Exmark 920 manual

LAZER Z ® D-SERIES For Serial Nos. 920,000 & Higher Lazer Z (LZD) Units Part No. 4500-919 Rev . A[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals known to the State of Califor nia to cause cancer , bir th defects, or other reproductiv e har m. Important: The engine in this product is not equipped with a spark ar rester mufer . It is a violation of Califor nia Public Resource Code (CPRC) Se[...]

Introduction CONGRATULATIONS on the purc hase of your Exmark Mo w er . T his product has been carefully designed and man ufactured to gi ve you a maxim um amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for your Exmark mow er . BEFORE OPERATING Y OUR MO W[...]

Contents Introduction . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . 3 Safety .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. 5 Safety Aler t Symbol . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. [...]

Safety Safety Safety Alert Symbol This lawn mow er meets or ex ceeds the B71.4 specications of the American National Standards Institute in effect at the time of production. Exmark designed and tested this lawn mo wer to offer reasonably safe ser vice; howev er , failure to comply with the following instr uctions may result in personal injur y .[...]

Safety • Inspect the area where the equipment is to be used and remov e all rocks , to ys , stic ks , wires , bones , and other foreign objects which can be thrown b y the machine and ma y cause personal injur y to the operator or bystanders . DANGER In cer tain conditions diesel fuel is extremel y ammable and v apors are explosiv e. A re o[...]

Safety guards , switches and other devices in place and in proper working condition. • Never mo w with the discharge deector raised, remov ed or altered unless there is a g rass collection system or m ulch kit in place and w orking properly . • Do Not change the engine g o v ernor setting or ov erspeed the engine. • P ark mac hine on level[...]

Safety Figure 3 1. Safe Zone-Use the mower here on slopes less than 15 degrees 2. Danger Zone-Use a walk behind mower and/or hand trimmer on slopes greater than 15 degrees, near drop-offs and water . 3. W ater • R emov e or mark obstacles suc h as rocks , tree limbs , etc . from the mo wing area. T all g rass can hide obstacles . • W atc h for [...]

Safety negative ter minal rst and the positiv e last. R econnect positi ve rst and negativ e last. • Use care when c hecking blades . W rap the blade(s) or wear glov es , and use caution when ser vicing them. Only replace damaged blades . Nev er straighten or weld them. • Keep hands and feet awa y from moving par ts . If possible, Do Not [...]

Safety W ARNING Hydraulic uid escaping under pressure can penetrate skin and cause injur y . Fluid accidentally injected into the skin must be surgically remov ed within a few hour s by a doctor familiar with this for m of injur y or gangr ene may result. • If equipped, make sure all h ydraulic uid hoses and lines are in good condition and [...]

Safety Safety and Instructional Decals • Keep all safety signs legible. Remov e all grease, dirt and debris from safety signs and instructional labels . • R eplace all w orn, damaged, or missing safety signs . • When replacement components are installed, be sure that current safety signs are afxed to the replaced components . • If an att[...]

Safety 103-0223 103-0261 103-1798 103-2076 103-7218 107-2102 12[...]

Safety 109-0872 109-1214 109-1215 109-1399 109-2219 109-2263 13[...]

Safety 109-2264 109-2478 109-2951 109-3148 14[...]

Safety 1 16-0127 1 16-0404 1 16-0997 1 16-2643 1 16-3303 1 16-5074 1 16-5185 1. PTO–engage 2. PTO–disengage 1 17–2718 15[...]

Safety 19426-87881 19426-87903 107-9866 1. Fast 3. Neutral 2. Slow 4. Reverse 16[...]

Specications Specications Model Numbers Serial Nos: 920,000 and Higher LZD25KD605; LZD25KD725 Systems Engine • Engine Specications: See your Engine Owner’ s Manual • Engine Oil T ype: Exmark 4–Cycle Premium Engine Oil • RPM: Full Speed: 3850 ±50 RPM (PTO not engag ed) Idle: 1400 ±100 RPM Fuel System • Capacity: 15.5 gal. (58.[...]

Specications – Moving motion control levers outward (in slots) loc ks the drive system in neutral. • PTO Engag ement Switch: Engag es electric clutch (to dri v e belt) which engages mow er blades . • P arking Brake Lev er: Engag es parking brake . • Deck Height Adjustment Lev er: Sets cutting height to desired position. • Deck Lift Ass[...]

Specications Dimensions Overall Width: 60 inch Deck 72 inch Deck Without Deck 53.5 inches (135.9 cm) 61.5 inches (156.2 cm) Deector Up 61.4 inches (156.0 cm) 74.3 inches (188.7 cm) Deector Down 72.8 inches (184.9 cm) 85.8 inches (217.9 cm) Overall Length: 60 inch Deck 72 inch Deck R oll Bar - Up 81.9 inches (208.0 cm) 85.8 inches (217.9 cm[...]

Operation Product Overview Figure 4 1. Motion control levers 5. Engine Controls (right console) 2. Parking brake 6. Seat belt 3. Height of cut adjustment 7. Rollover Protection System (ROPS) 4. Fuel cap (both sides) Operation Note: Deter mine the left and right sides of the machine from the nor mal operating position. Controls Motion Control Levers[...]

Operation and moving the throttle lever to the rear will decrease engine speed. Mo ving the throttle forw ard into the detent is full throttle. Brake Lever Located on left side of unit, just to the front of the console. The brake lever eng ages a parking brake on the driv e wheels . Pull the lever up and rearward to engage the brak e . Push the lev[...]

Operation PTO Engagement Switch Located on right fuel tank. Switch must be pulled out (up) to engag e the blades . Switch is pushed in to diseng age the blades . Note: If the engine o verheats , the PTO will automatically disengage. T he PTO cannot be engag ed until the engine has cooled do wn. T o re-engag e the PTO , push PTO switc h in to the di[...]

Operation Important: Do Not use kerosene or gasoline instead of diesel fuel. F ailure to obser ve this caution will damage the engine. Do Not overll fuel tank. Fill the fuel tank to the bottom of the ller neck. The empty space in the tank allo ws the fuel to expand. Overlling may result in fuel leakage or damage to the engine or emission s[...]

Operation 7. T urn ignition switch to the “ON” position. Depress the glow plug switch and the glo w plug light will turn on. Hold switch as required by chart belo w . T urn the ignition switc h to the “ST ART” position. R elease the ignition switch as soon as the engine starts . Glow Plug Chart Ambient T emperature Hold Glow Plugs On Abov e[...]

Operation Driving the Machine CAUTION Machine can spin ver y rapidly by positioning one lever too much ahead of the other . Operator may lose control of the machine, which may cause damage to the machine or injur y . • Use caution when making tur ns. • Slow the machine down before making shar p tur ns. Important: T o begin mov ement (forw ard o[...]

Operation The deck can be raised by pulling the dec k lev er up and/or by pushing do wn on the foot operated deck lift assist lev er located at the front right corner of the oor pan. Note: When changing the cutting height positions, alw ays come to a complete stop and disenga ge the PT O . Figure 9 1. Lever in transport and 5 inch (12.7 cm) cutt[...]

Operation Figure 1 1 1. Spring disc washer (cone towards bolt head) 3. 3/8 nyloc-torque to 30-35 ft-lb (41-47 N-m) 2. Front right anti-scalp bracket shown 4. 3/8-24 x 2 GR8 torque to 50-55 ft-lb (68-75 N-m) 9. If the 3/8 nyloc nut has been remo v ed, re-install and tor que to 30–35 ft-lb (41–47 N-m) (Figure 11). T ransporting T ransporting a Un[...]

Maintenance Maintenance Note: Determine the left and right sides of the mac hine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental starting of the engine could seriousl y injure you or other bystanders. Remo ve the key fr om the ignition s witch, enga ge parkin[...]

Maintenance Maintenance Ser vice Inter v al Maintenance Procedur e Every 200 hours • Grease the brake brackets . Every 400 hours • Replace the fuel lter/water separator (more often in dir ty or dusty conditions). Every 500 hours • Check the wheel hub slotted nut tor que specications . • Check the wheel lug nuts . • Chang e the h ydr[...]

Maintenance Check the v oltage of the battery with a digital voltmeter . Locate the voltage reading of the battery in the table and charge the battery for the recommended time inter v al to bring the charge up to a full c harge of 12.6 v olts or g reater . Important: Mak e sure the negativ e batter y ca ble is disconnected and the batter y charger [...]

Maintenance Figure 12 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 positiv e cable to the positiv e terminal of the booster batter[...]

Maintenance W ARNING Incor rect installation of the blade or components used to retain the blade can be dangerous. F ailure to use all original components and assembled as sho wn could allow a blade or blade component to be thrown out from under the deck r esulting in serious personal injur y or death. Always install the original Exmark blades, bla[...]

Maintenance the Engine Owner ’ s Manual for additional information.) Every 600 hours— Replace the air cleaner elements. (May need more often under severe conditions. See the Engine Owner ’ s Manual for additional information.) 1. Stop engine, wait for all moving parts to stop , and remov e k ey . Engag e parking brak e . 2. Unhook tw o air ?[...]

Maintenance 2. Check tire pressure in drive tires . 3. Inate driv e tires to 10 psi (69 kP a). 4. Semi-pneumatic caster tires do not need to be inated. Note: Do Not add an y type of tire liner or foam ll material to the tir es. Excessi v e loads created b y foam lled tires ma y cause failures to the h y dro dri v e system, frame, and ot[...]

Maintenance Wheel Hub - Slotted Nut T orque Specication Service Interval: After the rst 100 hours Every 500 hours thereafter T or que the slotted n ut to 211-260 ft-lb (286-352 N-m). Note: Do Not use anti-seize on wheel hub . Lubricate Caster Wheel Hubs Service Interval: As required 1. Stop engine, wait for all moving parts to stop , and remo[...]

Maintenance (bushings are located to the inside of the ange bearings). Lubricate Motion Control Bronze Bushings Service Interval: Every 160 hours 1. Stop engine, wait for all moving parts to stop , and remov e k ey . Engag e parking brak e . 2. Unhook seat latch and tilt seat up . 3. Lubricate bronze bushings on ange bearings securing the mot[...]

Maintenance 6. Raise the rear of mac hine up and support with jack stands (or equi valent suppor t) just high enough to allow dri v e wheels to turn freely . 7. Start engine and move throttle control ahead to full throttle position. Move the speed control levers to the full speed and r un for sev eral minutes . Shut down machine and rechec k oil le[...]

Maintenance Figure 16 1. Oil dipstick 2. Drain cock 4. R einstall all drain plugs and hoses and tighten drain coc k. 5. Fill radiator with a 50/50 mix of water and Dex-Cool© coolant as specied in the Check Engine Coolant Level Section, allowing some room (approximately 1/2 inc h (12.7 mm)) for expansion. Add 50/50 coolant mix to o v erow bot[...]

Maintenance • Fuel tank bulkhead tting nuts . • Bolts retaining stub shaft to engine ywheel. Adhesiv es suc h as “Loctite R C/609 or R C/680” or “F el-Pro Pro-Loc k R etaining I or R etaining II” are used on the following: Fuel tank studs , where studs are inserted into tank. Mobil HTS Grease (Or Food-Grade Anti-seize) Mobil HTS g[...]

Maintenance the chain bolts in the dec k lift arms making sure they don ’ t mo v e while tightening . 9. Loosen the four n uts whic h secure the front swiv els (tw o per side) until the front chains are loose and front of dec k is supported by the 3/4 inch (19 mm) bloc k. Do Not loosen the front chain hardware . 10. On left side, adjust front swi[...]

Maintenance Figure 18 1. Front of unit 2. Alignment holes Figure 19 1. Spring idler pulley 3. Right side idler pulley (adjustable) 2. Front of unit Alternator Belt T ension Stop engine, wait for all moving parts to stop and remov e k ey . Eng age parking brake . Tilt seat and remo v e air deector panel T o tighten alternator belt, loosen both up[...]

Maintenance CAUTION Raising the mower deck for ser vice or maintenance r elying solely on mechanical or hy draulic jacks could be dangerous. The mechanical or hy draulic jacks may not be enough support or may malfunction allo wing the unit to fall, which could cause injur y . Do Not rely solely on mechanical or h ydraulic jacks for suppor t. Use ad[...]

Maintenance Electric Clutch Adjustment No adjustment necessar y . Ho wev er when the clutch brake has w orn to the point where the clutch no longer engag es consistently , the shim can be remo v ed to extend the clutc h life. Figure 22 1. Armature 5. Brake spacer 2. Field shell 6. Re-gap shim 3. Rotor 7. Brake pole 4. Brake mounting bolt Remo ving [...]

Maintenance Figure 25 1. Feeler gauge • If the g ap is less than 0.010 inc h, then reinstall the shim and reference the T roubleshooting section. • If the g ap is sufcient, proceed to the safety check in step F. F . P erfor m the following safety check: a. Sit on the seat and star t the engine. b . Mak e sure the blades Do Not engag e with t[...]

Maintenance CAUTION Raising the mower deck for ser vice or maintenance relying solely on mechanical or h ydraulic jacks could be danger ous. The mechanical or h ydraulic jacks may not be enough suppor t or may malfunction allowing the unit to fall, which could cause injur y . Do Not rel y solely on mechanical or h y draulic jacks for suppor t. Use [...]

Maintenance Motion Control Damper Adjustment The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance . See Figure 29 for mounting options . Figure 29 1. Motion control bracket 2. Least resistance (softest feel) 3. Medium resistance (medium feel) 4. Most resistance (rmest feel) 5. T orque nyloc nut to[...]

Maintenance Cleaning Clean Engine Cooling System Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) CAUTION Excessi v e de bris around the engine cooling air intak e and inside of the pump dri v e belt compar tment and damaged or missing r ub ber bafes can cause the engine and hy draulic system to[...]

Maintenance Clean Debris From Machine Service Interval: Before each use or daily 1. Stop engine, wait for all moving parts to stop , and remov e k ey . Engag e parking brak e . 2. Clean off any oil, debris, or grass build-up on the machine and cutting deck, especially under dec k belt shields , around the fuel tank, around engine and exhaust area. [...]

T roubleshooting T roubleshooting 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 ov erlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessive . 1. Reduce the g round speed. 2. Oil level in the crankcase is low . 2. Add oil to the crankcase. 3. Dir ty air lter . 3. Clean or replace the air cleaner element. 4. Coolant lev el is lo w . 4. Add coolant. 5. Debris on or around radiator . 5. Remov e debr[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. T emperature is increasing on coolant temperature g auge. 1. Turn unit off and allow engine and engine components to cool. 2. Coolant lev el is lo w . 2. Add coolant. 3. Debris on or around radiator . 3. Remov e debris. W ar ning buzzer emits continuous beep . (See also Engine o verheat[...]

Schematics Schematics Electrical Diagram 52[...]

Schematics Electrical Schematic 53[...]

Conditions and Products Co vered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty Company , pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair , replace or adjust any part on these products and found by us (in the ex ercise of our reasonable discretion) to be defect iv e in factor[...]

Notes: 55[...]

Notes: 56[...]

Service Record Date: Description of W ork Done: Service Done By: 57[...]

58[...]

G01 1841 Figure 31 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees . Use the slope indicator to determine the degree of slope of hills before operating. Do Not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2.[...]

MID-MOUNT RIDING A CCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF A CCESSORIES AND OPTIONS W ALK-BEHIND A CCESSORIES AND OPTIONS GRASS CA TCHER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM FULL SUSPENSION SEA T DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V PO WER PORT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED[...]