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: The engine in this product is not equipped with a spark arrester muffler. It is aviolation of Califor...
Page 3 - Introduction; CONGRATULATIONS; on the purchase of your
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 4 - Contents
Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...
Page 5 - 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 ...
Page 6 - 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 on levelground, in an open area, when the engineis cold. Wipe up any gasoline that spills. • Ne...
Page 7 - Do Not remove roll bar.; Operation; NEVER
Safety CAUTION Fuel tank vent is located inside the rollbar tube. Removing or modifying the rollbar could result in fuel leakage and violateemissions regulations. • Do Not remove roll bar. • Do Not weld, drill, or modify roll bar inany way. • Check that the operator’s presence controls,safety switch...
Page 8 - Slope Operation; Use; Extreme; caution when mowing and/or turning; Do Not mow slopes when grass is wet.
Safety • Be aware of the mower discharge path and directdischarge away from others. • Do Not operate the mower under the influenceof alcohol or drugs. • Use extreme care when loading or unloading themachine into a trailer or truck. • Use care when approaching blind corners, shrubs,trees, or other ob...
Page 9 - Drive slowly and carefully.; Maintenance and Storage; Always shield eyes and face from battery.; Do Not swallow electrolyte.
Safety WARNING There is no rollover protection when the rollbar is down. Wheels dropping over edges,ditches, steep banks, or water can causerollovers, which may result in serious injury,death or drowning. • Keep the roll bar in the raised and lockedposition and use seat belt. • Lower the roll bar on...
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; Engine
Specifications Specifications Model Numbers Serial Nos: 850,000 and Higher LZAS22KA484; LZAS22KA484CA; LZAS23KC524; LZAS25KC604; LZAS26LKA604; LZAS27KC524;LZAS27KC524CA; LZAS27KC604; LZAS27KC604CA; LZAS29KA724 Systems Engine • Engine Specifications: See your Engine Owner’sManual • RPM: Full Speed: 3...
Page 16 - Seat
Specifications – Moving motion control levers outward (in slots) locks the drive system in neutral. • PTO Engagement Switch: Engages electric clutch(to drive belt) which engages mower blades. • Parking Brake Lever: Engages parking brake. • Parking Brake Release Button: Releases parkingbrake. • Deck ...
Page 17 - – 48 and 52 inch Decks: “B” Section belt with; Dimensions
Specifications – 48 inch Deck: 16.25 inches (41.3 cm) – 52 inch Deck: 18.00 inches (45.7 cm) – 60 inch Deck: 20.50 inches (52.1 cm) – 72 inch Deck: 24.50 inches (62.2 cm) • Blade Spindles: Solid steel spindles with 1.00 inch(25 mm) I.D. bearings. • Deck Drive: Electric clutch: – 48 and 52 inch Decks...
Page 18 - Accessory Weight Table Worksheet:; The 72 inch deck does not require a weight kit.
Specifications Tread Width: (Center to Center ofTires, Widthwise) 48 inch Deck 52 inch Deck Drive Wheels 36.2 inches(91.9 cm) 38.5 inches(97.8 cm) Caster Wheels 32.8 inches(83.3 cm) 32.8 inches(83.3 cm) 60 inch Deck 72 inch Deck Drive Wheels 41.6 inches(105.7 cm) 43.6 inches(110.7 cm) Caster Wheels ...
Page 19 - Torque Requirements; Product Overview
Product Overview *60 inch units which already have an under toe boardmount weight as standard requires 116-1238 front toeboard top mount kit instead of 116-1173. Torque Requirements Bolt Location Torque Blade Drive SheaveMounting Nut 140-145 ft-lb (190-197N-m) Blade Mounting Bolt(lubricate with anti...
Page 20 - Determine the left and right sides of the; Controls; Motion Control Levers; Choke Control; Throttle Control; The LCD indicator appears in the message
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 ofthe console control the forward and reverse motionof the machine. Moving the levers forward or backward turn...
Page 21 - Pull the lever up and rearward to engage the brake.; Ignition Switch; Brake must be engaged, motion control; Hour Meter; If the ignition key is turned to the “ON”; Fuel Gauge
Operation Pull the lever up and rearward to engage the brake. Depress the release button and push downward todisengage the brake. Figure 7 1. Release button 2. Park brake The unit must be tied down and brake engaged whentransporting. Ignition Switch Located on right console (see Figure 6). The ignit...
Page 22 - Drive Wheel Release Valves; The handle must be horizontal and against; PTO Engagement Switch; The indicator normally appears when the; Warning Buzzer
Operation The fuel level is shown on a bar display. The indicatorlight appears when the fuel level is low (approximatelyone gallon remaining in the tank). Drive Wheel Release Valves WARNING Hands may become entangled in the rotatingdrive components below the engine deck,which could result in serious...
Page 23 - Deck Lift Pedal; Located at the right front corner of the floor pan.; Transport Lock; Never use methanol, gasoline; overfill fuel tank. Fill the fuel tank to the; Operating Instructions; The roll bar is an integral and; The knob must be completely latched with the
Operation Figure 11 1. Green 3. Red 2. Yellow 4. Bar display Warning Buzzer (KawasakiLiquid-Cooled Only) Located on the side of the right hand console (seeFigure 6). The buzzer is a warning signal that the engine isoverheating. See the Troubleshooting section. Deck Lift Pedal Located at the right fr...
Page 24 - Always use the seat belt with the; Open the Fuel Shut-Off Valve; Do Not crank the engine
Operation 2. Apply forward pressure to the upper hoop of the roll bar. 3. Pull the knob and rotate 90° to hold in the unlatched position to lower the roll bar. 4. To return to the operate position, raise the roll bar, and then rotate knobs 90° so that the tabsinterlock partially. Apply forward press...
Page 25 - Engaging the PTO; Operator must be in seat before the; Disengaging the PTO; Use caution when making turns.
Operation attempts. Failure to follow these guidelinescan burn out the starter motor. 7. If the choke is in the “ON” position, gradually return choke to the “OFF” position as the enginewarms up. Engaging the PTO DANGER The rotating blades under the mower deckare dangerous. Blade contact can causeser...
Page 26 - Driving Forward; Adjusting the Cutting Height; When changing the cutting height
Operation Figure 15 1. Neutral lock position(handles out) 4. Forward 2. Neutral operate position(handles in) 5. Neutral (operate) 3. Front of Unit 6. Reverse Driving Forward 1. Release the parking brake. 2. Move the motion control levers inward to the center to the neutral position. 3. To move forwa...
Page 27 - Adjusting the Anti-Scalp Rollers; For Maximum Deck Flotation,; Transporting; Transporting a Unit
Operation 5. Insert the height adjustment pin into the hole corresponding to the desired cutting height. See the decal on the side of the deck lift plate forcut heights. 6. Push the deck lift pedal, release the transport lock and allow the deck to lower to the cutting height. Adjusting the Anti-Scal...
Page 28 - Loading a Unit; Do Not attempt to turn the unit
Operation CAUTION This unit does not have proper turnsignals, lights, reflective markings, or aslow moving vehicle emblem. Driving on astreet or roadway without such equipmentis dangerous and can lead to accidentscausing personal injury. Driving on a streetor roadway without such equipment may alsob...
Page 29 - 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 30 - Periodic Maintenance; Check Engine Oil Level; Service Interval: Before each use or daily; Stop engine and wait for all moving parts to stop.; Check Battery Charge; Service Interval: As required; To prevent damage due to freezing, battery
Maintenance Maintenance Service Interval Maintenance Procedure Every 500 hours • Replace the secondary air cleaner element (May need more often under severe conditions. See the Engine Owner’s Manual for additional information.) • Change the hydraulic filter and fluid.• Check the wheel hub slotted nu...
Page 31 - Check the weak battery for terminal corrosion; Make sure the booster is a good and fully charged; The following instructions are adapted; Do Not lean over the batteries.; Be sure the vent caps are tight and level.
Maintenance VoltageReading PercentCharge MaximumChargerSettings ChargingInterval 11.7–12.0 0–25% 14.4 volts/4amps 3 Hours 11.7 or less 0% 14.4 volts/2amps 6 Hours orMore Recommended JumpStarting Procedure Service Interval: As required 1. Check the weak battery for terminal corrosion (white, green, o...
Page 32 - Check Mower Blades
Maintenance Figure 20 1. Positive (+) cable on discharged battery 2. Positive (+) cable on booster battery 3. Negative (–) cable on the booster battery 4. Negative (–) cable on the engine block 5. Booster battery 6. Discharged battery 7. Engine block 4. Connect the other end of the positive cable to...
Page 34 - Check Seat Belt; Check for Loose Hardware; Service Air Cleaner; Service Interval: Every 250 hours—Replace; Change Engine Oil; Service Interval: After the first 5 hours; Check Hydraulic Oil Level; Service Interval: Every 50 hours
Maintenance Check Seat Belt Service Interval: Before each use or daily Visually inspect seat belt for wear, cuts, and properoperation of retractor and buckle. Replace beforeoperating if damaged. Check for Loose Hardware Service Interval: Before each use or daily 1. Stop engine, wait for all moving p...
Page 35 - Check Tire Pressures; Check Condition Of Belts; Lubricate Grease Fittings; See chart for service intervals.; Lubricate Caster Wheel Hubs
Maintenance Figure 24 1. Full 2. Add Note: The oil level on the dipstick will be incorrect if the oil is checked when the unit is hot. 7. If the dipstick oil level is at the “add” mark add Exmark Premium Hydro oil. 8. Replace hydraulic reservoir cap and tighten until snug. Do Not overtighten. Check ...
Page 36 - To prevent seal and bearing damage,; Lubricate Brake Handle Pivot; Lubricate Deck Lift Pivot; Service Interval: Every 100 hours; Check Spark Plugs; Service Interval: Every 200 hours; Change Fuel Filter
Maintenance Figure 25 1. Seal guard 2. Spacer nut with wrenchflats 2. Remove caster wheel from caster forks. 3. Remove seal guards from the wheel hub. 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...
Page 37 - Service Interval: Every 500 hours; Check; Service Interval: After the first 100 hours
Maintenance Replacement Filters Kohler Kohler P/N 24 050 13 Kawasaki (Air-Cooled &Liquid-Cooled) Kawasaki P/N 49019-7005 Note: It is important to reinstall the fuel line hoses and secure with plastic ties the same as they wereoriginally installed at the factory to keep the fuel lineaway from com...
Page 38 - Keep out of reach of children and pets.
Maintenance Note: Do Not use anti-seize on wheel hub. • Style B (yellow zinc): 1. Remove and discard the cotter pin. 2. Torque the slotted nut to 200 ft-lb (271 N-m). 3. Check distance from bottom of slot in nut to inside edge of hole. Two threads (0.1 inch) orless should be showing. Figure 27 1. 0....
Page 40 - On threads of Blade Bolts. See; Check Mower; Dielectric Grease; Adjustments; Check the tire pressure in the drive tires. Proper
Maintenance Thread locking adhesives are required for somehardware on engines — see the Engine manual. Copper-Based Anti-seize Copper-based anti-seize is used in the followinglocation: On threads of Blade Bolts. See Check Mower Blades section. Dielectric Grease Dielectric grease is used on all blade...
Page 42 - Torque the front and rear; Pump Drive Belt Tension; Drive Wheel
Maintenance 16. If the deck is too low, tighten the single point adjustment bolt by rotating it clockwise. Ifthe deck is too high, loosen the single pointadjustment bolt by rotating it counterclockwise. Note: Loosen or tighten the single point adjustment bolt enough to move the height-of-cutplate mo...
Page 44 - Electric Clutch Adjustment
Maintenance 18. Rotate the drive wheel release handle to the “operating” position. Refer to the Drive Wheel Release Valves section in Operation. 19. Install the rear tires and torque lug nuts to 90-95 ft-lb (122-129 N-m). 20. Remove jack stands. Electric Clutch Adjustment No adjustment necessary; ho...
Page 45 - Troubleshooting; Temporarily
Maintenance Figure 38 1. Feeler gauge • If the gap is less than 0.010 inch, thenreinstall the shim and reference the Troubleshooting section. • If the gap is sufficient, proceed to thesafety check in step F. F. Perform the following safety check: a. Sit on the seat and start the engine. b. Make sure...
Page 46 - Adjusting the height:
Maintenance Figure 39 1. Double nuts 8. Shut off unit. Remove jumper wire from wire harness and plug connector into seat switch. 9. Remove the jack stands. 10. Raise the deck and re-install the height of cut pin. 11. Check that the machine does not creep in neutral with the park brakes disengaged. M...
Page 47 - Adjusting the Tilt
Maintenance Figure 42 1. Bolts 4. Nuts 2. Control lever 5. Slotted holes 3. Control arm shaft 2. Move the control lever to the next set of holes. Secure the lever with the two bolts. 3. Repeat the adjustment for the opposite control lever. Adjusting the Tilt The motion control levers can be tilted f...
Page 48 - Cleaning; Clean Debris From Machine
Maintenance Cleaning Clean Engine and ExhaustSystem Area Service Interval: Before each use or daily (May be required moreoften in dry or dirtyconditions.) CAUTION Excessive debris around engine cooling airintake and exhaust system area can causeengine, exhaust area, and hydraulic systemto overheat w...
Page 49 - Waste Disposal; Motor Oil Disposal
Maintenance Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants tothe environment. Dispose of used oil at a certifiedrecycling center or according to your state and localregulations. Battery Disposal DANGER Battery electrolyte contains sulfuric acid,which is poisonous ...
Page 50 - 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 53 - Schematics; Electrical Diagram — Air–Cooled
Schematics Schematics Electrical Diagram — Air–Cooled G008587 P T O S W IT C H SE A T SWITCH IGNITION SWITCH FUSE BLOCK REGUL A T OR G R OUND P T O C L U T C H S TA R T REL A Y LH NEUTRAL SWITCH RH NEUTRAL SWITCH BRAKE SWITCH S TA R T RED HOUR METER/MODULE L T. GREEN YELLO W T A N BR OWN WHITE ORANG...
Page 54 - Electrical Diagram — Liquid–Cooled
Schematics Electrical Diagram — Liquid–Cooled P T O SWITCH SE A T SWITCH IGNITION SWITCH FUSE BLOCK REGUL A T O R G R OUND P T O CLUTCH S TA R T REL A Y S TA R T RED HOUR METER/MODULE L T. GREEN YELLO W T A N BR OWN WHITE ORANGE GR A Y VIOLET BLUE GREEN RED BLA CK ORANGE ORANGE M A G PINK FUEL SOLEN...
Page 55 - Electrical Logic Schematic — Air-Cooled
Schematics Electrical Logic Schematic — Air-Cooled BN BN B U BK Y W T PK BN PK OR GN S R PK PK PK L TGR GY GY PK V BN V OR GN OR R PK R BK GND PK BK BN BN BK PK BK GND 15A F4 GY R I B A W V B U V V BK + S - FUEL SENDER 10A F3 (BRAKE) SW6 PK OR R F2 25A P T O CLUTCH B U 1 2 5 4 7 8 (P T O S W IT C H ...
Page 56 - Electrical Schematic — Liquid-Cooled
Schematics Electrical Schematic — Liquid-Cooled 2 R A I 3 1 2 4 A 4 7 4 1 6 5 A 3 1 6 B C B B 8 2 3 5 4 5 1 2 S SW1 (IGNITION) KEY SW Ignition s wit c h t e rm in a l lo c a ti o n s vi e wed f ro m b a c k OPTIONAL A C C E S S O R IE S OFF = no connections ON = BRIA S T A R T = BRIS BN BN V B U BK ...
Page 57 - Hydraulic Diagram
Page 61 - Service Record
Service Record Date: Description of Work Done: Service Done By: 61
Page 64 - M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S; SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS; WALK-BEHIND ACCESSORIES AND OPTIONS
M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS WALK-BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO-MULCH SYSTEM TURF STRIPER STANDON CUSTOM RIDE SEAT SUSPENSION SYSTEM FULL SUSPENSION SEAT DECK LIFT ASSIST KIT HITCH KI...
