Exmark Laser Z LZZ23KC486, Operator'S Manual

Page 1: ...LAZER Z MODELS For Serial Nos 850 000 Higher Lazer Z LZZ Units Part No 4500 560 Rev B ...

Page 2: ...da The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer...

Page 3: ...lable online at http www exmark com manuals htm 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 They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before l...

Page 4: ...te Brake Handle Pivot 36 Lubricate Deck Lift Pivot 36 Check Spark Plugs 36 Change Hydraulic System Filter and Fluid 37 Wheel Hub Slotted Nut Torque Specification 37 Check Spark Arrester if equipped 38 Thread Locking Adhesives 38 Copper Based Anti seize 38 Dielectric Grease 39 Adjustments 39 Deck Leveling 39 Pump Drive Belt Tension 41 Deck Belt Tension 41 Adjusting the Parking Brake 41 Electric Clu...

Page 5: ...gns All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate or service the equipment Local regulations may restrict the age of the operator Only adults and mature teenagers should operate a mower and even mature teenagers should have adult supervision Be sure a teenager 1 has read and understands the Operator s Ma...

Page 6: ...perate without entire exhaust system in place and in proper working condition DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline cont...

Page 7: ...r with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting or overspeed the engine Stop engine wait for all moving parts to s...

Page 8: ... to be mowed Use a walk behind mower and or a hand trimmer near drop offs ditches steep banks or water Figure 3 Figure 3 1 Safe Zone Use the mower here on slopes less than 15 degrees 2 Danger Zone Use a walk behind mower and or hand trimmer on slopes greater than 15 degrees near drop offs and water 3 Water Remove or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hi...

Page 9: ...Do Not store near flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Disconnect batt...

Page 10: ...to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system For Kohler EFI Units WARNING Fuel system co...

Page 11: ...essory has been installed make sure current safety signs are visible New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and in...

Page 12: ...Safety 107 2102 107 2112 109 3148 109 7232 1 Fast 3 Neutral 2 Slow 4 Reverse 109 7330 109 7929 12 ...

Page 13: ... fast 3 Choke on 2 Throttle slow 4 Choke off 109 9361 Deck Drive Belt Routing 116 0090 116 0157 1 See Operator s manual 116 0165 For Style B Slotted Nuts See Wheel Hub Slotted Nut Torque Specification in the Maintenance section 116 0205 116 0211 13 ...

Page 14: ...Nuts See Wheel Hub Slotted Nut Torque Specification in the Maintenance section 116 2844 EFI Units Only 1 Throttle fast 2 Throttle slow 117 2718 Message Display 1 Fuel 6 Hour meter 2 Empty 7 PTO 3 Half 8 Parking brake 4 Full 9 Neutral 5 Battery 10 Operator presence switch 14 ...

Page 15: ...Safety PTO Switch Symbols 1 PTO disengage 2 PTO engage 109 7069 15 ...

Page 16: ...her engines 260 CCA Battery Voltage 12 Volt Low Voltage Light RH control panel Polarity Negative Ground Fuses All units 25 amp main fuse 25 amp charging system fuse 10 amp PTO fuse 15 amp accessory fuse Safety Interlock System LCD indicators appear for the PTO park brake drive levers and operator presence in the message display on the RH control panel PTO must be disengaged brake engaged and motio...

Page 17: ...d seat with Custom Ride Seat Suspension or Deluxe Suspension Seat Adds approximately 1 inch 2 5 cm to seat height Seat Isolation System is standard on all units Mounting Hinged seat frame to tilt up seat Held in tilted position with prop rod Adjustable fore and aft on seat tracks Armrests Standard seat foam padded adjustable flip up armrests Suspension seat molded adjustable flip up armrests Seat ...

Page 18: ...8 inch Deck 5 5 inches 14 cm 52 inch Deck 5 5 inches 14 cm 60 inch Deck 5 5 inches 14 cm 72 inch Deck 5 5 inches 14 cm Cutting Height Adjustment Foot activated lever is used to adjust the cutting height from 1 inch 2 5 cm to 5 1 2 inches 14 cm in 1 4 inch 6 4 mm increments Mulching Kit Optional Dimensions Overall Width 48 inch Deck 52 inch Deck Without Deck 45 7 inches 116 1 cm 45 7 inches 116 1 c...

Page 19: ...t Identify the accessories and correct deck size and place the corresponding values in the Accessory Score column If the Total Accessory Score meets the following add the recommended weight kit Note The 72 inch deck does not require a weight kit 48 inch Deck 52 inch Deck 60 inch Deck Accessory Score Light Kit 2 2 2 Michigan Seat CRSS 11 10 3 Bagger 0 0 3 Pneumatic Caster Tires 7 6 5 Mulch Kit 3 3 ...

Page 20: ...saki 34HP Kohler 38HP 27 33 ft lb 37 45 N m 17 23 ft lb 23 31 N m 27 33 ft lb 37 45 N m 27 33 ft lb 37 45 N m 17 21 ft lb 23 28 N m 17 21 ft lb 23 28 N m Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Motor Mounting Bolts 72 77 ft lb 98 104 N m Wheel Hub Slotted Nut Style A 211 260 ft lb 286 352 N m Wheel Hub Slotted Nut Style B minimum 200 ft lb 271 N m Rollover Protection System Roll Bar 1 2 inch ...

Page 21: ...I Located on right console black lever see Figure 6 The choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the ON position and moving the choke lever to the rear to the detent will put the choke in the OFF position Do Not run a warm engine with choke in the ON position Figure 6 Right Console 1 Fuses 4 PTO engagement switch 2 Message display 5 Thrott...

Page 22: ...gine has run Figure 9 1 LCD Indicators 2 Low fuel indicator light 3 Fuel level bar display 4 Low voltage indicator light 5 Hour Voltage display Hours are recorded when the key is on and the engine is running battery voltage is 12 8V or higher or when the key is on and the operator is in the seat The hour meter is recording when the decimal point is flashing in Hour Voltage display Hours are displa...

Page 23: ... against the stop Note The handle must be horizontal and against the stop for operation Do Not tow machine PTO Engagement Switch Located on right console see Figure 6 Switch must be pulled out up to engage the blades Switch is pushed in to disengage the blades The LCD indicator will appear when the PTO switch is disengaged see Figure 9 Low Voltage Indicator Located on the right console in the mess...

Page 24: ... you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all the necessary inspection and maintenance steps Operating Instructions Raise the Rollover Protection System ROPS Important The roll bar is an integral and effective safety device Keep the roll bar in the raised and locked position when operating the mower Lower...

Page 25: ...cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor 7 If the choke is in the ON position gradually return choke to the OFF position as the engine warms up Engaging the PTO DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck whe...

Page 26: ...e in the seat the brake lever must be disengaged pushed down before the motion control levers can be moved in or the engine will stop When the motion control levers are positioned fully outward apart in the T slot the drive system is in the neutral lock position Figure 14 Note The N LCD indicator appears when both levers are in the neutral lock position When the motion control levers are moved dir...

Page 27: ...ock control 5 Insert the height adjustment pin into the hole corresponding to the desired cutting height See the decal on the side of the deck lift plate for cut heights 6 Push the deck lift pedal release the transport lock and allow the deck to lower to the cutting height Adjusting the Anti Scalp Rollers It is recommended to change the anti scalp roller position when the height of cut has changed...

Page 28: ...nit If individual ramps must be used use enough ramps to create an unbroken ramp surface wider than the unit Do Not exceed a 15 angle between ramp and ground or between ramp and trailer or truck Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward Avoid sudden deceleration while backing unit down a ramp to avoid tipping backward Loading a Unit Use extreme caution when l...

Page 29: ...mpt 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 29 ...

Page 30: ...e specifications Check the wheel lug nuts Check the park brake adjustment Before each use or daily Check the engine oil level Check the mower blades Check the safety interlock system Check the rollover protections systems roll bar knobs Check the seat belt Check for loose hardware Clean the engine and exhaust system area Clean the hydro fan cooling guards Clean the grass and debris build up from t...

Page 31: ...and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling 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 v...

Page 32: ...nch here for blade installation This nut has been torqued to 90 110 ft lb 122 149 N m 2 Torque to 55 60 ft lb 75 81 N m Apply lubricant to threads as needed to prevent seizing Copper based anti seize preferable Grease acceptable substitute C Apply lubricant to threads of blade bolt to prevent seizing Copper based anti seize preferable Grease acceptable substitute Install blade bolt finger tight Pl...

Page 33: ...ove left motion control lever in engine must initiate shutdown after 1 2 second has elapsed Repeat again moving the right lever in then moving both levers in engine must initiate shutdown after 1 2 second has elapsed whether operator is on seat or not Note If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER Important It is essential that operato...

Page 34: ...tighten filter an additional 1 2 to 3 4 turn 5 Clean around oil fill cap and remove cap Fill to specified capacity and replace cap 6 Use oil recommended in engine owner s manual Do Not overfill Start the engine and check for leaks 7 Wipe up any spilled oil from engine deck mounting surfaces Check Hydraulic Oil Level Service Interval Every 50 hours 1 Stop engine and wait for all moving parts to sto...

Page 35: ...Chart Fitting Locations Initial Pumps Number of Places Service Interval 1 Deck and Pump Idler Pivots 1 2 Yearly 2 Front Caster Pivots 0 2 Yearly See step 3 for special lubrication instructions on the front caster pivots 3 Lubricate front caster pivots once a year Remove hex plug and cap Thread grease zerk in hole and pump with grease until it oozes out around top bearing Remove grease zerk and thr...

Page 36: ...ly more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Reapply thread locking adhesive Lubricate Brake Handle Pivot Service Interval Every 200 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate brake handle pivot with a spray type lubricant or light oil Lub...

Page 37: ... catch pan under the hydro 5 Carefully clean area around the filters It is important that no dirt or contamination enter the hydraulic system 6 Using a socket unscrew filters to remove and allow oil to drain 7 Before installing the new filters apply a thin coat of Exmark Premium Hydro oil on the surface of the two rubber seals 8 Install the new filters and torque to 14 ft lb 19 N m 9 Fill the hydr...

Page 38: ... may ignite gasoline vapors even after the engine is stopped Hot particles exhausted during engine operation may ignite flammable materials Fire may result in personal injury or property damage Do Not refuel or run engine unless spark arrester is installed 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Wait for muffler to cool 3 If any breaks in the screen or...

Page 39: ...l or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Deck Leveling 1 Position the mower on a flat surface 2 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Check the tire pressure in the dr...

Page 40: ...rface 3 Front blade tip 10 Loosen the jam nuts on the top of each deck link Fine tune the adjuster on the front deck lift assembly by turning it to get 3 inch 7 6 mm height see Figure 28 To increase the height turn the adjuster clockwise to decrease turn counterclockwise Figure 28 1 Adjuster link 3 Adjuster 2 Jam nut 11 The back tip of the blade should measure 3 1 4 inches 8 3 cm Fine tune rear ad...

Page 41: ...ry 500 hours thereafter Check to make sure brake is adjusted properly This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced 1 Drive the machine onto a level surface 2 Disengage the blade control switch PTO move the motion control levers to the neutral locked position and set the parking brake 3 Stop the engine wait for all moving parts to ...

Page 42: ...e standard nut one turn from the swivel and repeat step 11 drive release valves must be in the released position on the hydros 13 If the hub moves very freely relative to the caliper then tighten the standard nut one turn against the swivel and repeat step 11 14 Once step 11 is achieved hold the threaded rod end with a tool and tighten the lock nut against the standard nut Do Not allow the cable t...

Page 43: ...0 95 ft lb 122 129 N m 20 Remove jack stands Electric Clutch Adjustment No adjustment necessary however some later model year units have been built with clutches that contain a brake shim When the clutch brake has worn to the point where the clutch no longer engages consistently the shim can be removed to extend the clutch life Figure 32 1 Armature 5 Brake spacer 2 Field shell 6 Re gap shim 3 Roto...

Page 44: ...ap is less than 0 010 inch then reinstall the shim and reference the Troubleshooting section If the gap is sufficient proceed to the safety check in step F F Perform the following safety check a Sit on the seat and start the engine b Make sure the blades Do Not engage with the PTO switch off and the clutch disengaged If the clutch does not disengage reinstall the shim and reference the Troubleshoo...

Page 45: ...emperature Note The motion control lever needs to be in neutral while making any necessary adjustments 7 Bring the motion control levers into the neutral position Adjust pump control rod lengths by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse Figure 36 Move the motion control levers to the reverse position and while applying slight pre...

Page 46: ...es Secure the lever with the two bolts 3 Repeat the adjustment for the opposite control lever Adjusting the Tilt The motion control levers can be tilted fore or aft for maximum operator comfort 1 Loosen the upper bolt holding the control lever to the control arm shaft 2 Loosen the lower bolt just enough to pivot the control lever fore or aft Figure 39 Tighten both bolts to secure the control in th...

Page 47: ... area and hydraulic system to overheat which can create a fire hazard Clean all debris from engine and exhaust system area 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all debris from rotating engine air intake screen around engine shrouding and exhaust system area 3 Wipe up any excessive grease or oil around the engine and exhaust system area Remove ...

Page 48: ...ne and cutting deck especially under deck belt shields around the fuel tank around engine and exhaust area Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise deck to the transport 5 1 2 inch 14 cm cutting height position Lift the front of unit and support unit using jack stands or equ...

Page 49: ...s skin can cause severe burns Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is being replaced or if the unit containing the battery is no long...

Page 50: ...y or switch is defective 7 Contact an Authorized Service Dealer Starter does not crank 8 Faulty module 8 Replace module 1 Fuel tank is empty 1 Fill the fuel tank 2 Fuel shutoff valve is closed 2 Open the fuel shutoff valve 3 Oil level in the crankcase is low 3 Add oil to the crankcase 4 The throttle and choke are not in the correct position 4 Be sure the throttle control is midway between the SLOW...

Page 51: ...w cutting blade s 3 Mower deck is not level 3 Level mower deck from side to side and front to rear 4 Underside of mower is dirty 4 Clean the underside of the mower 5 Tire pressure in drive tires not correct 5 Adjust tire pressure in the drive tires 6 Blade spindle bent 6 Contact an Authorized Service Dealer Uneven cutting height 7 Tips of adjacent blades are at an uneven cutting height Blades tips...

Page 52: ...cessary 2 Low voltage supply at the clutch 2 Check coil resistance battery charge charging system and wiring connections and replace if necessary 3 Damaged coil 3 Replace clutch 4 Inadequate current supply 4 Repair or replace clutch lead wire or electrical system Clean connector contacts Clutch will not engage 5 Rotor armature airgap is too large 5 Remove shim or replace clutch 52 ...

Page 53: ...PINK PINK RED BLACK PINK GRAY PINK BLUE BLACK BLACK BLACK TVS DIODE BROWN BLACK VIOLET PINK 2 1 1 3 2 4 5 6 7 8 1 A B 2 3 1 5 4 1 2 5 4 3 1 2 1 2 1 2 9 12 3 10 1 8 6 5 11 2 4 7 B A 7 4 5 9 3 6 8 1 2 C A B A B 2 6 3 5 4 1 1 2 2 1 2 1 2 1 A B 9 7 4 1 2 3 8 4 1 2 3 5 3 7 1 2 6 8 4 5 B C A 3 1 6 4 5 2 5 3 2 1 4 A B 7 1 6 12 A B IGNITION SWITCH NOTE CONNECTORS VIEWED FROM MATING CONNECTOR TERMINAL CONN...

Page 54: ...RAY PINK BLUE BLACK BLACK BLACK TVS DIODE BROWN BLACK VIOLET PINK 2 1 1 1 1 3 2 4 5 6 7 8 1 A B 2 3 1 5 4 1 2 5 4 3 1 2 1 2 1 2 9 12 3 10 1 8 6 5 11 2 4 7 B A 7 4 5 9 3 6 8 1 2 C A B A B 2 6 3 5 4 1 1 2 2 1 2 1 2 1 A B 9 7 4 1 2 3 8 4 1 2 3 5 3 7 1 2 6 8 4 5 B C A 3 1 6 4 5 2 5 3 2 1 4 A B 7 1 6 12 A B IGNITION SWITCH NOTE CONNECTORS VIEWED FROM MATING CONNECTOR TERMINAL CONNECTIONS TERMINAL A ACC...

Page 55: ... DIODE U2 NEUT_R SW5 B MAG REG START FUEL SOLINIOD AC STARTER AC IGNITION MODULES SPARK PLUG SPARK PLUG KAW TWIN NEUT_L SW4 12 B 10 KEY_S 9 KEY_A 4 SEAT 11 BRAKE 2 NEUTRAL 3 PTO 5 FUEL 1 START_RELAY 7 MAGNETO 6 FUEL_SOLENOID 8 GROUND HOUR METER 2 R A I A 4 7 1 3 6 5 A 3 SW1 1 B B C B 8 2 4 5 IGNITION 4 6 5 1 KEY SW OPTIONAL ACCESSORIES 2 S Ignition switch terminal locations viewed from back OFF no...

Page 56: ... U2 NEUT_R SW5 B MAG ECU REG START FUEL SOLINIOD AC STARTER AC IGNITION MODULES SPARK PLUG SPARK PLUG KAW TWIN NEUT_L SW4 12 B 10 KEY_S 9 KEY_A 4 SEAT 11 BRAKE 2 NEUTRAL 3 PTO 5 FUEL 1 START_RELAY 7 MAGNETO 6 FUEL_SOLENOID 8 GROUND HOUR METER 2 R A I A 4 7 1 3 6 5 A 3 SW1 1 B B C B 8 2 4 5 IGNITION 4 6 5 1 KEY SW OPTIONAL ACCESSORIES 2 S Ignition switch terminal locations viewed from back OFF no c...

Page 57: ...Schematics Hydraulic Diagram 57 ...

Page 58: ...here are no other express warranties except for engine and special emission system coverage All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service Contact any Exmark S...

Page 59: ...Notes 59 ...

Page 60: ...Notes 60 ...

Page 61: ...Service Record Date Description of Work Done Service Done By 61 ...

Page 62: ...62 ...

Page 63: ...se the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 63 ...

Page 64: ...DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB Place Model No and Serial No Label Here Included in the Literature Pack or Fill i...