddenly X IMPROPER FUEL X DIRT IN FUEL LINE DIRTY AIR FILTER FAULTY SPARK PLUG ENGINE OVERLOADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN X X X X X X X X X X X X X X X X X X Lacks power X X X X X X Operates erratically X X X X X X Knocks or pings X Skips or misfires X X X X X Backfires X X X Overheats X X High fuel consumption X X - 37 - X X
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10. 2-Year Limited Warranty Exmark Turf Equipment (For units purchased on or after October 1, 2004) Conditions and Products Covered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part manufactured by Exmark and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship for a period of two years.
SERVICE RECORD Date Description of Work Done - 40 - Service Done By
ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) S THI S IS THIS I A2 0 ° S L OP E E SLOPE 10° SL OPE A 15 ° SL OP THIS IS A THIS IS A 5° FOLD ALONG APPROPRIATE LINE EXAMPLE: COMPARE SLOPE WITH FOLDED EDGE.
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT MICRO-MULCH SYSTEM ROLL OVER PROTECTION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONTAINER TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO-MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER Check us out on the Web: www.exmark.
