Page 2 - WARNING; CALIFORNIA
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects, orother reproductive harm. Important: When the mower is used or operated on any California forest, brush or grass coveredland, a working sp...
Page 3 - EXMARK PARTS PLUS® PROGRAM
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...
Page 4 - Introduction; CONGRATULATIONS
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefullydesigned and manufactured to give you a maximumamount of dependability and years of trouble-freeoperation. This manual contains operating, maintenance,adjustment, and safety instructions for your Exmark...
Page 5 - Contents
Contents Introduction ........................................................... 4Safety ..................................................................... 6 Safety Alert Symbol ......................................... 6Safe Operating Practices .................................. 6Safety and Ins...
Page 6 - Safety; Safety Alert Symbol; Safe Operating Practices; Training; CAUTION
Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both inthis manual and on the machine to identify importantsafety messages which must be followed to avoidaccidents This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Figure 2 1. Safety alert symbol The s...
Page 7 - DANGER; Avoid prolonged breathing of vapors.
Safety DANGER In certain conditions gasoline is extremelyflammable and vapors are explosive. A fire or explosion from gasoline can burnyou, others, and cause property damage. • Fill the fuel tank outdoors in an openarea, when the engine is cold. Wipe upany gasoline that spills. • Never refill the fu...
Page 8 - Operation; NEVER; Slope Operation; Extreme
Safety Operation WARNING Operating engine parts, especially themuffler, become extremely hot. Severe burnscan occur on contact and debris, such asleaves, grass, brush, etc. can catch fire. • Allow engine parts, especially the muffler,to cool before touching. • Remove accumulated debris from mufflera...
Page 9 - Do Not mow slopes when grass is wet.; Drive slowly and carefully.
Safety DANGER Operating on wet grass or steep slopes cancause sliding and loss of control. Wheelsdropping over edges, ditches, steep banks, orwater can cause rollovers, which may resultin serious injury, death or drowning. • Do Not mow slopes when grass is wet. • Do Not mow near drop-offs or near wa...
Page 10 - Maintenance and Storage
Safety Maintenance and Storage • Disengage drives, lower implement, set parkingbrake, stop engine and remove key or disconnectspark plug wire. Wait for all movement to stopbefore adjusting, cleaning or repairing. • Keep engine, engine area, and pump drive beltcompartment free from accumulation of gr...
Page 11 - Safety and Instructional Decals
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease,dirt and debris from safety signs and instructionallabels. • Replace all worn, damaged, or missing safetysigns. • When replacement components are installed, besure that current safety signs are affixed to there...
Page 15 - Specifications; Model Numbers
Specifications Specifications Model Numbers Serial Nos: 720,000 and Higher LZ27KC604 Systems Engine • Engine Specifications: See your Engine Owner’sManual • RPM: Full Speed: 3750 ±50 RPM (No Load)Idle: 1500 RPM Fuel System • Capacity: 13.5 gal. (51.0 L) • Type of Fuel: Regular unleaded gasoline, 87o...
Page 16 - Hydrostatic Ground Drive System; Cutting Deck; Dimensions
Specifications – Optional suspension seat: molded adjustable flip-up armrests. • Seat Safety Switch: Incorporated into theSafety Interlock System. Time delay seat switcheliminates rough ground cut-outs. Hydrostatic Ground Drive System • Hydrostatic Pumps: Two Hydro Gear variabledisplacement piston p...
Page 17 - Torque Requirements; Product Overview
Product Overview Overall Height: Roll Bar - Up Roll Bar - Down 71.9 in. (182.6 cm) 53.8 inches (136.7 cm) Tread Width: (Center to Center ofTires, Widthwise) Drive Wheels 41.9 inches (106.4 cm) Caster Wheels 37.3 inches (94.7 cm) Wheel Base: (Center of Caster Tire toCenter of Drive Tire) 53.7 inches ...
Page 18 - Controls
Operation Operation Note: Determine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control levers located on each side of theconsole control the forward and reverse motion ofthe machine. The levers control the flow of hydraulicoi...
Page 19 - Drive Wheel Release Valves; Operating Instructions; Open the Fuel Shut-Off Valve
Operation Drive Wheel Release Valves Located on the top right front corner of hydrostaticpumps. Drive wheel release valves are used to release thehydrostatic drive system to allow the machine to bepushed without the engine running. Unhook seatlatch and tilt seat up to gain access to pumps. With a 7/...
Page 20 - Do Not crank the engine; Engaging the PTO; Operator must be in seat before the; Disengaging the PTO; Use caution when making turns.
Operation 4. Place the throttle midway between the “SLOW” and “FAST” positions. 5. On a cold engine, push the choke lever forward into the “ON” position. On a warm engine, leave the choke in the “OFF”position. 6. Turn ignition switch to the “START” position. Release the switch as soon as the engine ...
Page 21 - Driving Forward; Driving in Reverse; Adjusting the Cutting Height
Operation When levers are centered in the T-slot the drivesystem is in the neutral position. With levers movedout in the T-slot the drive system is in the neutral lockposition (Figure 6). Figure 6 1. Handles Out (NeutralLock) 5. Neutral 2. Handles In (Neutral) 6. Reverse 3. Front of Unit 7. Neutral ...
Page 22 - When changing the cutting height; Adjusting the Anti-Scalp Rollers; For Maximum Deck Flotation,
Operation deck lift assist lever located at the front rightcorner of the floor pan. Note: When changing the cutting height positions, always come to a complete stopand disengage the PTO . Figure 8 1. Lever in transport and 5 inch (12.7 cm) cutting heightposition 4. Insert the height adjustment pin i...
Page 23 - Transporting; Transporting a Unit; Loading a Unit
Operation Figure 10 1. Spring disc washer(cone towards nut ) 3. 3/8 nyloc-torque to 30-35ft-lb (41-47 N-m) 2. Front right anti-scalpbracket shown 4. 3/8-16 whizlock nuttorque to 30-35 ft-lb(41-47 N-m) Transporting Transporting a Unit Use a heavy-duty trailer or truck to transport themachine. Lock br...
Page 24 - Do Not attempt to turn the unit
Operation Important: Do Not attempt to turn the unit while on the ramp, you may lose control anddrive off the side. Avoid sudden acceleration when driving up a rampand sudden deceleration when backing down a ramp.Both maneuvers can cause the unit to tip backward. 24
Page 25 - Maintenance
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING While maintenance or adjustments are beingmade, someone could start the engine.Accidental starting of the engine couldseriously injure you or other bystanders. Remove the key f...
Page 26 - Periodic Maintenance; Check Engine Oil Level; Service Interval: Before each use or daily; Check Battery Charge; Service Interval: Monthly
Maintenance Maintenance Service Interval Maintenance Procedure Every 200 hours • Grease the brake brackets. Every 500 hours • Check the wheel hub slotted nut torque specifications.• Check the wheel lug nuts. Monthly • Check the battery charge. Yearly • Grease front caster pivots.• Grease the deck dr...
Page 27 - Check Mower Blades
Maintenance VoltageReading PercentCharge MaximumChargerSettings ChargingInterval 12.6 orgreater 100% 16 volts/7amps NoChargingRequired 12.4 – 12.6 75–100% 16 volts/7amps 30 Minutes 12.2 – 12.4 50–75% 16 volts/7amps 1 Hour 12.0–12.2 25–50% 14.4 volts/4amps 2 Hours 11.7–12.0 0–25% 14.4 volts/4amps 3 H...
Page 28 - Check Seat Belt; Check for Loose Hardware; Service Air Cleaner; Service Interval: Every 50 hours—Service
Maintenance 1. Check starting circuit. Starter should crank with, parking brake engaged , PTO disengaged and motion control levers moved out in the neutral lock position. The operator does not need to be in the seat to start the engine. Try to start with operator in seat , parking brake disengaged, ...
Page 29 - Change Engine Oil; Service Interval: After the first 5 hours; Check Hydraulic Oil Level; Check Tire Pressures; Service Interval: Every 40 hours; Check Condition Of Belts; Service Interval: Every 40 hours; Lubricate Grease Fittings
Maintenance 6. Do Not wash or use pressurized air to clean paper element or inner element. 7. Reinstall elements. Position the cover so that the rubber dust ejector is pointing downward andsecure with retaining clips. Change Engine Oil Service Interval: After the first 5 hours Every 100 hours/Yearly...
Page 30 - Lubricate Caster; Lubricate Caster Wheel Hubs; Service Interval: Yearly
Maintenance Lubrication Chart Fitting Locations Initial Pumps Number of Places Service Interval 1. FrontCasterWheel Hubs *0 2 *Yearly 2. FrontCasterPivots *0 2 *Yearly 3. HeightAdjustmentShaftBearings 1 5 40 Hours 4. DeckDrive BeltIdler Arm 1 1 Yearly 5. BrakeBrackets 1 2 200 Hours 6. MuleDrive Belt...
Page 31 - To prevent seal and bearing damage,; Lubricate Brake Handle Pivot; Check Spark Plugs; Service Interval: Every 160 hours
Maintenance 4. Remove one of the spacer nuts from the axle assembly in the caster wheel. Note that threadlocking adhesive has been applied to lock thespacer nuts to the axle. Remove the axle (withthe other spacer nut still assembled to it) fromthe wheel assembly. 5. Pry out seals, and inspect bearin...
Page 32 - Change Fuel Filter; Before reinstalling new filter, fill; Thread Locking Adhesives
Maintenance Change Fuel Filter Service Interval: As required A fuel filter is installed between the fuel tanks and theengine. Replace when necessary. Replacement Filters Kohler Kohler P/N 2405010 Change Hydraulic SystemFilter Service Interval: After the first 250 hours Yearly thereafter Note: Use on...
Page 33 - Check Mower; Dielectric Grease; Adjustments; Deck Leveling
Maintenance • Caster wheel spacer nuts. • Fuel tank bulkhead fitting nuts. Adhesives such as “Loctite RC/609 or RC/680” or“Fel-Pro Pro-Lock Retaining I or Retaining II” areused on the following: Fuel tank studs, where studs are inserted into tank. Mobil HTS Grease (OrFood-Grade Anti-seize) Mobil HTS...
Page 34 - Pump Drive Belt Tension
Maintenance all the chains is approximately equal. Make sureall chain attachment bolts are tight. Repositionanti-scalp rollers and tighten securely. Figure 14 1. Apply downward pressure here 2. Place locking pliers here to hold spring 3. 10 1/2 inches (26.7 cm) 4. Remove force on deck springs by loo...
Page 35 - Deck Belt Tension; Brake Link
Maintenance Figure 16 1. Spring idler pulley 3. Right side idler pulley(adjustable) 2. Front of unit Deck Belt Tension Self-tensioning - No adjustment necessary. Belt Guide Adjustment 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Remove the belt shield o...
Page 36 - Electric Clutch Adjustment
Maintenance between the spring retainer bracket and theadjacent nyloc nut. Tighten the jam nut abovethe trunnion roller. 4. If adjustment is necessary, loosen the nut directly below the yoke. Turn the bottom nut(below washer) until the correct measurementis obtained (see Figure 18) turn nut clockwis...
Page 37 - Temporarily; Brake must be engaged and
Maintenance 1. This adjustment must be made with the drive wheels turning. First raise the frame and block upso that drive wheels can rotate freely. 2. Remove the electrical connection from the seat safety switch, located directly to the left of the seatswitch assembly beside the hydraulic oil reser...
Page 38 - Adjust Seat Switch
Maintenance Figure 22 1. Motion control bracket 2. Least resistance (softest feel) 3. Medium resistance (medium feel) 4. Most resistance (firmest feel) 5. Torque nyloc nut to 200 in-lb (16.7 ft-lb). Bolt mustprotrude past end of nyloc nut after torque. 6. Damper 7. Damper must move freely on bolt. A...
Page 39 - Cleaning; Service Interval: Every 80 hours; Motor Oil Disposal; Do Not swallow electrolyte.
Maintenance Cleaning Clean Engine CoolingSystem Service Interval: Before each use or daily (May be required moreoften in dry or dirtyconditions.) CAUTION Excessive debris around the engine coolingair intake and inside of the pump drivebelt compartment and damaged or missingrubber baffles can cause t...
Page 41 - Troubleshooting; condition prior to mower use.
Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, do not overlook the simple causes. For example: starting problems could be causedby an empty fuel tank. The followi...
Page 43 - Schematics; Electrical Diagram
Schematics Schematics Electrical Diagram SE AT DEL AY MODULE DIODE 3. S TA R T POSITION 1. OFF 2 . R UN B + I + S CIRCUIT "MAKE" X + Y NONE B + I + A IGNITION SWITCH TERMINAL CONNECTIONS TERMINAL A VO LT A GE REGUL AT OR TERMINAL B B ATTE R Y TERMINAL I HOUR METER , ENGINE , P TO SWITCH TERM...
Page 44 - Hydraulic Diagram
Page 46 - Service Record
Service Record Date: Description of Work Done: Service Done By: 46
Page 48 - Riding Accessories
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...
