Exmark Turf Tracer TT18KC, Turf Tracer TT22KC, Turf Tracer TT19KA, Turf Tracer TT23KC Operator's Manual

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
WARNING
IMPORTANT
POTENTIAL HAZARD This product is a piece of power equipment.
WHAT CAN HAPPEN Failure to follow safe operating pr actices 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 condit ion.
Stop engine and remove spark plug wire(s) or r emove key and
wait for all moving parts to stop before adjusting, servicing, or performing maintenance.
If mower deck becomes clogged, stop engine and remove spark
plug wire(s) or remove key and wait for all m oving par ts to stop before cleaning blockage.
Keep hands, feet and clothing away from power driven parts. Keep off mower unless seat platf o r m is pr ovided. Keep others off mower.
WARNING
WARNING
POTENTIAL HAZARD Gasoline is harmful or f at a l if swallowed. Long-term exposure to
vapors has caused cancer in laboratory animals.
WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness.
HOW TO AVOID THE HAZARD
Avoid prolonged breathing of vapors. Keep face away from nozzle and gas tank/container opening. Keep away from eyes and skin. Never siphon by mouth.
Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously. Exmark, or its distributors and dealers, accept not responsibility for variations which may be evident in the actual
specifications of its products and the statements and descriptions contained in this publication
.
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. Distributor ships part(s) to dealer or customer, as requested by dealer, same day, overnight UPS Distributor bills dealer for part and freight charges where applicable.
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus central time, with an Exmark Parts Plus

order of six (6) line items or less.

order, he contacts Exmark by 3:00 p.m.,
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by distributor, same day, overnight UPS Exmark bills the distributor for parts and shipping charges, where applicable.
5. The customer pays for the part and freight
if it is shipped under the Exmark Parts Plus

and if it arrives in
accordance to the program.
6. Who pays for the part and freight
if it fails to arrive overnight in accordance to the program? A. Under any circumstance the customer does not pay. B. If the part does not arrive overnight due to:

1. The dealer not submitting the Exmark Parts Plus
order to his Exmark distributor by 1:00 p.m., the dealer
pays for the part and freight.
2. The Distributor being unable to ship the part the same day or not submitting 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 restrictions apply
-- The Exmark Parts Plus

Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is only available in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus must be six (6) line items or less. Exclusions from the Exmark Parts Plus

orders must be received by Exmark by 3:00 p.m., central time. Orders

Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
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CONGRATULATIONS
on the purchase of your Exmark Mower. This product has been carefully designed and manufactur ed to give you a maximum amount of dependability and years of trouble-free oper at ion.
OPERATOR'S MANUAL
This manual contains assembly, operating, m aint enance, adjustment and safety
instructions for your Exmark m ower.
READ THIS MANUAL IN ITS ENTIRETY.
instructions, you will prolong the life of your mower, maintain its maximum eff iciency 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 distribut or s 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 stations. They carry ample stock of ser vice parts or can secur e t hem promptly for you from the factor y.
All Exmark parts are thoroug hly test ed and inspect ed before leaving the factory, however, attention is required on your part if you are t o obt ain the fullest measure of satisfaction and performance.
BEFORE OPERATING YOUR MOWER, CAREFULLY
By following the operating, maintenance and safety
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TABLE OF CONTENTS
1. SAFETY.............................................................................................PAGE
1.1 Safety Alert Symbol......................................................................................1
1.2 Training ........................................................................................................1
1.3 Preparation..............................................................................................1 - 3
1.4 Operation.................................................................................................3 - 4
1.5 Maintenance & Storage........................................................................... 4 - 5
1.6 Riding Attachments....................................................................................... 5
1.7 Safety Signs ....................................................................................... ....5 - 7
2. SPECIFICATIONS
2.1 Model Number..............................................................................................8
2.2 Engine..........................................................................................................8
2.3 Fuel System..................................................................................................8
2.4 Electrical System..........................................................................................8
2.5 Steering/Brake Control .................................................................................8
2.6 Transmission................................................................................................ 8
2.7 Wheel Drive System.....................................................................................8
2.8 Tires .............................................................................................................9
2.9 Deck.............................................................................................................9
2.10 Dimensions..................................................................................................9
2.11 Torque Requirements................................................................................10
3. ASSEMBLY INSTRUCTIONS
3.1 to 3.10 Assembly................................................................................. 10 - 13
4. OPERATION INSTRUCTIONS
4.1 Controls...............................................................................................13 - 15
4.2 Pre-Start..............................................................................................15 - 17
4.3 Operation Instructions..........................................................................17 - 18
4.4 Transporting ...............................................................................................19
5. MAINTENANCE & ADJUSTMENTS
5.1 Periodic Maintenance ..........................................................................19 - 26
5.2 Adjustments.........................................................................................26 - 30
6. TROUBLE SHOOTING
6.1 Mower Tacks Left or Right..........................................................................30
6.2 Mower Cuts Unevenly.................................................................................30
6.3 Engine Will Not Start ...........................................................................30 - 31
7. HYDRAULIC SCHEMATIC
8. WIRING DIAGRAMS
.....................................................................................33
...........................................................................32
.
9
WARRANTY
.............................................................................................34 - 35
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1.SAFETY
1.1 SAFETY ALERT SYMBOL
THIS SAFETY ALERT SYMBOL
THE MACHINE TO IDENTIFY IMPORTANT SAFETY MESSAGES WHICH MUST BE
FOLLOWED TO AVOID ACCIDENTS. THIS SYMBOL MEANS:
IS USED BOTH IN THIS MANUAL AND ON
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
The safety alert symbol appears above information which alerts you of unsafe actions or
situations and will be followed by the word
When used with t he word DANGER: IT DENOTES THAT AN EXTREME HAZARD
ISTS WHICH WOULD RESULT IN HIGH PROBABILITY OF DEATH OR
EX
IRREPARABLE INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.
When used with t he word WARNING: IT DENOTES THAT A HAZARD EXISTS WHICH
CAN RESULT IN INJURY OR DEATH IF PROPER PRECAUTIONS ARE NOT TAKEN.
When used with t he word CAUTION: IT DENOTES A REMINDER OF SAFETY
PRACTICES OR DIRECTS ATTENTION TO UNSAFE PRACTICES WHICH COULD
RESULT IN PERSONAL INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.
DANGER, WARNING
1.2 TRAINING
1.2.1 Regard the Exmark mower as a piece of power equipm ent and t each this regard to all who operate this unit.
1.2.2 Read the instructions carefully. Familiarize yourself with the cont r ols and the proper use of the equipment.
1.2.3 Never allow children, teenagers, or people unfamiliar with these inst r u ct ions t o use the mower.
1.2.4 Avoid mowing while people, especially children or pets, are nearby. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.
CAUTION.
, or
1.3 PREPARATION
1.3.1 The use of personal protective equipment , such as (but not limited to) protection for the eyes, ears, feet and head is r ecom m ended.
1.3.2 While mowing, always wear substantial footwear and long trousers. Do not operate equipment when barefoot or when wearing open sandals.
1.3.3 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones and other f or eign objects which may damage the equipment or cause personal injury to the operat or or bystander s.
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POTENTIAL HAZARD Engine exhaust contains carbon monoxide, which is
an odorless deadly poison.
WHAT CAN HAPPEN Carbon monoxide can kill you and is also known to the
State of California t o cause birth defects.
HOW TO AVOID THE HAZARD Do not run engine indoors or in a small confined area
where dangerous carbon monoxide fumes can collect.
WARNING
POTENTIAL HAZARD In certain conditions gasoline is extremely flammable
and highly explosive.
WHAT CAN HAPPEN A fire or explosion from gasoline can bur n you, ot hers,
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 m ay be ignited by spark.
Refuel only in a well ventilated area, or refuel
outdoors.
Store gasoline in an approved container and keep it
out of the reach of children.
Add fuel before start ing the engine. Never remove the
cap of the fuel tank or add fuel when engine is running or when the engine is hot.
Never fill the fuel tank so that the gasoline level rises
above a level that is 1/2” below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage.
If fuel is spilled, DO NOT attempt to start the engine.
Move away from the area of the spill and avoid creating any source of ignition unt il fuel vapors have dissipated.
DANGER
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POTENTIAL HAZARD In certain conditions gasoline is extremely flammable
and highly explosive.
WHAT CAN HAPPEN A static charge can ignite g asoline 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 f illing.
Do not fill gasoline containers inside a vehicle or on a
truck or trailer bed because inter ior car pets or plastic truck bed liners may insulate the container and slow the loss of any static charge.
When practical, r emove gas-powered equipment from
the truck or trailer and refuel the equipment with its wheels on the ground.
If this is not possible, then refuel such equipment on a
truck or trailer from a portable container, rather t han 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.
DANGER
1.4 OPERATION
Although hazard control and accident prevention are parti al l y 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, mai nt enance and st orage of the equipment. It is essential that all Operator Saf ety Mechanisms be connected and in operating condition prior to use for mowing.
1.4.1 Give complete, undivided attention to the job at hand.
1.4.2 Mow only in daylight or in good artif icial light.
when children or others are in the area.
1.4.3 When f easible, avoid operating the equipment in wet grass.
1.4.4 Use
traction and/or control could occur. Mow mowers, never up and down. Loss of control and/or loss of oper at or ’s footing could result in a fall with an arm or leg getting under the mower or engine deck and sustaining serious injury. Drive slower on slopes. slopes greater than 20 degrees. Watch for ditches, holes, rocks, dips, and rises which can cause erratic handlebar movement and loss of footing. Keep away from drop-offs and steep banks. Avoid sudden starts. Look down and behind you before and while moving backwards. wet - slippery conditions create hazardous footing, af fect steering, and reduce traction and braking. T he oper ator is responsible for safe operation on slopes. See inside the back cover to determine the approximate slope angle of the area to be mowed.
EXTREME
DO NOT
caution when mowing and/or turning on slopes as loss of
across
DO NOT
slopes with walk behind
operate the mower
DO NOT
mow slopes when grass is
operate on
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1.4.5 Stop the blades when crossing surfaces other than g r ass; and when
transporting the mower to and fr om the area to be mowed.
1.4.6 Never operate the mower with defective guards, shields, or covers. Always
have safety shields, guards, switches, and other devices in place and in proper working condition.
1.4.7
Do Not
change the engine governor setting s or over speed t he engine. Operating an engine at excessive speed may increase the hazard of personal injury.
1.4.8 Place transmission in neutral, disengage blade dr ive before starting engine.
1.4.9 Start the engine caref ully with feet well away from the blades.
1.4.10 Keep hands, feet and clothing away from r otating parts while the mower is being operated.
1.4.11 Stop the engine and remove plug wire(s) or ignition key:
a) Before checking, cleaning or work ing on the mower. b) After striking a foreign object (inspect the mower f or damage and make
repairs before restart ing and operating the mower).
1.4.12 Stop the engine:
a) Before clearing blockages. b) Whenever you leave the mower. c) Before refueling. d) Before making height adj ustments.
1.4.13 Before stopping the eng ine, r e t ur n the throttle control to the idle position for 30 seconds to allow the engine to cool down.
1.4.14 The fuel system is provided with a shut-off valve. The fuel shut-off valve is used to shut off the fuel when:
a) The machine will not be used for a few days. b) During transport to and from the job. c) When parking inside a building.
1.4.15 This mower was designed for one operator only. Keep all others away fr om
mower during operation.
1.4.16
Do Not
mow without the grass deflector or entire grass collection system in
place and in proper working condition.
1.4.16 If j u m p st ar ting is required:
a) connect the positive (+) power cable from the positive post on the boost er
battery to the positive 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 batt er y cables in the r everse or der afterstarting.
1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maintenance, follow the engine manufacture’s recommendations
precisely as stated in the engine manual.
1.5.2 When making adjustments while the engine is running, such as carburetor and
motion control linkage adjust m ent s, stand to one side and keep clear of moving/rotating components, such as engine screen, drive belts and sheaves.
Do Not
moving/rotating components.
wear loose fitting clothing or jewelry that could get tangled in
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1.5.3 Keep engine and engine area free f rom accumulation of grass, leaves,
excessive grease or oil and other debris which can accumulate in these areas. These materials can become combustible and may result in a fire.
1.5.4 Store fuel in a container specif ically designed for this purpose in a cool, dry place.
1.5.5 Keep the mower and fuel container in locked storage to prevent children from
playing or tampering with them.
1.5.6 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.
1.5.7 Maximum mowing results and safety can only be achieved if the mower is properly
maintained and operated correctly.
1.5.8. Check all bolts frequently to maintain proper tightness.
1.5.9. Keep all guards, shields and all safety devices in place and in safe working
condition.
1.5.10 Frequently check for worn or det er iorating components that could create a hazard.
1.5.11 All replacement part s m ust be the same as or equivalent to the parts supplied
as original equipment.
POTENTIAL HAZARD Hydraulic fluid escaping under pressure can penetrat e
skin and cause injury.
WHAT CAN HAPPEN Fluid accidentally injected into the skin must be
surgically removed within a few hours by a doctor familiar with this form of injury or gangrene ma y result .
HOW TO AVOID THE HAZARD Make sure all hydraulic fluid hoses and lines are in
good condition an all hydraulic connections and fittings are tight before applying pressure to hydraulic system.
Keep body and hands away from pinhole leaks or
nozzles that eject high pressure hydraulic fluid.
Use cardboard or paper to find hydraulic leaks. Safely relieve all pressure in the hydraulic system
before performing any work on t he hydraulic system.
1.6 RIDING ATTACHMENTS
Use only may create a hazardous condition resulting in injury.
Exmark
riding attachments. The use of other than Exmark riding attachments
WARNING
1.7 SAFETY SIGNS
1.7.1 Keep all safety signs legible. Remove all grease, dirt and debris from safety
signs.
1.7.2 Safety signs must be replaced if t hey are m issing or illegible.
1.7.3 When new components are installed, be sure that current safety signs are
affixed to the replaced components.
1.7.4 New safety signs may be obtained from your authorized Exmark equipment
dealer or distributor or fr om Exmar k Mfg. Co. Inc.
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1.7.5 Safety signs may be affixed by peeling off the backing to expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.
1.7.6 Familiarize yourself with the following safety signs and instruction labels. They
are critical to the safe operation of your Exmark commercial mower.
PART NO. 613295 LOCATION: Console
PART NO. 403005 LOCATION: LH & RH Front Top
Surface of Mower Deck
BELT ROU TING
STA TIONARY IDLER
PART NO. 613100 LOCATION: Top of Mower Deck
Beneath Center Shield
PART NO. 413214 LOCATION: Right Side of Hydro Control Crank Arm
DECK DRIVE BELT: TR-52"- # 543749
TR-60"- # 543523
TTH-52&60"- # 603306
STA TIONARY IDLER POSITION: TURF RANGER
PART NO. 403143 LOCATION: Rear Surface of Engine Deck
PART NO. 603845 LOCATION: Left Rear Corner of Engine Deck
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p
PART NO. 323540 LOCATION: Front of Mower
Deck Top Surface
PART NO. 303517 LOCATION: LH Side of Rear Surface
of Engine Deck
PART NO. 523552 LOCATION: On Top of
Hydraulic Tank
PART NO. 303508 LOCATION: On Top RH Surface
of Mower Deck
PART NO. 513746 LOCATION: Surface of
Engine Deck Next to Muffler
PART NO. 553049 LOCATION: On Top Front LH
Surface of Mower Deck
PART NO. 513747 LOCATION: To
Front of Battery Cover
PART NO. 303293 LOCATION: Top Surface
of Fuel Tank
PART NO. 303102 LOCATION: Upper
Handles
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2. SPECIFICATIONS
2.1 MODEL NUMBER: Serial No.s 160,000 - 189,999
Serial No.s 160,000 - 219,999 Serial No.s 190,000 - 219,999 Serial No.s 220,000
& Higher:
: TT18KC : TT22KC : TT19KA
TT23KC
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 Capacity: 5.0 gal. (18.9 L.)
2.3.2 Type of Fuel: Regular using the research method, it should be a 90 oct ane minimum.
2.3.3 Fuel Filter: Replaceable in-line
2.3.4 Fuel Shut-Off Valve: 1/ 4 turn
unleaded
gasoline, 87 octane or higher. I n count r ies
2.4 ELECTRICAL SYSTEM:
2.4.1 Charging System: Flywheel Alternator
2.4.2 Charging Capacity: 15 amp
2.4.3 Battery Type: BCI Group U1 235 amps at O° F
2.4.4 Battery Voltage: 12 Volt; Polarity, negative ground.
2.4.5 Fuses: blade type, 20 amp to charging circuit; 20 amp to electr ic clut ch.
2.4.6 Safety Interlock System: Operator must have OPC (O per at or Presence Control) levers held in contact with handle grips, tr ansmission in neutral and blade clutch disengaged to start engine. Release of OPC levers will cause the engine to stop if hydro transmission is
engaged
is
.
not
in neutral and/or blade clutch
2.5 STEERING/BRAKE CONTROL:
Fingertip drive control levers provide independent speed control, braking and neutral to each drive wheel for moving forward or r everse, stopping and power turning.
2.6 TRANSMISSION:
Twin Hydrostatic Drive
2.6.1 Two Hydro Gear BDP-10L series variable displacement pumps independently coupled to two high efficiency Parker / Ross wheel drive motors .
2.6.2 Hydraulic Filter is replaceable cartridge type.
F)
F)
P/N 513211: 10 microns, 18 psi bypass (Summer use above 32° P/N 523541: 40 microns, 18 psi bypass (Winter use below 32°
2.6.3 Speed Range: Forward 0 - 6.2 mph (10.0 km/h)
Reverse 0 - 2.2 mph (3.5 km/h)
2.7 WHEEL DRIVE SYSTEM:
Drive wheels are direct coupled to Parker/Ross wheel drive motors with 1.0" (25.4 mm) tapered shaft.
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2.8 TIRES
Drive Front Caster
Size................ 16 x 7.50-8.......................... 9 x 3.50-4
Quantity......................2........................................ 2
Tread..........Turf Saver/Turf Master..................Smooth
Ply Rating...................4........................................ 4
Pressure........14 psi(97 kPa) ..................22 psi(152 kPa)
2.9 DECK
2.9.1 Model Numbers: FMD603 and FMD523
2.9.2 Cutting Width: 60 in.(152.4 cm.) 52 in.(132.1 cm.)
2.9.3 Discharge: Right Side
2.9.4 Optional Mulch Kit and Bagger available.
2.9.5 Blade Size: 60" - (3 ea.) 20. 50 in.(52.1 cm.)
52" - (3 ea.) 18.00 in.(45.7 cm . )
2.9.6 Type of Drive: Electric clutch mounted on engine shaft. Blades driven by two
belts with self tensioning idlers.
2.9.7 Adjustable anti-scalp rollers(6 ea.)
2.9.8 Cutting Height: Adjusts in 1/2”(1.3 cm) increments from 1 1/ 2” ( 3.8 cm) to 4
1/2”(11.5 cm).
2.9.9 Deck Mounting: Full floating deck is attached 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
Discharge chute up
(Transport only)
2.10.2 Overall Length:
Overall Length
2.10.3 Curb Weight:
Total weight
∗∗∗∗
Weights will vary slightly depending on engine option.
2.10.4 Overall Height: 43.5”(110.5)
2.10.5 Tread Width (to out side of tires): 37.5” (95.3 cm)
62.7” 70.5”
(159.3 cm) (179.1 cm)
53.0” 60.9”
(134.6 cm) (154.6 cm)
w/52” Deck w/60” Deck
78.75” 79.25”
(200.0 cm) (201.3 cm)
w/52” Deck w/60” Deck
648 lbs. 678 lbs. (294 kg) (307 kg)
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