Exmark HP User Manual
WARNING
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
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.
IMPORTANT
When the mower is used or oper ated on any California forest, brush or grass covered land, a working
spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 442
Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.
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 no responsibility for variations which may be evident in the actual
specifications of its products and the statements and descriptions contained in this publication.
i
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
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 available
only 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
3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus
orders must be received by Exmark by
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.
order
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.
ii
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 oper at ion.
OPERATOR'S MANUAL
This manual contains assembly, operating, m aint enance, adjustment and safety
instructions for your Exmark m ower.
BEFORE OPERATING YOUR MOWER,
CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
By following the operating, maintenance and safety instructions, you will prolong
the life of your mower, mainta in it s m aximum efficiency and promote safe operat ion.
If additional inform at ion 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 t o pr ovide prom pt and efficient service in the
field or at their service stations. T hey carr y ample stock of service parts or can
secure them promptly for you fr om the factory.
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.
iii
TABLE OF CONTENTS
1. SAFETY PAGE
1.1 Safety Alert Symbol ..............................................................................1
1.2 Training.................................................................................................1
1.3 Preparation........................................................................................1-3
1.4 Operation...........................................................................................4-5
1.5 Maintenance & Storage......................................................................5-7
1.6 Safety Signs.....................................................................................7-10
2. SPECIFICATIONS
2.1 Model Numbers...................................................................................11
2.2 Engine ................................................................................................11
2.3 Fuel System........................................................................................ 11
2.4 Electrical System ...........................................................................11-12
2.5 Cooling System...................................................................................12
2.6 Operator Controls...............................................................................12
2.7 Seat...............................................................................................12-13
2.8 Hydrostatic Ground Drive System.......................................................13
2.9 Tires & Wheels ................................................................................... 13
2.10 Cutting Deck..................................................................................13-14
2.11 Dimensions....................................................................................14-15
2.12 Torque Requirements ........................................................................ 15
3. ASSEMBLY INSTRUCTIONS
3.1 Uncrate Mower....................................................................................15
3.2 Service Battery...............................................................................15-18
3.3 Install Drive Wheels............................................................................18
3.4 Check Tire Pressure........................................................................... 18
3.5 Install
3.6 Install
3.7 Install Canister Air Cleaner (Kohler 26 HP EFI Only).......................... 19
3.8 Install Motion Control Levers...............................................................20
3.9 Position Discharge Chute....................................................................20
3.10 Service Engine.................................................................................... 20
3.11 Service Engine Coolant..................................................................20-21
3.12 Service Hydraulic Oil........................................................................... 21
Seat Retaining Rod (Standard Seat) or Seat (Suspension Seat) 18
Foot Lift Assist (Kohler 26 HP EFI Only)...................................19
4. OPERATION INSTRUCTIONS
4.1 Controls.........................................................................................21-24
4.2 Pre-Start............................................................................................. 24
4.3 Mowing ..........................................................................................24-25
4.4 Transporting...................................................................................25-27
5. MAINTENANCE & ADJUSTMENTS
5.1 Periodic Maintenance.....................................................................27-41
5.2 Adjustments...................................................................................41-48
6. WASTE DISPOSAL
6.1 Motor Oil Disposal...............................................................................48
6.2 Engine Coolant Disposal..................................................................... 48
6.3 Mercury Switch Disposal.....................................................................49
6.4 Battery Disposal.............................................................................49-50
7. TROUBLE SHOOTING.....................................................................50-51
8. ELECTRICAL DIAGRAMS....................................................................52-58
9. HYDRAULIC DIAGRAM..............................................................................59
10. WARRANTY..........................................................................................60-61
iv
1. SAFETY
1.1 SAFETY ALERT SYMBOL
THIS SAFETY ALERT S YMBOL IS USED BOTH IN THIS MANUAL AND ON THE
MACHINE TO IDENTIFY IMPORTANT SAFETY MESSAGES WHICH MUST BE
FOLLOWED TO AVOID ACCIDENTS. THIS
The safety alert symbol appears above information which alerts you of unsafe actions or
situations and will be followed by the word DANGER, WARNING, or CAUTION.
When used with t he word DANGER: IT DENOTES THAT AN EXTREME HAZARD
EXISTS WHICH WOULD RESULT IN HIGH PROBABILITY OF DEATH OR
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.
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 ructions to
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.
ALERT SYMBOL MEANS:
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
1.3 PREPARATION
1.3.1 The use of per sonal pr ot ective equipment, such as (but not limited to) pr otection
for the eyes, ears, feet and head is r ecom m ended.
POTENTIAL HAZARD
♦ This machine produces sound levels in excess of 85
dBA at the operator’s ear when in operation.
WHAT CAN HAPPEN
♦ Exposure to sound levels of 85 dBA or above for
extended periods of time can cause hearing loss.
HOW TO AVOID THE HAZARD
♦ Wear hearing protection when operating this machine.
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 t he 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.
CAUTION
- 1 -
WARNING
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.
DANGER
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.
- 2 -
DANGER
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 than
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.
WARNING
POTENTIAL HAZARD
♦ Gasoline vapor can collect inside enclosed trailers and
may be ignited by electrical sparks or hot
engine/exhaust components.
WHAT CAN HAPPEN
♦ Explosion and fire may occur, resulting in proper t y
damage, personal injury and/or death.
HOW TO AVOID THE HAZARD
♦ Provide adequate ventilation of any enclosed trailer to
prevent build up of gasoline vapors, especially at floor
level.
♦ Never refuel equipment inside an enclosed tr ailer .
♦ Be sure all fuel tanks and gasoline st or age containers
have proper caps installed to prevent spillage and
minimize vapor escaping into the trailer.
♦ Do not place any equipment that is leaking gasoline in
an enclosed trailer.
- 3 -
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 i nvol ved in
the operation, transport, maintenance and st orage of t he equi pment . It is essential
that all Operator Safety Mechanisms be connect ed and i n operat ing condition prior
to use for mowing.
POTENTIAL HAZARD
♦ Operating engine parts, especially the m uffler, become
extremely hot.
WHAT CAN HAPPEN
♦ Severe burns can occur on contact.
♦ Debris, such as leaves, grass, brush, etc. can cat ch fire.
HOW TO AVOID THE HAZARD
♦ Allow engine parts, especially the muff ler , to cool before
touching.
♦ Remove accumulated debris from muffler and engine area.
♦ Install and maintain in working order a spar k arrester before
using equipment on forest - covered, grass-covered, brushcovered unimproved land.
WARNING
WARNING
POTENTIAL HAZARD
♦ Hands, feet, hair, clothing, or accessories can become
entangled in rotating part s.
WHAT CAN HAPPEN
♦ Contact with rotating parts can cause traum at ic am putation
or severe lacerations.
HOW TO AVOID THE HAZARD
♦ Operate equipment with all guards in place.
♦ Keep hands, feet, hair, je welry, or clot hing away from
rotating parts.
1.4.1 Give complete, undivided attent ion t o the job at hand.
1.4.2 Mow only in daylight or good artificial light. NEVER carry passengers.
DO NOT operate the mower when children or others are in the area.
1.4.3 When feasible, avoid operating the equipment in wet grass.
1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of traction
and/or tip-over could occur. Drive slower on slopes. Progressively great er care
is needed as the slope increases. DO NOT mow slopes greater t han 15
degrees. Watch for ditches, holes, rocks, dips, and rises that change the
operating angle. Keep away from drop-offs and steep banks. Avoid sudden
starts when mowing uphill - mower may tip backwards. Loss of traction may
occur going downhill - weight transfer to the front wheels may cause drive
wheels to slip and cause loss of braking. DO NO T m ow slopes when grass is
wet - slippery conditions affect steering and r educe traction and braking. The
operator is responsible for safe operation on slopes. See inside the back cover
to determine the approximate slope angle of the area to be mowed.
- 4 -
1.4.5 Use EXTREME caution when backing up. LOOK BEHIND YOU!
1.4.6 Stop the blades when crossing surfaces other than grass and when transporting
the mower to and from the area to be m owed.
1.4.7 Never operate the mower with damaged guards, shields, or covers. Always have
safety shields, guards, switches, and other devices in place and in proper
working condition.
1.4.8 DO NOT chang e the engine governor settings or overspeed the eng ine. Operating
an engine at excessive speed may increase the hazard of personal injury.
1.4.9 Disengage blade dr ive before starting engine.
1.4.10 Start
the engine carefully with feet well away from the blades.
1.4.11 Keep hands, feet and clothing away from r ot a t ing parts while the mower is being
operated.
1.4.12 Stop the engine and remove ignition k ey:
• Before checking, cleaning or work ing on the mower.
• After striking a foreign object (inspect the m ower for damage and make
repairs before restart ing and operating the mower).
• Before clearing blockages.
• Whenever you leave the mower.
Stop the engine:
• Before refueling.
• Before dumping the gr ass cat c her .
1.4.13 Allow the engine to cool before stopping t he engine.
1.4.14 The fuel system is provided with a shut-off valve. Shut off the fuel:
• When the machine will not be used for a few days.
• During transport to and f r om the job.
• When parked 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 discharge chute in place.
1.4.17 If jump starting is required:
a) connect the positive (+) power cable from the posit ive post on the booster
battery to the positive terminal post on the st ar t er 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 order after starting.
1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maint enance, follow the engine manufacturer’s r ecom m endat ions
precisely as stated in the engine manual.
1.5.2 Disconnect the batt er y cable from the negative battery post when the unit will be
allowed to sit for more than 30 days without use.
1.5.3 Allowing batteries to stand for an extended period of time without recharging
them will result in reduced performance and ser vice life. To preserve optimum
battery performance and lif e, recharge batteries in storage when the open
circuit voltage drops to 12.4 volts.
Note: To prevent damage due to freezing, battery should be fully charged
before putting away for winter storag e.
- 5 -
1.5.4 Store f uel in a container specifically designed for this pur pose 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 safet y can only be achieved if the m ower is
properly maintained and operated correctly.
1.5.8 Check all bolts frequently to maintain proper t ightness.
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 deterior ating components that could create a hazard.
1.5.11 All replacement parts must be the same as or equivalent to the parts supplied as
original equipment.
WARNING
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 gangr ene m ay 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.
For Kawasaki Liquid-Cool ed uni ts:
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 and touching a hot radiat or
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.
- 6 -
POTENTIAL HAZARD
♦ Engine coolant is toxic.
WHAT CAN HAPPEN
♦ Swallowing coolant can cause poisoning.
HOW TO AVOID THE HAZARD
♦ Do not swallow
♦ Keep out of reach of children and pets.
For Kohler 26 HP EFI Units:
POTENTIAL HAZARD
♦ Fuel system components are under high pressure.
WHAT CAN HAPPEN
♦ The use of improper components can r esult in system
failure, gasoline leakage and possible explosion.
HOW TO AVOID THE HAZARD
♦ Use only approved fuel lines and fuel filters for high
pressure systems.
CAUTION
WARNING
1.6 SAFETY SIGNS
1.6.1 Keep all safety signs legible. Remove all gr ease, dir t and debris from safet y
signs and instructional labels.
1.6.2 Safety signs must be replaced if they are missing or illegible.
1.6.3 When new components are installed, be sur e 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 fr om Exmark Mfg. Co. Inc.
1.6.5 Safety signs may be affixed by peeling of f the backing to expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.
1.6.6 Familiarize yourself with the following safety signs and inst r uction labels. They
are critical to the safe operation of your Exmark commercial mower.
PART NO. 103-0166
LOCATION: LH Side of Console
- 7 -
PART NO. 103-0210
LOCATION: RH Side of Console
Serial Nos. 220,000 and Higher
PART NO. 1-643401
LOCATION: On Tilt Switch
PART NO. 65-2690
LOCATION: Top of Radiator Trim Plate
LH & RH Sides
Serial Nos. 220,000 thru 251,999
PART NO. 1-643372
LOCATION: Top LH Side of Console, Under Front of Seat
PART NO. 103-1077
LOCATION: Top LH Side of Mower Deck
next to Stiffener
PART NO. 1-633345
LOCATION: RH Side of Cutting
Height Adjustment Plate
PART NO. 1-403005
LOCATION: Left and Right Corners
of Mower Deck
Serial Nos. 251,999 and Lower
PART NO. 1-633354
LOCATION: Top of Console
PART NO. 1-633706
LOCATION: LH Side of Cutting
Height Adjustment Plate
- 8 -
Kohler 26 HP EFI Units Only
PART NO. 1-643288
LOCATION: Panel behind LH Fuel Tank.
PART NO. 1-513748
LOCATIONS: -Rubber Heat Shield
Behind Seat (serial
numbers 259,9999
and lower only)
-Bottom Side of
Floorpan
PART NO. 1-633313
LOCATION: RH Side on Top
Front Mower Deck
PART NO. 1-523552
LOCATION: Top of Hydraulic
Reservoir, Under the Seat
PART NO. 1-643222
LOCATION: Left of Center on Mower
Deck, Under Floor Pan
PART NO. 1-323540
LOCATION: Left Rear Corner Top
of Mower Deck
PART NO. 1-513742
LOCATION: Top of Mower Deck Belt
Shields, Left and Right Sides
PART NO. 1-633922
LOCATION: Front Center on Top
of Mower Deck
Kohler 26 HP EFI Units Only
PART NO. 103-0161
LOCATION: Below Center of
Console
All Units except Kohler 26 HP EFI
PART NO. 103-0162
LOCATION: Below Center
of Console
Kawasaki Liquid-Cooled Units Only
PART NO. 1-643253
LOCATION: LH and RH Sides of Radiator Mount Plate
PART NO. 1-633462
LOCATION: Rubber Heat Shield
Flap behind Seat
PART NO. 103-0368
LOCATION: Rubber Heat Shield Flap behind Seat
- 9 -
PART NO. 1-633827
p
LOCATION: Top LH Side of Mower Deck Frame
Serial Nos. 251,999 and Lower
PART NO. 1-513747
LOCATION: Top Center of Console, Under Front of Seat
PART NO. 1-643339
LOCATION: Top of Right Engine Baffle
PART NO. 1-303508
LOCATION: RH Side on Top Rear of
Mower Deck
PART NO. 1-303293
LOCATION: On Top of
Fuel Tanks
Serial Nos. 251,999 and Lower
PART NO. 1-513929
LOCATION: Hydraulic Reservoir Mounting Bracket,
Under the Seat
Serial Nos. 252,000 and Higher
PART NO. 103-0245
LOCATION: To
of console
PART NO. 1-633702
LOCATION: Bottom Side of Floor Pan
- 10 -
2. SPECIFICATIONS
2.1 MODEL NUMBER:
Serial Nos. 160,000 – 189,999
LZ18KC523; LZ22KC523; LZ25KC523; LZ22KC603; LZ25KC603
Serial Nos. 190,000 – 219,999
LZ18KC523; LZ22KC523; LZ22LKA523; LZ23KC523; LZ25KC523; LZ22KC604;
LZ22LKA604; LZ23KC604; LZ25KC604; LZ26KC604; LZ25KC724; LZ26KC724
Serial Nos. 220,000 – 259,999
LZ22LKA523; LZ23KC523; LZ25KC523; LZ22LKA604; LZ23KC604; LZ25KC604;
LZ26KC604; LZ23LKA604;
Serial Nos. 260,000 and Higher
LZ25KC524; LZ23LKA524; LZ23KA604; LZ23KC604; LZ25KC604; LZ26KC604;
LZ23LKA604; LZ26KC724; LZ27LKA604; LZ27LKA724
2.2 ENGINE:
2.2.1 Engine Specifications: See your Engine Owner’s Manual
2.2.2 RPM: 18, 22, 23, & 25 HP Kohler
Full Speed: 3600 RPM (No Load) Idle:1500 RPM
26 HP EFI Kohler and 23 HP Kawasaki Liquid-cooled models
Full Speed: 3750 RPM (No Load) Idle:1500 RPM
27 HP Kawasaki Liquid-cooled models
Full Speed: 3750 RPM (No Load) Idle: 2200 RPM
2.3 FUEL SYSTEM
2.3.1 Capacity: 9.0 g al. (34 L.) for Serial Nos. 160,000-189,999
11.0 gal. (42 L.) f o r Ser ial Nos. 190,000 & Higher
2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or higher
2.3.3 Fuel Filter:
Kohler Air-cooled units: In-line 15 Micron Kohler P/N 2405002.
Kohler 26 HP EFI units: In-line 22 Micron Exmark P/N 99- 9403 (low pressure).
Kawasaki Liquid-cooled units: In-line 40 Micron Kawasaki P/N 49019-1055
Kawasaki Air-cooled units: In-line Kawasaki P/N 49019-7001
2.3.4 Fuel Shut-Off Valve: 1/4 turn increments ( left tank, “OFF”, right tank)
2.4 ELECTRICAL SYSTEM
2.4.1 Charging System: All Kohler & Kawasaki Air - c ooled unit s - Flywheel Alternator
2.4.2 Charging Capacity: All Kohler & Kawasaki Air-cooled units - 15 amps
2.4.3 Battery Type: BCI Group U1
2.4.4 Battery Voltage: 12 Volt
2.4.5 Polarity: Negative Ground
2.4.6 Fuses: Kohler Air-cooled units –Two 20 amp blade type
Kohler 26 HP EFI units – Two 20 amp and one 10 amp blade type
LZ25KC724; LZ26KC724
and 22 HP Kawasaki Liquid-cooled models
In-line 10 Micron Kohler P/N 2405003 (high pressure).
Kawasaki 22 & 23 HP Liquid-cooled units - External Alternator
Kawasaki 27 HP Liquid-cooled units – 3 Phase Flywheel Alternator
Kawasaki 22 & 23 HP Liquid-cooled units – 37 amps
Kawasaki 27 HP Liquid-cooled units – 30 amps
Kawasaki 22, 23, & 27 HP Liquid-cooled units – One 20 amp and t wo 30
amp blade type
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2.4.7 Safety Interlock System:
For Kohler units Serial Nos. 251,999 and Lower and all 22 & 23 HP Kaw asaki
Liquid-cooled units:
Operator must be in seat with Blades disengaged, brake engaged, and
motion control levers out (neutral lock) to start engine.
For Kohler (Serial Nos. 252,000 & Higher), all Kaw a saki Air - c ooled and all 27 HP
Kawasaki Liquid-cooled units:
Blades must be disengaged, brake engaged, and motion control l evers out
(neutral lock) to start engi ne. (It is not necessary for the operator t o be in the
seat to start the engine.)
For all units:
Operator must be in seat when Blades are engaged, brake i s disengaged, or
motion control levers are moved in or engine will stop.
Engine will stop if either the left, the right, or both levers are moved from neutral
lock position while brake is engaged.
2.4.8 Tilt Switch: (Serial Nos. 220,000 & Higher) Shuts off the engine when the unit is
tilted more than 60° from horizontal.
2.5 COOLING SYSTEM (Kawasaki Liquid-cooled units only)
2.5.1 Fan: 22 & 23 HP units: Thermostatically controlled electric
27 HP units: Electric with continuous operation with engine running
2.5.2 Coolant Liquid:
Kawasaki 22 HP Liquid cooled: 50/50 mix of ethylene glycol and water.
Kawasaki 23 & 27HP Liquid-cooled: 50/50 mix of DexCool© extended life
antifreeze and water.
2.5.3 Coolant Capacity: 4 quarts
2.6 OPERATOR CONTROLS
2.6.1 Steering and Motion Control:
Separate levers, on each side of the console, contr ol speed and dir ect ion of
travel of the respective drive wheels.
Steering is controlled by varying the position of the levers relative to each other.
Moving motion control levers outward
(in slots) locks the drive system in neutral.
NOTE: Newer motion control levers are adjust able t o two heights.
2.6.2 Blade Engagement Switch: Engag es elect ric clutch (to drive belt) which
engages mower blades.
2.6.3 Parking Brake Lever: Sets br akes.
2.6.4 Deck Height Adjustment Lever: Sets cutting height to desired posit ion.
2.6.5 Deck Lift Assist Lever: Kohler 26 HP EFI unit s and all 72” units – Foot pedal that
assists in raising the deck. (This lever is an optional accessor y for all other
units.)
2.7 SEAT
2.7.1 Type: All units except Kohler 26 HP EFI - Standar d seat with high back, foam
padded (internal suspension) and armrests.
Kohler 26 HP EFI units - Deluxe suspension seat with high back, low prof ile
foam-in-place cushion (dampened, adjust able spr ing suspension) and armrests.
(This seat is an optional accessory for all other units)
2.7.2 Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other
components. Held in tilted position with prop rod. Adjustable fore and aft seat t r ack.
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2.7.3 Armrests: Standard seat: foam padded flip-up armrests.
Serial Nos. 252,000 and Higher: Armrests with height adjustment.
Optional suspension seat: molded adjustable f lip-up
armrests.
2.7.4 Seat Safet y Switch: Incor por ated into the Safety Interlock System. Time delay
seat switch eliminates rough ground cut-outs.
2.8 HYDROSTATIC GROUND DRIVE SYSTEM
2.8.1 Hydrostatic Pumps: T wo Hydro Gear BDP- 10L variable displacement piston pumps.
2.8.2 Wheel Motors: T wo Parker/Ross with 1 1/4” tapered shafts.
2.8.3 Hydraulic Oil Type: Synthetic Mobil 1 15W- 50.
2.8.4 Hydraulic Oil Capacity: 2.1 qt.(2.0 L.)
2.8.5 Hydraulic Filter: Replaceable cartridge type.
P/N 1-513211: 10 microns, 18 psi bypass (Summer use above 32° F)
P/N 1-523541: 40 microns, 18 psi bypass (Winter use below 32° F)
2.8.6 Speeds: 18, 22, 23, & 25 HP Kohler & Kawasaki Air-cooled
and 22 HP
Kawasaki Liquid-cooled models:
Serial Nos. 160,000-189,999 Serial Nos. 190,000 & Higher
0 - 9.0 mph (14.5 km/hr ) forward. 0 - 9.4 mph (15.1 km/hr) forward.
0 - 4.2 mph (6.8 km/hr ) r everse. 0 – 6.0 mph (9.7 km/hr) r everse.
26 HP Kohler EFI and 23 & 27 HP Kawasaki Liquid-cooled models:
0-9.8 mph (15.8 km/hr ) forward.
0-6.3 mph (10.1 km/hr ) r everse.
2.8.7 Drive wheel release valves allow machine to be moved when engine is not running.
2.9 TIRES AND WHEELS
2.9.1 Tires Drive Front Cstr.
Qty:..........................................2....................................2
Ply:..........................................4....................................4
Infl: ......................................13 psi (90 kPa).............13 psi (90 kPa)
Serial Nos. 160,000–189,999
Size:.................................23 x 10.5-12................13 x 5.00-6
Tread:...............................“Turfmate”...................... Smooth
Kohler Air-cooled Units - Serial Nos. 190,000 - 259,999
Size: w/52”Deck ...............23 x 9.5-12..................13 x 5.00-6
Size: w/60”&72”
Tread:...............................“Turf Master”..................Smooth
Kohler and Kawasaki Air-cooled units Serial Nos. 260,000 & Higher and all
Kawasaki Liquid-cooled Units
Size: w/52” Deck...............23 x 9.5-12.....................13 x 6.50-6
Size: w/60” & 72” Deck.....24 x 12.0-12...................13 x 6.50-6
Tread:...............................“Turf Master”..................Smooth
Deck .......24 x 12.0-12................13 x 6.50-6
2.10 CUTTING DECK
2.10.1 Cutting Width: 72 in. (182.9 cm)
60 in. (152.4 cm)
52 in. (132.1 cm)
2.10.2 Discharge: Side
2.10.3 Blade Size: (3 ea.) w/52” Deck 18.0 in. (45.7 cm)
w/60” Deck 20.5 in. (52.1 cm)
w/72” Deck 24.5 in. (62.2 cm)
2.10.4 Blade Spindles: Solid steel spindles with1” I.D. bearings.
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2.10.5 Deck Drive: Electric clutch mounted on horizontal eng ine shaft. “B” Section belt
(with self-tensioning idler) from electric clutch to transfer shaft mounted on deck .
Blades are driven by one “B” Section belt (w/self-tensioning idler) from transfer
shaft on deck to blade spindles.
2.10.6 Deck: Full floating deck is attached to out- front support frame. Six anti-scalp
rollers provide maximum turf prot ect ion. Dual deck support shafts add to the
stability of the deck. Deck design allows for bagging, m ulching or side discharge.
Deck Depth:
52” Deck (Serial Nos. 259,999 & Lower): 5.0” (12.7 cm)
52” Deck (Serial Nos. 260,000 & Higher : 5.5” (14.0 cm)
60” Deck (Serial Nos. 160,000-189,999): 5.0” (12.7 cm)
60” Deck (Serial Nos. 190,000
72” Deck: 5.5” (14.0 cm)
2.10.7 Cutting Height Adjustment : an extra-long cushioned lever is used to adjust the
cutting height fr om 1 1/ 2” ( 3.8 cm) to 5” (10.2 cm.) in 1/2” (1.3 cm.) increments
for Serial Nos. 160,000-189,999 and 1/4” (.64 cm) increments for Ser ial No.
190,000 & higher. The cutting height adjustment handle has a transport posit ion
and all adjustments can be made while the operator remains seated. Kohler 26
HP EFI units and all 72” units also have a foot operat ed deck lift assist lever to
aid in raising the deck. (T he deck lift assist lever is an optional accessory for all
other units.)
2.10.8 Mulching Kit: Optional.
2.11 Dimensions
2.11.1 Overall Widt h:
& higher): 5.5” (14.0 cm)
without deck deflector up deflector down
Serial Nos. 160,000-259,999 w/52” Deck 49.8 in. (126.5 cm) 53.4 in. (135.6 cm) 63.1 in. (160.3 cm)
Serial Nos. 260,000 & Higher w/52” Deck 49.8 in. (126.5 cm) 53.4 in. (135.6 cm) 64.2 in. (163.1 cm)
Serial Nos. 160,000-189,999 w/60” Deck 53.8 in. (136.7 cm) 61.4 in. (156.0 cm) 71.0 in. (180.3 cm)
Serial Nos. 190,000 & Higher w/60” Deck 53.5 in. (135.9 cm) 61.4 in. (156.0 cm) 72.9 in. (185.2 cm)
Serial Nos. 190,000 & Higher w/72” Deck 57.3 in. (145.5 cm) 73.2 in. (185.9 cm) 84.3 in. (214.1 cm)
2.11.2 Overall Length:
All Air-cooled units - w/52” & 60” decks - 78. 5 in. (199.4 cm)
w/72” deck – 82.6 in. (209.8 cm)
Kawasaki Liquid-cooled units – w/52” & 60” decks – 80.7 in. (205. 0 cm )
w/72” deck – 84.8 in. (215.4 cm)
2.11.3 Overall Height:
Serial Nos. 160,000-189,999: 44 in. (111.8 cm . )
Air-cooled units Serial Nos. 190,000
& higher: 44.5 in. (113.0 cm.)
Kawasaki Liquid-cooled units – 47.7 in (121.2 cm)
2.11.4 Tread W idth: (center to center of t ires, widthwise)
Drive wheels:
Serial Nos. 160,000 & Higher w/52” Deck – 39.7 in. ( 100. 1 cm )
Serial Nos. 160,000
– 189,999 w/60” Deck - 43.7 in. (111.0 cm)
Serial Nos. 190,000 & Higher w/60” Deck – 41.9 in. ( 106. 4 cm )
Serial Nos. 190,000 & Higher w/72” Deck – 45.9 in. ( 116. 6 cm )
Casters:
w/52” Deck – 37.0 in. (93.9 cm)
w/60” Deck – 39.0 in. (99.1 cm)
w/72” Deck – 47.6 in. (120.9 cm)
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2.11.5 Wheel Base: (center of caster tire t o center of drive tire)
w/52” & 60” Decks - 50.3 in. (127.8 cm)
w/72” Deck – 54.5 in. (138.4 cm)
2.11.6 Curb Weig ht*
Air-cooled units:
Serial Nos. 160,000 & Higher w/52” Deck – 976 lbs. ( 443. 6 kg)
Serial Nos. 160,000
–189,999 w/60” Deck – 1000 lbs. (454.5 kg )
Serial Nos. 190,000 & Higher w/60” Deck – 1033 lbs. (469.5 kg)
Serial Nos. 190,000 & Higher w/72” Deck – 1106 lbs. (501.7 kg)
22 & 23 HP Kawasaki Liquid-cooled units:
w/52” Deck – 1,196 lbs. (542.5 kg)
w/60” Deck – 1,218 lbs. (552.5 kg)
27 HP Kawasaki Liquid-cooled units:
w/60” Deck – 1,298 lbs. (588.9 kg )
w/72” Deck – 1,306 lbs. (592.6 kg )
* Note: Weight will vary slightly, depending on engine option.
2.12 TORQUE REQUIREMENTS
Bolt Location Torque
Cutter Housing Spindle Nut................................ 75-80 ft-lbs.
Blade Mounting Bolt........................................ 115-120 f t-lbs.
Engine Deck/Front Frame Mount........................ 30-35 ft-lbs.
Anti-Scalp Roller Bolts........................................ 40-45 ft-lbs.
Engine Mounting Bolts (Kohler).......................... 30-35 ft-lbs.
Engine Mounting Bolts (Kawasaki) ..................... 25-30 ft-lbs.
Wheel Lug Nuts.................................................. 90-95 f t-lbs.
Wheel Motor Mounting Bolts............................... 72-77 ft-lbs.
Wheel Hub Slotted Nut............................minimum125 ft-lbs.
3. ASSEMBLY INSTRUCTIONS
3.1 UNCRATE MOWER
3.2 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.
For Serial Nos. 252,000 and higher.
The machine is shipped with a filled lead acid battery.
3.2.1 Tilt seat up to gain access to the battery.
DANGER
POTENTIAL HAZARD
♦ Charging the battery may produce explosive gasses
WHAT CAN HAPPEN
♦ Battery gasses can explode causing serious injury.
HOW TO AVOID THE HAZARD
♦ Keep sparks, flames, or cigarettes away from battery.
♦ Ventilate when charging or using batter y in an
enclosed space.
♦ Make sure venting path of battery is always open once
battery is filled with acid.
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3.2.2 Check the voltag e of the battery with a digital voltmeter. Locat e the voltage reading
of the battery in the table below and charge the bat tery for the recommended time
interval to bring the charge up t o a full charge of 12.6 volts or greater.
IMPORTANT: Make sure the negative battery cables are disconnected and the
battery charger used for charging the battery has an output of 16 volts and 7
amps or less to avoid damaging the batter y (see char t below f or r ecom mended
charger settings).
Voltage
Reading
12.6 or greater 100% 16 volts/7 amps No Charging Required
12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes
12.2 – 12.4 50 – 75% 16 volts/7 amps 1 Hour
12.0 – 12.2 25 – 50% 14.4 volts/4 amps 2 Hours
11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours
11.7 or less 0% 14.4 volts/2 amps 6 Hours or More
Percent
Charge
Charger Settings
CAUTION
POTENTIAL HAZARD
♦ If the ignition is in the “ ON” position there is potential
for sparks and engag em ent of components.
WHAT CAN HAPPEN
♦ Sparks could cause an explosion or moving parts
could accidentally engage causing personal injury.
HOW TO AVOID THE HAZARD
♦ Be sure ignition switch is in the “OFF” position before
charging the battery.
3.2.3 Connect the negative battery cables.
NOTE: If the positive cable is also disconnected, connect the positive (red)
cable and the red wire to the positive term inal on the battery first, then connect
the negative (black) cable and white/white wire to the negative terminal on the
battery (red wire and white/white wire are only on some units). Slip insulator boot
over the positive terminal.
NOTE: If time does not perm it char ging 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 suf ficiently charge the battery.
Maximum
Charging Interval
For Serial Nos. 251,999 and lower.
The machine is shipped with a dry battery.
3.2.4 Remove battery from machine. Tilt seat up to gain access to t he bat tery.
Disconnect battery cables – negative (black) cable fi rst . Remove battery
hold-down and lift battery out.
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