Exmark Lazer Z XS manual

For Serial Nos. 440,000 & Higher Part No. 103-6698[...]

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 requ[...]

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 - PART NO. 1-513748 LOCATIONS: Bottom Side of Floorpan DO NOT OPERA TE WITHOUT GUARD IN PLACE. 1-513748 PART NO. 1-513746 LOCATIONS: Rear RH Frame PART NO. 1-403005 LOCATION: Left and Right Corners of Mower Deck PART NO. 103-3979 LOCATION: RH Side of Console PART NO. 103-3794 LOCATION: LH Side of Console PART NO. 1-643222 LOCATION: Left of Cent[...]

- 10 - PART NO. 1-303508 LOCATION: RH Side on Top Rear of Mower Deck PART NO. 103-6936 LOCATION: Rubber Heat Shield Flap Behind Seat PART NO. 107-2112 LOCATION: Top Center of Floorpan PART NO. 1-633922 LOCATION: Front Center on Top of Mower Deck PART NO. 1-633706 LOCATION: LH Side of Cutting Height Adjustment Plate PART NO. 103-6935 LOCATION: Botto[...]

- 11 - 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: 1500 RPM 2.3 FUEL SYSTEM 2.3.1 Capacity: 15.5 gal. (56.8 L.) 2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or higher 2.3.3 Fuel Filter: In-line 30 Micron Briggs P/N 695327. 2.3[...]

- 12 - 2.6 SEAT 2.6.1 Type: Deluxe suspension seat high back, low profile foam-in-place cushion (dampened, adjustable spring suspension) and armrests, adjustable back angle. 2.6.2 Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other components. Held in tilted position with scissor-type links.. Adjustable fore and aft seat tr[...]

- 13 - 2.10 DIMENSIONS 2.10.1 Overall Width: without deck deflector up deflector down 60” Deck 54.5 in. (138.4 cm) 61.4 in. (156.0 cm) 72.2 in. (183.4 cm) 72” Deck 58.5 in. (148.6 cm) 73.2 in. (185.9 cm) 84.3 in. (214.1 cm) 2.10.2 Overall Length: Roll Bar – Up Roll Bar - Down 60” Deck 82.2 in. (208.8 cm) 92.3 in. (234.4 cm) 72” Deck 86.0 [...]

- 14 - c) LOOSELY install the lower roll bar hardware (four 3/8-16 x 1 capscrews, four spring disk washers and four 3/8-16 whizlock nuts) from the bolt bag to the tubes on each side as shown in Figure 2. NOTE: Be sure the spring disk washer cone is installed towards the head of the capscrew. FIGURE 2 LOWER ROLL BAR INSTALLATION 3.2.5 Install the up[...]

- 15 - 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[...]

- 16 - 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[...]

- 17 - 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,[...]

- 18 - 4. OPERATION INSTRUCTIONS 4.1 CONTROLS 4.1.1 Familiarize yourself with all controls before operating the mower. 4.1.2 Motion Control Levers : Located on each side of the console. The left lever controls the flow of hydraulic oil from the left hydrostatic pump to the left drive wheel motor. The right lever controls the flow of hydraulic oil f[...]

- 19 - CAUTION POTENTIAL HAZARD ♦ Machine can spin very rapidly by positioning one lever too much ahead of the other. WHAT CAN HAPPEN ♦ Operator may lose control of the machine, which may cause damage to the machine or injury. HOW TO AVOID THE HAZARD ♦ Use caution when making turns. ♦ Slow the machine down before making sharp turns. 4.1.3 T[...]

- 20 - 4.1.9 Hour Meter : Located on the right fuel tank. The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run. If the ignition switch is left on without engine running, hour meter will not run. NOTE: This switch is not a low oil sensor and will not alert the opera[...]

- 21 - On a cold engine, place the throttle midway between the “SLOW” and “FAST” positions and push choke lever forward into the “ON” position. Turn ignition switch to the “start” position. Release the switch as soon as the engine starts. IMPORTANT: DO NOT crank the engine continuously for more then ten (10) seconds at a time. If th[...]

- 22 - Rotate ignition switch to “OFF” position. Remove the key to prevent children or other unauthorized persons from starting engine. Close fuel shut-off valve when machine will not be used for a few days, when transporting, and when the unit is parked inside a building. 4.4 TRANSPORTING 4.4.1 Transporting a Unit : Use a heavy-duty trailer or[...]

- 23 - not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp. Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15 ° . A steeper angle may cause mower deck components to get caught as the unit moves from ramp to t[...]

- 24 - 5.1.2 Check battery charge : Service Interval: Monthly Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries in storage when the open circuit voltage drops to 12.4 volts. Note: To prevent dama[...]

- 25 - CAUTION POTENTIAL HAZARD ♦ Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury. HOW TO AVOID THE HAZARD ♦ DO NOT rely sole[...]

- 26 - FIGURE 7 BLADE BOLT INSTALLATION 5.1.6 Check safety interlock system . Service Interval: Daily a ) Check starting circuit. Starter should crank with, parking brake engaged, PTO disengaged and motion control levers moved out in the neutral lock position. The operator does not need to be in the seat to start the engine. Try to start with opera[...]

- 27 - 5.1.7 Check rollover protections systems (roll bar) pins Service Interval: Daily a) Make sure latch pin and hair pin are fully installed and lanyard is in good condition. 5.1.8 Check for loose hardware . Service Interval: Daily a) Stop engine, wait for all moving parts to stop, and remove key. b) Visually inspect machine for any loose hardwa[...]

- 28 - 5.1.11 Check hydraulic oil level : Service Interval: 40 hr. a) Stop engine and wait for all moving parts to stop. b) Clean area around hydraulic reservoir cap and remove cap. Oil level should be to the top of the baffle inside the tank. If not, add oil. Use only Mobil 1 15W-50 synthetic motor oil. Replace hydraulic reservoir cap and tighten [...]

- 29 - LUBRICATION CHART FITTING LOCATIONS INITIAL PUMPS NO. of PLACES SERVICE INTERVAL 1. Front Caster wheel hubs ∗ 0 2 ∗ yearly 2. Front Caster Pivots ∗ 0 2 ∗ yearly 3. Height Adj. Shaft Bearings 1 5 40 hours 4. Deck Drive Belt Idler Arm 1 1 Yearly 5. Brake Brackets 1 2 200 hours 6. Mule Drive Belt Idler Arm 1 1 Yearly 7. Pump Drive Belt [...]

- 30 - h) If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to (1) spacer nut and thread onto the axle with the wrench flats facing outward. Do not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer surface of the spacer nut to the end of[...]

- 31 - 5.1.20 Check spark plugs : Service Interval: 160 hrs. a) Remove spark plugs, check condition and reset gaps, or replace with new plugs. See Engine Owners Manual. 5.1.21 Change fuel filter : Service Interval: As Required a) A fuel filter is installed between the fuel tanks and the engine. Replace when necessary. Replacement Filters Briggs and[...]

- 32 - 5.1.24 Fuel Tank – mounting hardware specification. When installing the nuts on the fuel tank studs, fully tighten the nyloc nut and back off 1/2 turn. This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels. 5.1.25 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut[...]

- 33 - e) Move lever out of transport (or 5” (12.7 cm) cutting height) position and down onto height adjustment pin to mow at selected height. f) To transport, move lever back up to transport (or 5” (12.7 cm) cutting height) position. Note: The foot operated deck lift assist lever can be used to momentarily lift the deck to clear objects. Be su[...]

- 34 - j) On left side, adjust front swivel using the locking nut behind the swivel until the front chain is tight and all slack is removed from linkage. Do not lift front of deck off 3/4” (19 mm) block. Secure front swivel using locking nut in front of swivel. Repeat for right side. k) Recheck that the 3/4” (19 mm) blocks fit just snugly under[...]

- 35 - FIGURE 12 MULE DRIVE BELT ADJUSTMENT 5.2.5 Deck Belt Tension . a) The deck belt is tensioned by a self-tensioning idler, no adjustment is necessary . 5.2.6 Belt Guide Adjustment . a) Stop engine, wait for all moving parts to stop, and remove key. b) Remove the belt shield on the right side of mower deck. c) Note belt guide bolted to deck nea[...]

- 36 - g) If a 1/4” to 5/16” (6.4 – 7.9 mm) gap can no longer be achieved because there is no clearance between nyloc nut below the spring and the jam nut above the trunion or there are no threads left on the bottom nyloc nut, the length of the brake rod can be adjusted. Remove a pin from a yoke at either end of the brake rod and lengthen (or[...]

- 37 - e) If adjustment is needed, loosen the nut against the yoke and while applying slight rearward pressure on the motion control lever, turn the head of the adjustment bolt in the appropriate direction until lever is centered (keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move t[...]

- 38 - c) Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic system oil up to operating temperature. d) Unhook seat latch and tilt seat forward. e) Loosen lock nuts from the ball joints at each end of the RH pump control linkage. (See Figure 17). NOTE: The nut to the front of the unit on the RH rod has le[...]

- 39 - 5.2.14 Caster pivot bearings pre-load adjustment . a) Remove dust cap from caster and tighten nyloc nut until washers are flat and back off 1/4 of a turn to properly set the pre-load on the bearings. If disassembled, make sure the spring washers are reinstalled as shown in Figure 18. 6. WASTE DISPOSAL 6.1 MOTOR OIL DISPOSAL Engine oil and hy[...]

- 40 - 6.3 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 [...]

- 41 - e) Check that the PTO is disengaged. f) Check that the spark plug wires are properly connected. g) Check for loose or faulty wiring connections. h) Check for corrosion at all wiring connections. Even minor corrosion may cause a faulty connection. Clean connector terminals thoroughly with electrical contact cleaner, apply dielectric grease an[...]

- 42 - 8. ELECTRICAL DIAGRAM[...]

- 43 - 9. HYDRAULIC DIAGRAM[...]

- 44 - 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 [...]

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

46[...]

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