Exmark LAZER Z Operator'S Manual Download Page 46 | Manualshive

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ENGINE TROUBLESHOOTING TABLE

PROBLEM

NO

FUEL

IMPROPER

FUEL

DIRT IN

FUEL LINE

DIRTY AIR

FILTER

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

AIR

SCREEN

INSUFFICIENT

BATTERY

CHARGE

Will not start

X

X

X

X X X

X

Hard starting

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

Operates erratically

X

X

X

X X X X

Knocks or pings

X

X X

Skips or misfires

X

X

X

X X

Backfires

X

X

X X X

Overheats

*

X

X

X X X

High fuel

consumption

X

X X X

6.4 ENGINE WARNING SYSTEMS

For Kohler EFI Units Only:

6.4.1 Electronic Control Unit Malfunction Indicator

The electronic control unit (ECU) continuously monitors operation of the EFI
system. If a problem or fault within the system is detected, the malfunction
indicator light (MIL) is illuminated. The MIL is the red light located on the control
console between the key switch and the throttle controls. Follow the
troubleshooting steps outlined in the Kohler engine operator’s manual if the MIL is
illuminated.

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Summary of Contents for LAZER Z

Page 1: ...For Serial Nos 600 000 Higher Part No 109 2695 REV C ...

Page 2: ...from eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES...

Page 3: ...bmitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 3 Exmark being unable to ship the part and the Exmark parts order is received by 3 00 p m central time Exmark pays for the part and freight 4 If the part does not arrive overnight due to the shipper UPS the shipper pays for the freight and Exmark pays for the part The following res...

Page 4: ...ower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor 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 s...

Page 5: ...tic Ground Drive System 13 2 8 Tires Wheels 13 2 9 Cutting Deck 13 14 2 10 Dimensions 14 2 11 Torque Requirements 14 3 OPERATION INSTRUCTIONS 3 1 Controls 15 17 3 2 Pre Start 17 18 3 3 Operating Instructions 18 19 3 4 Transporting 19 21 4 MAINTENANCE ADJUSTMENTS 4 1 Periodic Maintenance 21 32 4 2 Adjustments 32 39 5 WASTE DISPOSAL 5 1 Motor Oil Disposal 39 5 2 Battery Disposal 39 6 TROUBLE SHOOTIN...

Page 6: ...urself with the controls and the proper use of the equipment If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 1 2 ...

Page 7: ...d highly explosive WHAT CAN HAPPEN A fire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD DO NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only outdoors Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove ...

Page 8: ...e then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignited by electrical sparks ...

Page 9: ...and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without guard...

Page 10: ...rogressively greater care is needed as the slope increases Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Avoid sudden starts when mowing uphill Mower may tip backwards Be aware that loss of traction may occur going downhill Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking ...

Page 11: ... place and in proper working condition 1 4 9 DO NOT change the engine governor settings or overspeed the engine Operating an engine at excessive speed may increase the hazard of personal injury 1 4 10 Disengage PTO before starting engine 1 4 11 Start the engine carefully with feet well away from the blades 1 4 12 Keep hands feet and clothing away from rotating parts while the mower is being operat...

Page 12: ...f 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 voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage 1 5 4 Keep engine engine area and pump drive belt compartment free from accumu...

Page 13: ...ING POTENTIAL HAZARD Fuel system components are under high pressure WHAT CAN HAPPEN The use of improper components can result in system failure gasoline leakage and possible explosion HOW TO AVOID THE HAZARD Use only approved fuel lines and fuel filters for high pressure systems 1 6 SAFETY SIGNS 1 6 1 Keep all safety signs legible Remove all grease dirt and debris from safety signs and instruction...

Page 14: ...k PART NO 98 5954 LOCATION Under Mower Deck Belt Shield s PART NO 103 1214 LOCATION LH Side of Console All units except Kohler EFI PART NO 103 4474 LOCATION Top Front of RH Fuel Tank PART NO 107 2112 LOCATION Top Center of Floorpan PART NO 107 2102 LOCATION Inside Surface of Upper Roll bar PART NO 109 1215 LOCATION RH Side of Console Kohler EFI units PART NO 103 5456 LOCATION Top Front of RH Fuel ...

Page 15: ...at PART NO 103 5881 LOCATION Rubber Heat Shield Flap behind Seat PART NO 1 303508 LOCATION RH Side on Top Rear of Mower Deck PART NO 1 643339 LOCATION Top of Right Engine Baffle PART NO 103 6319 LOCATION Back of Seat PART NO 103 9255 LOCATION Top of console Kohler EFI Units Only PART NO 103 2750 LOCATION Panel behind LH Fuel Tank PART NO 1 513748 LOCATIONS Bottom Side of Floorpan ...

Page 16: ...N Top of Hydraulic Reservoir Under the Seat Kohler EFI Units Only PART NO 103 0261 LOCATION RH Front of Console PART NO 103 3270 LOCATION RH Air Cleaner Mount Plate All Units except Kohler EFI PART NO 103 4930 LOCATION Right of Choke Control on RH Fuel Tank Kohler EFI Units Only PART NO 103 3679 LOCATION Right of Throttle Control on RH Fuel Tank All Units except Kohler EFI PART NO 103 1798 LOCATIO...

Page 17: ...ust be disengaged brake engaged and motion control levers out neutral lock to start engine It is not necessary for the operator to be in the seat to start the engine 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 i...

Page 18: ...ype Use Mobil 1 15W 50 Synthetic motor oil 2 7 4 Hydraulic Oil Capacity 2 1 qt 2 0 L 2 7 5 Hydraulic Filter Replaceable cartridge type P N 1 513211 10 microns 18 psi bypass Summer use above 32 F 0 C P N 1 523541 40 microns 18 psi bypass Winter use below 32 F 0 C 2 7 6 Speeds 0 9 8 mph 15 8 km hr forward 0 6 3 mph 10 1 km hr reverse 2 7 7 Drive wheel release valves allow machine to be moved when en...

Page 19: ... Up Roll Bar Down 71 9 in 182 6 cm 53 8 in 136 7 cm 2 10 4 Tread Width center to center of tires widthwise w 60 Deck w 66 Deck w 72 Deck Drive wheels 41 9 in 106 4 cm 45 9 in 116 6 cm 45 9 in 116 6 cm Caster wheels 37 3 in 94 8 cm 42 3 in 107 4 cm 47 3 in 120 1 cm 2 10 5 Wheel Base center of caster tire to center of drive tire w 60 Decks w 66 Deck w 72 Deck 53 7 in 136 4 cm 55 3 in 138 4 cm 59 1 i...

Page 20: ...ed to move forward or backward in a straight line Movement of the left lever forward will cause the left drive wheel to rotate in a forward direction Movement of the right lever forward will cause the right drive wheel to rotate in a forward direction To stop forward travel pull the levers back to the neutral position To turn left while moving forward move the left lever back toward neutral to slo...

Page 21: ...op the blades 3 1 5 Choke Control All units except Kohler EFI Located on right fuel tank 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 will put the choke in the OFF position DO NOT run a warm engine with choke in the ON position 3 1 6 Throttle Control Located on right fuel tank Throttle is ...

Page 22: ...ne running Unhook seat latch and tilt seat up to gain access to pumps With a 7 16 wrench turn both valves one turn counter clockwise to release drive system Turn clockwise to reset system DO NOT overtighten DO NOT tow machine 3 1 13 Electronic Control Unit Malfunction Indicator Kohler EFI units only The electronic control unit ECU continuously monitors operation of the EFI system If a problem or f...

Page 23: ...tor to be in the seat to start the engine On a cold engine place the throttle midway between the SLOW and FAST positions and push choke lever forward except Kohler EFI units into the ON position Turn ignition switch to the start position Release the switch as soon as the engine starts IMPORTANT DO NOT crank the engine continuously for more then ten 10 seconds at a time If the engine does not start...

Page 24: ...ttle to the midway position Push in on the switch to the STOP position stopping the PTO 3 3 6 Stopping Engine Bring unit to a full stop Disengage the PTO move motion control levers out to the neutral lock position and set parking brake Before stopping the engine place the throttle control midway between the slow and fast positions Allow the engine to run a minimum of 15 seconds then stop the engin...

Page 25: ...amp 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 3 4 2 Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side ...

Page 26: ...cool completely before service or making repairs around the engine area 4 1 PERIODIC MAINTENANCE 4 1 1 Check engine oil level Service Interval Daily a Stop engine and wait for all moving parts to stop Make sure unit is on a level surface b Check with engine cold c Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick and push it all the way down into the tube Remove the...

Page 27: ... performing any welding on the equipment 4 1 3 Clean engine cooling system Service Interval Daily or more often in dry conditions CAUTION POTENTIAL HAZARD Excessive debris and damaged or missing rubber baffles can cause the engine and hydraulic system to overheat WHAT CAN HAPPEN Excessive debris around the engine cooling air intake and inside of the pump drive belt compartment can create a fire ha...

Page 28: ...4 1 5 Check mower blades Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Lift deck and secure in raised position as stated in Section 4 1 4 c Inspect blades and sharpen or replace as required d Re install the blades if they were removed in the following order See Figure 3 1 Install bushing through blade with bushing flange on bottom grass side of blade 2 Ins...

Page 29: ... in seat parking brake engaged PTO engaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat again with the right lever in then with both levers in starter must not crank b Check the kill circuits Run engine at one third throttle dis...

Page 30: ...t into the engine e DO NOT wash or use pressurized air to clean paper element or inner element f Reinstall elements Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips 4 1 10 Check Spark Arrester Kohler EFI engines only Service Interval 50 hours WARNING POTENTIAL HAZARD Hot exhaust system components may ignite gasoline vapors even after the engin...

Page 31: ...lace hydraulic reservoir cap and tighten until snug Do not overtighten NOTE The baffle is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 C Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150...

Page 32: ...uctions on the front casters wheel hubs c 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 thread plug back in Place cap back on 4 1 16 Lubricate caster wheel hubs Service Interval Once Yearly a Stop engine wait for all moving parts to stop and remove key b Remove caster wh...

Page 33: ...and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely 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 Re apply threadlocking adhesive 4 1 17 Lubricate seat switch actuator Service Interval 160 hrs a Stop engine wait for all moving parts to stop and re...

Page 34: ... high pressure WHAT CAN HAPPEN The use of improper components can result in system failure gasoline leakage and possible explosion HOW TO AVOID THE HAZARD Use only approved fuel lines and fuel filters for high pressure systems Note For Kohler EFI units use only high pressure clamps and SAE R7 or R9 hose available from Exmark or Kohler Clamps require special pliers P N 1 643394 Oetiker P N 14100118...

Page 35: ...t No 2445504 is recommended for relieving pressure and purging air in the fuel system To relieve the system of pressure a Stop engine wait for all moving parts to stop and remove key b Allow the engine to cool completely c Connect the black tester hose from the Kohler pressure gauge to the test valve in the fuel rail d Route the clear hose into a portable gasoline container and depress the button ...

Page 36: ...N M b Check distance from bottom of slot in nut to inside edge of hole Two threads 0 1 or less should be showing c If more than two threads 0 1 are showing remove nut and install washer PN 1 523157 between hub and nut d Torque the slotted nut to 125 ft lbs 169 N M e Then tighten nut until the next set of slots line up with the cross hole in shaft f Replace cotter pin NOTE Do not use antiseize on w...

Page 37: ...e corresponding to desired cutting height and install hairpin cotter See decal on the side of deck lift plate e Move lever out of transport or 5 12 7 cm cutting height position and down onto height adjustment pin to mow at selected height f To transport move lever back up to transport or 5 12 7 cm cutting height position Note The foot operated deck lift assist lever can be used to momentarily lift...

Page 38: ...ar deck lift arms Loosen jam nuts and back off the socket head adjusting screws on the bottom of the arms until the chains are just loose Turn the socket head adjusting screws in until slack is taken out of each chain Tighten the jam nuts Tighten the chain bolts in the deck lift arms making sure they don t move while tightening i Loosen the four 4 nuts which secure the front swivels two per side u...

Page 39: ...top and remove key b Check to make sure the center of the bolt head in the center of the spring loaded pulley on left side engine deck support is positioned between the centers of the two alignment holes in the left support plate See Figure 9 It is necessary to adjust the belt tension when the center of the bolt head is at or below the center of the bottom alignment hole c When adjustment is neces...

Page 40: ...layed seat switch When the operator raises off the seat with either the brake disengaged or the PTO engaged the engine should stop after 1 2 second has elapsed b To adjust seat switch actuator rod length loosen lock nut on bottom of the actuator rod 5 16 x 7 bolt and adjust the nuts to move the actuator plate washer up or down on the rod then retighten 4 2 7 Belt Guide Adjustment a Stop engine wai...

Page 41: ...djustment a Check for brake link 2 75 7 0 cm measurement as described in section 4 2 8 b Engage brake lever lever up c Measure the distance between the trunion roller and the rod collar Measurement should be 1 4 6 4 mm to 5 16 7 9 mm See Figure 11 d If adjustment is necessary loosen the nut directly below the yoke Turn the bottom nut below washer until the correct measurement is obtained See Figur...

Page 42: ...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 f Repeat on opposite side ...

Page 43: ...rs at full forward speed to bring hydraulic system oil up to operating temperature d Unhook seat latch and tilt seat forward e Loosen lock nuts from the ball joints at each end of the LH pump control linkage See Figure 14 NOTE The nut to the front of the unit on the LH rod has left hand threads FIGURE 14 MOTION CONTROL ADJUSTMENT f Start engine Brake must be engaged and motion control levers out t...

Page 44: ...rs are reinstalled as shown in Figure 15 5 WASTE DISPOSAL 5 1 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 5 2 BATTERY DISPOSAL DANGER POTENTIAL HAZARD Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns WHAT CAN HAPPEN ...

Page 45: ...e sure the seat switch is properly adjusted See Section 4 2 6 e Make sure the parking brake is set and motion control levers are moved out neutral lock position f Check that the PTO is disengaged g Check that the spark plug wires are properly connected h Check for loose or faulty wiring connections i Check for corrosion at all wiring connections Even minor corrosion may cause a faulty connection C...

Page 46: ...s or misfires X X X X X Backfires X X X X X Overheats X X X X X High fuel consumption X X X X 6 4 ENGINE WARNING SYSTEMS For Kohler EFI Units Only 6 4 1 Electronic Control Unit Malfunction Indicator The electronic control unit ECU continuously monitors operation of the EFI system If a problem or fault within the system is detected the malfunction indicator light MIL is illuminated The MIL is the r...

Page 47: ... 42 7 ELECTRICAL DIAGRAM KOHLER 23 27 HP AIR COOLED UNITS ...

Page 48: ... 43 ELECTRICAL DIAGRAM KOHLER EFI UNITS ...

Page 49: ... 44 8 HYDRAULIC DIAGRAM ...

Page 50: ...sfied 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 The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty ...

Page 51: ... as required maintenance in the written instructions must be warranted for the warranty period of two years If any such part fails during the period of warranty coverage it must be repaired or replaced by Exmark Manufacturing Company Any such part repaired or replaced under the warranty must be warranted for a time not less than the remaining warranty period 2 Any warranted part that is scheduled ...

Page 52: ... 47 NOTES ...

Page 53: ... 48 NOTES ...

Page 54: ... 49 SERVICE RECORD Date Description of Work Done Service Done By ...

Page 55: ... 50 ...

Page 56: ...AC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER STANDON WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 2004 2005 EXMARK MFG CO INC PART NO 109 2695 REV C INDUSTRIAL PARK BOX 808 402 223 6300 BEATRICE NE 68310 FAX 4...

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