Exmark Lazer ZHP manual

For Serial Nos. 540,000 & Higher Part No. 103-9182[...]

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 Pr eparation ........................................................................[...]

- 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 A LERT! YOUR SA FETY IS INVOLVED! The saf ety alert symbol appears above inform at ion w hich alerts you to[...]

- 2 - 1.3.4 Thoroug hly inspect t he ar ea where the equipment is t o be used and r em ove all stones, stick s, wires, bones, and other f oreign obj ect s which may damage the 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 pois[...]

- 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 - 1.4 OPERA TION Although hazard control and acci dent prevent ion partiall y are dependent upon t he design and configurat i on of t he equipment, these f act ors are al so dependent upon the awareness, concern, prudence, and proper t r ai ni ng of the personnel involved in the operation, transport, maint enance, and storage of the equipment. [...]

- 5 - DA NGER POTENT IAL HAZARD ♦ Mow ing on wet gr ass or steep slopes can cause sliding and loss of cont r ol. W HAT CAN HAPPEN ♦ W heels dropping over edges, ditches, st eep bank s, or water can cause rollovers, which may result in serious injury, death or dr owning. HOW TO AVO ID THE HAZARD ♦ Do not mow slopes when grass is wet. ♦ Do no[...]

- 6 - WA RNING POTENT IAL HAZARD ♦ There is no r ollover pr ot ect ion when the roll bar is down. W HAT CAN HAPPEN ♦ W heels dropping over edges, ditches, st eep bank s, or water can cause rollovers, which may result in serious injury, death or dr owning. HOW TO AVO ID THE HAZARD ♦ Keep the roll bar in t he r aised and locked position and use[...]

- 7 - 1.4.16 This mower was designed f or one oper ator 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 there is a g r ass collect ion system or m ulch kit in place and working pr operly. 1.4.18 Be aware of the mower discharg e and direct discharg e awa[...]

- 8 - WA RNING POTENT IAL HAZARD ♦ Hydraulic fluid escaping under pr essur e can penet rate skin and cause injur y. W HAT CAN HAPPEN ♦ Fluid accidentally injected into t he skin must be surgically removed within a few hours by a doctor fam iliar with this f orm of injury or g angrene may result . HOW TO AVO ID THE HAZARD ♦ Make sure all hydra[...]

- 9 - Type A Anti-Scalp Rollers Only – See Figure 10 PART NO. 1- 323540 LOCATIO N: Left Front Cor ner PART NO. 1- 403005 LOCATIO N: Left and Right Corners of Mower Deck PART NO. 1- 303508 LOCATIO N: Front Right Corner Top of Mower Deck PART NO. 1- 633922 LOCATIO N: Front Left Cor ner Top of Mower Deck PART NO. 1- 513746 LOCATI ON: Rear of Engine [...]

- 10 - 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: Serial Nos. 510,000 & Hi gher : LHP4419KA; LHP4819KA; LHP4820KC; LHP4823KA LHP5220KC; LHP5223KC; LHP5223KA; 2.2 ENGINE: 2.2.1 Engine Specif ications: See Your Eng ine Owner’s Manual 2.2.2 RPM: Full Speed: 3600 RPM (No Load) Idle: 1500 RPM PART NO. 1- 653147 LOCATI ON: Lefthand Side of Cutting Heigh[...]

- 11 - 2.3 FU EL SYSTEM 2.3.1 Capacity: 11.2 g al. (42 L.) 2.3.2 Type of Fuel: Regular unleaded g asoline, 87 octane or hig her . 2.3.3 Fuel Filter: For Kohler: Replaceable in-line 15 Micron Kohler P/N 2405002 For Kawasaki: Replaceable in-line Kaw asaki P/ N 49019- 2075 2.3.4 Fuel Shut-Of f Valve: 1/ 4 t urn increments ( lef t tank , “OFF”, r i[...]

- 12 - 2.6.3 Armrests: Standard seat: f oam padded flip-up ar mrests wi th height adjustment. Optional suspensi on seat: molded adjustable f lip-up armrests. 2.6.4 Seat Saf et y Switch: Incor porated into the Saf ety Inter lock System. Time delay seat switch eliminates r oug h ground cut- out s. 2.7 HYDROSTA TIC GROUND DRIVE SYSTE M 2.7.1 Hydrostat[...]

- 13 - 2.10 DIMENSIONS 2.10.1 O verall W idth: Without deck Discharge chute up Discharge chut e down w/44” Deck 43.9 in. (111.5 c m) 47.4 in. (120.3 cm ) 54.7 in. (138.9 cm ) w/48” Deck 45.9 in. (116.6 c m) 50.3 in. (122.4 cm ) 58.1 in. (147.6 cm ) w/52” Deck 47.9 in. (121.7 c m) 54.7 in. (138.9 cm ) 63.2 in. (160.5 cm ) 2.10.2 O verall Leng [...]

- 14 - 3.2.2 Raise the rear of the unit and support it with jack stands or eq uivalent support. CA UTION POTENT IAL HAZARD ♦ Raising the r ear of the unit f or assembly 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 unction allowi[...]

- 15 - c) Locate the upper u- shaped sect ion of the roll bar . I nstall the upper roll bar section using t he t wo 1/2-13 x 3 1/4 capscrews f r om st ep b and t wo 1/2-13 hex flange lock nuts. Do not over tig h t en. Make sur e upper r oll bar can pivot fr eely. Notes: • Make sure the capscrew and nuts are installed with the nut t o the inside o[...]

- 16 - 3.3.2 Check the voltag e of the bat tery with a digital voltmeter . Locate the voltag e r eading of the batter y in the t able below and charg e t he bat tery for t he recommended time interval to bring the charge up t o a full charg e of 12.6 volts or g reater. IMPORT A NT: M ak e sure the negat ive battery cables are disconnected and the b[...]

- 17 - b) Remove the f our 5/16-18 whizlock nuts f rom the seat t r ack studs at the bottom o f the sea t. Retain for use later. c) Alig n the seat track studs on the bott om of the seat with the holes in t he seat f r am e. Place seat on top of t he f rame and secure with the f our 5/16-18 whizlock nuts remove in step b). 3.7 INSTA LL MOTION CONTR[...]

- 18 - 3.10 S E RVICE HYDRA ULIC OIL The machine is shipped with hydraulic oil in the reser voir. Run t he machine for approximately 15 minutes to allow any extra air to purg e out of t he hydraulic system. Check hydraulic re ser voir and if necessary fill the r eservoir to the appropriate level with Mobil 1 15W -50 synthetic mot or oil. Replace hy[...]

- 19 - Pulling the l evers back f rom t he neut r al position will cause the respective drive wheels to rotate in a reverse direct ion ( s pr ing tension can be f elt when moving into reverse f rom neutr al). To tur n t o the left while backing, move the lef t lever f or ward t oward neutr al. To turn to t he right while backing , move the right le[...]

- 20 - Brake must be engaged, moti on cont rol l evers out (neutral l ock posi tion) and PTO swit ch “O FF” t o st art engine. (It is not necessar y for the operat or t o be in the seat to st ar t the engine.) 4.1.9 Hour M eter : Located on the rig ht fuel tank . The hour met er is connected to a pressur e switch installed in t he engine block [...]

- 21 - 4.3.3 Starting Eng ine : Brake must be engaged , the PTO sw i t ch disengaged , and the motion control levers out ( neut r al l ock position). (T he operator does not need t o be in the seat to st ar t the engine.) On a cold engine, place the throttle midway betw een t he “SLOW ” and “ FAST ” positions and push choke lever f orward t[...]

- 22 - Befor e st opping the engine, place t he t hrottle contr ol midw ay between the “slow” and “f ast ” posit ions. Allow the engine to run a m inim um of 15 seconds; then stop the eng ine. Rotate ig nit ion switch to “OFF” position. Remove the key to prevent childr en or other unauthor ized persons f rom star t ing engine. Close fue[...]

- 23 - 4.4.2 Loading a Unit : Use extr em e caution when loading units on trailer s or truck s. One f ull width ramp t hat is wide enough to extend beyond the rear tires is recommended inst ead of individual ramps for each side of the unit . The lower rear section of the tract or f rame extends back bet ween the rear wheels and serves as a stop for[...]

- 24 - d) If the oil level is low, add oil to bring t he oil level up to the “FULL” m ar k on the dipstick . Use oil as specif ied in the Eng ine O wner’s Manual. DO NOT overf ill. IMPORT A NT : DO NOT operate th e engine with the oil le ve l below the “LOW” (or “A DD”) mark on the dipsti ck, or over the “FULL” mark. 5.1.2 Clean e[...]

- 25 - b) Raise deck t o t he transport ( 4. 5 ” ( 11. 4cm ) cutting heig ht) position. Lif t the fr ont of unit and support unit using jack st ands or equivalent support. 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 ♦ Th[...]

- 26 - CA UTION POTENT IAL HAZARD ♦ Operating a mower deck with loose or weakened blade bolts can be danger ous. W HAT CAN HAPPEN ♦ A loose or weakened blade bolt could allow a blade rotating at a high speed to come out f rom under t he deck , causing serious injur y or pr oper t y damage. HOW TO AVO ID THE HAZARD ♦ Always re-install original[...]

- 27 - 5.1.8 Check f or loose hardware . Service Interval : Dai l y a) St op eng ine, wait for all m oving par t s to stop, and r em ove key. b) Visually inspect machine for any loose hardware or any other possible problem. T ighten hardware or corr ect the problem bef ore operating . 5.1.9 Service air cleaner . Service Interval: 50 hrs. More often[...]

- 28 - 5.1.12 Check tire pr essur es : Service Interval: 40 hrs. a) Stop eng ine, wait f or all moving part s to stop, and r em ove k ey. b) Check tire pressur e in dr ive tires. c) Inf late drive tires to 13 psi ( 90 k Pa). d) Semi-pneumat ic cast er tires do not need to be inf lated. NOT E: Do not ad d any type o f tire liner or foam fill ma teri[...]

- 29 - 5.1.15 Lubricat e caster wheel hubs: Service Interval: Once Yearly a) Stop engine, wait f or all m oving parts to st op, and remove key. b) Remove caster wheel from caster f orks. c) Remove seal guards f rom the wheel hub. d) Remove one of the spacer nuts fr om the axle assembly in the caster wheel. Note that t hread locking adhesive has bee[...]

- 30 - b) Lubricat e br onze bushing s on br ak e handle pivot with a spray type lubricant or light oil. 5.1.18 Lubricate brak e rod bushings : Service Interval: 160 hrs. a) St op eng ine, wait for all m oving par t s to stop, and r em ove key. b) Unhook seat latch and tilt seat up. c) Lubricate br onze bushings on each end of brake r od shaf ts wi[...]

- 31 - IMPORT AN T : Bef or e reinstalling new f ilt er, f ill it with M obil 1 15W -50 and apply a thin coat of oil on t he surface of the rubber seal. Tur n the filt er clockwise until rubber seal contact s the filt er adapter then tight en t he f ilter an addit ional 2/ 3 t o 3/4 turn. e) Fill reser voir as st at ed in Sect ion 5.1.11. f) Raise [...]

- 32 - 5.1.28 Dielectric grease is used on all blade type electrical connections to pr event corrosion and loss of contact. 5.2 A DJUSTMENTS IMPORTA NT: Disengage PTO, shut of f engine, w ait f or al l moving parts to stop, and remove key before servicing, cl eani ng or making adjustments to the uni t. 5.2.1 Cutting Heig ht Adjustm ent . a) Stop ma[...]

- 33 - FIGURE 10 A NTI-SCALP ROLLER A DJUSTMENT 5.2.2 Deck Leveling: a) Position mower on a f lat surf ace. b) Stop eng ine, wait for all m oving par t s to stop, and r em ove key. c) Check t ir e pr essur e in dr ive tires. Proper inf lation pressure f or tires is 13 psi (90 kPa). Adjust if necessar y. Semi-Pneumatic cast er t ires do not need to [...]

- 34 - j) On lef t side, adjust f ront swivel using the lock ing nut behind the swivel until the f r ont chain is tight and all slack is removed f r om link age. Do not lift fr ont of deck of f 1- 1/ 8” (2.9 cm) block . Secure f ront swivel using locking nut in f r ont of swivel. Repeat f or r ig ht side. FIGURE 11 SWIVEL ADJUST M ENT SPRING CO M[...]

- 35 - b) Measure the leng th of t he spr ing . Measurement should be 2.75” (7. 0 cm) between washers (see Figure 12). c) If adj ust ment is necessary, tig ht en t he lock nut direct ly below the yoke and loosen the two nuts jamm ed t ogether below the spring . T urn the nut dir ect ly below the washer until the correct m easur em ent is obtained[...]

- 36 - c) Begin with either t he lef t or r ig ht motion contr ol lever. Move lever to the neutral position and pull lever back until the clevis pin (on arm below pivot shaft ) cont act s the end of t he slot (just beg inning to put pressure on spring), See Fig ure 14. d) Check where lever is relative to notch in console (should be center ed allowi[...]

- 37 - NOTE: The nuts to the rear of the uni t on each rod have left-hand threads. FIGURE 14 RH MOTIO N CO NTROL A DJUSTMENT f ) Start eng ine. Brake must be engaged and motion cont rol l evers out to start engine. O perat or does not have t o be in the seat because of the jumper wire being used . Run eng ine at full thr ottle and release brak e. g[...]

- 38 - j ) Shut of f unit . Remove jumper wire fr om wire harness connector and plug connector into seat switch. 5.2.12 Caster pivot bearings pr e- load adj ustment. a) Remove dust cap f rom caster and t ig hten nyloc nut until washers are flat and back off 1/4 of a t urn to properly set t he pr e- load on the bearing s. If disassem bled make sure [...]

- 39 - 7. TROUBLE SHOOTING 7.1 MOWER PULLS LEFT OR RIGH T (W/LEVERS FULLY FORWA RD). a) Refer t o T racking Adj ust ment Section 4.1. 3. b) Check air pr essur e in dr ive tires; 13 psi. Semi-pneumat ic casters do not req uire inflat ion. c) Check reverse indicat or and motion control link age adjust m ent . See Section 5.2.10 and 5. 2. 11. 7.2 MOWE[...]

- 40 - ENGINE TROUBLESHOOTING TA BLE PROBLEM NO FUEL IMPROPER FUEL DIRT IN FUEL LI NE DIRTY AIR FILTER FAULTY SPARK PLUG ENGINE OVERLOADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN W ill not start X X X X X X Hard start i ng X X X X X X X Stops s uddenly X X X X X X X Lacks p ower X X X X X X X X Operates erratically X X X X X X X Kn[...]

- 41 - 8. ELECTRICA L DIAGRA M – KA WASA KI UNITS[...]

- 42 - ELECTRICA L DIAGRA M – KOHLER UNITS[...]

- 43 - 9. HYDRA ULIC DIAGRA M[...]

- 44 - 10. 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[...]

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

- 46 -[...]

® 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[...]