Exmark Lazer Z HP manual

For Serial Nos. 540,000 & Higher Part No. 103-9172[...]

- i - WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment. W HAT CAN HAPPEN ♦ Failure to f ollow safe operating pr act ices can result in serious operator inj ur y or even death. HOW TO AVO ID THE HAZARD ♦ Keep all shields, guar ds, and saf ety devices (especially the grass discharge system) in place and in pr oper working[...]

- ii - EXMARK PA RTS PLUS ® PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not ha ve the Ex mark part in stock, Exmark w ill 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 "dow n" unit at the tim[...]

iii CONGRAT ULATIONS on t he purchase of your Ex m ark Mower. This product has been caref ully designed and manufact ured to give y ou a maximum amount of dependability and years of tr ouble- f ree operat ion. OPERA TOR'S M ANUA L This manual cont ains assem bly, oper at ing , maintenance, adj ust ment, and saf ety instructi ons for your E xma[...]

- iv - TA BLE OF CONTENTS 1 . S A F E T Y P A G E 1.1 Safety A lert Symb ol ....................................................................................... 1 1.2 Traini ng ......................................................................................................... 1 1.3 Prepar ation .............................................[...]

- 1 - 1. SA FETY 1.1 SA FETY A LERT SYMBOL This SAFET Y ALERT SYMBOL is used both in this manual and on t he m achine t o identif y import ant safet y messag es which must be followed to avoid accidents. Th is symbol means: A TTENTION! BECOME A LERT! YOUR SA FETY IS INVOLVED! The saf ety alert symbol appears above inform at ion which alerts you to [...]

- 2 - 1.3.4 Thoroug hly inspect t he ar ea where the equipment is t o be used and r em ove all stones, stick s, wires, bones, and other f oreign obj ect s which may damage t he equipment or cause per sonal inj ur y to the operator or bystander s. WA RNING POTENT IAL HAZARD ♦ Engine exhaust contains carbon m onoxide, which is an odorless deadly po[...]

- 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flamm able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g asoline vapors. A f ire or explosion from g asoline can burn you, others, and cause property damag e. HOW TO AVO ID THE HAZARD ♦ Purchase and store g asoline only in an approved cont[...]

- 4 - 1.4 OPERA TION Although hazard control and acci dent prevent i on are partially dependent upon t he design and configurat i on of t he equi pment, these fact ors are al so dependent upon the awareness, concern, prudence, and proper t r ai ni ng of t he personnel involved in the operation, t ransport , maintenance, and st orage of t he equi pm[...]

- 5 - DA NGER POTENT IAL HAZARD ♦ Mow ing on wet g r ass or st eep slopes can cause sliding and loss of cont r ol. W HAT CAN HAPPEN ♦ W heels dropping over edges, ditches, st eep bank s, or water can cause rollovers, which may result in serious injury, death or dr owning. HOW TO AVO ID THE HAZARD ♦ Do not mow slopes when grass is wet. ♦ Do [...]

- 6 - WA RNING POTENT IAL HAZARD ♦ There is no r ollover prot ection when the roll bar is down. W HAT CAN HAPPEN ♦ W heels dropping over edges, ditches, st eep bank s, or water can cause rollovers, which may result in serious injury, death or dr owning. HOW TO AVO ID THE HAZARD ♦ Keep the roll bar in t he r aised and locked position and use s[...]

- 7 - 1.4.17 Do Not mow with the discharge def lector raised, r em oved or alt er ed unless t her e is a grass collect ion system or mulch kit in place and working properly. 1.4.18 Be aware of the mower discharg e and direct discharg e away from ot her s. 1.4.19 Do Not operate m ower under t he inf luence of alcohol or dr ugs. 1.4.20 Use extra care[...]

- 8 - WA RNING POTENT IAL HAZARD ♦ Hydraulic fluid escaping under pr essur e can penet rate skin and cause injur y. W HAT CAN HAPPEN ♦ Fluid accidentally injected into t he skin must be surgically removed within a few hours by a doctor fam iliar with this f orm of injury or g angrene may result . HOW TO AVO ID THE HAZARD ♦ Make sure all hydra[...]

- 9 - PART NO. 1- 633313 LOCATI ON: RH Side on Top Front of Mower Deck PART NO. 1- 403005 LOCATIO N: Left and Right Corners of Mower Deck PART NO. 1- 513742 LOCATIO N: Top of Mower Deck Belt Shields, Left and Right Sides PART NO. 103- 7491 LOCATI ON: LH Side on Top Fr ont of Mower Deck PART NO. 98- 5954 LOCATIO N: Under Mower Deck Belt Shield(s) PA[...]

- 10 - DO NO T O PE RA TE WI THO UT GUA RD IN P L A C E . 1-513748 PART NO. 1- 643222 LOCATIO N: Left of Center on Mower Deck , Under Floor Pan PART NO. 1- 633462 LOCATI ON: Rubber Heat Shield Flap behind Seat PART NO. 103- 0368 LOCATI ON: Rubber Heat Shield Flap behind Seat PART NO. 1- 303508 LOCATIO N: RH Side on Top Rear of Mower Deck PART NO. 1[...]

- 11 - PART NO. 1- 633706 LOCATI ON: LH Side of Cutting Height Adjustm ent Plate Type A Anti-scalp Roller s Only – See Figure 11 PART NO. 1- 323540 LOCATIO N: Left Rear Corner Top of Mower Deck PART NO. 1- 633922 LOCATIO N: Front Center on T op of Mower Deck PART NO. 1- 523552 LOCATIO N: Top of Hy draulic Reservoir, Under the Seat Kohler EFI Unit[...]

- 12 - 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: 2.2 ENGIN E: 2.2.1 Engine Specifications: See your Eng ine Owner’s Manual 2.2.2 RPM: Full Speed: 3750 RPM (No Load) Idle: 1500 RPM 2.3 FU EL SYSTEM 2.3.1 Capacity: 13.5 gal. ( 51 L. ) 2.3.2 Type of Fuel: Reg ular unleaded gasoline, 87 octane or higher 2.3.3 Fuel Filter: All units except Kohler EFI: In-[...]

- 13 - 2.5.5 Deck Lif t Assist Lever: Foot pedal that assist s in raising the deck . 2.6 SEA T 2.6.1 Type: All units except Kohler EFI : Standard seat with high back , foam padded ( int er nal suspension) and armrest s. Kohler EFI units : St andar d seat with high back, f oam padded (inter nal suspension) , armrests and a cust om r ide suspension s[...]

- 14 - 2.9.5 Deck Drive: Elect r ic clut ch m ounted on horizontal engine shaf t. “B” Sect ion belt (with self- t ensioning idler) f r om electric clutch t o t ransfer shaf t mount ed on deck . Blades are driven by one “B” Section belt ( w/self -tensioning idler ) from t ransfer shaft on deck to blade spindles. 2.9.6 Deck: Full floating dec[...]

- 15 - W heel Lug Nu ts ............................................................. 90- 95 f t-lbs. (122-129 N-m) W heel M otor Mounting Bolt s ............................................ 72- 77 f t-lbs. (98-104 N-m) W heel Hub Slott ed N ut ..............................................mi nimum125 ft-lbs. (169 N-m) Ro llover Protection S ystem [...]

- 16 - FIGURE 2 LOWER ROLL BAR INSTA LLA TION 3.2.5 Install the upper u- shaped sect ion of the r oll bar . (Reference Fig ure 3 f or alignment and inst allat ion instructions below): a) Locate t he lat ch pin assem blies (pin and hairpin connected with a lanyard). b) Inst all a 1/ 2- 13 x 3 1/4 capscr ew in the washer on the lanyard of each pin as[...]

- 17 - FIGURE 3 UPPER ROLL BA R I NSTA LLA TION 3.3 SE RV ICE BA TTERY The ma chine is sh ipped with a filled lead acid b attery. 3.3.1 Unhook seat latch and tilt seat up to gain access to t he bat t ery. DA NGER POTENT IAL HAZARD ♦ Charging t he bat tery may produce explosive gasses W HAT CAN HAPPEN ♦ Battery gasses can explode causing ser iou[...]

- 18 - CA UTION POTENT IAL HAZARD ♦ If t he ignition is in the “ O N” position there is pot ent ial for spar ks and engag ement of com ponent s. W HAT CAN HAPPEN ♦ Sparks could cause an explosion or m oving par t s could accidentally engage causing personal injury. HOW TO AVO ID THE HAZARD ♦ Be sure ignit ion switch is in the “ O FF” [...]

- 19 - e) Secur e air cleaner by tightening t he tensioning bolt and spr ing assembly until ends of clam p ar e appr oximat ely ½” (12. 7 m m) apart. 3.8 INSTA LL MOTION CONTROL LEVERS . 3. 8. 1 Loosen and remove the two (2) 3/ 8” x 1” bolt s and spr ing disc washers w hich attach the m ot ion control levers to the cont r ol ar m shaft s f o[...]

- 20 - NOTE: T he baff le is labeled “HOT” and “COLD”. T he oil level varies w it h t he temperat ur e of the oil. T he “HOT” level show s t he level of oil when it is at 225°F (107°C). T he “COLD” level shows the level of t he oil when it is at 75° F ( 24° C) . Fill to the appropriat e level depending upon t he temperatur e of [...]

- 21 - CA UTION POTENT IAL HAZARD ♦ Machine can spin v er y rapidly by posit ioning one lever too much ahead of the other. W HAT CAN HAPPEN ♦ Operator m ay lose contr ol of the machine, which may cause damage t o t he m achine or inj ury. HOW TO AVO ID THE HAZARD ♦ Use caution when making t ur ns. ♦ Slow the machine down before mak ing shar[...]

- 22 - NOTE: T his switch is not a low oil sensor and will not alert the operator if the engine oil is low. 4.1.10 Fuel Shut-Of f Valve : Locat ed dir ect ly below right side of console, next to cubby. The f uel shut-of f valve is used to shut off the f uel when the machine will not be used for a f ew days, during transport t o and f rom t he j ob [...]

- 23 - 4.3 OPERA TING INSTRUCTIONS 4.3.1 Operate unit s with the roll bar in the raised and locked posit ion and use seat belt. There is no r ollover prot ection when the roll bar is down. If it is necessar y to lower roll bar do not wear the seat belt . Raise the roll bar as soon as clearance per m its. 4.3.2 Open f uel shut - off valve (l eft or [...]

- 24 - IMPORT A NT : Operator must be in seat bef ore t he PTO can be engaged. Set thro ttle to "midw ay" po sition. Pu ll outw ard on the sw itch to th e “ROTATE” posi tion. Accele rate to full thro ttle to begin mo wing. 4.3.5 Stopping PTO : Set throttle to the “midw ay” posi tion. Push i n on the sw itch to the “STO P” posi[...]

- 25 - WA RNING POTENT IAL HAZARD ♦ Loading a unit on a t r ailer or t ruck increases t he possibility of back ward tip-over. W HAT CAN HAPPEN ♦ Backward tip-over of t he unit could cause serious injury or death. HOW TO AVO ID THE HAZARD ♦ Use extreme caution when operating a unit on a ramp. ♦ Use only a single, f ull width ramp; DO NO T us[...]

- 26 - WA RNING POTENT IAL HAZARD ♦ The engine can becom e very hot. W HAT CAN HAPPEN ♦ Touching a hot engine can cause severe burns. HOW TO AVO ID THE HAZARD ♦ Allow the engine to cool complet ely bef ore service or making r epairs around the eng ine ar ea. 5.1 PERIODIC MA INTENANCE 5.1.1 Check eng ine oil level : Service Interval : Dai l y [...]

- 27 - 5.1.3 Clean engine cooling system : Service Interval: Dai ly or more often in dry condit ions CA UTION POTENT IAL HAZARD ♦ Excessive debris and damaged or missing r ubber baff les can cause the engine and hydraulic system to overheat. W HAT CAN HAPPEN ♦ Excessive debris around the engine cooling air int ake and inside of t he pum p dr iv[...]

- 28 - d) Re-install the blades (if t hey w er e r em oved) in the following order ( See Figu re 7): 1) I nst all bushing throug h blade with bushing flang e on bot t om ( grass) side of blade. 2) I nstall bushing/blade com bo int o spindle. 3) I nst all blade bolt and spring disc washer. Be sure t he spr ing disc washer cone is installed towards t[...]

- 29 - Try to sta rt with operat or i n seat , parking br ak e engaged, PTO engaged and motion contr ol levers in t he neutral lock position - st arter must not crank . Try to sta rt with operat or i n seat , par k ing brak e engaged, PT O disengaged, and the l ef t mot i on cont rol lever in, starter must not crank, repeat ag ain with the right le[...]

- 30 - 5.1.10 Check Spark Arrester Kohler EFI engines onl y: Service Interval: 50 hours WA RNING POTENT IAL HAZARD ♦ Hot exhaust system components m ay ig nit e g asoline vapors even after t he eng ine is stopped. ♦ Hot particles exhausted during engine operation m a y ignite f lammable m at er ials. W HAT CAN HAPPEN ♦ Fire may result in per [...]

- 31 - 5.1.13 Check tire pr essur es : Service Interval: 40 hrs. a) Stop engine, wait f or all moving part s to stop, and r em ove key. b) Check tire pr essur e in drive tires. c) Inf late drive tires to 13 psi ( 90 k Pa). d) Cast er t ir es do not need t o be inf lated. NOT E: Do not ad d any type of tire liner or foa m fill material to the tire s[...]

- 32 - c) Lubr icat e front cast er pivots once a year. Rem ove hex plug and cap. Thread g rease zerk in hole and pump with gr ease unt il it oozes out around top bearing . Rem ove g r ease zerk and thread plug back in. Place cap back on. 5.1.16 Lubricate caster wheel hubs: Service Interval: O nce Yearly a) Stop engine, wait fo r all m o ving par t[...]

- 33 - 5.1.18 Lubricate brak e handle pivot : Servi ce I nt erval : 160 hrs. a) Stop engine, wait f or all moving part s t o st op, and r emove key. b) Lubricate bronze bushings on br ak e handle pivot with a spray type lubricant or light oil. 5.1.19 Lubricate brak e rod bushings : Servi ce I nt erval : 160 hrs. a) Stop eng ine, wait for all m ovin[...]

- 34 - Note: For Kohler EFI units use only high pressure clam ps and SAE R7 or R9 hose available from Exm ar k or Kohler. Clam ps r equir e special plier s P/ N 1- 643394 (Oetiker P/ N 14100118 or Kohler P/N 2445505) f or installation. Replacement Filter s Exmark P/N 99- 9403 ( low pressure) Kohler EFI Kohler P/N 2405003 ( hig h pressure) Kohler Ai[...]

- 35 - b) Allow the eng ine to cool complete ly. c) Connect the black tester hose f rom t he Kohler pr essur e g auge to the t est valve in the fuel rail. d) Route the clear hose into a portable g asoline container and depress the button on the t ester relief valve. 5.1.25 Change hydraulic system f ilter : Service Interval: Af t er Fi rst 250 hrs. [...]

- 36 - a) Pump dr ive sheave set screws. b) Square head set scr ews on Hydro pump control ar ms. c) Sheave retaining bolt in t he end of engine cr ank shaft. d) Caster wheel spacer nuts e) Fuel tank bulk head fitt ing nuts. f) Cut t er housing spindle nut. Adhesives such as “Loctite RC/609 or RC/ 680” or “Fel-Pro Pr o- Lock Retaining I or Ret[...]

- 37 - g) Adjust anti-scalp roller s f or Norm al O per at ing Conditions. Place r oller s in one of t he posit ions shown in Figure 11. Rollers will maintain 3/ 4 in. (19 mm) clearance to the g round to minimize goug ing and roller wear or dam ag e. For Maximum Deck Fl otation, place ro ller s one hole posit ion lower. Rollers should mainta in 1/ [...]

- 38 - h) Loosen the t wo (2) t op chain bolt s in slot s in t he rear deck lif t arms . Loosen jam nuts and back off the socket head adj usting screws on the bottom of the arms until t he chains ar e j ust loose. Tur n t he sock et head adjusting screws in until slack is t ak en out of each chain. T ighten the j am nuts. Tig ht en the chain bolts [...]

- 39 - Reposition the adjust ing pulley to the bott om of the slot. NOTE: W hen installing a new belt, it is necessar y to r eposit ion the right adjusting pulley upward in the slot in order to position the center of the spring loaded pulley between the alignm ent holes. FIGURE 13 MULE DRIVE BELT A DJUSTMENT 5.2.5 Deck Belt T ension . a) The deck b[...]

- 40 - FIGURE 14 BELT GUIDE POSITIO NING 5.2.8 Brake Link Adjustment . Check to make sur e br ak e is adjusted proper ly. a) Disengag e br ak e lever (lever down). b) Measure the leng t h of the spring . Measurement should be 2. 75” ( 7. 0 cm) between washers (see Figure 15). c) If adj ustment is necessary, t ig ht en t he nut directly below the [...]

- 41 - FIGURE 16 THROTTLE T ENSI ON 5.2.11 Electric Clutch Adj ustment : No adjustment necessary. 5.2.12 Reverse Indicator Adj ust m ent : a) Stop engine, wait f or all moving part s to stop, and r em ove key. b) Unhook seat lat ch and t ilt seat for ward. c) Beg in with either the lef t or right m ot ion cont r ol lever. Move lever to the neutral [...]

- 42 - 5.2.13 Motion control linkag e adj ustment . WA RNING POTENT IAL HAZARD ♦ Engine must be r unning and drive wheels must be turning so m ot ion cont r ol adj ustment can be perf ormed. W HAT CAN HAPPEN ♦ Contact with moving parts or hot surfaces m ay cause personal injury. HOW TO AVO ID THE HAZARD ♦ Keep fing er s, hands, and clothing c[...]

- 43 - f) St ar t engine. Brake must be engaged and mot i on cont rol levers out to start engine. O perat or does not have t o be in the seat because of the jumper wire bei ng used. Run eng ine at full t hrottle and release br ak e. g) The reverse indicator spr ing must be corr ect before t he f ollowing adjustment s can be m ade. See Section 5.2.1[...]

- 44 - 6.2 BA TTERY DIS P O SA L DA NGER POTENT IAL HAZARD ♦ Battery electr olyte cont ains sulf uric acid, which is poisonous and can cause severe burns W HAT CAN HAPPEN ♦ Swallow ing electrolyte can be f at al or if it t ouches skin can cause severe burns. HOW TO AVO ID THE HAZARD ♦ W ear saf ety glasses to shield eyes, and rubber g loves t[...]

- 45 - g) Check that the spar k plug wires are properly connected. h) Check for loose or f aulty wiring connections. i) Check f or cor rosion at all wiring connections. Even minor cor r osion m ay cause a fault y connection. Clean connect or terminals thor oug hly w it h electrical contact cleaner , apply dielectric grease and reconnect . NOTE: Whe[...]

- 46 - 8. ELECTRICA L DIAGRA M – KOHLER 23 & 27 HP A IR-COOLED UNITS[...]

- 47 - ELECTRICA L DIAGRA M – KOHLER EFI UNITS[...]

- 48 - 9. HYDRA ULIC DIAGRA M[...]

- 49 - 10. 2-Yea r Limited Warranty Exmark Turf Equipment (For units pur chased on or af ter October 1, 2004) Conditions and Products Covered Exmark M fg. Co. Inc. and its affiliate, Exmark W arranty Company, pursuant to an agreement betw een them, jointly warrant on the terms and conditions herein, that w e will repair, replace or adjust any part [...]

- 50 -[...]

® M FG . CO. IN C. SEE EXMA RK’S COMPLETE LINE OF A CCESSORIES RIDING A CCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT KI T MICRO-MULCH SY ST EM ROLL OVER PROTECT ION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONT AINER TURF ST RIPER ULTRA VAC COLLECT ION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WA LK BEHIND A C[...]