Exmark LAZER Z LZX680KC486 Operator'S Manual Download Page 52 | Manualshive

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Troubleshooting

Problem

Possible Cause

Corrective Action

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. 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.

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Summary of Contents for LAZER Z LZX680KC486

Page 1: ...LAZER Z X SERIES For Serial Nos 312 000 000 Higher Lazer Z LZX Units Part No 4501 196 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: ... Lift Pivot 38 Check Spark Plugs 38 Change Hydraulic System Filter and Fluid 38 Wheel Hub Slotted Nut Torque Specification 39 Check Spark Arrester if equipped 39 Thread Locking Adhesives 39 Mobil HTS Grease Or Food Grade Anti seize 39 Copper Based Anti seize 40 Dielectric Grease 40 Adjustments 40 Deck Leveling 40 Pump Drive Belt Tension 42 Deck Belt Tension 42 Adjusting the Parking Brake 42 Electr...

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: ... area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Do Not operate 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 ...

Page 7: ...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 Park machine on level ground Stop engine wait for all moving parts to stop remove key and enga...

Page 8: ...nd 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 hide obstacles Watch for ditches holes r...

Page 9: ...l 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 battery or remove spark plug wire before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s or w...

Page 10: ...uel system components with original Exmark parts 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 ...

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 109 3148 109 7232 1 Fast 3 Neutral 2 Slow 4 Reverse 109 7330 109 8483 All Units Except EFI 1 Throttle fast 3 Choke on 2 Throttle slow 4 Choke off 12 ...

Page 13: ...Safety 109 9361 Deck Drive Belt Routing 116 0090 116 0157 1 See Operator s Manual 116 0205 116 0211 116 0752 1 Latch 2 Unlatch 13 ...

Page 14: ...s Only 1 Throttle fast 2 Throttle slow 116 3303 117 2718 116 5944 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 PTO Switch Symbols 1 PTO disengage 2 PTO engage 14 ...

Page 15: ...Safety 109 7069 15 ...

Page 16: ...mmended Minimum Battery CCA Kohler 940 980 engines 340 CCA All other 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 th...

Page 17: ...spension seat with high back armrests and integral safety switch Seat height remains the same For LZX801KA606SS LZX940KC606 LZX940KC726 LZX980KC606 LZX980KC726 Deluxe suspension adjustable spring suspension seat with high back armrests and integral safety switch Seat height remains the same Mounting Hinged seat frame to tilt up seat Held in tilted position with prop rod Adjustable fore and aft on ...

Page 18: ...scharge 48 inch Deck 3 anti scalp rollers 52 inch Deck 3 anti scalp rollers 60 inch Deck 4 anti scalp rollers 72 inch Deck 6 anti scalp rollers Deck Depth 48 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 ...

Page 19: ...ired for the unit 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 3 2 Michigan Seat CRSS 11 12 3 Bagger 0 0 3 Pneumatic Caster Tires 6 8 ...

Page 20: ... 680 740 Kohler 749 Kohler 940 Kohler 980 Kawasaki 801 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 27 33 ft lb 37 45 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 211 260 ft lb 286 352 N m Rollover Protection System Roll Bar 1 2 inch Mounting Bolts 75 80 ft lb 102 108 N m Clutch Retaini...

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: ... 1 LCD Indicators 2 Low fuel indicator light 3 Fuel level bar display 4 Low voltage indicator light 5 Hour Voltage display The hour meter is recording when the decimal point is flashing in Hour Voltage display Hours are displayed when the key is off or when the machine is running Note If the ignition key is turned to the ON position for a few seconds before cranking the engine the battery voltage ...

Page 23: ... 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 8 Low Voltage Indicator Located on the right console in the message display see Figure 6 and Figure 8 A low voltage condition less than 1...

Page 24: ...ission system Make sure 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 op...

Page 25: ...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 when the blades are engaged ...

Page 26: ...on when making turns Slow the machine down before making sharp turns Important To begin movement forward or backward the operator must be 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 F...

Page 27: ...r and the rear of the machine will move towards the rear and to the left 3 To stop position both motion control levers in the neutral operate position Adjusting the Cutting Height The cutting height of the mower deck is adjusted from 1 to 5 1 2 inches 2 5 cm to 14 cm in 1 4 inch 6 4 mm increments 1 Stop the machine and move the motion control levers outward to the neutral locked position 2 Disenga...

Page 28: ...position lower Rollers should maintain 1 4 inch 6 4 mm clearance to the ground Do Not adjust the rollers to support the deck 7 Be sure the roller bolts are installed with the spring disc washer between the head of the bolt and the mounting bracket Figure 18 8 Torque the 3 8 24 x 2 Gr 8 hex capscrew to 50 55 ft lb 68 75 N m Figure 18 Figure 18 1 Spring disc washer cone towards bolt head 3 3 8 nyloc...

Page 29: ...he tractor frame extends back between the rear wheels and serves as a stop for tipping backward Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the gro...

Page 30: ...s Check the wheel lug nuts Check the park brake adjustment After the first 250 hours Change the hydraulic filter and fluid 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 ...

Page 31: ...nals 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 circ...

Page 32: ...t 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 immediately damage the electrical and or EFI system Be certa...

Page 33: ...connect Check Mower Blades Service Interval Before each use or daily 1 Stop engine wait for all moving parts to 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 section 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 bla...

Page 34: ...e right lever in then with both levers in starter must not crank 2 Check the kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must initiate shutdown after approximately 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise off ...

Page 35: ...ngine Owner s Manual for additional information Every 500 hours Replace the secondary air cleaner element May need more often under severe conditions See the Engine Owner s Manual for additional information 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 See the Engine Owner s Manual for maintenance instructions Check Air Filter Assembly if equipped Service In...

Page 36: ...he seat all the way back then lift the seat to access the caps on the LH and RH hydro drives 4 Clean the area around hydraulic reservoir cap and remove cap 5 Wipe the dipstick clean and re insert the cap back into the hydro Lightly tighten the cap 6 Remove the cap again and check the level of the oil on the dipstick See Figure 25 for oil levels Figure 25 1 Full 2 Add Note The oil level on the dips...

Page 37: ...e wheel hub 4 Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has been applied to lock the spacer nuts to the axle Remove the axle with the other spacer nut still assembled to it from the wheel assembly 5 Pry out seals and inspect bearings for wear or damage and replace if necessary 6 Pack the bearings with a NGLI grade 1 multi purpose gre...

Page 38: ...ters for high pressure systems Replacement Filters Kohler Kohler P N 24 050 13 Kawasaki Kawasaki P N 49019 7005 Kohler EFI Kohler P N 25 050 42 Note It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage Change Hydraulic System Filter and Flu...

Page 39: ...6 352 N m Note Do Not use anti seize on wheel hub Check Spark Arrester if equipped Service Interval Every 50 hours WARNING Hot exhaust system components 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 i...

Page 40: ...UTION Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous The mechanical 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 o...

Page 41: ...ost conditions the back blade tip should be adjusted 1 4 inch 6 4 mm higher than the front Figure 28 1 3 1 4 inches 8 3 cm 4 3 inches 7 6 cm 2 Back blade tip 5 Level surface 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 cm height see Figure 29 To increase the height turn the adjuster cloc...

Page 42: ...ecessary Adjusting the Parking Brake 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...

Page 43: ... lb 122 129 N m 16 Remove jack stands 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 32 1 Armature 5 Brake spacer 2 Field shell 6 Re gap shim 3 Rotor 7 Brake pole 4 Brake mounting bolt Removing the Shim 1 Stop engine wait for all moving pa...

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: ...ottle and release brake 6 Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature 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 direc...

Page 46: ...usted higher or lower for maximum operator comfort 1 Remove the two bolts holding the control lever to the control arm shaft Figure 39 Figure 39 1 Bolts 4 Nuts 2 Control lever 5 Slotted holes 3 Control arm shaft 2 Move the control lever to the next set of holes Secure the lever with the two bolts 3 Repeat the adjustment for the opposite control lever Adjusting the Tilt The motion control levers ca...

Page 47: ... tracking is obtained Figure 40 RH Motion Control Shown 1 Screw 3 Motion control lever 2 Cover plate 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 washers are reinstalled as shown in Figure 41 Figure 41 1 Spring disc ...

Page 48: ...an cooling guards will allow the hydro system to run cooler and improve the life of the hydro system 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Slide seat all the way back then lift the seat to access the LH and RH hydro drive area 3 Remove accumulated debris from the hydro fan cooling guards Clean Debris From Machine Service Interval Before each use or d...

Page 49: ...fety 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 Management and disposal practices must be within relevant federal state or local laws If a battery is being replaced or if the ...

Page 50: ...Fuse is blown 6 Replace the blown fuse 7 Relay 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 th...

Page 51: ...2 Install new 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...

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: ...K 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 CONNECT...

Page 54: ...ET ENGINE FUEL SENDER B BROWN PINK PINK 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 VI...

Page 55: ...IODE 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 c...

Page 56: ...2 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 con...

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

Page 58: ... 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 Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website ...

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: ...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 Some accessories and options not available for some models Place Model No and Serial No Label Here Included in the Literature Pack or Fill...

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