Exmark LAZER Z Manual

Loose Parts

Note: Use the chart below to verify that all parts have been shipped.

1. Remove sides and top of crate from the base.
2. Remove roll bar components from the crate.
3. Remove roll bar tubes from sides of crate.
4. Remove the two brackets used to mount the bottom of the upper roll bar tube to the crate.
5. Remove the 1/2-13 x 3 1/4 capscrews and 1/2-13 hex flange lock nuts from the two brackets at each end of the upper roll bar tube and retain for later use.
   
6. Remove the (4) 1/4" lag screws holding the wheel hub brackets to the crate bottom and discard.
7. Raise the rear of the unit approximately 10-12" and support it with jack stands or equivalent support.
   
   POTENTIAL HAZARD
   • Raising the rear of the unit for assembly 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 solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

8. Locate the left and right lower roll bar tubes.
9. Align lower roll bar tubes along rear engine frame.
   
10. LOOSELY install lower roll bar hardware (four 3/8-16 x 1 capscrews, four spring disk washers and four 3/8-16 whizlock nuts) to the tubes on each side. (Fig. 2).
    NOTE: Be sure the spring disk washer cone is installed towards the head of the capscrew.
11. Locate the latch pin assemblies (pin and hairpin connected with a lanyard).
12. Insert a 1/2-13 x 3 1/4 capscrew (removed in step 5) into the bent tab washer on the lanyard of each pin assembly.
    
    Note: Make sure the bent tab in the washer is towards the head of the bolt.
13. Lightly oil the inside surfaces of the ear-shaped plates at the upper end of the lower roll bar tubes (Fig. 3).
14. Locate the upper u-shaped section of the roll bar. Install the upper roll bar section using the two 1/2- 13 x 3 1/4 capscrews and two 1/2-13 hex flange lock nuts (removed in step 5). Do not over tighten. Make sure upper roll bar can pivot freely.
    Notes:
    • Make sure the capscrew and nuts are installed with the nut to the inside of the roll bar.
    • Make sure the tab on the lanyard washer is installed as shown and points toward the front of the unit.
15. Raise the roll bar into the upright position and secure with the latch pin assemblies on each side. Install latch pin from outer surface of roll bar assembly and secure with the hairpin to the inside.
16. Torque all lower roll bar hardware attached to the machine frame to 30-35 ft-lbs. (41-47 N-m).
17. Tighten the front knobs against the upper roll bar ends.

Installing the Drive Wheels

1. Remove the 1/2-20 drive wheel nuts (installed on studs of drive motors; See Fig. 2) and retain for wheel mounting. Remove and discard shipping brackets mounted on wheel hubs.
2. Mount drive wheels with the valve stem to the outside of the unit. Secure using four (4) 1/2-20 wheel nuts removed in step 1.
3. Torque to 95 ft-lbs (128 N M)

Checking Tire Pressure

1. Check the tire pressure in the drive tires. Proper inflation for drive tires is 13 psi (90 kPa).
2. Adjust if necessary.

Installing the Seat

1. Remove seat assembly from the crate.
2. Locate the four 5/16-18 whizlock nuts packaged with the roll bar hardware.
3. See Figure 4. Align the seat track studs on the bottom of the seat with the holes in the seat frame. Place seat on top of the frame and secure with the four 5/16-18 whizlock nuts identified in step 2.
   
4. 31 HP Briggs & Stratton units only:
   1. Route the switch wire from the seat over the top of the front seat frame crossmember.
   2. Using one of the two wire ties included secure the wire near where the seat hold up rod is connected to the seat frame.
   3. Using the second wire tie, secure the wire again to approximately the middle of the seat hold up rod.
   4. Connect the seat wire to the main wiring harness lead. Slowly lower the seat checking that the wire cannot contact any moving parts or pinch points. Readjust wire ties if necessary.

Servicing the Battery

Battery posts, terminals, and related accessories contain lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
The machine is shipped with a filled lead acid battery.

1. Unhook seat latch and tilt seat up to gain access to the battery.
   
   POTENTIAL HAZARD
   • Charging the battery may produce explosive gasses

WHAT CAN HAPPEN

• Battery gasses can explode causing serious injury.

HOW TO AVOID THE HAZARD

• Keep sparks, flames, or cigarettes away from battery.
• Ventilate when charging or using battery in an enclosed space.
• Make sure venting path of battery is always open once battery is filled with acid.

2. Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater.
   
   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 chart below for recommended charger settings).

   Voltage Reading	Percent Charge	Maximum Charger Settings	Charging Interval
   12.6 or greater	100%	16 volts/7 amps	No Charging Required
   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 Hours
   11.7 – 12.0	0 – 25%	14.4 volts/4 amps	3 Hours
   11.7 or less	0%	14.4 volts/2 amps	6 Hours or More

   
   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 charging the battery.

3. Connect the negative battery cables.
   NOTE: If the positive cable is also disconnected, connect the positive (red) cable to the positive battery terminal first, then the negative (black) cable and green/white wire to the negative battery terminal. Slip insulator boot over the positive terminal.
   NOTE: If time does not permit charging the battery, or if charging equipment is not available, connect the negative battery cables and run the vehicle continuously for 20 to 30 minutes to sufficiently charge the battery.
   

Install Canister Air Cleaner

Kohler

1. Remove air cleaner (with bracket attached) from seat frame. Keep air cleaner and mounting bracket together.
2. Remove the top two valve cover mounting screws from both left and right side engine valve covers. Keep screws for re-attaching air cleaner.
3. Position the air cleaner assembly over the engine, aligning air cleaner bracket holes with top holes in the valve covers. Reinstall valve cover screws through air cleaner bracket and torque to 70 in. lb. (4.9 N-m).
4. Remove plastic plugs from air intake elbow on engine and air cleaner hose. Adjust the air cleaner and hose as required and connect intake hose to air cleaner outlet. Position and tighten the two hose clamps to secure the hose connections.
5. Secure air cleaner by tightening the tensioning bolt and spring assembly until ends of clamp are approximately ½" (12.7 mm) apart.

Kawasaki

1. Remove air cleaner (with bracket attached) and hose clamp from the carton located on the floor pan. Keep air cleaner and mounting bracket together.
2. Loosely assemble the hose clamp onto the air cleaner intake hose.
3. Remove the protective tape from the carburetor intake. Slide the air cleaner intake hose onto the carburetor while aligning the four bracket mounting holes with the appropriate screws in the engine.
4. Remove the air cleaner assembly. Remove and retain the four screws from the engine (two top carburetor screws and two screws toward the rear of the engine).
5. Re-assemble the air cleaner assembly to the engine re-using the four screws removed in step 5. Tighten the rear screws securely. Torque the two carburetor bolts to 52 in. lbs. (5.9 N-m).
6. Check to be sure the air cleaner intake hose adequately engages the carburetor intake. Tighten the hose clamp.
7. Locate the front engine panel and four black flanged screws in a bag in the carton. Assemble the panel to the front of the engine and secure with screws.
8. Secure air cleaner by tightening the tensioning bolt and spring assembly until ends of clamp are approximately ½" (12.7mm) apart.

Briggs & Stratton

1. Remove air cleaner (with bracket and intake hose attached) from seat frame. Keep air cleaner and mounting bracket together.
2. Set the air cleaner on top of the engine with the air intake hose to the right hand side (from the operator's position), roughly aligning the mounting holes. Note the orientation of the air inlet on the air cleaner. This should be pointing straight up. If not, remove the metal bracket. While slightly spreading the air cleaner mounting base, rotate the air cleaner body accordingly. Reassemble the metal bracket to the air cleaner base. Repeat if necessary.
3. Once the inlet is vertical, secure the air cleaner to the engine using the two longer M8 screws located in a bag in the cubby on the mower. (Discard the shorter screws. They are not used in this application).
4. Rotate the air intake hose to align with the carburetor intake. Remove and discard the plastic cap from the carburetor intake. Locate the wire style hose clamp in the cubby. Slide it on the air intake hose. Slide the air intake hose onto the carburetor intake. Check to be sure the air cleaner intake hose adequately engages the carburetor intake and the air cleaner elbow. Tighten both wire style hose clamps securely.
5. Locate the inlet rain cap and flat band style clamp in the cubby. Install the clamp on the cap, and the cap on the air cleaner inlet. Tighten the clamp just snug. Over tightening will damage the cap and possibly the air cleaner inlet.

Installing the Motion Control Levers

1. Loosen and remove the two (2) 3/8" x 1" bolts and spring disc washers which attach the motion control levers to the control arm shafts for shipping and the two (2) 3/8" x 1" bolts and spring disc washers which are screwed into the control arm shafts.
2. Install the left motion control lever onto the control arm shaft on the left side of the console.
   
3. Place the lever (with the mounting plate towards the rear) on the outside of the control arm shaft and secure with the bolts and washers removed in step 1.
4. Position the lever so the bolts are in the center of the slots on the lever mounting plate and tighten until snug.
5. Repeat on opposite side of unit.
   NOTE: There are two lever height options available. Place the levers in the top two holes to increase height of the levers, or in the bottom two holes to decrease the height of the levers.
6. Align the levers front/rear position. With the levers in the neutral position, loosen the hardware and adjust the levers sliding and/or tilting the lever(s) forward or backward until properly aligned and tighten hardware.
   
7. 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 bending them outward. Move them back to the drive position and check for clearance. Repeat if necessary.

Positioning the Discharge Chute

1. Loosen two (2) 5/16" nyloc nuts attaching discharge chute. Lower the discharge chute into position. Retighten nyloc nuts until chute is snug but can pivot freely.

Servicing the Hydraulic Oil

The machine is shipped with hydraulic oil in the reservoir.

1. Run the machine for approximately 15 minutes to allow any extra air to purge out of the hydraulic system.
2. Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 15W-50 synthetic motor oil.
3. Replace hydraulic reservoir cap and tighten until snug. Do not overtighten.

NOTE: The baffle is labeled "HOT" and "COLD". The oil level varies with the temperature of the oil. The "HOT" level shows the level of oil when it is at 225°F (107°C). The "COLD" level shows the level of the oil when it is at 75°F (24°C). Fill to the appropriate level depending upon the temperature of the oil. For example: If the oil is about 150°F (65°C). Fill to halfway between the "HOT" and "COLD" levels. If the oil is at room temperature (about 75°F (24°C)), fill only to the "COLD" level.