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Exmark LAZER Z DS Series Operator's Manual

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LAZER Z
DS-SERIES
®
For Serial Nos.
400,000,000 & Higher
Part No. 4503-187 Rev. B

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Summary of Contents for Exmark LAZER Z DS Series

  • Page 1 LAZER Z DS-SERIES ® For Serial Nos. 400,000,000 & Higher Part No. 4503-187 Rev. B...
  • Page 2 SAE testing and gross/net power rating standards (J1940, J1995, J1349). Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously.

  • Page 3: Introduction

    All Exmark parts are thoroughly tested and inspected before leaving the factory, however, attention is required on your part if you are to obtain the fullest measure of satisfaction and performance.

  • Page 4: Table Of Contents

    Contents Dielectric Grease..........45 Adjustments ............46 Deck Leveling ..........46 Introduction ............3 Pump Drive Belt Tension........47 Safety ..............5 Deck Belt Tension ..........47 Safety Alert Symbol ......... 5 Mule Drive Belt Tension Adjustment ....47 Safe Operating Practices ........5 Secondary Mule Belt Drive Tension Safety and Instructional Decals ......11 Adjustment(Rear Discharge Units Specifications ............18...

  • Page 5: Safety

    Institute in effect at the time of production. explain this material to them; other languages may be available on our website. Exmark designed and tested this lawn mower to offer • Become familiar with the safe operation of the reasonably safe service; however, failure to comply equipment, operator controls, and safety signs.
  • Page 6 Safety bones, and other foreign objects which can be DANGER thrown by the machine and may cause personal In certain conditions during fueling, static injury to the operator or bystanders. electricity can be released causing a spark which can ignite fuel vapors. A fire or DANGER explosion from fuel can burn you and others In certain conditions diesel fuel is extremely...
  • Page 7 Safety Operation damage and make repairs before restarting and operating the mower). WARNING – Before clearing blockages. Operating engine parts, especially the muffler, – Whenever you leave the mower. become extremely hot. Severe burns can occur • Stop engine, wait for all moving parts to stop, and on contact and debris, such as leaves, grass, engage parking brake: brush, etc.
  • Page 8 Safety • Be aware that operating on wet grass, across steep DANGER slopes or downhill may cause the mower to lose Operating on wet grass or steep slopes can cause traction. Loss of traction to the drive wheels may sliding and loss of control. Wheels dropping over result in sliding and a loss of braking and steering.
  • Page 9 Charging or jump starting the battery may • Any accessories, alterations, or attachments added produce explosive gases. Battery gases can to the ROPS must be approved by Exmark. explode causing serious injury. • Keep sparks, flames, or cigarettes away Maintenance and Storage from battery.
  • Page 10 • Follow the attachment manufacturer's Unauthorized modifications to the original recommendation for weight limits for towed equipment or failure to use original Exmark equipment and towing on slopes. Towed parts could lead to serious injury or death. weight must not exceed the weight of the Unauthorized changes to the machine, engine, machine, operator, and ballast;...

  • Page 11: Safety And Instructional Decals

    Exmark equipment dealer or labels. distributor or from Exmark Mfg. Co. Inc. • Replace all worn, damaged, or missing safety • Safety signs may be affixed by peeling off the signs.
  • Page 12 Safety 112-9028 1. Warning—stay away from moving parts; keep all guards in place. 115-2903 116-8598 1. Grease Rear Discharge Units Only 117–2718 115-4212 1. Hydraulic oil level 3. Warning—do not touch the hot surface. 2. Read the Operator's Manual. 120-0625 1.
  • Page 13 Safety 126-4755 1. Parking brake-released 2. Parking brake-engaged 3. Warning-Read the Operator’s Manual. Do Not operate this machine unless you are trained. Wear hearing protection. 126-4664 4. Warning-Stay away from moving parts; keep all guards in place. Stop engine and remove key before adjusting, servicing, or cleaning.
  • Page 14 Safety 126-4757 126-4759 1. Read the Operator’s manual. 1. Start relay 4. Oil pressure relay 2. Remove the ignition key and read the instructions before 2. Fan relay 5. Charge relay servicing or performing maintenance. 3. Glow relay 3. Height of cut 126-4760 Pump Belt Routing 126-4758...
  • Page 15 Safety 126-4848 1. Fuel-Off 3. Left tank 2. Right tank 126-4859 1. Cutting/dismemberment hazard, fan and entanglement hazard, fan blades-Stay away from moving parts; keep all guards in place. Stop engine and remove key before adjusting, servicing or cleaning. 126-4761 1.
  • Page 16 Safety 126-4763 1. Engine-Off PTO-Push down to disengage 2. Engine-On 6. Glow plug-Press and hold for 15 seconds. 3. Engine-Start 7. See Operator’s manual. 4. PTO-Pull up to engage 126-6599 Rear Discharge Units 1. Thrown objects hazard 2. Cutting/dismemberment - keep bystanders a of hand - stay away from safe distance from the moving parts;...
  • Page 17 Safety 126-4743 1. Machine speed 5. Reverse 2. Fast 6. Read the Operator’s manual before servicing or performing maintenance. 3. Slow 7. Rotate counterclockwise to release; rotate clockwise to lock. 4. Neutral 8. Push the machine. 132-0871 1. Warning—read the Operator’s Manual; do not operate this 4.

  • Page 18: Specifications

    • Engine Specifications: See your Engine Owner’s Manual Note: If the engine coolant level is below the • Engine Oil Type: Exmark 4–Cycle Premium indicator line on the overflow bottle when the Engine Oil engine is cold, the coolant temperature gauge may not register correctly during operation and/or •...
  • Page 19 • Wheel Motors: Two Parker/Ross with 1 1/4 inch idler) from electric clutch to deck. tapered shafts. – Blades Driven By: • Hydraulic Oil Type: Exmark Premium Hydro oil. ◊ Side Discharge: One “B” Section belt • Hydraulic Oil Capacity: 5.5 qt. (5.2 L) (w/self-tensioning idler) from transfer shaft on deck to blade spindles.

  • Page 20: Dimensions

    Specifications The cutting height adjustment handle has a All Units: (cont'd.) transport position and all adjustments can be made while the operator remains seated. Units also have a foot operated deck lift assist lever to Roll Bar - Up Roll Bar - Down aid in raising the deck.

  • Page 21: Torque Requirements

    Product Overview Curb Weight: Product Overview Discharge 60 inch Deck 72 inch Deck Side 1545 lb (701 kg) 1645 lb (746 kg) Rear 1552 lb (704 kg) 1629 lb (739 kg) Torque Requirements Bolt Location Torque Blade Drive Sheave 90-110 ft-lb (122-149 Mounting Nut N-m) Cutter Housing Spindle...

  • Page 22: Operation

    Operation Operation and moving the throttle lever to the rear will decrease engine speed. Moving the throttle forward into the detent is full throttle. Note: Determine the left and right sides of the machine from the normal operating position. Brake Lever Controls Located on left side of unit, just to the front of the console.
  • Page 23 Operation Important: Do Not rotate the knob too far, as during transport to and from the jobsite, and when parked inside a building. this may cause the machine to creep in neutral. Refer to the Motion Control Linkage Adjustment The valve has three positions, each position made section in Maintenance.

  • Page 24: Pre-Start

    Operation Low Oil Pressure Light due to lower temperatures (wax appearance, which may plug filters). Located on the right fuel tank. Use of summer grade diesel fuel above 20°F (-7°C) Light will come on when engine oil pressure is low will contribute toward longer life of the pump or lost.
  • Page 25 Operation Note: It is not necessary for the operator to be mower. Lower the roll bar temporarily only when absolutely necessary. in the seat to start the engine. 4. Place the throttle midway between the “SLOW” 1. Remove the hairpin cotter pins and remove the and “FAST”...
  • Page 26 Operation Driving the Machine DANGER An uncovered discharge opening will allow CAUTION objects to be thrown in an operator’s or Machine can spin very rapidly by positioning one bystander’s direction. Also, contact with the lever too much ahead of the other. Operator may blade could occur.
  • Page 27 Operation 3. To move forward in a straight line, move both To turn right, release pressure on the RH motion levers forward with equal pressure. control lever and the rear of the machine will move towards the rear and to the right. To turn left, release pressure on the LH motion control lever and the rear of the machine will move towards the rear and to the left.
  • Page 28 Operation See the decal on the side of the deck lift plate for • Side Discharge Units: cut heights. A. Be sure the roller bolts are installed with 5. Move the deck height lever out of the transport the spring disc washer between the head position (or 5 inch (12.7 cm) cutting height) and of the bolt and the mounting bracket (see down onto the height adjustment pin to mow at...

  • Page 29: Transporting

    Operation Figure 13 Figure 14 1. 3/8 nyloc-torque to 30-35 3. Spacer ft-lb (41-47 N-m) 1. Bolt 3. Nut 2. Anti-scalp rollers 4. Bolt 2. Bumper Note: The foot operated deck lift assist lever can be 7. Move each bumper to the desired position and secure them with the bolts and nuts.
  • Page 30 Operation times (4X) as long as the height of the trailer or truck bed to the ground. A steeper angle may cause mower components to get caught as the unit moves from the ramp to the trailer or truck. Steeper angles may also cause the machine to tip or lose control.
  • Page 31 Operation g027996 Figure 17 1. Full-width ramp in 4. Ramp is at least four stowed position times (4X) as long as the height of the trailer or truck bed to the ground 2. Side view of full-width 5. H= height of the trailer or ramp in loading position truck bed to the ground 3.

  • Page 32: Maintenance

    Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING WARNING While maintenance or adjustments are being The engine can become very hot. Touching a hot made, someone could start the engine. engine can cause severe burns.

  • Page 33: Periodic Maintenance

    “FULL” storage when the open circuit voltage drops to 12.4 mark on the dipstick. Exmark 4-Cycle Premium volts. Engine Oil is recommended; refer to the Engine...
  • Page 34 Maintenance Check the voltage of the battery with a digital DANGER voltmeter. Locate the voltage reading of the battery in Jump starting a weak battery that is cracked, the table and charge the battery for the recommended frozen, has low electrolyte level, or an time interval to bring the charge up to a full charge open/shorted battery cell, can cause an of 12.6 volts or greater.

  • Page 35: Check Mower Blades

    Maintenance Figure 19 Blade on Side Discharge Unit Shown 1. Install bushing in blade prior to installing bushing in Figure 18 spindle. 1. Positive (+) cable on discharged battery 2. Positive (+) cable on booster battery B. Install bushing/blade assembly into spindle. 3.

  • Page 36: Check Safety Interlock System

    Always install the original Exmark blades, blade bushings, and blade bolts as shown. Check Safety Interlock System Service Interval: Before each use or daily Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use.
  • Page 37 Maintenance Check Engine Starting Circuit Chart Note: In the Check Engine Starting Circuit Chart, the state of system item that is bold is being checked in each scenario. System Parking Brake Motion Control Levers Operator Outcome (Blades) Engaged Disengaged Both levers moved in, or either Operator Starter must in seat...
  • Page 38 Maintenance Check Shutdown Circuit Chart Note: The state of system item(s) that is bold is being checked in each scenario. System Engine Parking Motion Control Operator Outcome Brake (Blades) Levers Running idle Disengaged Disengaged Both levers moved Raise off Engine must (1/3 throttle) out (neutral lock), of seat (but...

  • Page 39: Check Rollover Protections Systems (Roll Bar) Pins

    Before reinstalling new filter, apply a thin coating Every 600 hours— Replace of Exmark 4-Cycle Premium Engine Oil on the the air cleaner elements. surface of the rubber seal. Turn filter clockwise (May need more often until rubber seal contacts the filter adapter then under severe conditions.

  • Page 40: Check Hydraulic Oil Level

    Oil level should be to the top of the Note: See chart for service intervals. baffle inside the tank. If not, add oil. Use Exmark 1. Stop engine, wait for all moving parts to stop, and Premium Hydro oil. Replace hydraulic reservoir remove key.

  • Page 41: Wheel Hub - Slotted Nut Torque Specification

    Place cap back on. 7. Insert one bearing, one new seal into the wheel. Wheel Hub - Slotted Nut Note: Seals (Exmark P/N 103-0063) must be replaced. Torque Specification 8. If the axle assembly has had both spacer nuts...

  • Page 42: Lubricate Brake Handle Pivot

    Replace when necessary. Bronze Bushings Replacement Filters Service Interval: Every 160 hours Exmark P/N 112-7836 1. Stop engine, wait for all moving parts to stop, and Change Hydraulic System remove key. Engage parking brake. 2. Unhook seat latch and tilt seat up.

  • Page 43: Check Engine Coolant Level

    Coolant level Important: Before reinstalling new filter, fill should be at the indicator line on the overflow it with Exmark Premium Hydro oil and apply bottle. a thin coat of oil on the surface of the rubber 4.

  • Page 44: Check Spark Arrester (If Equipped)

    Maintenance 2. Unhook seat latch, tilt seat up and tilt hood 5. Fill radiator with a 50/50 mix of water and forward to gain access to the cooling area. Do Havoline coolant as specified in the Check ™ Not raise radiator, as it may not fully drain in that Engine Coolant Level Section, allowing some position.

  • Page 45: Thread Locking Adhesives

    Maintenance • Between the cutter housing spindle and sheave. WARNING • Under top cutter housing bearing guard. Hot exhaust system components may ignite fuel vapors even after the engine is stopped. Hot • Between the jackshaft and bearings and the particles exhausted during engine operation may jackshaft and sheaves (side discharge units only).

  • Page 46: Adjustments

    Maintenance Adjustments socket head adjusting screws in until slack is taken out of each chain. Tighten the jam nuts. Tighten Note: Disengage PTO, shut off engine, wait for the chain bolts in the deck lift arms making sure all moving parts to stop, engage parking brake, and they don’t move while tightening.

  • Page 47: Pump Drive Belt Tension

    Maintenance inch drive breaker bar and 9/16 inch socket works Spring Compression Distance Chart best). Distance Reposition the adjusting pulley towards the Side Discharge Units— 13 1/2 inches (34.3 cm) bottom of the slot. Cut Height 2 inches or Note: When installing a new belt, it is necessary above to reposition the right adjusting pulley upward in Side Discharge Units—...

  • Page 48: Secondary Mule Belt Drive Tension Adjustment(Rear Discharge Units Only)

    Maintenance Secondary Mule Belt 3. Note belt guide bolted to deck near the shield support stud and right-hand pulley. Guide should Drive Tension Adjustment be 1/8 inch (3.2 mm) away from the belt, with (Rear Discharge Units Only) bolt-end of guide near end of slot (Figure 27). 4.

  • Page 49: Electric Clutch Adjustment

    Maintenance 5. Remove the rear tires from the machine. 13. If a brake component has been removed or replaced, see the steps below; otherwise proceed 6. Remove any debris from the brake area. to step 14. 7. Engage the parking brake (lever up). Burnishing the Brake Procedure: 8.
  • Page 50 Maintenance Figure 29 Figure 30 1. Armature 5. Brake spacer 2. Field shell 6. Re-gap shim 1. Brake mounting bolt 2. Shim 3. Rotor 7. Brake pole 4. Brake mounting bolt B. Using needle nose pliers, or by hand, take hold of the tab and remove the shim (Do Not Removing the Shim: discard the shim until proper clutch function...

  • Page 51: Reverse Indicator Adjustment

    Maintenance 5. 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 the lever to the appropriate position).
  • Page 52 Maintenance because of the jumper wire being used. Run CAUTION engine at full throttle and release brake. Raising the mower deck for service or 7. The reverse indicator spring must be correct maintenance relying solely on mechanical before the following adjustments can be made. or hydraulic jacks could be dangerous.

  • Page 53: Motion Control Damper Adjustment

    Maintenance Motion Control Damper Adjustment The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance. See Figure 36 for mounting options. Figure 37 1. Spring disc washers Figure 36 1. Motion control bracket 2.

  • Page 54: Cleaning

    Maintenance Cleaning CAUTION Excessive debris around engine and exhaust system area can cause engine, exhaust area, and Clean Engine Cooling hydraulic system to overheat which can create System a fire hazard. Clean all debris from engine and exhaust system Service Interval: Before each use or daily area.

  • Page 55: Clean Debris From Machine

    Maintenance Battery Disposal Clean Debris From Machine Service Interval: Before each use or daily DANGER 1. Stop engine, wait for all moving parts to stop, and Battery electrolyte contains sulfuric acid, which remove key. Engage parking brake. is poisonous and can cause severe burns. Swallowing electrolyte can be fatal or if it touches 2.

  • Page 56: Troubleshooting

    Troubleshooting Troubleshooting 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 overlook the simple causes. For example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of trouble.
  • Page 57 Troubleshooting Problem Possible Cause Corrective Action Engine overheats. 1. Engine load is excessive. 1. Reduce the ground speed. 2. Oil level in the crankcase is low. 2. Add oil to the crankcase. 3. Dirty air filter. 3. Clean or replace the air cleaner element. 4.
  • Page 58 Troubleshooting Problem Possible Cause Corrective Action Warning buzzer emits continuous beep. (See 1. Temperature is increasing on coolant 1. Turn unit off and allow engine and engine also Engine overheats). temperature gauge. components to cool. 2. Coolant level is low. 2.

  • Page 59: Schematics

    Schematics Schematics Electrical Diagram...
  • Page 60 Schematics Electrical Schematic...
  • Page 61 No Claim of breach of warranty shall be cause for cancellation There are no other express warranties except for engine and or rescission of the contract of sale of any Exmark mower. special emission system coverage. All implied warranties of merchantability (that the...
  • Page 63 G011841 Figure 38 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.
  • Page 64 Pack) or Fill in Below Engine Model No. and Spec. No. Model No. Engine Serial No. (E/No) Serial No. ©2016 Exmark Mfg. Co., Inc. Part No. 4503-187 Rev. B Industrial Park Box 808 (402) 223-6375 Beatrice, NE 68310 Fax (402) 223-5489...

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