Exmark Lazer Z XP manual

For Serial Nos. 510,000 & High er Part No. 103-737 2 Rev. B[...]

i WA RN ING POTENTIAL HAZARD ♦ This product is a piece of pow er equipment. W HAT CAN HAPPEN ♦ Fail ure to fo llow safe ope ratin g practice s can resul t in seri ous 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 p roper working con[...]

- ii - EXMARK PA RTS PLUS ® PROGRA M EFFECTIVE DATE: Septemb er 1, 1995 Program If your Ex mark dealer doe s not have the Exmark part in stock , Exmark w ill get the part s to the dea ler the nex t business day or the part w ill be FREE* Guaran teed!! How the Program W orks 1. If dealer does not have p art in stock f or a "dow n" unit at[...]

- iii - CONGR ATULAT IONS on t he purchase o f your Exmark Mower. This pr oduct has been carefully designed and manufactured to give you a max imum amount of dependability and years of trouble-free operation. O P E R ATO R ' S M AN U AL This manual contains assembly, operating, maintenance, adjustment, and safety instructions f or your Exmark [...]

- iv - TABLE OF CONTENTS 1 . S A F E T Y P A G E 1.1 Safety Alert Symbo l ...............................................................................1 1.2 Traini ng .................................................................................................1 1.3 Prepar ation .................................................................[...]

- 1 - 1. SAFETY 1.1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL is used both in this manual and on the machine to identif y important safety messages which must be followed to avoid accidents. This symbol means: A TTEN TION! BECO ME A LERT! YOU R SA FETY IS IN VOL VED! The safety alert symbol appears above in f ormation which alerts you to unsafe [...]

- 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 da mage the equipment or cause personal injury to the opera tor or bystanders. WA RN ING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison. W HAT CA[...]

- 3 - 1.4 OPERA TION Although hazard control and accident p revention are partially dependent upon the design and configuration of the equipment, these factors are also dependent upon the awareness, concer n, prudence, and proper training of the personnel involved in the operation, transport, ma intenance, and storage of the equipment. It is essen [...]

- 4 - DA NG ER POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can cause sliding and loss of control. W HAT CAN HAPPEN ♦ W heels dropping over edges, ditches, steep banks, o r water can cause rollovers, which may resul t in serious injury, death or drowning. HOW TO AVOID THE HAZARD ♦ Do not mow slopes w hen grass is wet. ♦ Do not mow[...]

- 5 - W A RNIN G POTENTIAL HAZARD ♦ There is no rollover protection when the roll bar is down. W HAT CAN HAPPEN ♦ W heels dropping over edges, ditches, steep banks, o r water can cause rollovers, which may resul t in serious injury, death or drowning. HOW TO AVOID THE HAZARD ♦ Keep the roll bar in the raised and loc ked position and use seat [...]

- 6 - 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 the mower under the in f luence of alcohol or drugs. 1.4.20 Use extra care when app[...]

- 7 - WA RN ING POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure can pene trate skin and cause injury. W HAT CAN HAPPEN ♦ Fluid accidentally injected int o the skin must be surgically removed within a few hours by a doctor familiar with t his form of injury or gangr ene may result. HOW TO AVOID THE HAZARD ♦ Make sure all hydraulic f[...]

- 8 - DO NOT OPER A TE WIT HO UT GU ARD IN PLACE. 1-513748 1.6 SA FETY 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 i f they are missing or illegible. 1.6.3 W hen new components are installed, be sure that current safety signs are affix[...]

- 9 - PART NO. 1- 643222 LOCATIO N: Left of Center on M ower Deck , Under Floor Pa n PART NO. 1- 633706 LOCATION: LH Side of Cutting H eight Adjust ment Plate PART NO. 1- 633313 LOCATION: RH Side o n Top Fr ont Mo wer Deck PART NO. 10 3-5881 LOCAT ION: Engin e Ac cess Pane l Behind th e Seat PART NO. 1- 633922 LOCATIO N: Front Center on Top of Mowe[...]

- 10 - PART NO. 98- 5954 LOCATI ON: - Under LH and RH Belt Shields - Radiator F an Pum p Idler Arm - On En gine Belt Guard behind S eat -O n P u m p Mountin g Plate behind Se at PART NO. 10 3-2076 LOCATIO N: Top of Radiator Trim Plate, LH & RH Sides PART NO. 10 3-1596 LOCATIO N: Center Inside of the Rear Bum per PART NO. 10 3-3276 LOCA TION: En[...]

- 11 - 2. SPECIFIC ATIONS 2.1 MODEL NUMBE R: 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 Capacit y: 15.5 gal. ( 56.8 L.) 2.3.2 Type of Fuel: Diesel fuel, 40 cetane or higher Note : Do not use kerosene or gasoline instea[...]

- 12 - 2.6.3 Parking Brake Lever : Eng ag es p a rk ing b rak e. 2.6.4 Deck Height Adjustment Lever : Sets cutting height to desired position. 2.6.5 Deck Lift Assist Lever: F oot pedal that assists in raising the deck. 2.7 SEAT 2.7.1 Type: Deluxe suspension seat wi th hig h back, low profile foam-in-place cushion (dampened, adjustable spring suspen[...]

- 13 - 2.10.8 Cutting Height Adjustm ent: an extr a-long cushioned lever is used to adjust the cuttin g hei ght fro m 1 1/2” (3.8 c m) to 5” (10.2 cm.) i n 1/4 ”(6.4 mm) i ncreme nts. The cutting height adjustment handle has a transport position and all adjustm ents can be made while the operator remains seated. Units also have a foot operate[...]

- 14 - 3. ASSEMBLY INSTRUCTIONS 3.1 UNCR A TE MOW E R 3.2 INSTA LL ROLLOVER PROTECTION SYSTEM (ROLL B AR) 3.2.1 Disassemble roll bar from the crate. a) Remove roll bar tubes from sides o f crate and remove screws tha t 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 r[...]

- 15 - a) Locate the latch pin assemblies (pin and hairpin connected w ith a lanyard). b) Install a 1/2-13 x 3 1/4 c apscrew in the washer on the lany ard of each pin assembly. Note: Make sure the bent tab in the w asher is towards the head of the bolt. b) Lightly oil the inside surfaces of the ear-shaped p lates at the upper end of the lower roll [...]

- 16 - 3.5.1 Tilt s eat up to gain acces s to th e ba ttery . DA NG ER POTENTIAL HAZARD ♦ Charging the battery may produce explosiv e gases W HAT CAN HAPPEN ♦ Battery gases can explode causin g serious injury. HOW TO AVOID THE HAZARD ♦ Keep sparks, flames, or cigarettes away from batt ery. ♦ Ventilate when charging or using battery in an en[...]

- 17 - 3.6 INSTA LL MOTION CONTROL LEVER S 3.6.1 Loosen and remove the tw o ( 2 ) 3/ 8”x1” bolts and spring disk washers w hich att ach the motion control levers to the control arm shafts for shipping and the two (2) 3/8” x 1” bolts and spring dis k washers which are screw ed int o t he control arm shafts. a) Inst all the left motion contro[...]

- 18 - WA RNING POTENTIAL HAZARD ♦ Engine coolant is hot and pressurized. ♦ Radiator and surrounding parts are hot. W HAT 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 r[...]

- 19 - IMPORTANT: To begin movement (forward or backward) the operator mus t be in the seat, the b rake lever must be disengaged (pushed do wn) before the motion control levers can be moved in or the engine will kill. W hen levers are centered in the T-slot the drive sy stem is in the neutral position. W ith levers moved out in the T-slot the drive[...]

- 20 - Stop machine and wait for all moving parts to stop. Enga ge 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 righ t and co untercl ockw ise to cause the ma chine to tra ck mo re to the le f t. Adjust in quarter-tur n[...]

- 21 - 4.1.10 Fuel Gauge : Located on the left fuel tank. T he fuel g auge monitors the amount of f uel in the left t ank only. Use the fuel from th e ri gh t fuel tan k first. W hen the ri ght fuel ta nk is empty sw i tch to the le f t fuel tank. Fuel gauge will monitor the rema ining fuel. 4.1.11 Drive W heel Release Valves : Locat ed on the top [...]

- 22 - c) W hen 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 alter nator is not charging. Perform the following steps. 1. Turn the unit off, allow the engine and en gine components to cool. 2. Check the oil level and fill, if necessary, as described in Secti[...]

- 23 - 4.3.4 Engaging P TO : DA NG ER POTENTIAL HAZARD ♦ The rotating blades under the mow er deck are dangerous. W HAT 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 en gaged. DA NGER POTENTIAL HAZARD ♦ An uncovered discha[...]

- 24 - CA UT IO N 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 stre et or roadway. W HAT CAN HAPPEN ♦ Driving on a street or roadway without such equipment is dangerous and can le ad to accidents causing personal injury[...]

- 25 - DO NOT att empt t o turn the unit while on the ramp, you may lose control and drive off the side. Avoid sudden acceleration w hen driving up a ramp and sudden deceleration when backing down a ramp. Bo th maneuvers can cause the unit to tip backward. 5. MAINTEN ANCE & ADJUSTMENTS WA RN IN G POTENTIAL HAZARD ♦ W hile maintenance or adjus[...]

- 26 - e) If t he 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 lif e coolant, which can be identified by its orange color. WA RNING POTENTIAL HAZARD ♦ Engine coolant is hot and pressurized. ♦ Radiator[...]

- 27 - Voltage Reading Percent Charge Maximu m Charger Settings Cha rgin g Inte rval 12.6 or greater 100% 16 volts/ 7 amps No Charg ing Requir ed 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 Hour s 11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours[...]

- 28 - G00 84 CA UTION POTENTIAL HAZARD ♦ Operating a mower deck w ith loose or weakened blade bolts can be dangerous. W HAT 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[...]

- 29 - Run engine at one-third throttle, with brak e disengaged, move levers in and raise off seat (but do not get off o f machine) engine mu st st op after 1 /2 second has elapsed. Again, run engine at one-third thrott le, brake engaged, and move left motion control lever in - engine must stop. Repeat again m oving the right lever in , then moving[...]

- 30 - a) Stop engine, wait for all moving parts to stop, and re move key. b) Tilt seat up and tilt hood forward to gain access to the engine area. c) Drain oil while eng ine is w arm f rom operation. d) Remove the oil d rain plug. There are two oil drain plugs available. One drain plug is located at the front of the en gine; the other is located o[...]

- 31 - Drain coolant when engine is cool. Coolant may be drained from the radi ator by loosening the drain cock in the r ight rear corner. T he 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 [...]

- 32 - 5.1.13 Check hydraulic oil level : Service Interval: 40 hr. a) Stop engine and w ait for all moving parts to stop. b) Clean area around hydraulic reservoir cap and re move cap. Oil level should be to the to p o f the b affle inside the tank. I f not , ad d oil. U se o nly Mob il 1 15W-50 synthetic m otor oil. Replace hydraulic reservoir cap [...]

- 33 - LUBRICA TION CH ART FITTING LOCAT IONS INITIAL PUMPS NO. of PLACE S SERVIC E INTERVAL 1. Front Cas ter whee l hubs ∗ 0 2 ∗ Yearl y 2. Front Caster Pivots ∗ 0 2 ∗ Yearly 3. Height Adj. Sh aft Bear ings 1 5 40 hours 4. Deck Drive Belt Idler Ar m 1 1 Yearl y 5. Brak e Brack ets 1 2 200 hours 6. Fan Pum p Be lt Idler Arm 1 1 40 hours 7. [...]

- 34 - onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut. i) Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing. j) W ith the open end of the w heel facing up, fill t he area inside the wheel around the axle [...]

- 35 - 5.1. 22 Replace fuel f ilter : 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 le f t hand front corner of engine deck. a) Close f uel shut off valve. b) Disconnect the sensor wire, remove the drain plug and discard the o -ring. c) Rem ove fuel f ilter wit[...]

- 36 - a) Torque the slotted nut to 125 ft-lbs. (169 N-m). b) Check distance from bottom of sl o t in nut to inside edge of hole. Two threads (0.1” (.25 cm)) or less should be showing. c) If m ore than two thr eads (0.1” (2.5 mm )) are showing r emove nut and install washer (PN 1-523157) betw een hub and nut. d) T o rque the slotted nut to 125 [...]

- 37 - NOTE: When changing cutting height positions, always come to a complete stop and disengage the PT O. FIGURE 11 CUTTING HEIG HT POSITIO N d) I nsert height adjustm ent pin into hole corresponding to desired cutting height and install hairpin cotter. See decals on the side of deck li ft plate. e) Move lever out of the transport ( or 5” (12.7[...]

- 38 - b) Stop engine, wait for all moving parts to stop, and remove key. c) Check tire pressure of drive tires. If needed, adjust to 10 psi (69 kPa). Semi-pneumatic caster tires do not need to be inflated. d) Set anti-scalp rollers to top holes or remove them completely for this adjustment. e) Raise the deck to t he 5” height position (also tr a[...]

- 39 - 5.2.3 W heel Drive Pump Belt Tension . Self-tensi oning - No adjustment necessary. 5.2.4 Fan Pump Belt Tension. Self-tensi oning – No adjustment necessary. 5.2.5 Mule Drive Belts Tension Adjustment . Self-tensi oning idlers, adjust as foll ows: a) Stop engine, wait for all moving part s to stop, and remove key. b) Check to make sure the co[...]

- 40 - d) If adj ustment is necessary , loosen t he bolt securing the belt guide and make proper adjustment. Tighten hardware. FIGURE 15 BELT GUIDE POSITIONI NG 5.2.9 Brake Link Adjustm ent . Check to make sure b rake is adjusted properly . a) Disengage brake lever (lever down). b) Measure the length of the spring. Measurement should be 2.75” (7 [...]

- 41 - 5.2. 10 Adjust Thrott le Lever Tension . a) Stop engine, wait for all moving part s to stop, and remove key. b) Tension in throttle lever can be adjusted by adjusting the tightness of the lever pivot bolt, which is located under the console (See Fi gure 17). FIGURE 17 THROTTLE TENSION 5.2.11 Electric Clutch Adjustment : No adjustment is nece[...]

- 42 - 5.2.13 Motion control linkage adjustment . W A RNING POTENTIAL HAZARD ♦ Engine must be running and drive w heels must be turning so motion control adjustment can be pe rformed. W HAT 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 rot[...]

- 43 - NOTE: The nuts to the front of the unit on RH rod has left-hand threads. FIGURE 19 MOTION CONTROL A DJUSTMENT f) St art engine. Brake must be engaged and motion control levers ou t to start engine. Operator does not have to be in the seat. Run engine at full thr ott le and release brake. g) The reverse indicat or spring must be correct befor[...]

- 44 - 6. W A STE DIS POSAL 6.1 MOTOR OIL D ISPOSAL 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 COOLA NT DISPOS AL CA UT IO N POTENTIAL HAZARD ♦ Engine coolant is toxic. W HAT CAN HAPPEN ♦ Swallowing coolant [...]

- 45 - 6.4 BATT ERY DISPO SAL DA NG ER POTENTIAL HAZARD ♦ Battery electrolyte contains sulfuric acid, which is poisonous and can cause sev ere burns W HAT CAN HAPPEN ♦ Swallowing electr olyte can be fatal or if it touches skin can cause severe bu rns. HOW TO AVOID THE HAZARD ♦ W ear safety glasses to shield eyes, and rubber gl oves to protect[...]

- 46 - g) Check for corrosion at all wiring connections. Ev en minor corrosion may cause a faulty connection. Clean connec tor terminals thoroughly with electrical contact cleaner; apply dielectric grease and reconnect. NOTE: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors. NOTE: After carefully checking[...]

- 47 - 2. Look at the temperature gauge to determine if temperature continues to increase. If it does, turn the unit off and allow the engine and engine components to cool. 3. Check the coolant level. If necessary fill with coolant as described in Section 5.1.2. 4. Remove any debris on o r around the radiator that may restrict airflow. 5. Check to [...]

- 48 - 8. ELECTRIC AL DIAGR A M[...]

- 49 - 9. HYDRAULIC DIAGR A M[...]

- 50 - 10. 2-Year Limited Warranty Exmark Turf Equipment (For units purchas ed on or after October 1, 2004) Conditions and Pro ducts Covered Exmark M fg. Co. Inc. and it s affiliate, Ex mark Warranty Company, pursuant to an ag reement betw een them, jointly warrant on th e terms and condition s herein, that w e will repair, replace or ad just any p[...]

- 51 - NOTES[...]

- 52 - NOTES[...]

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

- 54 -[...]

® M FG . CO. IN C. SEE EXMARK’S COMPLETE LINE OF ACCESSORIES RIDING A C CESSORIES CUSTOM RIDE SEA T SUSPENSIO N SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT K IT MICRO-MULCH SYSTEM ROLL OVER PROT ECTION S YSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONT AINER TURF ST RIPER ULTRA VAC C OLLECTION S YSTEM ULTRA VAC Q UICK DISPOSAL S YSTEM WALK BEHIND A[...]