Exmark Laser Z CT Operator's Manual
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Exmark Laser Z CT Operator's Manual

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For Serial Nos.
540,000 & Higher
Part No. 103-9180

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Summary of Contents for Exmark Laser Z CT

  • Page 1 For Serial Nos. 540,000 & Higher Part No. 103-9180...
  • 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 ..................8-10 2. SPECIFICATIONS Model Numbers ................10 Engine ....................10 Fuel System ................10-11 Electrical System ................11 Operator Controls................11 Seat....................11 Hydrostatic Ground Drive System.............12 Tires &...

  • 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 partially are 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

    1.4.16 This mower was designed for one operator only. Keep all others away from mower during operation. 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.

  • 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. 103-4903 LOCATION: Top Front of RH Tank PART NO. 103-4930 LOCATION: Right of Choke Control on RH Tank PART NO. 103-4892 LOCATION: Right of Throttle Control on RH Tank PART NO. 107-2102 PART NO. 98-5954 LOCATION: RH Inside Surface LOCATION: Under Mower Deck of Upper Roll bar Belt Shield(s)

  • Page 15: Specifications

    PART NO. 1-653477 LOCATION: Left of Center on Mower Deck, Under Floor Pan PART NO. 103-7491 LOCATION: On Top LH Side of Mower Deck PART NO. 103-9116 LOCATION: Bottom Side of Floor Pan PART NO. 1-513748 LOCATION: Bottom of Floorpan PART NO.

  • Page 16: Electrical System

    2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or higher. 2.3.3 Fuel Filter: Replaceable in-line Briggs and Stratton P/N 493629 2.3.4 Fuel Shut-Off Valve: in-line, 1/4 turn 2.4 ELECTRICAL SYSTEM 2.4.1 Charging System: Flywheel Alternator 2.4.2 Charging Capacity: 15 amps 2.4.3 Battery Type: BCI Group U1 2.4.4...

  • Page 17: Hydrostatic Ground Drive System

    2.7 HYDROSTATIC GROUND DRIVE SYSTEM 2.7.1 Hydrostatic Pumps: Two Hydro Gear BDP-10A variable displacement piston pumps. 2.7.2 Wheel Motors: Two Hydro Gear wheel drive motors with 1 1/4” tapered shafts. 2.7.3 Hydraulic Oil: Use Mobil 1 15W-50 Synthetic Motor Oil. 2.7.4 Hydraulic Oil Capacity: 2.1 qt.

  • Page 18: Torque Requirements

    2.10.4 Tread Width: (center to center of tires, widthwise) 44” Deck 48” Deck 52” Deck Drive Wheels 34.9 in. (88.6 cm) 34.9 in. (88.6 cm) 34.9 in. (88.6 cm) Front Casters 32.7 in. (83.1 cm) 32.7 in. (83.1 cm) 34.1 in. (86.6 cm) 2.10.5 Wheel Base: (center of caster tire to center of drive tire)
  • Page 19 b) Align lower roll bar tubes along wheel motor channels as shown in Figure 2. c) LOOSELY install 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.

  • Page 20: 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 21: 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 22: Install Seat

    FIGURE 4 PARK BRAKE ADJUSTMENT 3.7 INSTALL SEAT 3.7.1 Remove seat assembly from the crate. Remove the four 5/16-18 whizlock nuts from the seat track studs at the bottom of the seat. Retain for use later. Align the seat track studs on the bottom of the seat with the holes in the seat frame.

  • Page 23: Position Discharge Chute

    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.
  • Page 24 To turn left while moving forward, move the left lever back toward neutral to slow the left drive wheel. 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.

  • Page 25: Pre-Start

    4.1.8 Ignition Switch: Located on the right tank. The ignition switch is used to start and stop the engine. The switch has three positions “OFF”, “ON” and “START”. Insert the 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 26: Mowing

    4.3.3 Starting Engine: Brake must be engaged, the PTO switch disengaged, and the motion control levers out (neutral lock position). (The operator does not need to be in the seat to start the engine.) On a cold engine, place the throttle midway between the “SLOW” and “FAST” positions and place the choke to the “ON”...

  • Page 27: Transporting

    Before stopping the engine, place the throttle control midway between the “slow” and “fast” positions. Allow the engine to run a minimum of 15 seconds; then stop the engine. Rotate ignition switch to “OFF” position. Remove the key to prevent children or other unauthorized persons from starting engine.

  • Page 28: Maintenance & Adjustments

    4.4.2 Loading a Unit: Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit. The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward.
  • Page 29 Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick. Screw dipstick into place. Remove the dipstick and read the oil level. If the oil level is low, wipe off the area around the oil fill cap, remove cap, and fill to the “FULL”...
  • Page 30 5.1.4 Clean grass build-up under deck. Service Interval: Daily Stop engine, wait for all moving parts to stop, and remove key. Raise deck to the transport (4.5” (11.4cm) cutting height) position. Lift the front of unit and support unit using jack stands or equivalent support. CAUTION POTENTIAL HAZARD ♦...
  • Page 31 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 32 5.1.7 Check rollover protections systems (roll bar) pins Service Interval: Daily 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 Stop engine, wait for all moving parts to stop, and remove key. Visually inspect machine for any loose hardware or any other possible problem.
  • Page 33 5.1.12 Check tire pressures: Service Interval: 40 hrs. Stop engine, wait for all moving parts to stop, and remove key. Check tire pressure in all four tires. Inflate caster tires to 16 psi (1100 kPa). Inflate drive tires to 13 psi (90 kPa). NOTE: Do not add any type of tire liner or foam fill material to the tires.
  • Page 34 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 35 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 36: Adjustments

    Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely. Start engine and move throttle control ahead to full throttle position. Move the speed control levers to the full speed and run for several minutes. Shut down machine and recheck oil level.
  • Page 37 5.2.1 Cutting Height Adjustment. Stop machine and move drive levers out to neutral lock position. Disengage PTO. Raise the deck lever to the transport position (also the 4.5” (11.4 cm) cutting height position). See Figure 10. NOTE: When changing cutting height positions, always come to a complete stop and disengage the PTO.
  • Page 38 Set anti-scalp rollers to top holes or remove completely for this adjustment. Raise the deck to the 4.5” (11.4 cm) height position and take as much force as possible off of the two large deck lift springs by loosening the nuts at the front of each spring.
  • Page 39 5.2.4 Deck Belt Tension. Self-tensioning - No adjustment necessary. 5.2.5 Adjust Seat Switch. If necessary, adjust the seat actuator rod length to where the machine will shut off when the operator raises off the seat (with brake disengaged or PTO engaged) but will continue to run with operator in seat (a slight shift in weight should not shut machine off).
  • Page 40 FIGURE 14 THROTTLE TENSION 5.2.8 Electric Clutch Adjustment: No adjustment necessary. 5.2.9 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 15.
  • Page 41 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.

  • Page 42: Waste Disposal

    The left rod assembly controls the left wheel and the right rod assembly controls the right wheel. Bring the LH motion control lever into the neutral position. Adjust the LH pump control rod length by rotating the tracking adjustment knob in the appropriate direction until the wheels slightly creep in reverse.

  • Page 43: 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 44: Trouble Shooting

    ENGINE TROUBLESHOOTING TABLE FAULTY BLOCKED INCORRECT DIRTY IMPROPER DIRT IN DIRTY AIR ENGINE PROBLEM SPARK FUEL FUEL FUEL FUEL LINE FILTER OVERLOADED PLUG FILTER LEVEL SCREEN Will not start Hard starting Stops suddenly Lacks power Operates erratically Knocks or pings Skips or misfires Backfires Overheats...

  • Page 45: Electrical Diagram

    8. BRIGGS & STRATTON ELECTRICAL DIAGRAM...

  • Page 46: Hydraulic Diagram

    9. HYDRAULIC DIAGRAM...

  • Page 47: Warranty

    This warranty replace or adjust any part manufactured by Exmark and found extends only to turf equipment operated under normal by us (in the exercise of our reasonable discretion) to be conditions.
  • Page 48 NOTES - 43 -...
  • Page 49 NOTES - 44 -...

  • Page 50: Service Record

    SERVICE RECORD Date Description of Work Done Service Done By - 45 -...
  • Page 51 - 46 -...
  • Page 52 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. © 2004-2005 EXMARK MFG. CO. INC. PART NO. 103-9180 INDUSTRIAL PARK BOX 808 (402) 223-6300 BEATRICE, NE 68310 FAX (402) 223-5489 ®...

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