Exmark 4500-501 Rev A manual

LAZER Z ® XS DIESEL MODELS For Serial Nos. 790,000 & Higher Part No. 4500-501 Rev . A[...]

W ARNING CALIFORNIA Proposition 65 W ar ning Diesel engine exhaust and some of its constituents are known to the State of Califor nia to cause cancer , bir th defects, and other reproductive har m. Important: When the mo wer is used or operated on an y Califor nia forest, br ush or grass co vered land, a w orking spark ar rester must be attached to[...]

Introduction CONGRATULATIONS on the purc hase of y our Exmark Mower . This product has been carefully designed and manufactured to gi ve you a maxim um amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for your Exmark mow er . BEFORE OPERATING YOUR MOWER, C[...]

Contents Introduction .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 3 Safety .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . 5 Safety Aler t Symbol . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . [...]

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both in this manual and on the mac hine to identify important safety messag es whic h must be follo wed to av oid accidents This symbol means: ATTENTION! BECOME ALERT! Y OUR SAFETY IS INV OLVED! Figure 2 1. Safety alert symbol The safety alert symbol appears abov e infor [...]

Safety DANGER In cer tain conditions diesel fuel is extremely ammable and v apors are explosi ve. A re or explosion from diesel fuel can bur n y ou, others, and cause proper ty damage. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any diesel fuel that spills. • Never rell the fuel tank or drain the mac[...]

Safety • Be sure all driv es are in neutral and parking brake is engag ed before starting engine. Use seat belts with the roll bar in the raised and loc ked position. • Never operate the mo wer with damaged guards , shields , or cov ers . Alw ays hav e safety shields , guards , switc hes and other devices in place and in proper w orking conditi[...]

Safety 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. W ater • R emove or mark obstacles such as roc ks , tree limbs , etc . from the mowing area. T all grass can hide obstacles . • W atc h for dit[...]

Safety • P ark mac hine on lev el ground. Never allow untrained personnel to ser vice machine . • Use jack stands to suppor t components when required. • Carefully release pressure from components with stored energ y . • Disconnect batter y or remov e spark plug wire before making any re pairs . Disconnect the negative terminal rst and t[...]

Safety Safety and Instructional Decals • Keep all safety signs legible . R emov e all grease, dirt and debris from safety signs and instr uctional labels . • R e place all worn, damaged, or missing safety signs . • When replacement components are installed, be sure that cur rent safety signs are afx ed to the replaced components . • If a[...]

Safety 103-0223 103-0261 103-1798 103-2076 103-7218 107-2102 1 1[...]

Safety 107-21 12 109-0872 109-1214 109-1215 109-1399 109-2219 109-2263 12[...]

Safety 109-2264 109-2478 109-2951 109-3148 13[...]

Safety 109-6855 109-7949 1 16-0127 1 16-0404 1 16-0997 19426-87881 19426-87903 14[...]

Safety 107-9866 1. Fast 2. Slow 3. Neutral 4. Reverse 15[...]

Specications Specications Model Numbers Serial Nos: 790,000 and Higher LXS25KD605; LXS25KD665; LXS25KD725 Systems Engine • Engine Specications: See y our Engine Owner’ s Manual • RPM: Full Speed: 3850 ±50 RPM (No Load) Idle: 1400 RPM Fuel System • Capacity: 15.5 gal. (58.6 L) • T ype of Fuel: Diesel fuel, 40 cetane or higher or [...]

Specications • Mounting: Hing ed to tilt up for access to hy draulic pumps , batter y and other components . Held in tilted position with scissor—type links . Adjustable fore and aft seat trac k. • Ar mrests: Molded adjustable ip-up ar mrests . • Seat Safety Switc h: Incorporated into the Safety Interloc k System. Time delay seat swit[...]

Specications Dimensions Overall Width: 60 inch Deck 66 inch Deck 72 inch Deck Without Deck 53.5 inches (135.9 cm) 57.3 inches (145.5 cm) 61.5 inches (156.2 cm) Deector Up 61.4 inches (156.0 cm) 68.0 inches (172.7 cm) 74.3 inches (188.7 cm) Deector Down 72.8 inches (184.9 cm) 79.4 inches (201.7 cm) 85.8 inches (217.9 cm) Overall Length: 60 [...]

Operation Product Overview Figure 4 1. Motion Control Lever 5. Controls 2. Parking Brake Lever 6. Seat Belt 3. Height-of-Cut Lever 7. Roll Bar 4. Fuel Cap (Both Sides) Operation Note: Deter mine the left and right sides of the machine from the nor mal operating position. Controls Motion Control Levers The motion control lev ers located on each side[...]

Operation and “STAR T”. Inser t key into switch and rotate clockwise to the “ON” position. R otate cloc kwise to the next position to engag e the starter (key must be held against spring pressure in this position). Note: Brake must be eng aged, motion control lev ers out (neutral lock position) and PTO switc h “OFF” to start engine. (It[...]

Operation The v oltmeter measure the v oltage output of the alternator. Both high and lo w voltages will potentially damage the battery . Glow Plug Switch and Light Located on the right fuel tank. Depress and hold the switch to heat the glow plugs . The glow plug light comes on when the glow plug switch is depressed. The glo w plug light indicates [...]

Operation Operating Instructions Raise the Rollover Protection System (ROPS) Important: Low er the roll bar only when absolutely necessar y . 1. R emove the hairpin cotter pins and remov e the tw o roll bar pins (Figure 5). 2. Raise the roll bar to the upright position and install the tw o pins and secure them with the hairpin cotter pins (Figure 5[...]

Operation Engaging the PT O DANGER The rotating blades under the mow er deck are dangerous. Blade contact can cause serious injur y or kill y ou. Do Not put hands or feet under the mo wer or mow er deck when the blades are engaged. DANGER An unco vered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. [...]

Operation Figure 6 1. Handles Out (Neutral Lock) 5. Neutral 2. Handles In (Neutral) 6. Reverse 3. Front of Unit 7. Neutral Lock 4. Forward Driving F orw ard 1. R elease the parking brake . 2. Mov e the motion control lev ers inward to the center to the neutral unlock ed position. 3. T o mov e forward in a straight line apply equal forward pressure [...]

Operation deck lift assist lev er located at the front right corner of the oor pan. Note: When changing the cutting height positions, al w ays come to a complete stop and disengage the PTO . Figure 8 1. Lever in transport and 5 inch (12.7 cm) cutting height position 4. Insert the height adjustment pin into the hole cor responding to the desired [...]

Operation Figure 10 1. Spring disc washer (cone towards bolt head) 3. 3/8 nyloc-torque to 30-35 ft-lb (41-47 N-m) 2. Front right anti-scalp bracket shown 4. 3/8-24 x 2 GR8 torque to 50-55 ft-lb (68-75 N-m) 9. If the 3/8 nyloc nut has been remov ed, re-install and torque to 30–35 ft-lb (41–47 N-m) (Figure 10). T ransporting T ransporting a Unit [...]

Operation Important: Do Not attempt to tur n the unit while on the ramp , y ou may lose control and driv e of f the side. A v oid sudden acceleration when dri ving up a ramp and sudden deceleration when backing do wn a ramp . Both maneuv ers can cause the unit to tip backw ard. 27[...]

Maintenance Maintenance Note: Deter mine the left and right sides of the mac hine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental star ting of the engine could seriously injure y ou or other bystanders. Remo ve the k ey from the ignition switch and engage par[...]

Maintenance Maintenance Ser vice Inter v al Maintenance Procedure Every 500 hours • Chang e the hy draulic lter (Ev er y 250 hours/yearly if using Mobil 1 15W50) • Check the wheel hub slotted n ut torque specications . • Check the wheel lug nuts . Every 600 hours • R eplace the air cleaner elements . (May need more often under severe [...]

Maintenance used for charging the batter y has an output of 16 v olts and 7 amps or less to av oid dama ging the batter y (see char t for recommended charger settings). V oltage Reading Percent Charge Maximum Charger Settings Charging Inter v al 12.6 or g reater 100% 16 v olts/7 amps No Charging R equired 12.4 – 12.6 75–100% 16 v olts/7 amps 30[...]

Maintenance motion control levers mov ed out in the neutral lock position. The operator does not need to be in the seat to start the engine. T ry to start with operator in seat , parking brake disengag ed, PTO disengag ed and motion control levers in the neutral lock position - starter must not crank . T ry to start with operator in seat , parking [...]

Maintenance 5. Check the condition of the inner element. R eplace whenever it appears dirty , typically every other time the paper element is replaced. Clean the base around the inner element before removing, so dirt does not get into the engine . 6. Do Not wash or use pressurized air to clean paper element or inner element. 7. R einstall elements [...]

Maintenance 3. R emove left and right belt shields on deck and lift up oor pan to inspect dec k driv e belt. 4. Check under machine to inspect the m ule driv e belt. R efer to Mule Driv e Belt T ension Adjustment section in Adjustments . Lubricate Grease Fittings Note: See char t for ser vice inter v als. 1. Stop engine , w ait for all moving pa[...]

Maintenance 3. R emove seal guards from the wheel hub . 4. R emove one of the spacer nuts from the axle assembly in the caster wheel. Note that thread locking adhesiv e has been applied to loc k the spacer nuts to the axle . Remo ve the axle (with the other spacer nut still assembled to it) from the wheel assembly . 5. Pr y out seals , and inspect [...]

Maintenance Change Fuel Filter/W ater Separator Service Interval: Every 400 hours/Y early (whichever comes rst) (more often in dirty or dusty conditions). DANGER Use of improper components can result in system f ailure, fuel leakage and possible explosion. • Ensure that an Authoriz ed Ser vice Dealer replace the fuel lter and an y component[...]

Maintenance 4. T or que the slotted n ut to 125 ft-lb (169 N-m). 5. Then tighten n ut until the next set of slots line up with the cross hole in shaft. 6. R e place cotter pin. Note: Do Not use anti-seize on wheel hub . Check Engine Coolant Level Service Interval: Before each use or daily 1. Stop engine and wait for all mo ving par ts to stop . Mak[...]

Maintenance Figure 14 1. Oil dipstick 2. Drain cock 4. R einstall all drain plugs and hoses and tighten drain cock. 5. Fill radiator with a 50/50 mix of water and Dex-Cool© coolant as specied in the Check Engine Coolant Lev el Section, allowing some room (approximately 1/2 inch (12.7 mm)) for expansion. Add 50/50 coolant mix to ov erow bottl[...]

Maintenance • Under top cutter housing bearing guard. • Between the jac kshaft and bearings and the jackshaft and sheav es . Copper-Based Anti-seize Copper-based anti-seize is used in the following locations: On threads of Blade Bolts See Check Mo wer Blades section. Dielectric Grease Dielectric grease is used on all blade type electrical conne[...]

Maintenance front swi vel using loc king nut in front of swi vel. R e peat for right side . 11. R echec k that the 3/4 inch (19 mm) bloc ks t just snugly under the brac kets and that the tension on all the c hains is appro ximately equal. Mak e sure all chain attac hment bolts are tight. R eposition anti-scalp rollers and tighten securely . Figu[...]

Maintenance Figure 17 1. Spring idler pulley 3. Right side idler pulley (adjustable) 2. Front of unit Deck Belt T ension Self-tensioning - No adjustment necessar y . Alternator Belt T ension Stop engine, wait for all mo ving par ts to stop and remov e key . Engag e parking brake . Tilt seat and remo ve air deector panel T o tighten alter nator b[...]

Maintenance Figure 19 1. Lever down (disengaged) 6. Remove pin to adjust rod length for additional brake adjustment 2. Lever up (engaged) 7. T runnion roller 3. Nyloc nut below trunnion roller 8. Spring retainer bracket 4. Nyloc nut below spring 9. 2 13/16 inches (7.1 cm) 5. 1/8 to 3/16 inch (3.2 to 4.8 mm) 10. Jam nut above trunnion roller Brake A[...]

Maintenance Motion Control Linkage Adjustment W ARNING Engine must be r unning and dri ve wheels must be tur ning so motion control adjustment can be perfor med. Contact with moving par ts or hot surfaces may cause personal injur y . Keep ngers, hands, and clothing clear of rotating components and hot surfaces. CAUTION Raising the mo wer deck fo[...]

Maintenance wheel m ust stop tur ning or slightly creep in reverse (Figure 22). Figure 22 Left-Hand Side of Unit 1. T urn LH tracking adjustment knob. (Do Not loosen any nuts on LH side) 10. Shut off unit. R emove jumper wire from wire harness connector and plug connector into seat switch. Motion Control Damper Adjustment The top damper mounting bo[...]

Maintenance Figure 25 1. Armature 5. Brake spacer 2. Field shell 6. Re-gap shim 3. Rotor 7. Brake pole 4. Brake mounting bolt Remo ving the Shim: 1. Stop engine, wait for all moving par ts to stop , and remov e key . Eng age parking brake . Allow the machine to cool completely before starting these instr uctions . 2. Using a pneumatic line , blo w [...]

Maintenance as shown. (Due to the wa y the rotor and ar mature faces w ear (peaks and valleys) it is sometimes difcult to measure the true gap .) Figure 29 1. Feeler gauge Figure 30 1. Feeler gauge • If the gap is less than 0.010 inch, then reinstall the shim and reference the T roubleshooting section. • If the gap is sufcient, proceed to[...]

Maintenance Cleaning Clean Engine Cooling System Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) CAUTION Excessi ve de bris around the engine cooling air intak e and inside of the pump driv e belt compartment and damaged or missing r ub ber bafes can cause the engine and hy draulic system to o [...]

Maintenance Clean Grass Build-Up Under Deck Service Interval: Before each use or daily 1. Stop engine , w ait for all moving parts to stop , and remov e key . Engage parking brake . 2. Raise deck to the transpor t (5 inch (12.7 cm) cutting height) position. Lift the front of unit and support unit using jack stands or equiv alent support. CAUTION Ra[...]

T roubleshooting T roubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mow er use. When a problem occurs , do not o verlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes o[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessive . 1. R educe the ground speed. 2. Oil lev el in the crankcase is lo w . 2. Add oil to the crankcase . 3. Dirty air lter . 3. Clean or replace the air cleaner element. 4. Coolant level is lo w . 4. Add coolant. 5. Debris on or around radiator . 5. R emove deb[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Oil level is low . 1. Check oil lev el. W arning buzzer emits intermittent beep. 2. Oil leaking from engine . 2. Contact A uthorized Ser vice Dealer . 1. Fuse is blown. 1. R eplace fuse. Check coil resistance , batter y charge, charging system, and wiring connections and replace if nece[...]

Schematics Schematics Electrical Diagram RED BLACK BLACK YELLOW/BLA CK PINK 2 4 1 5 3 YELLOW/RED ORANGE BLACK BLACK YELLOW/BLA CK BLACK PINK 5 4 3 2 1 RED 1 2 GROUND ORANGE BROWN/BLA CK PINK/BLACK BLACK RED BROWN/BLA CK YELLOW/BLA CK YELLOW/BLA CK YELLOW BLACK BLACK ORANGE/BLACK ORANGE/BLACK DK. GREEN DK. GREEN DK. GREEN VIOLET L T. BLUE L T. BLUE [...]

Schematics Electrical Logic Schematic 52[...]

Schematics Hydraulic Diagram 53[...]

Conditions and Products Co vered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty Company , pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair , replace or adjust any part on these products and found by us (in the ex ercise of our reasonable discretion) to be defect i ve in factor[...]

Notes: 55[...]

Notes: 56[...]

Service Record Date: Description of Work Done: Service Done By: 57[...]

58[...]

59[...]

MID-MOUNT RIDING A CCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF A CCESSORIES AND OPTIONS W ALK-BEHIND A CCESSORIES AND OPTIONS GRASS CA TCHER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM FULL SUSPENSION SEA T DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V PO WER PORT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED[...]