Exmark 4500-645 - Manuals - manualsarea.com

Page 2 - The engine in this product is not

Important: The engine in this product is not equipped with a spark arrester muffler. It is aviolation of California Public Resource Code(CPRC) Section 4442 to use or operate thisengine on any forest-covered, brush-covered, orgrass-covered land as defined in CPRC 4126.Other states or federal areas ma...

Page 3 - Introduction; CONGRATULATIONS; on the purchase of your

Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefullydesigned and manufactured to give you a maximumamount of dependability and years of trouble-freeoperation. This manual contains operating, maintenance,adjustment, and safety instructions for your Exmark...

Page 4 - Contents; Wheel Hub - Slotted Nut Torque

Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...

Page 5 - Safety; Safety Alert Symbol; Safe Operating Practices; Training

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both inthis manual and on the machine to identify importantsafety messages which must be followed to avoidaccidents. This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Figure 2 1. Safety alert symbol The ...

Page 6 - CAUTION

Safety CAUTION This machine produces sound levels inexcess of 85 dBA at the operator’s ear andcan cause hearing loss through extendedperiods of exposure. Wear hearing protection when operating thismachine. • Inspect the area where the equipment is to beused and remove all rocks, toys, sticks, wires,...

Page 7 - DANGER; Inspection; – Visually inspect the tank, hose, and fitting and

Safety DANGER LPG fuel is extremely flammable and vaporsare explosive. • In case of fire take the following steps: 1. If you can safely do so, stop the flow of gas as quickly as possible. Never putout flame unless gas can be shut off. 2. Notify the Fire Department and clear immediate area of all peo...

Page 8 - With each tank change:; Operation; WARNING

Safety – The LPG tank should be free of dents or damage. If the tank show signs of dents ordamage, replace it immediately. – Check the valve and fitting openings for dirt and debris. – Slowly open the valve all the way and listen for a continuous hiss from the regulator, itmay indicate a leak. – LPG...

Page 9 - NEVER; Slope Operation; Extreme

Safety WARNING Engine exhaust contains carbon monoxide,which is an odorless deadly poison that cankill you. Do Not run engine indoors or in a smallconfined area where dangerous carbonmonoxide fumes can collect. • Operate only in daylight or good artificial light,keeping away from holes and hidden ha...

Page 10 - Do Not mow slopes when grass is wet.; Drive slowly and carefully.

Safety DANGER Operating on wet grass or steep slopes cancause sliding and loss of control. Wheelsdropping over edges, ditches, steep banks, orwater can cause rollovers, which may resultin serious injury, death or drowning. • Do Not mow slopes when grass is wet. • Do Not mow near drop-offs or near wa...

Page 11 - Maintenance and Storage; Always shield eyes and face from battery.; Do Not swallow electrolyte.

Safety driving under any objects and Do Not contactthem. • In the event of a rollover, take the unit to anAuthorized Service Dealer to have the ROPSinspected. Maintenance and Storage • Disengage drives, lower implement, set parkingbrake, stop engine and remove key or disconnectspark plug wire. Wait ...

Page 13 - Safety and Instructional Decals

Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease,dirt and debris from safety signs and instructionallabels. • Replace all worn, damaged, or missing safetysigns. • When replacement components are installed, besure that current safety signs are affixed to there...

Page 18 - Specifications; Model Numbers; Engine; The LPG tank used on this mower; Electrical System

Specifications Specifications Model Numbers Serial Nos: 850,000 and Higher LZAS29KA604LP; LZAS29KA724LP; LZZ29KA606LP Systems Engine • Engine Specifications: See your Engine Owner’sManual • RPM: Full Speed: 3750 ±50 RPM (PTO notengaged) Idle: 1500 ±100 RPM Tank Type and Refilling Important: The LPG ...

Page 19 - Seat

Specifications Note: Motion control levers are adjustable to two heights. – Separate levers, on each side of the console, control speed and direction of travel of therespective drive wheels. – Steering is controlled by varying the position of the levers relative to each other. – Moving motion contro...

Page 20 - Cutting Deck; Cutting Height Adjustment:; Dimensions

Specifications Tires & Wheels Drive Pneumatic (Air filled) Quantity 2 Tread “Multi-Trac C/S” Size 24 x 12.00-12 Ply Rating 4 Pressure 13 psi (90 kPa) Front Caster Semi-Pneumatic Model LZAS-LP LZAS-LP LZZ-LP Deck Size 60 72 60 Quantity 2 2 2 Tread Smooth Smooth Smooth Size 13 x 5.00-6 13 x 6.50-6...

Page 21 - Accessory Weight Table Worksheet:; The 72 inch deck does not require a weight kit.

Specifications Tread Width: (Center to Center ofTires, Widthwise) 60 inch Deck 72 inch Deck Drive Wheels 41.6 inches(105.7 cm) 43.6 inches(110.7 cm) Caster Wheels 39.5 inches(100.3 cm) 47.1 inches(119.6 cm) Wheel Base: (Center of Caster Tire toCenter of Drive Tire) LZZ-LP Units: 60 inch Deck 50.6 in...

Page 22 - Torque Requirements; Product Overview

Product Overview Torque Requirements Bolt Location Torque Blade Drive SheaveMounting Nut LZZ-LP Units: LZAS-LP Units: 90-110 ft-lb (122-149 N-m) 140-145 ft-lb (190-197N-m) Cutter Housing SpindleNut (LZZ-LP Units Only) 160-185 ft-lb(217-251 N-m) Blade Mounting Bolt(lubricate with anti-seize) 55-60 ft...

Page 23 - Determine the left and right sides of the; Controls; Motion Control Levers; Throttle Control; Brake Lever; The LCD indicator appears in the message

Operation 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 ofthe console control the forward and reverse motionof the machine. Moving the levers forward or backward turn...

Page 24 - Ignition Switch; Hour Meter; Fuel Valve

Operation Figure 7 1. Release button 2. Park brake The unit must be tied down and brake engaged whentransporting. Ignition Switch Located on right console (see Figure 6). The ignition switch is used to start and stop theengine. The switch has three positions “OFF”, “ON”and “START”. Insert key into s...

Page 25 - This valve has a protective plastic; The brackets are located on the engine deck.; The handle must be horizontal and against

Operation Important: This valve has a protective plastic cap that should NEVER be removed. If thecap is damaged or missing, contact trained andqualified personnel immediately. LPG Cylinder Brackets The brackets are located on the engine deck. The LPG cylinder brackets are used to fasten theremovable...

Page 26 - Operating Instructions; The roll bar is an integral and

Operation In the non-latching position, the deck willautomatically return to the cutting height when thepedal is lowered (see item 3 in Figure 11). Figure 11 1. Latching position 3. Non-latching position 2. Transport lock control Pre-Start LPG tanks supplied from Exmark Do Not containLPG fuel for sh...

Page 27 - Open the Fuel Valve; Starting the Engine; Do Not crank the engine; Engaging the PTO; Operator must be in seat before the; Disengaging the PTO

Operation that the rear part of the seat is secured with theseat latch. Open the Fuel Valve 1. Slowly open the fuel valve to equalize the pressure in the tank. The fuel valve is located on the topend of the LPG tank. If the fuel valve is openedtoo quickly, the pressure relief valve is equippedwith a...

Page 28 - Driving the Machine; Use caution when making turns.

Operation Driving the Machine CAUTION Machine can spin very rapidly by positioningone lever too much ahead of the other.Operator may lose control of the machine,which may cause damage to the machineor injury. • Use caution when making turns. • Slow the machine down before makingsharp turns. Importan...

Page 29 - Driving in Reverse; Adjusting the Cutting Height; When changing the cutting height; Adjusting the Anti-Scalp Rollers; For Maximum Deck Flotation,

Operation Driving in Reverse 1. Move the motion control levers inward to the neutral operate position. 2. To move rearward in a straight line, move both levers rearward with equal pressure. To turn right, release pressure on the RH motioncontrol lever and the rear of the machine willmove towards the...

Page 30 - Do; adjust the rollers to support the deck.; Transporting; Transporting a Unit

Operation 1/4 inch (6.4 mm) clearance to the ground. Do Not adjust the rollers to support the deck. 7. For LZZ-LP Units: Be sure the roller bolts are installed with the spring disc washer betweenthe head of the bolt and the mounting bracket(Figure 18). For LZAS-LP Units: Be sure the whizlock nutsare...

Page 31 - If necessary, use assistance when loading.; – Transport tanks in an upright, vertical and; Loading a Unit; Do Not attempt to turn the unit

Operation WARNING Loading a unit on a trailer or truck increasesthe possibility of backward tip-over.Backward tip-over could cause serious injuryor death. • Use extreme caution when operating aunit on a ramp. • Use only a single, full width ramp; DoNot use individual ramps for each sideof the unit. ...

Page 33 - Maintenance

Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING While maintenance or adjustments are beingmade, someone could start the engine.Accidental starting of the engine couldseriously injure you or other bystanders. Remove the key f...

Page 34 - Periodic Maintenance; Check Engine Oil Level; Service Interval: Before each use or daily; Stop engine and wait for all moving parts to stop.; Check Battery Charge; Service Interval: As required; To prevent damage due to freezing, battery

Maintenance Maintenance Service Interval Maintenance Procedure 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.) • Change the hydraulic filter and fluid.• Check the wheel hub slotted nu...

Page 35 - Check the weak battery for terminal corrosion; Make sure the booster is a good and fully charged; The following instructions are adapted; Do Not lean over the batteries.; Be sure the vent caps are tight and level.

Maintenance VoltageReading PercentCharge MaximumChargerSettings ChargingInterval 11.7–12.0 0–25% 14.4 volts/4amps 3 Hours 11.7 or less 0% 14.4 volts/2amps 6 Hours orMore Recommended JumpStarting Procedure Service Interval: As required 1. Check the weak battery for terminal corrosion (white, green, o...

Page 36 - Check Mower Blades

Maintenance Figure 20 1. Positive (+) cable on discharged battery 2. Positive (+) cable on booster battery 3. Negative (–) cable on the booster battery 4. Negative (–) cable on the engine block 5. Booster battery 6. Discharged battery 7. Engine block 4. Connect the other end of the positive cable to...

Page 38 - Check Seat Belt; Check for Loose Hardware; Service Air Cleaner; Service Interval: Every 250 hours—Replace; Change Engine Oil; Service Interval: After the first 5 hours; Check Hydraulic Oil Level; Service Interval: Every 50 hours

Maintenance Check Seat Belt Service Interval: Before each use or daily Visually inspect seat belt for wear, cuts, and properoperation of retractor and buckle. Replace beforeoperating if damaged. Check for Loose Hardware Service Interval: Before each use or daily 1. Stop engine, wait for all moving p...

Page 39 - Check Tire Pressures; Check Condition Of Belts; Lubricate Grease Fittings; See chart for service intervals.; Lubricate Caster Wheel Hubs

Maintenance Figure 24 1. Full 2. Add Note: The oil level on the dipstick will be incorrect if the oil is checked when the unit is hot. 7. If the dipstick oil level is at the “add” mark add Exmark Premium Hydro oil. 8. Replace hydraulic reservoir cap and tighten until snug. Do Not overtighten. Check ...

Page 40 - To prevent seal and bearing damage,; Lubricate Brake Handle Pivot; Lubricate Deck Lift Pivot; Service Interval: Every 100 hours; Check Spark Plugs; Service Interval: Every 200 hours; Check LPG Tank

Maintenance Figure 25 1. Seal guard 2. Spacer nut with wrenchflats 2. Remove caster wheel from caster forks. 3. Remove seal guards from the wheel hub. 4. Remove one of the spacer nuts from the axle assembly in the caster wheel. Note that threadlocking adhesive has been applied to lock thespacer nuts...

Page 41 - Change LPG Tank; Valves and gauges may not

Maintenance Check the entire LPG fuel delivery system for damageor deterioration. Follow all the inspection checks asspecified in the Inspection section in Safety. Change LPG Tank Service Interval: As required Change the LPG tank outdoors in a well ventilatedarea. 1. Stop the machine on level ground...

Page 42 - Check; Service Interval: After the first 100 hours; Thread Locking Adhesives; Check Mower; Dielectric Grease

Maintenance CAUTION Raising the mower deck for service ormaintenance relying solely on mechanicalor hydraulic jacks could be dangerous. Themechanical or hydraulic jacks may not beenough support or may malfunction allowingthe unit to fall, which could cause injury. Do Not rely solely on mechanical or...

Page 43 - Adjustments

Maintenance Adjustments Note: Disengage PTO, shut off engine, wait for all moving parts to stop, engage parking brake, andremove key before servicing, cleaning, or making anyadjustments to the unit. CAUTION Raising the mower deck for service ormaintenance relying solely on mechanicalor hydraulic jac...

Page 44 - Torque the front and rear; Pump Drive Belt Tension

Maintenance Figure 29 1. Adjuster link 3. Adjuster 2. Jam nut For LZAS-LP Units: Loosen the whizlock nut onthe side of the yoke and the jam nut on top. Finetune the screw adjuster by turning it to get 3 inch(7.6 mm) height (see Figure 30). To increase the height, turn the adjuster screwclockwise; to...

Page 45 - Deck Belt Tension; Drive Wheel

Maintenance Deck Belt Tension Self-tensioning - No adjustment necessary. Adjusting the Parking Brake Service Interval: After the first 100 hours Every 500 hours thereafter Check to make sure brake is adjusted properly. Thisprocedure must be followed after the first 100 hoursor when a brake component...

Page 46 - Electric Clutch Adjustment

Maintenance 14. Once step 11 is achieved, hold the threaded rod end with a tool and tighten the lock nut againstthe standard nut. Do Not allow the cable to turnwhen the nuts are tightened. 15. After adjusting the brakes on both sides of the mower, cycle the brake handle a minimum of sixtimes to allo...

Page 48 - Troubleshooting; Temporarily

Maintenance Figure 37 1. Feeler gauge • If the gap is less than 0.010 inch, thenreinstall the shim and reference the Troubleshooting section. • If the gap is sufficient, proceed to thesafety check in step F. F. Perform the following safety check: a. Sit on the seat and start the engine. b. Make sure...

Page 49 - Adjusting the height:

Maintenance Figure 38 1. Double nuts 8. Shut off unit. Remove jumper wire from wire harness and plug connector into seat switch. 9. Remove the jack stands. 10. Raise the deck and re-install the height of cut pin. 11. Check that the machine does not creep in neutral with the park brakes disengaged. M...

Page 50 - Adjusting the Tilt

Maintenance Figure 41 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 can be tilted f...

Page 51 - Cleaning; Clean Debris From Machine

Maintenance Cleaning Clean Engine and ExhaustSystem Area Service Interval: Before each use or daily (May be required moreoften in dry or dirtyconditions.) CAUTION Excessive debris around engine cooling airintake and exhaust system area can causeengine, exhaust area, and hydraulic systemto overheat w...

Page 52 - Waste Disposal; Motor Oil Disposal

Maintenance Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants tothe environment. Dispose of used oil at a certifiedrecycling center or according to your state and localregulations. Battery Disposal DANGER Battery electrolyte contains sulfuric acid,which is poisonous ...

Page 53 - condition prior to mower use.

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 causedby an empty fuel tank. The followi...

Page 56 - Schematics; Electrical Diagram; Main Electrical

Schematics Schematics Electrical Diagram G013155 P T O S W IT C H SE A T SWITCH IGNITION SWITCH FUSE BLOCK REGUL A T OR G R OUND P T O C L U T C H S TA R T REL A Y LH NEUTRAL SWITCH RH NEUTRAL SWITCH BRAKE SWITCH S TA R T RED HOUR METER/MODULE L T. GREEN YELLO W T A N BR OWN WHITE ORANGE GR A Y VIOL...

Page 57 - Electrical Logic Schematic

Schematics Electrical Logic Schematic BN BN B U BK Y W T PK BN PK OR GN S R PK PK PK L TGR GY GY PK V BN V OR GN OR R PK R BK GND PK BK BN BN BK PK BK GND 15A F4 GY R I B A W V B U V V BK + S - FUEL SENDER 10A F3 (BRAKE) SW6 PK OR R F2 25A P T O CLUTCH B U 1 2 5 4 7 8 (P T O S W IT C H ) SW2 25A F1 ...

Page 58 - Hydraulic Diagram

Page 61 - Service Record

Service Record Date: Description of Work Done: Service Done By: 61

Page 64 - M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S; SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS; WALK-BEHIND ACCESSORIES AND OPTIONS

M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS WALK-BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO-MULCH SYSTEM TURF STRIPER STANDON CUSTOM RIDE SEAT SUSPENSION SYSTEM FULL SUSPENSION SEAT DECK LIFT ASSIST KIT HITCH KI...