Exmark Lazer ZXS manual

For Serial Nos. 600,000 & Higher Part No. 103-9911 Rev. A[...]

i WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment. W HAT CAN HAPPEN ♦ Failure to f ollow safe operating pr act ices can result in serious operator inj ur y or even death. HOW TO AVO ID THE HAZARD ♦ Keep all shields, guar ds, and saf ety devices (especially the grass discharge system) in place and in pr oper working con[...]

ii EXMARK PA RTS PLUS ® PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not have the Exmark part in stock, Exmark w ill get the parts to the dealer the next business day or the part will be FREE* Guaranteed!! How the Program Works 1. If dealer does not have part in stock for a "dow n" unit at the time of re[...]

iii CONGRAT ULATIONS on the purchase of your Exmark Mow er. This product has been caref ully designed and m anufactur ed t o give you a maximum amount of dependabilit y and years of tr ouble- free oper at ion. OPERA TOR'S MA NUA L This manual cont ains assem bly, oper at ing , maintenance, adj ust ment, and saf ety instructi ons for your E xma[...]

iv TA BLE OF CONTENTS 1 . S A F E T Y P A G E 1.1 Safety Alert Sy mbol .............................................................................1 1.2 Train ing ................................................................................................ 1 1.3 Preparat ion ......................................................................[...]

- 1 - 1. SA FETY 1.1 SA FETY A LERT SYMBOL This SAFET Y ALERT SYMBOL is used both in this manual and on t he m achine t o identif y import ant safet y messag es which must be followed to avoid accidents. T his symbol means: A TTENTION! BECOME ALERT ! YOUR SA FETY IS INVOLV ED! The saf ety alert symbol appears above inform at ion which alerts you to[...]

- 2 - 1.3.4 Thoroug hly inspect the area where the equipment is t o be used and remove all stones, stick s, wires, bones, and other f oreign obj ect s which may damage t he equipment or cause per sonal inj ury to the operator or bystander s. WA RNING POTENT IAL HAZARD ♦ Engine exhaust contains carbon m onoxide, which is an odorless deadly poison.[...]

- 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flamm able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g asoline vapors. A f ire or explosion from g asoline can burn you, others, and cause property damag e. HOW TO AVO ID THE HAZARD ♦ Purchase and store g asoline only in an approved cont[...]

- 4 - WA RNING POTENT IAL HAZARD ♦ Operating engine parts , especially the m uf fler , becom e extremely hot. W HAT CAN HAPPEN ♦ Severe burns can occur on contact. ♦ Debris, such as leaves, gr ass, br ush, et c. can catch f ir e. HOW TO AVO ID THE HAZARD ♦ Allow engine parts, especially the m uf f ler, to cool befor e touching. ♦ Remove a[...]

- 5 - • See inside the back cover t o det er m ine the approximate slope angle of the area to be mowed. • Progre ssively great er car e is needed as t he slope increases. • Alway s avoid sudden starting or st opping on a slope. If tires lose tract ion, disengage t he blades and proceed slowly off the slope. • Be aware that loss of t r act i[...]

- 6 - 1.4.16 This mower was designed f or one oper at or only. Keep all others away from mower during oper at ion. 1.4.17 Do Not mow with the discharge def lector raised, r em oved or alt er ed unless t here is a grass collect ion system or mulch kit in place and working properly. 1.4.18 Be aware of t he m ower discharg e and direct discharg e away[...]

- 7 - PART NO. 1- 303518 LOCAT ION: Tr ansmis sion Shifter Plate PART NO. 1- 513746 LOCAT ION: Engine Blower Housing Next to Muff ler PART NO. 1- 403005 LOCATIO N: Front Corners of Deck 32” & 36” – RH Front 48” – RH & LH Front PART NO. 1- 303508 LOCATIO N: Right Rear Corner of Dec k PART NO. 1- 303517 LOCATI ON: Left Side, Rear Su[...]

- 8 - Pistol Grip Handle Units PART NO. 1- 323550 LOCATIO N: Upper Handles (Both Sides ) PART NO. 1- 403143 LOCATI ON: Right Rear of Engine Deck ECS Handle Units PART NO. 103- 1623 LOCATI ON: Console Pistol Grip Handle Units PART NO. 103- 1967 LOCATI ON: Console[...]

- 9 - 2. SPECIFICA TIONS 2.1 MODEL NUMBER: M15KA322P; M 15KA362P; M15KA483P; M15KA362; M 15KA483 2.2 ENGINE 2.2. 1 Engine Specif icat ions: See your engine owner's manual. 2.2. 2 RPM (No Load): 3600 rpm 2.3 FUEL SY STEM 2. 3. 1 Capacity: 5 gal. ( 18.9 liter) 2.3. 2 Type of Fuel: Use only clean, f resh, re g ular grade, unleaded g asoline with [...]

- 10 - 2.9.3 Blade Siz e: Model 32 ......... 16.25 ( 41.3 cm) - Qty. 2 Model 36 ......... 18.00 ( 45.7 cm) - Qty. 2 Model 48 ......... 16.25 ( 41.3 cm) - Qty. 3 2.9.4 T ype of Drive: Manual engagement of belt with over-cent er lock . Blade belt tension is adjustable via turnbuck le. 2.9.5 Blade Br ak e: W hen t he blade eng agement cont rol is move[...]

- 11 - will kill the engine if either t he t ransmission shif t lever is not i n the neutral position or the PTO is en gage d . See Fig ures 1 and 2. 3.1.3 Drive Levers : Located on each side of t he upper handle assembly directly below the handle grips. See Figures 1 and 2. T hese levers individually control clutching action of the wheel drive bel[...]

- 12 - 3.1.5 PTO Engagem ent Lever : Located on the lef t side of t he upper handle. To eng age the blades, push t he lever f orward, or away from t he oper at or, until the turnbuck le lock s over-center. To diseng age the blades, pull t he lever t o t he r ear, or towards the oper at or . 3.1.6 Throt tle Control : The t hr ot t le control is loca[...]

- 13 - 3.3 OPERAT ING INSTRUCTIONS 3.3.1 Read the Eng ine Owner's Manual carefully for det ailed oper at ing instruct ions and maintenance reg arding the eng ine. Befo r e at t empting t o oper ate the unit, r efer t o Sect ion 1 (Safet y) and f ollow all safet y, oper at ing , and preparation g uidelines as stated in that sect ion. 3.3.2 Star[...]

- 14 - FIGURE 3 DRIVE LEVER, NEUTRA L LO CK/PA RK BRAKE OPERA TION For ECS Handles: T o lock the drive levers in “neutral l ock” , squeeze the drive levers to the “neut ral” position. See Fig ure 4 (b). Place t humbs on the inner thumb lobe of the neutral lock /park br ake latches and rot ate them to t he “ neut ral” position. See Fig u[...]

- 15 - FIGURE 4 DRIVE LEVER, NEUTRA L LO CK/PA RK BRAKE LA TCH OPERA TION 3.3.5 Drive W heel Engag em ent and Turning : W it h dr ive levers in the “ neut ral” or “par k brake” position, shif t transmission into desired gear . Sq ueeze both drive levers and move both neutral lock / park brak e latches f r om the “neutr al” or “park br[...]

- 16 - DA NGER POTENT IAL HAZARD ♦ An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s dir ection. Also, contact with the blade could occur. W HAT CAN HAPPEN ♦ Thrown objects or blade cont act can cause serious injury or death. HOW TO AVO ID THE HAZARD ♦ Never operate the mower with the discharg [...]

- 17 - 4. MAINTENA NCE AND A DJUSTMENTS 4.1 PERIODIC MA INTENA NCE WA RNING POTENT IAL HAZARD ♦ W hile maint enance or adj ustments are being made, someone could start t he eng ine. W HAT CAN HAPPEN ♦ Accidental start ing of the eng ine could seriously injure you or other bystanders. HOW TO AVO ID THE HAZARD ♦ Remove the key f rom the ig nit [...]

- 18 - 4.1.3 Clean gr ass build- up under deck and check m ower blades . Serv ice Interv al: Daily CA UTION POTENT IAL HAZARD ♦ Raising the m ower deck f or service or maint enance relying solely on mechanical or hydraulic jack s could be dangerous. W HAT CAN HAPPEN ♦ The mechanical or hydraulic j ack s may not be enough support or m ay malf un[...]

- 19 - Again, r un t he engine at one-t hir d thrott le, m ove the transmission shif ter lever to neutral, eng age the PT O and release the O PC levers - t he engine MUST stop . If the mow er engine does not st op under any of the above mentioned conditions, DO NOT OPERA TE. Contact your authorized Exmark service dealer. IMPORTA NT: It i s essent i[...]

- 20 - 3/16” TO 1/4”(.47-.64 cm) Drive Linkage Neutral Lock / Park Brake Latch FIGURE 7 PIST OL GRIP H A NDL ES NEUTRA L LOCK LEVER CLEARA NCE NOTE: Neutral l ock/ park brake l atch clearance should be checked w hen there is a slight upw ard force pl aced on t he dri ve lev ers to remove any "sl ack" i n t he l i nkage. f) Re-inst all[...]

- 21 - FIGURE 9 ECS HA NDLE DRIVE LEVER LI NKA GE I NSTALLA TIO N 4.1.6 Check f or loose hardware . Serv ice Interv al: Daily a) Stop engine and wait for all m oving par ts to stop. Rem ove k ey or spark plug wi re(s). b) Visually inspect machine for any loose hardware or any other possible problem. T ighten or replace any hardware bef ore operatin[...]

- 22 - 4.1.9 Check t ire pr essur es . Service Interval: P neuma tic (air-filled) Driv e Tires- 40 hrs. Semi-pneumatic Caster Tires – No maintenance a) St op eng ine and wait for all m oving par t s to stop. Rem ove spark plug wire(s). Check air pr essur e in dr ive tires; recommended tire pr essure is: 12 to 16 psi (83-110 k Pa) . b) I nf late t[...]

- 23 - LUBRICA TION CHART FI TTING L OCA TIONS INITIAL PUMPS FI TTING Q UAN TITY 32" 3 6 " 4 8 " SERVICE INTERVAL 1. Caster W heel Bearings 12 2 2 2 Daily 2. Caster Pivots 2 2 2 2 Daily 3. Drive W heels 18 2 2 2 Daily 4. Drive W heel Idler Arm 2 2 2 2 Daily 5. Brak e Arm 2 2 2 2 W eekly 6. Trans . Output Shaft Coupler 2 2 2 2 W eekly[...]

- 24 - 4.1.18 Thr ead lock ing adhesives Fel-Pro Pro- Lock "Nut-T ype" or Loct it e T hreadlocker "242" are used on t he f ollowing : a) All belt drive pulley setscrews. b) OPC lever setscrews. c) Pulley retaining bolt in end of eng ine crankshaf t. d) Fuel tank bulkhead f itting t hreads. Adhesives such as Loctit e "RC/609[...]

- 25 - d) Loosen but do not remove the two (2) axle pivot bolts and the t wo (2) axle adjustment bolts (See Figur e 11) . e) Place a jack under the r ear cent er of t he eng ine deck. f) Raise the back end of the eng ine deck up enoug h t o r em ove the two (2) axle adjustment bolt s. g) W ith the jack , raise or lower the back end of the engine de[...]

- 26 - CUTTING HEIGHT A DJUS TMENT (1" to 4 1/4") AXLE POSITION (FIG. 20) # OF SPACERS BELOW CASTER SUPPORT HUB NUMBER OF 1/4" BLADE SPACERS BELOW SPINDLE 1/2" 3/16" 4 3 2 1 0 A 0 0 1" (2.5 cm) 1 1/4" (3.2 cm) 1 1/ 2" (3.5cm) 1 3/4" (4.4cm) 2" (5.0cm) A 0 1 1 1/8" (2.9 cm) 1 3/8" (3.5 cm) [...]

- 27 - c) Belt m ust be t ight enough t o not slip during heavy loads while cutting gr ass. Overtensioning will reduce belt and spindle bear ing life. T o adjust belt t ension, loosen the 5/16" whizlock nut on tu r nbuck le and rotate the t urnbuckle; rot ate turnbuck le t oward rear of mower to tight en, and toward front of mower to loosen be[...]

- 28 - FIGURE 13 BLA DE BRAKE A DJUSTMENT 4.2.7 Belt G uide Adj ustment a) Stop engine and wait for all m oving parts to st op. Remove key or spark plug wi re(s). b) Engag e t he blade dr ive belt. c) Check belt guide under the eng ine deck f or pr oper adjustment ( See Figures 14 and 15). Adjust as necessar y. The disengag ed belt should not drag [...]

- 29 - FIGURE 18 SHIFTER LEVER TO T RA NSMISS ION T o adj ust the shif t er lever: a) Remove the 3/8" nyloc nut and spring disk washer fr om t he stud on top of t he transmission (See Fig ure 18). b) Remove the shif t er lever and bend it slightly. DO NOT bend the lever while it is attached to t he t ransmission. c) Re-install lever and tor q [...]

- 30 - FIGURE 19 UPPER HA NDLE HEIG HT A DJUSTMENT 4.2.14 W heel dr ive spring t ension adjustment . It may be necessary to increase wheel drive belt tension under cer t ain oper ating conditions such as, wet gr ass, hilly ter r ain, or while pulling a sulky. a) St op engine and wait for all moving parts to st op. Remove key or spark plug wi re(s).[...]

- 31 - b) Check to be sur e idler ar ms pivot fr eely, if not, lubr icat e idler pivots. c) Check for worn drive belts. NOTE: Wheel drive belts should be repl aced as a set . A new belt should not be mixed with a worn belt. d) Check drive linkag e adjustment - See Sect ion 4.1.5. e) Check f or pr oper tire pressure in drive tires. Recom mended tire[...]

- 32 - ENGINE TROUBLESHOOTING TA BLE PROBLEM NO FUEL IM PROPER FUEL DIRT IN FUEL DIRTY AIR FILTER FAULTY SPARK PLUG ENGINE OVER- LOADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN W ill not start X X X X X X Ha r d s ta r ti ng 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 Ope ra tes er rat ic al ly X X X X X X[...]

- 33 - 9. 2-Ye ar Limited Warranty Exmark Tu rf Equipment (For units pur chased on or af ter October 1, 2004) Conditions and Products Covered Exmark M fg. Co. Inc. and its affiliate, Exmark W arranty Company, pursuant to an agreement betw een them, jointly warrant on the terms and conditions herein, that w e will repair, replace or adjust any part [...]

- 34 - 10. Evap orative Emission Control Warran ty Statement California Evapor ative Emiss ion Control W ar ranty Statem ent Your W arr anty Rights and O bligations Introduction The California A i r Res ources Board and E xm ark Manufacturing Com pany are pleased to explain the evaporat ive emis s ion control system ’s warranty on your 2006 m ode[...]

- 35 - NOTES[...]

- 36 - NOTES[...]

- 37 - SERVICE RECORD Date Descripti on of Work Done Service Done By[...]

- 38 - T H I S I S A 1 5 ° S L O P E T H I S I S A 1 0 ° S L O P E T H I S I S A 5 ° S L O P E ALIGN THIS EDGE WITH A VERTICAL SURF ACE (TREE, BUILDING, FENCE POST , POLE ETC.) EXAMPLE: COMP ARE SLOPE WIT H FOLDED EDGE. FOLD ALONG APPROPRIA TE LINE T H I S I S A 2 0 ° S L O P E[...]

® M FG . CO. IN C. SEE EXMA RK’S COMPLETE LINE OF A CCESSORIES RIDING A CCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT K IT MICRO-MULCH SY ST EM ROLL OVER PROTECT ION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONT AINER TURF STRIPER ULTRA VAC COLLECT ION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WA LK BEHIND A CC[...]