Exmark Laser Z CT, Operator'S Manual

Page 1: ...For Serial Nos 540 000 Higher Part No 103 9180 ...

Page 2: ...rom eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES ...

Page 3: ...bmitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 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 The following res...

Page 4: ...wer maintain its maximum efficiency and promote safe operation 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 st...

Page 5: ... Uncrate Mower 13 3 2 Install Rollover Protection System Roll Bar 13 15 3 3 Service Battery 15 16 3 4 Install Drive Wheels 16 3 5 Check Tire Pressure 16 3 6 Check Park Brake 16 17 3 7 Install Seat 17 3 8 Install Motion Control Levers 17 18 3 9 Position Discharge Chute 18 3 10 Service Engine 18 3 11 Service Hydraulic Oil 18 4 OPERATION INSTRUCTIONS 4 1 Controls 18 20 4 2 Pre Start 20 4 3 Mowing 20 ...

Page 6: ...erator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 1 2 4 Avoid mowing while people especially children or pets are nearby Kee...

Page 7: ...an burn you others and cause property damage HOW TO AVOID THE HAZARD DO NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only outdoors Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when th...

Page 8: ...e then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignited by electrical sparks ...

Page 9: ...aintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without guards shi...

Page 10: ...rogressively greater care is needed as the slope increases Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Avoid sudden starts when mowing uphill Mower may tip backwards Be aware that loss of traction may occur going downhill Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking ...

Page 11: ...ards switches and other devices in place and in proper working condition 1 4 9 DO NOT change the engine governor settings or overspeed the engine Operating an engine at excessive speed may increase the hazard of personal injury 1 4 10 Disengage PTO before starting engine 1 4 11 Start the engine carefully with feet well away from the blades 1 4 12 Keep hands feet and clothing away from rotating par...

Page 12: ...ys without use 1 5 3 Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage 1 5 4...

Page 13: ...and shutting off the engine before performing any work on the hydraulic system 1 6 SAFETY SIGNS 1 6 1 Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels 1 6 2 Safety signs must be replaced if they are missing or illegible 1 6 3 When new components are installed be sure that current safety signs are affixed to the replaced components 1 6 4 New...

Page 14: ...of Mower Deck PART NO 1 513746 LOCATION On Engine Blower Housing PART NO 1 523552 LOCATION Top of Hydraulic Reservoir PART NO 98 5954 LOCATION Under Mower Deck Belt Shield s PART NO 103 2644 LOCATION Top of Hydraulic Reservoir PART NO 107 2102 LOCATION RH Inside Surface of Upper Roll bar PART NO 103 4903 LOCATION Top Front of RH Tank PART NO 103 4892 LOCATION Right of Throttle Control on RH Tank P...

Page 15: ...dle 1500 RPM 2 3 FUEL SYSTEM 2 3 1 Capacity 5 8 gal 21 9 L PART NO 103 7491 LOCATION On Top LH Side of Mower Deck PART NO 1 513748 LOCATION Bottom of Floorpan PART NO 107 2112 LOCATION Top Center of Floorpan PART NO 103 9116 LOCATION Bottom Side of Floor Pan PART NO 1 653147 LOCATION Lefthand Side of Cutting Height Adjustment Plate PART NO 1 653477 LOCATION Left of Center on Mower Deck Under Floor...

Page 16: ...f the respective drive wheels Steering is controlled by varying the position of the levers relative to each other Moving motion control levers outward in slots locks the drive system in neutral Motion control levers are adjustable to two heights 2 5 2 PTO Switch Engages electric clutch to drive belt which engages mower blades 2 5 3 Parking Brake Lever Engages parking brake 2 5 4 Deck Height Adjust...

Page 17: ...4 Blade Spindles solid steel spindles with 1 2 54 cm I D bearings 2 9 5 Deck Drive Electric clutch mounted on vertical engine shaft Blades are driven by one B Section belt w self tensioning idler direct from the engine 2 9 6 Deck Full floating deck is attached to out front support frame Maximum turf protection is provided anti scalp rollers 44 and 48 Decks Qty 3 52 Decks Qty 5 Deck design allows f...

Page 18: ...cker 55 60 ft lbs 75 81 N m 3 ASSEMBLY INSTRUCTIONS 3 1 UNCRATE MOWER 3 2 INSTALL ROLLOVER PROTECTION SYSTEM ROLL BAR 3 2 1 Disassemble roll bar from the crate a Remove roll bar tubes from sides of crate and remove screws that attach the wheel hub retaining plate to the bottom of the crate b Remove the two brackets used to mount the bottom of the upper roll bar tube to the crate Remove the 1 2 13 ...

Page 19: ...4 capscrew in the washer on the lanyard of each pin assembly Note Make sure the bent tab in the washer is towards the head of the bolt b Lightly oil the inside surfaces of the ear shaped plates at the upper end of the lower roll bar tubes c 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 from step b and two 1 2 13 hex flan...

Page 20: ...he battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater 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 chart below for recommended charger settings Voltage Reading Percent Charge Maximum Charger ...

Page 21: ...rge the battery 3 4 INSTALL DRIVE WHEELS 3 4 1 Mount drive wheels with the valve stem to the outside of the unit Secure using four 4 1 2 20 wheel nuts installed on studs in hubs for each wheel Torque to 95 ft lbs 128 NxM 3 5 CHECK TIRE PRESSURE 3 5 1 Check tire pressure in caster and drive tires Proper inflation pressure for caster tires is 16 psi 110 kPa Proper inflation for drive tires is 13 psi...

Page 22: ...r onto the control arm shaft See Figure 5 on the left side of the console 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 Position the lever so the bolts are in the center of the slots on the lever mounting plate and tighten until snug Repeat on opposite side of unit NOTE There are two lever height options avail...

Page 23: ...rature 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 4 OPERATION INSTRUCTIONS 4 1 CONTROLS 4 1 1 Familiarize yourself with all controls before operating the mower 4 1 2 Motion Control Levers Located on each side of the console The left lever controls the flow of hyd...

Page 24: ... moving parts to stop Engage park brake Unhook seat latch and tilt seat forward to gain access to the tracking knob Rotate the knob counter clockwise as viewed from the rear of the machine to cause the machine to track more to the right and clockwise to cause the machine to track more to the left Adjust in quarter turn increments until the machine tracks straight Check that the machine does not cr...

Page 25: ...The fuel gauge monitors the amount of fuel in the tank 4 1 12 Drive Wheel Release Valves Located on the right front corner of the hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running Unhook seat latch and tilt seat up to gain access to pumps With a 5 8 wrench turn both valves one turn counter cloc...

Page 26: ...an cause serious injury or kill you HOW TO AVOID THE HAZARD DO NOT put hands or feet under the mower or mower deck when the blades are engaged 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...

Page 27: ...required to drive on a public street or roadway WHAT CAN HAPPEN Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and or fines HOW TO AVOID THE HAZARD Do not drive a unit on a public street ...

Page 28: ...he slope This will minimize the ramp angle The trailer or truck should be as level as possible DO NOT attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward 5 MAINTENANCE ADJUSTMENTS WARNING POTENTIAL HAZARD While mainte...

Page 29: ... battery charge Service Interval Monthly Allowing batteries to stand for an extended period without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter s...

Page 30: ...r support Use adequate jack stands or equivalent support c Clean out any grass build up from underside of deck and in discharge chute 5 1 5 Check mower blades Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Lift deck and secure in raised position as stated in Section 5 1 4 c Inspect blades and sharpen or replace as required d Re install the blades if they we...

Page 31: ...or in seat parking brake engaged PTO engaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat again with the right lever in then with both levers in starter must not crank b Check kill circuits Run engine at one third throttle disen...

Page 32: ...Engine Owner s Manual Clean around oil filter and unscrew filter to remove Before reinstalling new filter apply a thin coating of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 2 3 to 3 4 turn e Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in engin...

Page 33: ...nterval Refer to chart a Stop engine wait for all moving parts to stop and remove key b Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule LUBRICATION CHART FITTING LOCATIONS INITIAL PUMPS NO of PLACES SERVICE INTERVAL 1 Front Caster wheel hubs w o Zerk 0 2 yearly 2 Front Caster Pivots 0 2 ye...

Page 34: ... new seal and bearing i With the open end of the wheel facing up fill the area inside the wheel around the axle full of NGLI grade 1 multi purpose grease j Insert the second bearing and new seal into the wheel k Apply a thread locking adhesive to the 2 nd spacer nut and thread onto the axle with the wrench flats facing outward l Torque the nut to 75 80 in lbs 8 9 N m loosen then re torque to 20 25...

Page 35: ...mage due to overheating 5 1 21 Check spark plug Service Interval 160 hrs a Remove spark plug check condition and reset gap or replace with new plug See Engine Owners Manual 5 1 22 Change fuel filter Service Interval As Required a A fuel filter is installed between the fuel tanks and the engine Replace when necessary For Kohler engines use Kohler P N 2405002 For Kawasaki engines use Kawasaki P N 49...

Page 36: ...r pin Note Do not use antiseize on the wheel hub 5 1 25 Fuel Tank mounting hardware specification When installing the nuts onto the fuel tank studs fully tighten the nyloc nut and back off 1 2 turn This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels 5 1 26 Thread locking adhesives such as Loctite 242 or Fel Pro Pro Lock Nut Type are used on the fo...

Page 37: ...djust anti scalp rollers for Normal Operating Conditions Stop engine wait for all moving parts to stop and remove key Place rollers in one of the positions shown in Figure 10 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 6 4 mm minimum clearance...

Page 38: ...ck lift handle While continuing to press down take the slack out of the rear chains and tighten hardware at the bottom of the rear chains Downward pressure may now be released i On left side adjust front swivel using the locking nut behind the swivel until the front chain is tight and all slack is removed from linkage Do not lift front of deck off 1 1 8 2 9 cm block Secure front swivel using locki...

Page 39: ...f the actuator rod 5 16 x 7 bolt and adjust the nuts to move the actuator plate up or down on the rod 5 2 6 Park Brake Adjustment a Stop engine wait for all moving parts to stop and remove key b Disengage the park brake c Loosen the jam nuts next to the yoke at each end of the park brake linkage See Figure 13 d Place a wrench on one of the two nuts near the front of the park brake linkage e Turn t...

Page 40: ...ck position e 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 Tighten lock...

Page 41: ...lock nuts from the ball joints at each end of the RH pump control linkage See Figure 15 NOTE The nuts to the rear of the unit on each rod have left hand threads FIGURE 15 RH MOTION CONTROL ADJUSTMENT f 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 releas...

Page 42: ...draulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations 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 ...

Page 43: ... engine c Make sure there is fuel in the fuel tank and that the fuel valve is open d Be sure the seat switch is properly adjusted See Section 5 2 5 e Make sure the parking brake is set and motion control levers are moved out neutral lock position f Check that the PTO is disengaged h Check that the spark plug wires are properly connected i Check for loose or faulty wiring connections j Check for co...

Page 44: ...OADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN Will not start X X X X X X Hard starting X X X X X X X Stops suddenly X X X X X X X Lacks power X X X X X X X X Operates erratically X X X X X X X Knocks or pings X X X Skips or misfires X X X X X Backfires X X X X X Overheats X X X X X High fuel consumption X X X X ...

Page 45: ...40 8 BRIGGS STRATTON ELECTRICAL DIAGRAM ...

Page 46: ...41 9 HYDRAULIC DIAGRAM ...

Page 47: ...with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extend...

Page 48: ... 43 NOTES ...

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Page 50: ... 45 SERVICE RECORD Date Description of Work Done Service Done By ...

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Page 52: ...ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER WARNING 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 ...