TURFTRACER®HP
SetupInstructions
ForSerialNos.850,000&Higher
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer
extranet.
DealerPack
Part#
DescriptionQty.Use
1-633023Stud,FuelTank2
322-3
Screw,HH5/16-18x3/4inch
2
3256-23
Washer,5/16inchSAE
4
1-805005
Washer,Lock5/16inchHeavy
2
1-633349
Spring,Compression
2
3296-47
Nut,Nyloc5/16-18inchThin
2
Installingthefueltank.
107-4543
Clamp,Tank
2
322-10
Screw,HH5/16-18x2
2
3256-3
Washer,5/16Std
2
104-8300
Nut,Nyloc5/16-18Flg
2
InstallingtheCAUnitfueltank
323-6
Screw,HH3/8-16x1inch
4
3290-357
Nut,Whizlock3/8-16inch
4
98–5975
Washer,SpringDisc
4
Installingthehandleassembly.
1-806003
Hairpin,Cotter
2
1-808280Pin,Clevis1
Installingthespeedcontrolrod.
322-9
Screw,HH5/16-18x13/4inch
2
3296-29
Nut,Nyloc5/16-18inch
2
3220-16
Nut,Jam3/8-24inchLH
2
Installingthewheeldrivelinkages.
1-303335Tie,Cable2
1-303287Tie,Cable4
Connectingwireharness.
103-2106
Key,ExmarkLogo
1
1-603511
Key,Standard
1
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
SAEatwasherand5/16inchlockwasherintothe
threadedholesintherightsideofthefueltank.Do
Notovertighten.
3.Placea5/16inchSAEatwasher,thenaspring,
overeachofthestudsandfastenwitha5/16inch
nylocnut.Tighten5/16inchnylocnutfullythen
backoffa1/2turn.Thisistoallowfornormal
fueltankexpansionandcontractionwithchangesin
temperatureandfuellevels.Donotovertighten.
4.Attachthefueltankhosetothetankttingand
securewiththeclampprovided.
InstallingtheFuelTank(CAUnits
Only)
1.Installthefueltankontopofthefueltanksupport.
Secureeachsideofthetankwithaclamp,5/16-18x
2screw,washer,and5/16nylocnut.
2.Attachthepurgehosefromthecanistertothetop
ttingofthefueltankasshownin
Figure1.
Figure1
1.Attachpurgehosefromcanistertotoptting
3.Attachthefueltankhosetothetankttingand
securewiththeclampprovided.
InstallingtheHandleAssembly
1.Positionthelowerendofthehandleassemblyon
theoutsideoftheupperrearsectionofthefueltank
andhandlesupport.
2.Installfour3/8-16x1inchbolts,fourspringdisk
washersfromtheoutsidein.Secureusingfour
3/8-16whizlocknutsontheinsideofeachhandle
supportandtightenuntilthespringdiskwashersare
at(Figure2).
Note:Besuretheconeofthespringdiskwasheris
againsttheheadofthebolt.
Figure2
1.Frontoftheunit
3.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.Throttlecontrollever
3.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.ConnectthetwoagterminalstotheOPCswitch
inanyorder.
4.Continueroutingthisleaddowntherightsideofthe
handleandconnecttheconnectorontheendtothe
parkbrakeswitch.
5.Fastentheharnesstotheleftsideofhandlewithtwo
largeplastictiesfromtheboltbag.
6.Fastentheharnesstotherighthandsideofthe
handleusingtwosmalltiesfromtheboltbag.
7.Fastentheharnesstothetwosmallholesinthe
channelundertheconsoleusingtwosmalltiesfrom
theboltbag.
Forelectricstartmodels:
1.Routethelong,unattachedwiringharnesslead
upthelefthandsideofthehandleandunderthe
console.
2.ConnectthetwoagterminalstotheOPCswitch
inanyorder.
3.Connecttheconnectortothekeyswitch.
4.Fastentheharnesstotheleftsideofhandlewithtwo
largeplastictiesfromtheboltbag.
5.FastentheleadsconnectingtotheOPCswitchto
thesmallholeinthechannelundertheconsoleusing
asmalltiefromtheboltbag.
ServicingtheBattery
WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
Important:Themachineisshippedwithalled
leadacidbattery.
DANGER
Chargingorjumpstartingthebatterymayproduce
explosivegases.Batterygasescanexplodecausing
seriousinjury.
•Keepsparks,ames,orcigarettesawayfrom
battery.
•Ventilatewhenchargingorusingbatteryinan
enclosedspace.
•Makesureventingpathofbatteryisalwaysopen
oncebatteryislledwithacid.
•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
11.7orless
0%
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
batteryterminalrst,thenthenegative(black)cable
tothenegativebatteryterminal.Slipinsulatorboot
overthepositiveterminal.
Note:Iftimedoesnotpermitchargingthebattery,
orifchargingequipmentisnotavailable,connect
thenegativebatterycableandrunthevehicle
continuouslyfor20to30minutestosufciently
chargethebattery.
CheckingTirePressure
1.Checkthetirepressureinthedrivetires.Proper
inationfordrivetiresis12-16psi(83-110kPa).
2.Adjustthetirepressurewithin12-16psi(83-110
kPa)rangetomakethetirecircumferencesmatchas
closelyaspossible.
GreasingtheUnit
Note:Theunitisnotgreasedatthefactory.
1.LubricatettingswithNGLIgrade#2multi-purpose
gungrease.RefertothefollowingchartandFigure8
forttinglocationsandinitialpumps.
LubricationChart
Fitting
Locations
Initial
Pumps
Numberof
Places
Service
Interval
1.FrontCaster
WheelBearings
122
Daily
2.FrontCaster
Pivots
22
Daily
3.PTO
Engagement
Bellcrank
11
40hours
4.PumpDrive
IdlerPivot
21
Yearly
5.ClutchArm
Pivot
11
40hours
6
LubricationChart
Fitting
Locations
Initial
Pumps
Numberof
Places
Service
Interval
6.PumpControl
Bearings
22
40hours
7.MowerDeck
IdlerPivots
21
Yearly
Number4(PumpDriveIdlerPivot)Locatedunder
theenginedeck.
Number5(ClutchArmPivot)Locatedunderthe
enginedeck.
Figure8
2.LubricatethepivotpointonPTOleverwithaspray
penetratinglubricant.
ServicingtheEngine
RefertoEngineOwner’sManual.
ServicingtheHydraulicOil
Themachineisshippedwithhydraulicoilinthe
reservoir.
1.Runthemachineforapproximately15minutesto
allowanyextraairtopurgeoutofthehydraulic
system.
2.Checkhydraulicreservoirandifnecessaryllthe
reservoirtotheappropriatelevelwithExmark
PremiumHydrooil.
3.Replacehydraulicreservoircapandtightenuntil
snug.DoNotovertighten.
Note:Thebafeislabeled“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
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