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

Air cooled models
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See also: Operator's Manual
For Serial Nos.
540,000 & Higher
Part No. 103-9172

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Summary of Contents for Exmark Lazer Z

  • Page 1 For Serial Nos. 540,000 & Higher Part No. 103-9172...
  • Page 2 Replacements may be ordered through the engine manufacturer. 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. Exmark, or its distributors and dealers, accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication.
  • 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 ..................... 8-11 2. SPECIFICATIONS Model Numbers ................... 12 Engine ......................12 Fuel System ....................12 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 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 ♦...

  • Page 12: Maintenance & Storage

    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.

  • 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 PART NO. 103-3979 PART NO. 103-3794 LOCATION: RH Side of Console LOCATION: LH Side of Console PART NO. 1-513742 LOCATION: Top of Mower Deck Belt Shields, Left and Right Sides Kohler EFI units All units except Kohler EFI PART NO. 103-5456 PART NO.
  • Page 15 PART NO. 1-643339 LOCATION: Top of Right Engine Baffle PART NO. 1-303508 LOCATION: RH Side on Top Rear of Mower Deck PART NO. 1-633702 LOCATION: Bottom Side of Floor Pan PART NO. 103-9255 LOCATION: Top of console DO NOT OPERATE WITHOUT GUARD IN PLACE.
  • Page 16 Type A Anti-scalp Rollers Only – See Figure 11 PART NO. 1-523552 PART NO. 1-323540 PART NO. 1-633922 LOCATION: Top of Hydraulic LOCATION: Left Rear Corner Top of LOCATION: Front Center on Top Reservoir, Under Mower Deck of Mower Deck the Seat All Units except Kohler EFI Kohler EFI Units Only...

  • Page 17: Specifications

    2.3.3 Fuel Filter: All units except Kohler EFI: 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). 2.3.4 Fuel Shut-Off Valve: 1/4 turn increments (left tank, “OFF”, right tank) 2.3.5...

  • Page 18: Seat

    2.5.5 Deck Lift Assist Lever: Foot pedal that assists in raising the deck. 2.6 SEAT 2.6.1 Type: All units except Kohler EFI: Standard seat with high back, foam padded (internal suspension) and armrests. Kohler EFI units: Standard seat with high back, foam padded (internal suspension), armrests and a custom ride suspension system.

  • Page 19: Dimensions

    2.9.5 Deck Drive: Electric clutch mounted on horizontal engine shaft. “B” Section belt (with self-tensioning idler) from electric clutch to transfer shaft mounted on deck. Blades are driven by one “B” Section belt (w/self-tensioning idler) from transfer shaft on deck to blade spindles. 2.9.6 Deck: Full floating deck is attached to out-front support frame.

  • Page 20: Assembly Instructions

    Wheel Lug Nuts .............90-95 ft-lbs. (122-129 N-m) Wheel Motor Mounting Bolts..........72-77 ft-lbs. (98-104 N-m) Wheel Hub Slotted Nut ..........minimum125 ft-lbs. (169 N-m) Rollover Protection System (Roll Bar) Mounting Bolts ..30-35 ft-lbs. (41-47 N-m) Clutch Retaining Bolt (secured with threadlocker)....55-60 ft-lbs. (75-81 N-m) 3.
  • Page 21 FIGURE 2 LOWER ROLL BAR INSTALLATION 3.2.5 Install the upper u-shaped section of the roll bar. (Reference Figure 3 for alignment and installation instructions below): a) Locate the latch pin assemblies (pin and hairpin connected with a lanyard). b) Install a 1/2-13 x 3 1/4 capscrew in the washer on the lanyard of each pin assembly.

  • Page 22: Service Battery

    FIGURE 3 UPPER ROLL BAR INSTALLATION 3.3 SERVICE BATTERY WARNING: 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. 3.3.1 Unhook seat latch and tilt seat up to gain access to the battery.

  • Page 23: Install Drive Wheels

    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 ♦...

  • Page 24: Install Motion Control Levers

    e) Secure air cleaner by tightening the tensioning bolt and spring assembly until ends of clamp are approximately ½” (12.7 mm) apart. 3.8 INSTALL MOTION CONTROL LEVERS. 3.8.1 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”...

  • Page 25: Operation Instructions

    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.
  • Page 26 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 ♦...

  • Page 27: Pre-Start

    NOTE: This switch is not a low oil sensor and will not alert the operator if the engine oil is low. 4.1.10 Fuel Shut-Off Valve: Located directly below right side of console, next to cubby. The fuel shut-off valve is used to shut off the fuel when the machine will not be used for a few days, during transport to and from the job site, and when parked inside a building.

  • Page 28: Operating Instructions

    4.3 OPERATING INSTRUCTIONS 4.3.1 Operate units with the roll bar in the raised and locked position and use seat belt. There is no rollover protection when the roll bar is down. If it is necessary to lower roll bar do not wear the seat belt. Raise the roll bar as soon as clearance permits. 4.3.2 Open fuel shut-off valve (left or right tank).

  • Page 29: Transporting

    IMPORTANT: Operator must be in seat before the PTO can be engaged. Set throttle to "midway" position. Pull outward on the switch to the “ROTATE” position. Accelerate to full throttle to begin mowing. 4.3.5 Stopping PTO: Set throttle to the “midway” position. Push in on the switch to the “STOP”...

  • 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 5.1.3 Clean engine cooling system: Service Interval: Daily or more often in dry conditions CAUTION POTENTIAL HAZARD ♦ Excessive debris and damaged or missing rubber baffles can cause the engine and hydraulic system to overheat. WHAT CAN HAPPEN ♦ Excessive debris around the engine cooling air intake and inside of the pump drive belt compartment can create a fire hazard.
  • Page 33 HOW TO AVOID THE HAZARD ♦ Always re-install original Exmark blades, blade bushings, spring disc washers, and blade bolts in the correct positions as shown.
  • Page 34 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 35 5.1.10 Check Spark Arrester Kohler EFI engines only: Service Interval: 50 hours WARNING POTENTIAL HAZARD ♦ Hot exhaust system components may ignite gasoline vapors even after the engine is stopped. ♦ Hot particles exhausted during engine operation may ignite flammable materials. WHAT CAN HAPPEN ♦...
  • Page 36 5.1.13 Check tire pressures: Service Interval: 40 hrs. Stop engine, wait for all moving parts to stop, and remove key. Check tire pressure in drive tires. Inflate drive tires to 13 psi (90 kPa). Caster tires do not need to be inflated. NOTE: Do not add any type of tire liner or foam fill material to the tires.
  • Page 37 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 38 5.1.18 Lubricate brake handle pivot: Service Interval: 160 hrs. a) Stop engine, wait for all moving parts to stop, and remove key. b) Lubricate bronze bushings on brake handle pivot with a spray type lubricant or light oil. 5.1.19 Lubricate brake rod bushings: Service Interval: 160 hrs.
  • Page 39 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 Exmark P/N 99-9403 (low pressure)
  • Page 40 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 41: Adjustments

    Pump drive sheave set screws. Square head setscrews on Hydro pump control arms. Sheave retaining bolt in the end of engine crankshaft. Caster wheel spacer nuts Fuel tank bulkhead fitting nuts. Cutter housing spindle nut. Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pro Pro-Lock Retaining I or Retaining II”...
  • Page 42 Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of the positions shown in Figure 11. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize gouging and roller wear or damage. For Maximum Deck Flotation, place rollers one hole position lower. Rollers should maintain 1/4 in.
  • Page 43 Loosen the two (2) top chain bolts in slots in the rear deck lift arms. Loosen jam nuts and back off the socket head adjusting screws on the bottom of the arms until the chains are just loose. Turn the socket head adjusting screws in until slack is taken out of each chain.
  • Page 44 Reposition the adjusting pulley to the bottom of the slot. NOTE: When installing a new belt, it is necessary to reposition the right adjusting pulley upward in the slot in order to position the center of the spring loaded pulley between the alignment holes. FIGURE 13 MULE DRIVE BELT ADJUSTMENT 5.2.5...
  • Page 45 FIGURE 14 BELT GUIDE POSITIONING 5.2.8 Brake Link Adjustment. Check to make sure brake is adjusted properly. a) Disengage brake lever (lever down). b) Measure the length of the spring. Measurement should be 2.75” (7.0 cm) between washers (see Figure 15). c) If adjustment is necessary, tighten the nut directly below the yoke and loosen the bottom nut (bottom one of the two tightened together) below the spring.
  • Page 46 FIGURE 16 THROTTLE TENSION 5.2.11 Electric Clutch Adjustment: No adjustment necessary. 5.2.12 Reverse Indicator Adjustment: Stop engine, wait for all moving parts to stop, and remove key. Unhook seat latch and tilt seat forward. Begin with either the left or right motion control lever. Move lever to the neutral position and pull lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginning to put pressure on spring), See Figure 17.
  • Page 47 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. WHAT CAN HAPPEN ♦ Contact with moving parts or hot surfaces may cause personal injury. HOW TO AVOID THE HAZARD ♦...

  • Page 48: Waste Disposal

    Start engine. Brake must be engaged and motion control levers out to start engine. Operator does not have to be in the seat because of the jumper wire being used. Run engine at full throttle and release brake. The reverse indicator spring must be correct before the following adjustments can be made.

  • Page 49: Battery Disposal

    6.2 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 ♦...

  • Page 50: 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 51: Electrical Diagrams

    8. ELECTRICAL DIAGRAM – KOHLER 23 & 27 HP AIR-COOLED UNITS - 46 -...

  • Page 52: Electrical Diagrams

    ELECTRICAL DIAGRAM – KOHLER EFI UNITS - 47 -...

  • Page 53: Hydraulic Diagram

    9. HYDRAULIC DIAGRAM - 48 -...

  • Page 54: Warranty

    Exmark service dealer replace or adjust any part manufactured by Exmark and found within the warranty period. This warranty extends only to by us (in the exercise of our reasonable discretion) to be turf equipment operated under normal conditions.
  • Page 55 - 50 -...
  • Page 56 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. © 2004 EXMARK MFG. CO. INC. PART NO. 103-9172 INDUSTRIAL PARK BOX 808 (402) 223-6300 BEATRICE, NE 68310 FAX (402) 223-5489 ®...

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