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Exmark LAZER Z DS-SERIES Operators, Operator'S Manual

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Exmark LAZER Z DS-SERIES Operators Operator'S Manual Download Page 42

Maintenance

Figure 19

1.

Front of unit

2.

Alignment holes

Figure 20

1.

Spring idler pulley

3.

Right side idler pulley
(adjustable)

2.

Front of unit

Alternator Belt Tension

Stop engine, wait for all moving parts to stop and
remove key. Engage parking brake.

Tilt seat and remove air deflector panel

To tighten alternator belt, loosen both upper and
lower alternator mounting bolts. Rotate alternator
out, away from engine and retighten hardware to
secure in place.

When properly tensioned, the alternator belt will
deflect 1/4 to 3/8 inch (7-9 mm) while applying 22
pounds of force to the belt midway between fan and
alternator.

Belt Guide Adjustment

1. Stop engine, wait for all moving parts to stop, and

remove key. Engage parking brake.

2. Remove the belt shield on the right side of mower

deck.

3. Note belt guide bolted to deck near the shield

support stud and right-hand pulley. Guide should
be 1/8 inch (3.2 mm) away from the belt, with
bolt-end of guide near end of slot (Figure 21).

4. If adjustment is necessary, loosen the bolt securing

the belt guide and make proper adjustment.
Tighten hardware.

Figure 21

1.

End of slot

2.

Belt guide

Parking Brake Adjustment

Service Interval: After the first 100 hours

Every 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 stop,

and remove the key.

4. Raise the back of the machine up and support the

machine with jack stands.

42

Summary of Contents for LAZER Z DS-SERIES Operators

Page 1: ...LAZER Z DS SERIES For Serial Nos 312 000 000 Higher Lazer Z LZDS Units Part No 4501 041 Rev A ...

Page 2: ...du Canada 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 manuf...

Page 3: ...e available online at http www exmark com 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 leaving...

Page 4: ...Pivot 36 Lubricate Brake Rod Bushings 36 Lubricate Motion Control Bronze Bushings 37 Drain Fuel Filter Water Separator 37 Change Fuel Filter Water Separator 37 Change Hydraulic System Filter 37 Check Engine Coolant Level 38 Change Engine Coolant 38 Check Spark Arrester if equipped 39 Thread Locking Adhesives 39 Mobil HTS Grease Or Food Grade Anti seize 40 Copper Based Anti seize 40 Dielectric Grea...

Page 5: ...d the Operator s Manual and other training material If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people oper...

Page 6: ...t operate without entire exhaust system in place and in proper working condition WARNING Diesel fuel is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by...

Page 7: ...e alert slow down and use caution when making turns Look behind and to the side before changing directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed Be aware of the mower discharge path and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use ex...

Page 8: ...eep banks or water can cause rollovers which may result in serious injury death or drowning Keep the roll bar in the raised and locked position and use seat belt Lower the roll bar only when absolutely necessary Do Not wear seat belt when the roll bar is down Drive slowly and carefully Raise the roll bar as soon as clearance permits Check carefully for overhead clearances i e branches doorways and...

Page 9: ...can be fatal or if it touches 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 In the event of an accident flush with water and call a doctor immediately CAUTION If the ignition is in the ON position there is potential for sparks and engagement of components Sparks could cause an explo...

Page 10: ...ing pressure 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 WARNING Fuel system components...

Page 11: ...y 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 instruc...

Page 12: ...Safety 103 0223 103 0261 103 1798 103 2076 103 7218 107 2102 12 ...

Page 13: ...Safety 109 0872 109 1214 109 1215 109 1399 109 2219 109 2263 13 ...

Page 14: ...Safety 109 2264 109 2478 109 2951 109 3148 14 ...

Page 15: ...Safety 116 0127 116 0404 116 0997 116 2643 116 3303 116 5074 116 5185 1 PTO engage 2 PTO disengage 117 2718 15 ...

Page 16: ...Safety 19426 87881 19426 87903 107 9866 1 Fast 3 Neutral 2 Slow 4 Reverse 16 ...

Page 17: ... disengaged or motion control levers are moved in or engine will stop Engine will stop if either the left the right or both levers are moved from neutral lock position while brake is engaged Engine Overheat Protection System PTO will disengage an alarm will sound and the coolant temperature gauge will be in the red area when the engine temperature reaches an overheat condition The PTO will not re ...

Page 18: ...eel release valves allow machine to be moved when engine is not running Tires Wheels Drive Front Caster Pneumatic Air Filled Semi Pneumatic Quantity 2 2 Drive Front Caster Tread Size Multi Trac C S Smooth Size 26 x 12 00 12 13 x 6 50 6 Ply Rating 4 Pressure 10 psi 69 kPa Cutting Deck Cutting Width 60 inch 152 4 cm 72 inch 182 9 cm Discharge Side Blade Size 3 ea 60 inch Deck 20 75 inches 52 7 cm 72...

Page 19: ...s 152 9 cm Curb Weight 60 inch Deck 72 inch Deck 1545 lb 701 kg 1645 lb 746 kg Torque Requirements Bolt Location Torque Blade Drive Sheave Mounting Nut 90 110 ft lb 122 149 N m Cutter Housing Spindle Nut 160 185 ft lb 217 251 N m Blade Mounting Bolt lubricate with anti seize 55 60 ft lb 75 81 N m Engine Deck Front Frame Mount Bolts 30 35 ft lb 41 47 N m Anti Scalp Roller Nyloc Nut See Figure 12 30...

Page 20: ...d and reverse motion of the machine Moving the levers forward or backward turns the wheel on the same side forward or reverse respectively Wheel speed is proportional to the amount the lever is moved Moving the levers outward from the center position into the T slot locks them in the neutral position Figure 5 Figure 5 1 Neutral lock position handles out 5 Neutral operate 2 Neutral operate position...

Page 21: ...jobsite and when parked inside a building The valve has three positions each position made in 1 4 turn increments Fuel Flow Valve Handle Position Off Right Right Tank Down Left Tank Left Fuel Gauge Located on the left fuel tank The fuel gauge monitors the amount of fuel in the left tank only Use the fuel from the right fuel tank first When the right fuel tank is empty switch to the left fuel tank ...

Page 22: ...essure Light Located on the right fuel tank Light will come on when engine oil pressure is low or lost Warning Buzzer Located behind the seat under the air deflector on the electrical panel The buzzer is a warning signal that the engine is overheating or the oil pressure is low See the Troubleshooting section Note If the engine coolant level is below the indicator line on the overflow bottle when ...

Page 23: ...r converting to biodiesel blends Contact your distributor if you wish for more information on biodiesel Operating Instructions Raise the Rollover Protection System ROPS Important Lower the roll bar only when absolutely necessary 1 Remove the hairpin cotter pins and remove the two roll bar pins Figure 6 2 Raise the roll bar to the upright position and install the two pins and secure them with the h...

Page 24: ...ered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blade could occur Thrown objects or blade contact can cause serious injury or death Never operate the mower with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly The PTO push pull switch engages ...

Page 25: ...her the drive system is in the neutral operate position Figure 7 1 Neutral lock position handles out 5 Neutral operate 2 Neutral operate position handles in 6 Reverse 3 Front of Unit 7 Neutral lock 4 Forward Driving Forward 1 Release the parking brake 2 Move the motion control levers inward to the center to the neutral position 3 To move forward in a straight line move both levers forward with equ...

Page 26: ...and install the hairpin cotter pin See the decal on the side of the deck lift plate for cut heights 5 Move the deck height lever out of the transport position or 5 inch 12 7 cm cutting height and down onto the height adjustment pin to mow at selected height Note The foot operated deck lift assist lever can be used to momentarily lift the deck to clear objects Be sure that PTO is disengaged Adjusti...

Page 27: ...ic tickets and or fines Do Not drive a unit on a public street or roadway WARNING Loading a unit on a trailer or truck increases the possibility of backward tip over Backward tip over could cause serious injury or death Use extreme caution when operating a unit on a ramp Use only a single full width ramp Do Not use individual ramps for each side of the unit If individual ramps must be used use eno...

Page 28: ...nd the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible Important 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 28 ...

Page 29: ...the mower blades Check the safety interlock system Check the rollover protections systems roll bar pins Check the seat belt Check for loose hardware Check engine coolant level Clean the engine cooling system Clean the engine and exhaust system area Clean the grass and debris build up from the machine and cutting deck Clean the grass build up from under the cutting deck Every 40 hours Check the hyd...

Page 30: ...rt the dipstick and push it all the way down into the tube Remove the dipstick and read the oil level 5 If the oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Exmark 4 Cycle Premium Engine Oil is recommended refer to the Engine Owner s manual for an acceptable alternative Do Not overfill Important Do Not operate the engine with the oi...

Page 31: ...ury Do Not jump start a weak battery if these conditions exist 2 Make sure the booster is a good and fully charged lead acid battery at 12 6 volts or greater Use properly sized jumper cables 4 to 6 AWG with short lengths to reduce voltage drop between systems Make sure the cables are color coded or labeled for the correct polarity CAUTION Connecting the jumper cables incorrectly wrong polarity can...

Page 32: ...stop and remove key Engage parking brake 2 Lift deck and secure in raised position as stated in the Clean Grass Build Up Under Deck procedure 3 Inspect blades and sharpen or replace as required 4 Reinstall the blades if they were removed in the following order A Install bushing through blade with bushing flange on bottom grass side of blade Figure 14 1 Install bushing in blade prior to installing ...

Page 33: ... rough terrain Run engine at one third throttle engage PTO and raise off of seat but do not get off of machine engine must initiate shutdown after one second has elapsed if the handles are in The delay will be 1 2 second if the handles are out Run engine at one third throttle with brake disengaged move levers in and raise off seat but do not get off of machine engine must initiate shutdown after 1...

Page 34: ...er to remove Before reinstalling new filter apply a thin coating of Exmark 4 Cycle Premium Engine Oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 full turn 6 Unlatch radiator and lift it up to access oil fill Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recom...

Page 35: ...op and remove key Engage parking brake 2 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 Number of Places Service Interval 1 Front Caster wheel hubs 0 2 Yearly 2 Front Caster Pivots 0 2 Yearly 3 Height Adjustment Shaft Bearings 1 5 40 Hours...

Page 36: ...le inside the nut 9 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing 10 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 11 Insert the second bearing and new seal into the wheel 12 Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with...

Page 37: ... fuel filter and any components for the fuel system Use only approved fuel lines hose clamps and fuel filters for high pressure systems Change Inline Fuel Filter Service Interval As required An inline fuel filter is installed between the fuel tank and the fuel pump Replace when necessary Replacement Filters Exmark P N 112 7836 Change Hydraulic System Filter Service Interval After the first 250 hou...

Page 38: ... orange color WARNING Engine coolant is hot and pressurized and radiator and surrounding parts are hot Spray or steam from hot pressurized liquid in the engine cooling system and touching a hot radiator may cause severe burns Allow the engine to cool completely before removing the radiator cap or servicing any component of the cooling system CAUTION Engine coolant is toxic Swallowing coolant can c...

Page 39: ...ine block and the coolant level drops add additional coolant to the radiator 8 When the radiator is completely full and no additional coolant can be added continue running and install the radiator cap Make sure that the cap is completely seated by pressing down firmly while turning until the cap stops Once the cap is installed the engine may be stopped Check Spark Arrester if equipped Service Inte...

Page 40: ...pport 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 mower on a flat surface 2 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Check tire pressure in drive tires Proper inflation pressure for tires is 10 p...

Page 41: ...Adjustment is made by turning the nut at the front of each spring clockwise will shorten the spring counterclockwise will lengthen the spring Lock in position with jam nuts Note When above adjustments have been made the front of the deck will be slightly lower than the rear of the deck Pump Drive Belt Tension Self tensioning No adjustment necessary Deck Belt Tension Self tensioning No adjustment n...

Page 42: ... on the right side of mower deck 3 Note belt guide bolted to deck near the shield support stud and right hand pulley Guide should be 1 8 inch 3 2 mm away from the belt with bolt end of guide near end of slot Figure 21 4 If adjustment is necessary loosen the bolt securing the belt guide and make proper adjustment Tighten hardware Figure 21 1 End of slot 2 Belt guide Parking Brake Adjustment Service...

Page 43: ...ieved because there is no clearance between the nyloc nut below the spring and the jam nut or there are no threads left in the bottom nyloc nut the length of the brake rod can be adjusted Remove a pin from a yoke at either end of the brake rod and lengthen or shorten the brake rod until the correct gap can be achieved 13 If a brake component has been removed or replaced see the steps below otherwi...

Page 44: ...r and armature If the gap is greater than 04 inch 1 mm proceed with the following steps A Loosen both brake mounting bolts one half to one full turn see Figure 24 Note Do Not remove the brake pole from the field shell armature The brake pole has worn to match the armature and needs to continue to match after the shim is removed to ensure proper brake torque Figure 24 1 Brake mounting bolt 2 Shim B...

Page 45: ...l lever back until the clevis pin on arm below pivot shaft contacts the end of the slot just beginning to put pressure on spring Figure 27 4 Check where lever is relative to notch in console should be centered allowing lever to pivot outward to the neutral lock position 5 If adjustment is needed loosen the nut against the yoke and while applying slight rearward pressure on the motion control lever...

Page 46: ...being used Run engine at full throttle and release brake 7 The reverse indicator spring must be correct before the following adjustments can be made See the Reverse Indicator Adjustment section Note The motion control lever needs to be in neutral while making any necessary adjustments The left rod assembly controls the left wheel and the right rod assembly controls the right wheel 8 Bring the moti...

Page 47: ... 4 Most resistance firmest feel 5 Torque nyloc nut to 200 in lb 16 7 ft lb Bolt must protrude past end of nyloc nut after torque 6 Damper 7 Damper must move freely on bolt Caster Pivot Bearings Pre Load Adjustment Remove dust cap from caster and tighten nyloc nut until washers are flat and back off 1 4 of a turn to properly set the pre load on the bearings If disassembled make sure the spring disc...

Page 48: ... 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 Remove air deflector panel from behind seat 3 Clean around flywheel cylinder head injectors and injector pump 4 Clean all debris from the exhaust system area 5 Wipe up any excessive grease or oil around the engine and exhaust area 6 Reinstall the...

Page 49: ...rt Use adequate jack stands or equivalent support 3 Clean out any grass build up from underside of deck and in discharge deflector Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations Battery Disposal DANGER Battery electrolyte contains sulfuric acid...

Page 50: ...h is defective 7 Contact an Authorized Service Dealer 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 is not in the correct position 4 Be sure the throttle control is midway between the SLOW and FAST positions 5 Dirt in fuel filter 5 Replace the fuel filter 6 Dirt wa...

Page 51: ...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 should be even within 3 16 inch which is approximately one blade thickne...

Page 52: ... emits intermittent beep 2 Oil leaking from engine 2 Contact Authorized Service Dealer 1 Fuse is blown 1 Replace fuse Check coil resistance battery charge charging system and wiring connections and replace if necessary 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 Inadequat...

Page 53: ...LACK PINK TEMP SWITCH YELLOW RED 1 2 1 2 1 2 6 5 4 7 3 2 1 8 B A A B C A B C BLACK A B C PTO LATCH RELAY UN LATCH RELAY PTO BROWN BLACK GRAY GRAY PINK BLACK PINK BLACK BLACK 1 B A 2 1 1 2 3 4 5 4 1 7 2 5 6 3 8 9 A B C A B C 2 1 1 1 1 2 3 4 5 1 4 2 3 1 2 1 2 1 4 5 3 2 1 1 2 2 1 1 3 2 1 1 5 4 3 2 1 1 1 5 4 3 2 1 1A 1B 2A 2B A B 8 7 6 5 4 3 2 1 1 1 1 1 1 2 1 2 1 2 3 4 5 1 A B C 1 3 1 5 4 2 5 3 2 1 4 ...

Page 54: ...Schematics Electrical Schematic 54 ...

Page 55: ...r Canada customers may also call 402 223 6375 If for any reason you are dissatisfied 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 If your product requires warranty service it must be returned to an autho...

Page 56: ...Notes 56 ...

Page 57: ...Service Record Date Description of Work Done Service Done By 57 ...

Page 58: ...58 ...

Page 59: ...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 59 ...

Page 60: ...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...

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