LAZER Z D-SERIES ® For Serial Nos. 920,000 & Higher Lazer Z (LZD) Units Part No. 4500-875 Rev.
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: The engine in this product is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code (CPRC) Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land as defined in CPRC 4126.
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY. Figure 1 1.
Contents Copper-Based Anti-seize .............................. 39 Dielectric Grease........................................... 39 Adjustments ..................................................... 39 Deck Leveling ............................................... 39 Pump Drive Belt Tension............................... 40 Deck Belt Tension ......................................... 40 Mule Drive Belt Tension Adjustment ............. 40 Alternator Belt Tension .................................
Safety Safety Safe Operating Practices Safety Alert Symbol Training • Read 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.
Safety • Inspect the area where the equipment is to be used and remove all rocks, toys, sticks, wires, bones, and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders. 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.
Safety guards, switches and other devices in place and in proper working condition. • Be aware of the mower discharge path and direct discharge away from others. • 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 operate the mower under the influence of alcohol or drugs. • Use extreme care when loading or unloading the machine into a trailer or truck.
Safety WARNING There is no rollover protection when the roll bar is down. Wheels dropping over edges, ditches, steep 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. Figure 3 1.
Safety negative terminal first and the positive last. Reconnect positive first and negative last. CAUTION • Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace damaged blades. Never straighten or weld them. If the ignition is in the “ON” position there is potential for sparks and engagement of components. Sparks could cause an explosion or moving parts could accidentally engage causing personal injury.
Safety WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. • If equipped, make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.
Safety Safety and Instructional Decals • New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg. Co. Inc. • Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels. • Replace all worn, damaged, or missing safety signs. • When replacement components are installed, be sure that current safety signs are affixed to the replaced components.
Safety 103-2076 103-0223 103-7218 103-0261 103-1798 107-2102 12
Safety 109-0872 109-1399 109-1214 109-2219 109-1215 109-2263 13
Safety 109-2264 109-2478 109-2951 109-3148 14
Safety 116-0127 116-3303 116-5074 116-0404 116-5185 1. PTO–engage 2.
Safety 19426-87881 19426-87903 107-9866 1. Fast 2. Slow 3. Neutral 4.
Specifications Specifications Model Numbers Serial Nos: 920,000 and Higher LZD25KD605; LZD25KD725 Systems • Operator must be in seat when PTO is engaged, brake is 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.
Specifications • • • • – Moving motion control levers outward (in slots) locks the drive system in neutral. PTO Engagement Switch: Engages electric clutch (to drive belt) which engages mower blades. Parking Brake Lever: Engages parking brake. Deck Height Adjustment Lever: Sets cutting height to desired position. Deck Lift Assist Pedal: Foot pedal that assists in raising the deck. Hydrostatic Ground Drive System • Hydrostatic Pumps: Two Hydro Gear PW variable displacement piston pumps.
Specifications Dimensions Torque Requirements Overall Width: Bolt Location Torque 90-110 ft-lb (122-149 N-m) 60 inch Deck 72 inch Deck Blade Drive Sheave Mounting Nut Without Deck 53.5 inches (135.9 cm) 61.5 inches (156.2 cm) Cutter Housing Spindle Nut 160-185 ft-lb (217-251 N-m) Deflector Up 61.4 inches (156.0 cm) 74.3 inches (188.7 cm) Blade Mounting Bolt (lubricate with anti-seize) 55-60 ft-lb (75-81 N-m) Deflector Down 72.8 inches (184.9 cm) 85.8 inches (217.
Operation Product Overview Operation Note: Determine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control levers located on each side of the console control the forward 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.
Operation and moving the throttle lever to the rear will decrease engine speed. Moving the throttle forward into the detent is full throttle. The valve has three positions, each position made in 1/4 turn increments. Fuel Flow Valve Handle Position Brake Lever “Off ” Right Located on left side of unit, just to the front of the console. Right Tank Down Left Tank Left The brake lever engages a parking brake on the drive wheels. Fuel Gauge Pull the lever up and rearward to engage the brake.
Operation PTO Engagement Switch Warning Buzzer Located on right fuel tank. Located behind the seat under the air deflector on the electrical panel. Switch must be pulled out (up) to engage the blades. Switch is pushed in to disengage the blades. 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 overheats, the PTO will automatically disengage. The PTO cannot be engaged until the engine has cooled down.
Operation Important: Do Not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine. rear part of the seat is secured with the seat latch. Do Not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows the fuel to expand. Overfilling may result in fuel leakage or damage to the engine or emission system. If possible, fill the fuel tank after each use.
Operation 7. Turn ignition switch to the “ON” position. Depress the glow plug switch and the glow plug light will turn on. Hold switch as required by chart below. Turn the ignition switch to the “START” position. Release the ignition switch as soon as the engine starts. DANGER 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. Thrown objects or blade contact can cause serious injury or death.
Operation Driving the Machine To turn left or right, pull the motion control lever back toward neutral in the desired turn direction. CAUTION The machine will move faster the farther the motion control levers are moved from the neutral position. Machine can spin very rapidly by positioning one lever too much ahead of the other. Operator may lose control of the machine, which may cause damage to the machine or injury. • Use caution when making turns. • Slow the machine down before making sharp turns. 4.
Operation 5. After adjusting the height of cut, adjust the anti-scalp rollers by removing the bolt and spring disc washer. The deck can be raised by pulling the deck lever up and/or by pushing down on the foot operated deck lift assist lever located at the front right corner of the floor pan. 6. Place the rollers in one of the positions shown (Figure 10). Rollers will maintain 3/4 inch (19 mm) clearance to the ground to minimize gouging and roller wear or damage.
Operation 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 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.
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING WARNING While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders. The engine can become very hot. Touching a hot engine can cause severe burns. Allow the engine to cool completely before service or making repairs around the engine area.
Maintenance Maintenance Service Interval Maintenance Procedure Every 200 hours • Grease the brake brackets. • Check the spark plugs. Every 400 hours • Replace the fuel filter/water separator (more often in dirty or dusty conditions). Every 500 hours • Check the wheel hub slotted nut torque specifications. • Check the wheel lug nuts. • Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50) Every 600 hours • Replace the air cleaner elements.
Maintenance Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater. DANGER Jump starting a weak battery that is cracked, frozen, has low electrolyte level, or an open/shorted battery cell, can cause an explosion resulting in serious personal injury.
Maintenance Figure 13 1. Install bushing in blade prior to installing bushing in spindle. Figure 12 1. 2. 3. 4. 5. 6. 7. Positive (+) cable on discharged battery Positive (+) cable on booster battery Negative (–) cable on the booster battery Negative (–) cable on the engine block Booster battery Discharged battery Engine block B. Install bushing/blade assembly into spindle. 4. Connect the other end of the positive cable to the positive terminal of the booster battery. 5.
Maintenance 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 1/2 second has elapsed. WARNING Incorrect installation of the blade or components used to retain the blade can be dangerous. Failure to use all original components and assembled as shown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death.
Maintenance 1. 2. 3. 4. 5. 6. 7. the Engine Owner’s Manual for additional information.) Every 600 hours— Replace the air cleaner elements. (May need more often under severe conditions. See the Engine Owner’s Manual for additional information.) Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. Unhook two air filter canister latches to gain access to the air cleaner element. Remove air cleaner canister cover and remove outer element.
Maintenance 2. Check tire pressure in drive tires. 3. Inflate drive tires to 10 psi (69 kPa). 4. Semi-pneumatic caster tires do not need to be inflated. Lubrication Chart Fitting Locations Note: Do Not add any type of tire liner or foam fill material to the tires. Excessive loads created by foam filled tires may cause failures to the hydro drive system, frame, and other components. Foam filling tires will void the warranty. Check Condition Of Belts Service Interval: Every 40 hours 1.
Maintenance Wheel Hub - Slotted Nut Torque Specification Not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8 inch (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut. Service Interval: After the first 100 hours Every 500 hours thereafter 9. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing. Torque the slotted nut to 211-260 ft-lb (286-352 N-m). 10.
Maintenance (bushings are located to the inside of the flange bearings). DANGER Use of improper components can result in system failure, fuel leakage and possible explosion. • Ensure that an Authorized Service Dealer replace the fuel filter and any components for the fuel system. • Use only approved fuel lines, hose clamps and fuel filters for high pressure systems. Lubricate Motion Control Bronze Bushings Service Interval: Every 160 hours 1. Stop engine, wait for all moving parts to stop, and remove key.
Maintenance Exmark Premium Hydro Oil is recommended. Refer to the chart for an acceptable alternative: Hydro Oil Change Interval Exmark Premium Hydro Oil (Preferred) 500 Hours Mobil 1 15W50 250 Hours 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.
Maintenance 3. Drain coolant when engine is cool. Coolant may be drained from the radiator by removing the drain plug in the right rear corner. The engine block may be drained by removing the rear radiator hose and/or by opening the drain cock on the right-hand side of the engine block (see Figure 16). 6. With the cap off the radiator, tilt hood closed and put the seat down. Start the engine as stated in the Operating Instructions Section. Return the seat up and hood forward to the open position. 7.
Maintenance Adjustments • Square head setscrews on Hydro pump control arms. Note: Disengage PTO, shut off engine, wait for all moving parts to stop, engage parking brake, and remove key before servicing, cleaning, or making any adjustments to the unit. • Sheave retaining bolt in the end of engine crankshaft. • Caster wheel spacer nuts. • Fuel tank bulkhead fitting nuts. CAUTION • Bolts retaining stub shaft to engine flywheel. Fuel tank studs, where studs are inserted into tank.
Maintenance Pump Drive Belt Tension the chain bolts in the deck lift arms making sure they don’t move while tightening. Self-tensioning - No adjustment necessary. 9. Loosen the four nuts which secure the front swivels (two per side) until the front chains are loose and front of deck is supported by the 3/4 inch (19 mm) block. Do Not loosen the front chain hardware. Deck Belt Tension Self-tensioning - No adjustment necessary. 10.
Maintenance 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 20). 4. If adjustment is necessary, loosen the bolt securing the belt guide and make proper adjustment. Tighten hardware. Figure 18 1.
Maintenance Electric Clutch Adjustment No adjustment necessary. However 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 21 1. Lever down (disengaged) Figure 22 6. Remove pin to adjust rod length for additional brake adjustment 7. Trunnion roller 8. Spring retainer bracket 1. 2. 3. 4. 2. Lever up (engaged) 3. Nyloc nut below trunnion roller 4. Nyloc nut below spring 9. 2 13/16 inches (7.1 cm) 5.
Maintenance Figure 25 Figure 23 1. Brake mounting bolt 1. Feeler gauge 2. Shim • If the gap is less than 0.010 inch, then reinstall the shim and reference the Troubleshooting section. B. Using needle nose pliers, or by hand, take hold of the tab and remove the shim (Do Not discard the shim until proper clutch function has been confirmed). • If the gap is sufficient, proceed to the safety check in step F. C.
Maintenance 5. 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 nut.
Maintenance Motion Control Damper Adjustment because of the jumper wire 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. The top damper mounting bolt can be adjusted to obtain a more desired motion control lever resistance. See Figure 29 for mounting options. Note: The motion control lever needs to be in neutral while making any necessary adjustments.
Maintenance Cleaning Clean Engine Cooling System Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) CAUTION Excessive debris around the engine cooling air intake and inside of the pump drive belt compartment and damaged or missing rubber baffles can cause the engine and hydraulic system to overheat which can create a fire hazard. Figure 30 1. Spring disc washers • Clean all debris from inside of pump drive belt compartment daily.
Maintenance Clean Debris From Machine CAUTION Excessive debris around engine and exhaust system area can cause engine, exhaust area, and hydraulic system to overheat which can create a fire hazard. Service Interval: Before each use or daily Clean all debris from engine and exhaust system area. 2. Clean off any oil, debris, or grass build-up on the machine and cutting deck, especially under deck belt shields, around the fuel tank, around engine and exhaust area. 1.
Maintenance Battery Disposal DANGER Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns. Swallowing electrolyte 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. Federal law states that batteries should not be placed in the garbage.
Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of trouble. Do not attempt to service or replace major items or any items that call for special timing of adjustment procedures (such as valves, governor, etc.).
Troubleshooting Problem Engine loses power Engine overheats. Possible Cause Corrective Action 1. Engine load is excessive 1. Reduce the ground speed. 2. Air cleaner is dirty. 3. Oil level in the crankcase is low. 4. Cooling fins and air passages for the engine are plugged. 5. Vent hole in the fuel cap is plugged. 6. Dirt in fuel filter. 7. Dirt, water, or stale fuel is in the fuel system. 2. Clean or replace the air cleaner element. 3. Add oil to the crankcase. 4.
Troubleshooting Problem Blades do not rotate. Possible Cause 1. Drive belt is worn, loose or broken. 1. Check the belt tension. 2. Drive belt is off pulley. 2. Check belt for damage; replace if necessary. Install drive belt and check belt guide for correct position. 3. Install new deck belt. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5. Replace the spring. 6. Engine has overheated; determine cause of overheat (see Engine overheats). 3.
Schematics Schematics Electrical Diagram 52
Schematics Electrical Schematic 53
Exmark Commercial Turf Equipment 2 Year Limited Warranty 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 Conditions and Products Covered Exmark Mfg. Co. Inc.
Notes: 55
Notes: 56
Service Record Date: Description of Work Done: 57 Service Done By:
G011841 Figure 31 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees. Use 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.
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID-MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM (ROPS) DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO-MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM OUT-FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL-TAIL WHEEL SN