Exmark Lazer HP manual

For Serial Nos. 440,000 & Hi g he r Part No. 103-5505 Rev. A[...]

i 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. ♦ [...]

ii EXMARK PARTS PLUS  PROGRAM EFFECTIVE DATE: September 1, 1995 Program If your Exmark dealer does not hav e the Exmark part in stock, Exmark will get the parts to t he 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 req[...]

iii 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 OPERATI[...]

iv TABLE OF CONTENTS 1 . S A F E T Y P A G E 1.1 Safety Alert Symbol ......................................................................................... 1 1.2 Training ............................................................................................................ 1 1.3 Preparation .................................................[...]

- 1 - 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 informati on which alerts you to unsafe actions or[...]

- 2 - 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 HAP[...]

- 3 - DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite gasoline 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. ♦ Al[...]

- 4 - 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 [...]

- 5 - 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 d[...]

- 6 - 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. ?[...]

- 7 - 1.4.17 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. 1.4.18 Be aware of the mower discharge and direct discharge away from others. 1.4.19 Do Not operate mower under the influence of alcohol or drugs. 1.4.20 Use extra care when approachin[...]

- 8 - 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 ho[...]

- 9 - 1.6 SAFETY SIGNS 1.6.1 Keep all safety signs legible. Remove all grease, dirt and debris from safety 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 sure that current safety signs are affixed to the replaced components. 1.6.4 New safety signs may[...]

- 10 - PART NO. 1-643222 LOCATION: Left of Center on Mower Deck, Under Floor Pan PART NO. 1-633313 LOCATION: RH Side on Top Front of Mower Deck PART NO. 1-403005 LOCATION: Left and Right Corners of Mower Deck PART NO. 103-2076 LOCATION: Top of Radiator Trim Plate LH & RH Sides PART NO. 1-643401 LOCATION: On Tilt Switch PART NO. 103-0262 LOCATIO[...]

- 11 - PART NO. 1-633706 LOCATION: LH Side of Cutting Height Adjustment Plate PART NO. 1-633462 LOCATION: Rubber Heat Shield Flap behind Seat PART NO. 1-303508 LOCATION: RH Side on Top Rear of Mower Deck PART NO. 1-643339 LOCATION: Top of Right Engine Baffle PART NO. 1-323540 LOCATION: Left Rear Corner Top of Mower Deck For Units with S/N 464,999 a[...]

- 12 - 2. SPECIFICATIONS 2.1 MODEL NUMBER: 2.2 ENGINE: 2.2.1 Engine Specifications: See your Engine Owner’s Manual 2.2.2 RPM: Full Speed: 3750 RPM (No Load) Idle: 2200 RPM 2.3 FUEL SYSTEM 2.3.1 Capacity: 13.5 gal. (51 L.) 2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or higher 2.3.3 Fuel Filter: In-line 40 Micron Kaw asaki P/N 49019-10[...]

- 13 - Drive Front Caster Pneumatic (Air-Filled) Pneumatic (Air-Filled) Semi-Pneumatic Quantity 2 2 2 Tread “Multi- Trac C/S” Smooth Smooth Size 24 x 12.00-12 13 x 6.50-6 13 x 6.50-6 Ply Rating 4 4 Pressure 13 psi (90 kPa) 13 psi (90 kPa) 2.7 SEAT 2.7.1 Type: Standard seat with high back, foam padded (internal suspension) and armrests. Optional[...]

- 14 - Deck Depth : 60” Deck: 5.5” (14.0 cm) 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 from 1 1/2” (3.8 cm) to 5” (10.2 cm.) in 1/4” (.64 cm) increments. The cutting height adjustment handle has a transport position and all adjustments can be made whil[...]

- 15 - 3. ASSEMBLY INSTRUCTIONS 3.1 UNCRATE MOWER 3.2 INSTALL ROLLOVER PROTECTION SYSTEM (ROLL BAR) 3.2.1 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 [...]

- 16 - FIGURE 2 LOWER ROLL BAR INSTALLATION 3.2.5 Install the upper u-shaped section of the roll bar. (Reference Figure 3 for alignment and installation instructions below): 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: Mak[...]

- 17 - FIGURE 3 UPPER ROLL BAR INSTALLATION 3.3 SERVICE BATTERY The machine is shipped with a filled lead acid battery. 3.3.1 Unhook seat latch and 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 AV[...]

- 18 - CAUTION POTENTIAL HAZARD ♦ If the ignition is in the “ON” position there is potential for sparks and engagement 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 cha[...]

- 19 - FIGURE 4 FIGURE 5 CONTROL ARM SHAFT LEVER ALIGNMENT b) If the ends of the levers hit against each other, while in the drive position (levers rotated in as far as possible), make adjustments by moving the levers outwards to the neutral lock position and carefully bend them outward. Move them back to the drive position and check for clearance,[...]

- 20 - CAUTION 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. With machine on level surface and with cool engine , remove radiator cap (under hood) and add a 50/50 mix of water and engine coolant until li[...]

- 21 - By moving both levers an equal amount forward or back from the neutral position the machine can be caused to move forward or backward in a straight line. Movement of the left lever forward will cause the left drive wheel to rotate in a forward direction. Movement of the right lever forward will cause the right drive wheel to rotate in a forw[...]

- 22 - 4.1.6 Throttle Control : Located on right fuel tank. Throttle is used to control engine speed. Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed. 4.1.7 Brake Lever : Located on left side of unit, just to the front of the console. The brake lever engages a parking brake o[...]

- 23 - 4.1.15 Warning Buzzer : Located behind the seat on the right hand side. When the engine is running and the buzzer emits a beep, the buzzer is warning signal the user that the engine is overheating. Perform the following step. 1. Disengage the mower blade, and idle down the engine. 2. Look at the temperature gauge to determine if the temperat[...]

- 24 - 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 ope[...]

- 25 - 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. ♦ [...]

- 26 - 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 eng[...]

- 27 - 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 an[...]

- 28 - 5.1.4 Clean engine cooling system : Service Interval: Daily or more often in dry conditions CAUTION POTENTIAL HAZARD ♦ Excessive debris and damaged or missing rubber baffles can cause the engine and hydraulic system to overheat. WHAT CAN HAPPEN ♦ Excessive debris around the engine cooling air intake and inside of the pump drive belt comp[...]

- 29 - c) Inspect blades and sharpen or replace as required. d) Re-install the blades (if they were removed) by placing a block of wood between the front or rear baffles and the blade then torque the blade bolts to 115-120 ft-lbs. (156-163 N-m). Be sure the spring disk washer cone is installed toward the bolt head (See Figure 7). CAUTION POTENTIAL [...]

- 30 - b) Check the kill circuits. Run engine at one-third throttle, disengage parking brake and raise off of seat (but do not get off of machine) engine must stop after approx. 1/2 second has elapsed (seat has time delay kill switch to prevent cut-outs on rough terrain). Run engine at one-third throttle, engage PTO and raise off of seat (but do no[...]

- 31 - 5.1.11 Check Spark Arrester Service Interval: 50 hours WARNING POTENTIAL HAZARD ♦ Hot exhaust system components may ignite gasoline vapors even after the engine is stopped. ♦ Hot particles exhausted during engine operation may ignite flammable materials. WHAT CAN HAPPEN ♦ Fire may result in personal injury or property damage. HOW TO AV[...]

- 32 - 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 radiator may cause severe burns. HOW TO AVOID THE HAZARD ♦ Allow the engine to cool completely before removing the ra[...]

- 33 - WARNING POTENTIAL HAZARD ♦ Engine compartment contains open belt drives and fans. ♦ Rotating components can cause injury WHAT CAN HAPPEN ♦ Fingers, hands, loose clothing, or jewelry can get caught by the rotating fan and drive shaft. HOW TO AVOID THE HAZARD ♦ Do not operate machine without the covers in place. ♦ Keep fingers, hands[...]

- 34 - NOTE: Do not add any type of tire liner or foam fill material to the tires. Excessive loads created by foam filled tires may cause failures to the hydro drive system, frame, and other components. Foam filling tires will void the warranty. 5.1.16 Check condition of belts : Service Interval: 40 hrs. a) Stop engine, wait for all moving parts to[...]

- 35 - c) Lubricate front caster pivots once a year. Remove hex plug and cap. Thread grease zerk in hole and pump with grease until it oozes out around top bearing. Remove grease zerk and thread plug back in. Place cap back on. 5.1.18 Lubricate caster wheel hubs: Service Interval: Once Yearly a) Stop engine, wait for all moving parts to stop, and r[...]

- 36 - 5.1.20 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. 5.1.21 Lubricate brake rod bushings : Service Interval: 160 hrs. a) Stop engine, wait for all moving parts to stop, an[...]

- 37 - Do not change hydraulic system oil (except for what can be drained when changing filter), unless it is felt the oil has been contaminated or been extremely hot. Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system. 5.1.26 Wheel hub - slotted nut torque specification. Service Interval: 500 hrs W[...]

- 38 - 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 10 CUTTING HEIGHT POSITION d) Insert height adjustment pin into hole corresponding to desired cutting height and install hairpin cotter[...]

- 39 - e) Raise the deck to the 5” (12.7 cm) 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 12. f) For 60” units - Lower the deck to the 1-1/2” (3.81 cm) height position. For 72” units – Lower the deck to the 1-1/2” (3.81 c[...]

- 40 - a) Stop engine, wait for all moving parts to stop, and remove key. b) Check to make sure the center of the bolt head in the center of the spring loaded pulley, on left side engine deck support, is positioned between the centers of the two alignment holes in the left support plate (See Figure 13). It is necessary to adjust the belt tension wh[...]

- 41 - FIGURE 14 BELT GUIDE POSITIONING 5.2.8 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” (7.0 cm) between washers (see Figure 15). c) If adjustment is necessary, tighten the nut directly below the yoke and loosen the[...]

- 42 - FIGURE 16 THROTTLE TENSION 5.2.11 Electric Clutch Adjustment : No adjustment necessary. 5.2.12 Reverse Indicator Adjustment : a) Stop engine, wait for all moving parts to stop, and remove key. b) Unhook seat latch and tilt seat forward. c) Begin with either the left or right motion control lever. Move lever to the neutral position and pull l[...]

- 43 - 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[...]

- 44 - f) Start engine. Brake must be engaged and motion control levers out to start engine. Operator does not have to be in the seat because of the jumper wire being used. Run engine at full throttle and release brake. g) The reverse indicator spring must be correct before the following adjustments can be made. See Section 5.2.12. NOTE: The motion[...]

- 45 - 6. WASTE DISPOSAL 6.1 MOTOR OIL DISPOSAL Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at a certified recycling center or according to your state and local regulations. 6.2 ENGINE COOLANT DISPOSAL CAUTION POTENTIAL HAZARD ♦ Engine coolant is toxic. WHAT CAN HAPPEN ♦ Swallowing coolant can cause [...]

- 46 - 6.4 BATTERY DISPOSAL DANGER POTENTIAL HAZARD ♦ Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns WHAT CAN HAPPEN ♦ Swallowing electrolyte can be fatal or if it touches skin can cause severe burns. HOW TO AVOID THE HAZARD ♦ Wear safety glasses to shield eyes, and rubber gloves to protect skin and [...]

- 47 - e) Make sure the parking brake is set and motion control levers are moved out (neutral lock position). f) Check that the PTO is disengaged. g) Check that the spark plug wires are properly connected. h) Check for loose or faulty wiring connections. i) Check for corrosion at all wiring connections. Even minor corrosion may cause a faulty conne[...]

- 48 - 8. ELECTRICAL DIAGRAM[...]

- 49 - 9. HYDRAULIC DIAGRAM[...]

- 50 - 10. Limited Warranty Exmark Turf Equipment Conditions and Products Cov ered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreem ent betw een them, jointly warrant on the terms and conditions herein, that w e will repair, replace or adjust any part m anufactured by Exmark and found by us (in the exercise of [...]

- 51- NOTES[...]

- 52- NOTES[...]

- 53- SERVICE RECORD Date Description of Work Done Service Done By[...]

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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 SELF STEERING SULKY GRASS CATCHER MICRO-MULCH ™ ACCESSORY WARNING The engine exhaust from this product contains chemicals know[...]