For Serial Nos. 440,000 & Higher Part No. 103-4778 Rev.
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 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 1.1 1.2 1.3 1.4 1.5 1.6 PAGE Safety Alert Symbol ...............................................................................1 Training .................................................................................................1 Preparation.........................................................................................1-2 Operation ...........................................................................................3-6 Maintenance & Storage .............
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.
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 ♦ Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. HOW TO AVOID THE HAZARD ♦ Do not mow slopes when grass is wet. ♦ Do not mow near drop-offs or near water. ♦ Do not mow slopes greater than 15 degrees. ♦ Reduce speed and use extreme caution on slopes. ♦ Avoid sudden turns or rapid speed changes.
WARNING POTENTIAL HAZARD ♦ There is no rollover protection when the roll bar is down. WHAT CAN HAPPEN ♦ Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. HOW TO AVOID THE HAZARD ♦ Keep the roll bar in the raised and locked position and use seat belt. ♦ Lower the roll bar only when absolutely necessary. ♦ Do not wear seat belt when the roll bar is down. ♦ Drive slowly and carefully.
1.4.17 1.4.18 DO NOT mow with the discharge deflector raised, removed, or altered unless there is a grass collection system or mulch kit in place and working properly. Be Aware of the mower discharge and direct discharge away from others. 1.4.19 1.4.20 DO NOT operate the mower under the influence of alcohol or drugs. Use extra care when approaching blind corners, shrubs, trees or other objects that may obscure vision. 1.4.
WARNING POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure can penetrate 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 may result. HOW TO AVOID THE HAZARD ♦ Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.
1.6 SAFETY SIGNS 1.6.1 1.6.2 Keep all safety signs legible. Remove all grease, dirt, and debris from safety signs and instructional labels. Safety signs must be replaced if they are missing or illegible. 1.6.3 When new components are installed, be sure that current safety signs are affixed to the replaced components. 1.6.4 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg. Co. Inc.
PART NO. 1-513746 LOCATION: Rear RH Side of Engine Deck PART NO. 103-1636 LOCATION: Top of Fuel Tanks PART NO. 1-523552 LOCATION: Top of Hydraulic Reservoir PART NO. 1-633313 LOCATION: RH Side on Top Front Mower Deck PART NO. 1-633706 LOCATION: LH Side of Cutting Height Adjustment Plate PART NO. 1-633922 LOCATION: Front Center on Top of Mower Deck PART NO. 1-643222 LOCATION: Left of Center on Mower Deck, Under Floor Pan PART NO. 1-643401 LOCATION: On Tilt Switch PART NO.
For Units with S/N 465,000 and Higher PART NO. 103-6320 LOCATION: Bottom Side of Floorpan For Units with S/N 464,999 and Lower PART NO. 103-1593 LOCATION: Bottom Side of Floorpan PART NO. 107-2102 LOCATION: Inside Surface of Upper Roll bar PART NO. 103-1596 LOCATION: Center Inside of the Rear Bumper PART NO. 103-3276 LOCATION: Engine Access Panel behind seat, LH Side next to Buzzer PART NO. 103-2076 LOCATION: Top of Radiator Trim Plate, LH & RH Sides PART NO.
2. SPECIFICATIONS 2.1 MODEL NUMBER: LZ27DD604; LZ27DD724; 2.2 ENGINE: 2.2.1 Engine Specifications: See your Engine Owner’s Manual 2.2.2 RPM: Full Speed: 3850 RPM (No Load) Idle: 1750 RPM 2.3 FUEL SYSTEM 2.3.1 2.3.2 2.3.3 2.3.4 Capacity: 15 gal. (56.8 L.) Type of Fuel: Diesel fuel, 40 cetane or higher Note: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine.
2.6.2 2.6.3 2.6.4 2.6.5 PTO Engagement Switch: Engages electric clutch (to drive belts) which engage mower blades. Parking Brake Lever: Engages parking brake. Deck Height Adjustment Lever: Sets cutting height to desired position. Deck Lift Assist Lever: Foot pedal that assists in raising the deck. 2.7 SEAT 2.7.1 2.7.2 2.7.3 2.7.4 Type: Deluxe suspension seat with high back, low profile foam-in-place cushion (dampened, adjustable spring suspension) and armrests.
2.10.6 2.10.7 Deck: Full floating deck is attached to out-front support frame. Six anti-scalp rollers provide maximum turf protection. Deck design allows for bagging, mulching or side discharge. Deck Depth: 5.5” (14.0 cm) 2.10.8 Cutting Height Adjustment: an extra-long cushioned lever is used to adjust the cutting height from 1 1/2” (3.8 cm) to 5” (10.2 cm.) in 1/4”(6.4 mm) increments.
3. ASSEMBLY INSTRUCTIONS 3.1 UNCRATE MOWER 3.2 INSTALL ROLLOVER PROTECTION SYSTEM (ROLL BAR) 3.2.1 3.2.2 Disassemble roll bar from the crate. a) Remove roll bar tubes from sides of crate and remove screws that attach the wheel hub retaining plate to the bottom of the crate. b) Remove the two brackets used to mount the bottom of the upper roll bar tube to the crate.
a) Locate the latch pin assemblies (pin and hairpin connected with a lanyard). b) Install a 1/2-13 x 3 1/4 capscrew in the washer on the lanyard of each pin assembly. Note: Make sure the bent tab in the washer is towards the head of the bolt. b) Lightly oil the inside surfaces of the ear-shaped plates at the upper end of the lower roll bar tubes. c) Locate the upper u-shaped section of the roll bar.
3.5 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 hands after handling. The machine is shipped with a filled lead acid battery. 3.5.1 Tilt seat up to gain access to the battery. DANGER POTENTIAL HAZARD ♦ Charging the battery may produce explosive gases WHAT CAN HAPPEN ♦ Battery gases can explode causing serious injury.
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. 3.6 INSTALL MOTION CONTROL LEVERS 3.6.
WARNING POTENTIAL HAZARD ♦ Engine coolant is hot and pressurized. ♦ Radiator and surrounding parts are hot. WHAT CAN HAPPEN ♦ Spray or steam from hot, pressurized liquid in the engine cooling system or touching a hot radiator may cause severe burns. HOW TO AVOID THE HAZARD ♦ Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system. CAUTION POTENTIAL HAZARD ♦ Engine coolant is toxic. WHAT CAN HAPPEN ♦ Swallowing coolant can cause poisoning.
IMPORTANT: To begin movement (forward or backward) the operator must be in the seat, the brake lever must be disengaged (pushed down) before the motion control levers can be moved in or the engine will kill. When levers are centered in the T-slot the drive system is in the neutral position. With levers moved out in the T-slot the drive system is in the neutral lock position (See Figure 7).
Stop machine and wait for all moving parts to stop. Engage park brake. Tilt seat forward to gain access to the tracking knob. Rotate the knob clockwise (as viewed from the rear of the machine) to cause the machine to track more to the right and counterclockwise to cause the machine to track more to the left. Adjust in quarter-turn increments until the machine tracks straight. Check that the machine does not creep when in neutral with the park brakes disengaged.
4.1.10 4.1.11 4.1.12 Fuel Gauge: Located on the left fuel tank. The fuel gauge monitors the amount of fuel in the left tank only. Use the fuel from the right fuel tank first. When the right fuel tank is empty switch to the left fuel tank. Fuel gauge will monitor the remaining fuel. Drive Wheel Release Valves: Located on the top right front corner of hydrostatic pumps. Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running.
c) When the engine is running and the buzzer emits intermittent beeps, the buzzer is warning the user that the engine oil pressure is low or the alternator is not charging. Perform the following steps. 1. Turn the unit off, allow the engine and engine components to cool. 2. Check the oil level and fill, if necessary, as described in Section 5.1.1. 3. Check for oil leaking from engine. If the engine is leaking, see Engine Service Dealer. Check to see if the water pump/alternator belt is intact.
4.3.4 Engaging PTO: DANGER POTENTIAL HAZARD ♦ The rotating blades under the mower deck are dangerous. WHAT CAN HAPPEN ♦ Blade contact can cause serious injury or kill you. HOW TO AVOID THE HAZARD ♦ DO NOT put hands or feet under the mower or mower deck when the blades are engaged. DANGER POTENTIAL HAZARD ♦ An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also, contact with blade could occur.
CAUTION POTENTIAL HAZARD ♦ This unit does not have proper turn signals, lights, reflective markings, or a slow moving vehicle emblem. These items are required to drive on a public street or roadway. WHAT CAN HAPPEN ♦ Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury. ♦ Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and/or fines.
DO NOT attempt to turn the unit while on the ramp, you may lose control and drive off the side. Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp. Both maneuvers can cause the unit to tip backward. 5. MAINTENANCE & ADJUSTMENTS WARNING POTENTIAL HAZARD ♦ While maintenance or adjustments are being made, someone could start the engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could seriously injure you or other bystanders.
e) If the coolant level is low, remove the cap to the overflow bottle and fill to the indicator line. Use coolant specified in Section 2.5.2. NOTE: Units should only be filled with Dex-Cool© extended life coolant, which can be identified by its orange color. WARNING POTENTIAL HAZARD ♦ Engine coolant is hot and pressurized. ♦ Radiator and surrounding parts are hot. WHAT CAN HAPPEN ♦ Spray or steam from hot, pressurized liquid in the engine cooling system or touching a hot radiator may cause severe burns.
Voltage Reading 12.6 or greater 12.4 – 12.6 12.2 – 12.4 12.0 – 12.2 11.7 – 12.0 11.7 or less 5.1.4 Maximum Charger Settings 16 volts/7 amps 16 volts/7 amps 16 volts/7 amps 14.4 volts/4 amps 14.4 volts/4 amps 14.4 volts/2 amps Charging Interval No Charging Required 30 Minutes 1 Hour 2 Hours 3 Hours 6 Hours or More Clean engine cooling system: a) 5.1.
CAUTION POTENTIAL HAZARD ♦ Operating a mower deck with loose or weakened blade bolts can be dangerous. WHAT CAN HAPPEN ♦ A loose or weakened blade bolt could allow a blade rotating at a high speed to come out from under the deck, causing serious injury or property damage. HOW TO AVOID THE HAZARD ♦ Replace the blade bolt after striking a foreign object. (Use only Exmark replacement parts PN 103-0862 – blade bolt and PN 103-0865 – spring disk washer).
Run engine at one-third throttle, with brake disengaged, move levers in and raise off seat (but do not get off of machine) engine must stop after 1/2 second has elapsed. Again, run engine at one-third throttle, brake engaged, and move left motion control lever in - engine must stop. Repeat again moving the right lever in, then moving both levers in - engine must stop whether operator is on seat or not. NOTE: If machine does not pass any of these tests, do not operate.
a) Stop engine, wait for all moving parts to stop, and remove key. b) c) Tilt seat up and tilt hood forward to gain access to the engine area. Drain oil while engine is warm from operation. d) Remove the oil drain plug. There are two oil drain plugs available. One drain plug is located at the front of the engine; the other is located on the right side. Either drain plug can be used. Allow oil to drain then replace the drain plug. e) f) Replace the oil filter every other oil change.
Drain coolant when engine is cool. Coolant may be drained from the radiator by loosening the drain cock in the right rear corner. The engine block may be drained by removing the rear radiator hose and/or by removing the drain plug from the engine block. The plug may be accessed from the right side of the unit and are located as shown in Figure 9. The engine has a socket head bolt for the drain plug. FIGURE 9 COOLANT PLUG LOCATION a) Re-install drain plug and hoses and tighten drain cock.
5.1.13 Check hydraulic oil level: Service Interval: 40 hr. a) Stop engine and wait for all moving parts to stop. b) 5.1.14 Clean area around hydraulic reservoir cap and remove cap. Oil level should be to the top of the baffle inside the tank. If not, add oil. Use only Mobil 1 15W-50 synthetic motor oil. Replace hydraulic reservoir cap and tighten until snug. DO NOT overtighten. NOTE: The baffle has two levels. The upper level represents the “HOT” level and the lower level represents the “COLD” level.
LUBRICATION CHART FITTING LOCATIONS 1. Front Caster wheel hubs 2. Front Caster Pivots 3. Height Adj. Shaft Bearings 4. Deck Drive Belt Idler Arm For Units With S/N 464,999 and Lower For Units With S/N 465,000 and Higher 5. Brake Brackets 6. Fan Pump Belt Idler Arm INITIAL PUMPS ∗0 ∗0 1 NO. of PLACES 2 2 5 SERVICE INTERVAL ∗yearly ∗yearly 40 hours 1 1 1 1 40 hours 1 2 1 1 1 1 1 1 1 1 2 2 yearly 200 hours 40 hours 7.
g) h) i) j) k) l) m) n) 5.1.18 5.1.19 Lubricate brake handle pivot: Service Interval: 160 hrs. a) Stop engine, wait for all moving parts to stop, and remove key. b) Lubricate bronze bushings on brake handle pivot with a spray type lubricant or light oil. Lubricate brake rod bushings: Service Interval: 160 hrs. a) b) 5.1.20 5.1.21 Insert (1) bearing, (1) new seal into the wheel. NOTE: Seals (Exmark PN 103-0063) must be replaced.
f) Start engine. Make sure warning light goes out. Check for leaks. IMPORTANT: Water or other contaminants in fuel can severely damage fuel pump and/or the other engine components. 5.1.22 Replace fuel filter: Service Interval: 800 hrs. A fuel filter is installed between the fuel tank and the injector pump and is located under the seat in the left hand front corner of engine deck. a) Close fuel shut off valve. b) Disconnect the sensor wire, remove the drain plug and discard the o-ring.
5.1.25 5.1.26 5.1.27 Wheel hub - slotted nut torque specification. Service Interval: 500 hrs When tightening the slotted nut on the wheel motor tapered shaft: a) Torque the slotted nut to 125 ft-lbs. (169 N-m). b) Check distance from bottom of slot in nut to inside edge of hole. Two threads (0.1” (.25 cm)) or less should be showing. c) If more than two threads (0.1” (2.5 mm)) are showing remove nut and install washer (PN 1-523157) between hub and nut. d) Torque the slotted nut to 125 ft-lbs. (169 N-m).
The deck can be raised by pulling the deck lever up and/or by pushing on the deck lift assist lever. NOTE: When changing cutting height positions, always come to a complete stop and disengage the PTO. FIGURE 11 CUTTING HEIGHT POSITION d) e) Insert height adjustment pin into hole corresponding to desired cutting height and install hairpin cotter. See decals on the side of deck lift plate. Move lever out of the transport (or 5” (12.
d) e) Set anti-scalp rollers to top holes or remove them completely for this adjustment. Raise the deck to the 5” height position (also transport position) and take all force off of the two large deck lift springs by loosening the nuts at the front of each spring. See Figure 13. f) Lower the deck to the 1-1/2” height position. Force the left rear deck support arm downward about 1/4” to get the deck to rest at the 1-1/2” height position.
5.2.4 Fan Pump Belt Tension. 5.2.5 Self-tensioning – No adjustment necessary. Mule Drive Belts Tension Adjustment. Self-tensioning idlers, adjust as follows: a) Stop engine, wait for all moving parts to stop, and remove key. b) Check to make sure the coils of the spring on the spring-loaded idler pulley measures as listed below. See Figure 14. Left Side Spring – 5 3/4” ± 1/8” (14.8 ± 0.3 cm) Right Side Spring – 5 1/2” ± 1/8” (14.0 ± 0.
FIGURE 15 BELT GUIDE POSITIONING 5.2.9 Brake Link Adjustment. Check to make sure brake is adjusted properly. a) Disengage brake lever (lever down). b) Measure the length of the spring. Measurement should be 2.75” (7 cm) (See Figure 16). c) If adjustment is necessary, adjust the nyloc nut at the bottom of the spring to achieve 2 3/4” (7 cm). d) Engage the brake lever (lever up). e) The space between the brake spring bracket and the nyloc nut under the spring should measure 3/16” to 1/4” (4.8 – 6.4 mm).
b) 5.2.11 5.2.12 Tension in throttle lever can be adjusted by adjusting the tightness of the lever pivot bolt, which is located under the console (See Figure 17). FIGURE 17 THROTTLE TENSION Electric Clutch Adjustment: No adjustment is necessary. Reverse Indicator Adjustment: a) Stop engine, wait for all moving parts to stop, and remove key. b) Tilt seat forward. c) Begin with either the left or right motion control lever.
5.2.13 Motion control linkage adjustment. WARNING POTENTIAL HAZARD ♦ Engine must be running and drive wheels must be turning so motion control adjustment can be performed. WHAT CAN HAPPEN ♦ Contact with moving parts or hot surfaces may cause personal injury. HOW TO AVOID THE HAZARD ♦ Keep fingers, hands, and clothing clear of rotating components and hot surfaces.
f) g) Start engine. Brake must be engaged and motion control levers out to start engine. Operator does not have to be in the seat. Run engine at full throttle and release brake. The reverse indicator spring must be correct before the following adjustments can be made. See Section 5.2.12. NOTE: The motion control lever needs to be in neutral while making any necessary adjustments. The left rod assembly controls the left wheel and the right rod assembly controls the right wheel.
Engine coolant is a 50/50 mixture of Dex-Cool© (ethylene glycol (anti-freeze) with addititives) and water. Ethylene glycol is a pollutant. Dispose of used engine coolant according to your state and local regulations. 6.3 MERCURY SWITCH DISPOSAL CAUTION POTENTIAL HAZARD ♦ The mercury contained in the tilt switch is poisonous. WHAT CAN HAPPEN ♦ Exposure to mercury can cause severe illness. HOW TO AVOID THE HAZARD ♦ Never attempt to open or repair the tilt switch ♦ Avoid contact with the mercury.
Federal law states that batteries should not be placed in the garbage. Management and disposal practices must be within relevant federal, state, or local laws. If a battery is being replaced or if the unit containing the battery is no longer operating and is being scrapped, take the battery to a local certified recycling center. If no local recycling is available return the battery to any certified battery reseller. 7. TROUBLE SHOOTING 7.1 MOWER PULLS LEFT OR RIGHT (W/LEVERS FULLY FORWARD).
When a problem occurs, do not overlook the simple causes. For example, starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of trouble. Do not attempt to service or replace major items or any items that call for special timing of adjustment procedures (such as valves, governor, etc.). Have this work done by your Engine Service Dealer.
c) When the engine is running and the buzzer emits intermittent beeps, the buzzer is warning the user that the engine oil pressure is low, OR the alternator is not charging. Perform the following steps. 1. Turn the unit off, wait for all moving parts to stop, and remove key. Allow the engine and engine components to cool. 2. Check the oil level and fill, if necessary, as described in Section 5.1.1. 3. Check for oil leaking from engine. If the engine is leaking, see Engine Service Dealer. 4.
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9.
10. Limited Warranty Exmark Turf Equipment 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. This warranty applies to Exmark turf equipment sold in the US or Canada.
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SERVICE RECORD Description of Work Done Date Done By - 54 - Service
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SEE EXMARK’S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z® LAZER Z® HP LAZER Z® XP LAZER Z® CT TURF RANGER® VIKING HYDRO TURF TRACER® TURF TRACER® HP METRO® METRO® HP ULTRA VAC™ ULTRA VAC™ QDS GRASS CATCHER SELF STEERING SULKY MICRO-MULCH™ ACCESSORY WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
