Exmark Lazer Z Operator's Manual
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Exmark Lazer Z Operator's Manual

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on the purchase of your new Exmark mower. This product has been carefully designed and manufactured to give you a
maximum amount of dependability and years of trouble-free operation. If additional information is needed, or should you require trained mechanic
service, contact your authorized Exmark equipment dealer or distributor. If you need to order replacement parts from your dealer, always give the
model number and serial number of your mower as well as the part number, description and quantity of the part needed.
The Serial No. plate is located on the right side of the console. For ease of ordering and reference, we suggest that you record the information
requested in the following identification table.
Place Model No. and Serial No. Label Here
(Included in Literature Pack)
or Fill in Below
Model No.
Serial No.
MFG. CO. INC.
Engine Model No. and Spec. No. (Code)
Engine Serial No. (E/No)
Date Purchased
For Serial Nos.
370,000 & Higher
320,000-369,999
®
®
Part No. 103-3058 Rev C.
and

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  • Page 1 If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor. If you need to order replacement parts from your dealer, always give the model number and serial number of your mower as well as the part number, description and quantity of the part needed.
  • Page 2 Public Resource Code. To acquire a spark arrester for your unit, see your Engine Service Dealer. 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 3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time, Exmark pays for the part and freight. 4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark pays for the part.
  • Page 4 If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor. All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS 1. SAFETY PAGE Safety Alert Symbol ..................1 Training ......................1 Preparation ....................1-3 Operation ....................4-7 Maintenance & Storage ................7-8 Safety Signs ..................... 8-12 2. SPECIFICATIONS Model Numbers ................... 12 Engine ....................12-13 Fuel System ....................13 Electrical System ..................

  • Page 6: Safety Alert Symbol

    MAY result in minor or moderate injury. 1.2 TRAINING 1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit. 1.2.2 Read the instructions carefully. Familiarize yourself with the controls and the proper use of the equipment.
  • Page 7 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 ♦...
  • Page 8 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 ♦...

  • Page 9: Operation

    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 that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing.
  • Page 10 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 ♦...
  • Page 11 1.4.5 A Rollover Protection System (ROPS) is available and its use is recommended for areas where there are slopes, drop-offs or water. IMPORTANT: When operating a machine with a ROPS always use the seatbelt. • Be certain that the seat belt can be released quickly if the machine is driven or rolls into ponds of water.

  • Page 12: Maintenance & Storage

    disconnect battery cables in the reverse order after starting. 1.5 MAINTENANCE AND STORAGE 1.5.1 For engine maintenance, follow the engine manufacturer’s recommendations precisely as stated in the engine manual. 1.5.2 Disconnect the battery cable from the negative battery post when the unit will be allowed to sit for more than 30 days without use.

  • Page 13: Safety Signs

    When new components are installed, be sure that current safety signs are affixed to the replaced components. 1.6.4 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg. Co. Inc. 1.6.5 Safety signs may be affixed by peeling off the backing to expose the adhesive surface.
  • Page 14 For Units with decal 106-6571 on the floorpan, reference the following decals: PART NO. 103-3996 LOCATION: LH Side of Console PART NO. 106-6571 LOCATION: Top Center of Floorpan PART NO. 103-3997 LOCATION: RH Side of Console For Units without decal 106-6571 on the floorpan, reference the following decals: PART NO.
  • Page 15 For All Units, reference the following decals: PART NO. 98-5954 LOCATION: Under Mower Deck PART NO. 1-513748 Belt Shield(s) LOCATIONS: Bottom Side of Floorpan PART NO. 1-403005 PART NO. 1-643401 LOCATION: Left and Right Corners LOCATION: On Tilt Switch of Mower Deck PART NO.
  • Page 16 PART NO. 1-633922 PART NO. 1-523552 LOCATION: Front Center on Top PART NO. 1-323540 LOCATION: Top of Hydraulic of Mower Deck LOCATION: Left Rear Corner Top Reservoir, Under the Seat of Mower Deck Kohler EFI Units Only All Units except Kohler EFI PART NO.

  • Page 17: Specifications

    PART NO. 1-303508 PART NO. 1-643339 LOCATION: RH Side on Top LOCATION: Top of Right Engine Baffle Rear of Mower Deck Kawasaki Liquid-Cooled Units Only PART NO. 103-0223 LOCATION: LH Side on Top of Radiator PART NO. 1-633702 LOCATION: Bottom Side of Floor Pan 2.

  • Page 18: Engine

    Fuel Filter: Kohler Air-cooled units: In-line 15 Micron Kohler P/N 2405002. Kohler EFI units: In-line 22 Micron Exmark P/N 99-9403 (low pressure). In-line 10 Micron Kohler P/N 2405003 (high pressure). Kawasaki Liquid-cooled units: In-line 40 Micron Kawasaki P/N 49019-1055 Kawasaki Air-cooled units: In-line Kawasaki P/N 49019-7001 2.3.4...

  • Page 19: Seat

    2.6.2 PTO Engagement Switch: Engages electric clutch (to drive belt) which engages mower blades. 2.6.3 Parking Brake Lever: Engages parking brake. 2.6.4 Deck Height Adjustment Lever: Sets cutting height to desired position. 2.6.5 Deck Lift Assist Lever: Foot pedal that assists in raising the deck. 2.7 SEAT 2.7.1 Type: All units except Kohler EFI - Standard seat with high back, foam padded...

  • Page 20: Cutting Deck

    2.10 CUTTING DECK 2.10.1 Cutting Width: 72 in. (182.9 cm) 60 in. (152.4 cm) 52 in. (132.1 cm) 2.10.2 Discharge: Side 2.10.3 Blade Size: (3 ea.) w/52” Deck 18.0 in. (45.7 cm) w/60” Deck 20.5 in. (52.1 cm) w/72” Deck 24.5 in. (62.2 cm) 2.10.4 Blade Spindles: Solid steel spindles with1”...

  • Page 21: Torque Requirements

    2.11.5 Wheel Base: (center of caster tire to center of drive tire) w/52” & 60” Decks - 50.3 in. (127.8 cm) w/72” Deck – 54.5 in. (138.4 cm) 2.11.6 Curb Weight* Air-cooled units: w/52” Deck – 1025 lbs. (465 kg) w/60”...

  • Page 22: Install Drive Wheels

    IMPORTANT: Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery (see the following chart for recommended charger settings). Voltage Percent Maximum...

  • Page 23: Connect Right Front Deck Lift Arm

    insert the “L” shaped end of the rod into the hole directly above the left-side hydraulic pump mounting hardware (the “L” must be positioned to the right). Position the seat retaining rod to the outside of the mounting tab on the seat frame and secure with 5/16”x 1”...

  • Page 24: Position Discharge Chute

    LEVERS IN MOTION ALIGNMENT CONTROL LEVER MOUNT PLATE TO THE REAR & OUTSIDE OF ARM SHAFT FIGURE 2 FIGURE 3 CONTROL ARM SHAFT LEVER ALIGNMENT 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.

  • Page 25: Service Hydraulic Oil

    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 liquid level is as high as possible without overflowing. Reinstall radiator cap, making sure that the cap is completely seated by pressing down firmly while turning until the cap stops.
  • Page 26 To turn right while moving forward, move the right lever back toward neutral to slow the right drive wheel. To make a zero turn to the left, pull the left lever back beyond neutral while holding the right lever slightly ahead of neutral. To make a zero turn to the right, pull the right lever back beyond neutral while holding the left lever slightly ahead of neutral.

  • Page 27: Controls

    4.1.8 Ignition Switch: Located on the lower center of console. The ignition switch is used to start and stop the engine. The switch has three positions “OFF”, “ON” and “START”. Insert key into switch and rotate clockwise to the “ON” position. Rotate clockwise to the next position to engage the starter (key must be held against spring pressure in this position).

  • Page 28: Pre-Start

    4.2 PRE-START 4.2.1 Fill fuel tanks. For best results use only clean, fresh regular grade unleaded gasoline with an octane rating of 87 or higher. Regular grade leaded gasoline may also be used; however, combustion chamber and cylinder head will require more frequent service.

  • Page 29: Mowing

    DANGER POTENTIAL HAZARD ♦ An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also, contact with the blade could occur. WHAT CAN HAPPEN ♦ Thrown objects or blade contact can cause serious injury or death. HOW TO AVOID THE HAZARD ♦...

  • Page 30: Maintenance & Adjustments

    WARNING POTENTIAL HAZARD ♦ Loading a unit on a trailer or truck increases the possibility of backward tip-over. WHAT CAN HAPPEN ♦ Backward tip-over of the unit could cause serious injury or death. HOW TO AVOID THE HAZARD ♦ Use extreme caution when operating a unit on a ramp. ♦...

  • Page 31: Periodic Maintenance

    WARNING POTENTIAL HAZARD ♦ The engine can become very hot. WHAT CAN HAPPEN ♦ Touching a hot engine can cause severe burns. HOW TO AVOID THE HAZARD ♦ Allow the engine to cool completely before service or making repairs around the engine area. 5.1 PERIODIC MAINTENANCE 5.1.1 Check engine oil level:...
  • Page 32 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. 5.1.3 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.
  • Page 33 Information located: • On console decal 103-1971 behind ignition switch • On decal 1-633462 behind seat on rubber heat shield flap Stop engine, wait for all moving parts to stop, and remove key. Air-cooled units - Clean all debris from rotating engine air intake screen and from around engine shrouding.
  • Page 34 CAUTION POTENTIAL HAZARD ♦ Operating a mower deck with loose or weakened blade bolts can be dangerous. WHAT 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.
  • Page 35 NOTE: If machine does not pass any of these tests, do not operate. Contact your authorized EXMARK SERVICE DEALER. IMPORTANT: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing.
  • Page 36 Reinstall elements. Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips. 5.1.10 Check Spark Arrester For Kawasaki Liquid-cooled 27 HP; Kohler EFI; Kawasaki Air-cooled 25 HP engines: Service Interval: 50 hours WARNING POTENTIAL HAZARD ♦...
  • Page 37 5.1.12 Change engine coolant: (Kawasaki Liquid-Cooled Units only) Service Interval: 4 years/4000 hours* – Dex-Cool© extended life coolant (orange color) * It is recommended to service at whichever interval happens first. Stop engine, wait for all moving parts to stop, and remove key. Machine must be positioned on level surface.
  • Page 38 b) Fill radiator with a 50/50 mix of water and Dex-Cool© coolant (as specified in Section 2.5.2), allowing some room (approximately 1/2” (12.7 mm)) for expansion. Add 50/50 coolant mix to overflow bottle on the left side of the engine as required to bring the level up to the indicator line on the bottle. WARNING POTENTIAL HAZARD ♦...
  • Page 39 Check tire pressure in Caster tires. Inflate caster tires to 13 psi (90 kPa). For units with Semi-Pneumatic Caster tires (without a valve stem): Caster tires do not need to be inflated. 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.
  • Page 40 Pack the bearings with NGLI grade #2 multi-purpose gun grease. Insert (1) bearing, (1) new seal, and (1) bearing spacer. NOTE: Seals (Exmark PN 103-0063) must be replaced. Insert Caster Spacer. With open end of wheel up, fill area inside wheel around caster spacer with NGLI grade #2 multi-purpose gun grease.
  • Page 41 Pack the bearings with a NGLI grade #1 multi-purpose grease. Insert (1) bearing, (1) new seal into the wheel. NOTE: Seals (Exmark PN 103-0063) must be replaced. 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.
  • Page 42 Note: For Kohler EFI units use only high pressure clamps and SAE R7 or R9 hose available from Exmark or Kohler. Clamps require special pliers P/N 1- 643394 (Oetiker P/N 14100118 or Kohler P/N 2445505) for installation. Replacement Filters...
  • Page 43 Service Interval: After First 250 hrs. Then yearly thereafter NOTE: Use only Exmark Part No. 1-513211 for summer use above 32° F (0°C) or Part No. 1-523541 for winter use below 32° F (0°C). Stop engine, wait for all moving parts to stop, and remove key.

  • Page 44: Adjustments

    5.1.27 Inspect electric clutch gap: Service Interval: 500 hrs Refer to section 5.2.11 for inspection and adjustment procedures. 5.1.28 Wheel hub - slotted nut torque specification. Service Interval: 500 hrs When tightening the slotted nut on the wheel motor tapered shaft: Torque the slotted nut to 125 ft.
  • Page 45 NOTE: When changing cutting height positions, always come to a complete stop and disengage the PTO. LEVER IN 1 1/2” (3.81 cm) CUTTING HEIGHT POSITION LEVER IN TRANSPORT AND 5”(12.7 cm) CUTTING HEIGHT POSITION INSERT PIN FIGURE 7 CUTTING HEIGHT POSITION Insert height adjustment pin into hole corresponding to desired cutting height and install hairpin cotter.
  • Page 46 For 52” and 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 cm) height position. Force the left rear deck support arm downward about 1/4” (6.4 mm) to get the deck to rest at the 1-1/2”...
  • Page 47 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 10). It is necessary to adjust the belt tension when the center of the bolt head is at or below the center of the bottom alignment hole.
  • Page 48 1/4” (6.4 mm) FROM EDGE OF SHEAVE TO SHANK OF BOLT 1/8” STATIONARY (3.2 mm) BELT GUIDE SHOWN FROM STATIONARY LEFT SIDE BELT GUIDE (S/N 369,999 & (S/N 369,999 & LOWER ONLY) LOWER ONLY) FIGURE 11 BELT GUIDE POSITIONING For Serial Nos. 369,999 and lower: There is a stationary belt guide at the rear center of the deck.
  • Page 49 FIGURE 13 THROTTLE TENSION 5.2.11 Electric Clutch Adjustment: For All units except 25 HP Kohler units with 52” decks: Units have Warner clutches and no adjustment is necessary. For 25 HP Kohler units with 52” decks: Determine the brand of clutch installed on your unit. Ogura clutches can be identified by 3 bolts with springs.
  • Page 50 allow the adjustment bolt to move the lever to the appropriate position). Tighten lock nut. Repeat on opposite side of unit. FIGURE 15 REVERSE INDICATOR ADJUSTMENT 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.
  • Page 51 Temporarily install a jumper wire across the terminals in the connector of the wiring harness. Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic system oil up to operating temperature. Tilt seat forward. Loosen lock nuts from the ball joints at each end of the LH pump control linkage.

  • Page 52: Waste Disposal

    5.2.14 Caster pivot bearings pre-load adjustment. 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 17.

  • Page 53: Mercury Switch Disposal

    Return the switch to your Exmark dealer if it is faulty and is being replaced or if the unit containing the switch is no longer operating and is being scrapped. If the switch is damaged or broken open use extreme caution in handling.

  • Page 54: Trouble Shooting

    NOTE: After carefully checking the above steps, attempt to start the engine. If it does not start, contact your authorized Exmark service dealer. IMPORTANT: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use.

  • Page 55: Trouble Shooting

    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. Do not attempt to service or replace major items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.).

  • Page 56: Electrical Diagrams

    8. ELECTRICAL DIAGRAM – KOHLER 20, 23, 25 & 27 HP AIR-COOLED UNITS - 51 -...
  • Page 57 ELECTRICAL DIAGRAM – KOHLER EFI UNITS For Units with 2 Relays (S/N 336,205 & Lower) - 52 -...
  • Page 58 ELECTRICAL DIAGRAM – KOHLER EFI UNITS (cont.) For Units with 3 Relays (S/N 336,206 & Higher) - 53 -...
  • Page 59 ELECTRICAL DIAGRAM – 25 HP KAWASAKI AIR COOLED - 54 -...
  • Page 60 ELECTRICAL DIAGRAM – 27 HP KAWASAKI LIQUID COOLED For Units without Overheat Buzzer (S/N 369,999 & Lower) - 55 -...

  • Page 61: Electrical Diagrams

    ELECTRICAL DIAGRAM – 27 HP KAWASAKI LIQUID COOLED For Units with Overheat Buzzer (S/N 370,000 & Higher) - 56 -...

  • Page 62: Hydraulic Diagram

    9. HYDRAULIC DIAGRAM - 57 -...

  • Page 63: Warranty

    Exmark; (vi) repair or replacement arising as a result of any operation from turf equipment that has been altered or modified so as to, in the determination of Exmark or Exmark Warranty Company, adversely affect the operation, performance or durability of the equipment or that has altered, modified or affected the turf equipment so as to change the intended use of the product;...
  • Page 64 Exmark Warranty Company, within the prescribed time, the Exmark warranty registration. The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein. Neither Exmark nor Exmark Warranty Company shall have any liability for any other cost, loss or damage, including but not limited to, any incidental or consequential loss or damage.
  • Page 65 NOTES - 60 -...

  • Page 66: Service Record

    SERVICE RECORD Date Description of Work Done Service Done By - 61 -...

  • Page 68: Grass Catcher

    State of California to cause cancer, birth defects, or other reproductive harm. ©1997-2002 PART NO. 103-3058 Rev C. EXMARK MFG. CO. INC. (402) 223-6300 INDUSTRIAL PARK BOX 808 FAX (402) 223-5489 BEATRICE, NE 68310 ALL RIGHTS RESERVED PRINTED IN U.S.A.

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