Page 2 - IMPORTANT
i WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system) in...
Page 3 - ii; EXMARK PARTS PLUS
ii EXMARK PARTS PLUS ® PROGRAM EFFECTIVE DATE: September 1, 1995 Program If your Exmark dealer does not have the Exmark part in stock, Exmark will 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 f...
Page 4 - BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS
iii CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment, and safety instr...
Page 5 - TABLE OF CONTENTS
iv TABLE OF CONTENTS 1. SAFETY PAGE 1.1 Safety Alert Symbol ............................................................................ 1 1.2 Training .............................................................................................. 1 1.3 Preparation ......................................
Page 6 - SAFETY ALERT SYMBOL; YOUR SAFETY IS INVOLVED!; CAUTION
- 1 - 1. SAFETY 1.1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents. This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol appears above ...
Page 7 - DO NOT
- 2 - 1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, ...
Page 9 - NEVER
- 4 - 1.4 OPERATION Although hazard control and accident prevention partially are dependent upon the design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence, and proper training of the personnel involved in the operation, transport, maintenan...
Page 10 - DANGER; Figure 1; SAFE ZONE FOR MOWING
- 5 - DANGER POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can cause sliding and loss of control. WHAT CAN HAPPEN ♦ Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. HOW TO AVOID THE HAZARD ♦ Do not mow slo...
Page 11 - WARNING; EXTREME; midway
- 6 - WARNING POTENTIAL HAZARD ♦ There is no rollover protection when the roll bar is down. WHAT CAN HAPPEN ♦ Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. HOW TO AVOID THE HAZARD ♦ Keep the roll bar in the rais...
Page 12 - MAINTENANCE AND STORAGE; Check all bolts frequently to maintain proper tightness.
- 7 - 1.4.16 This mower was designed for one operator only. Keep all others away from mower during operation. 1.4.17 Do Not mow with the discharge deflector raised, removed, or altered unless there is a grass collection system or mulch kit in place and working properly. 1.4.18 Be aware of the mower ...
Page 15 - Engine Specifications: See Your Engine Owner’s Manual
- 10 - 2. SPECIFICATIONS 2.1 MODEL NUMBER: Serial Nos. 510,000 & Higher : LHP4419KA; LHP4819KA; LHP4820KC; LHP4823KA LHP5220KC; LHP5223KC; LHP5223KA; 2.2 ENGINE: 2.2.1 Engine Specifications: See Your Engine Owner’s Manual 2.2.2 RPM: Full Speed: 3600 RPM (No Load) Idle: 1500 RPM PART NO. 1-653147...
Page 16 - ELECTRICAL SYSTEM; Optional seat accessories:
- 11 - 2.3 FUEL SYSTEM 2.3.1 Capacity: 11.2 gal. (42 L.) 2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or higher. 2.3.3 Fuel Filter: For Kohler: Replaceable in-line 15 Micron Kohler P/N 2405002 For Kawasaki: Replaceable in-line Kawasaki P/N 49019-2075 2.3.4 Fuel Shut-Off Valve: 1/4 turn i...
Page 17 - Size Qty
- 12 - 2.6.3 Armrests: Standard seat: foam padded flip-up armrests with height adjustment. Optional suspension seat: molded adjustable flip-up armrests. 2.6.4 Seat Safety Switch: Incorporated into the Safety Interlock System. Time delay seat switch eliminates rough ground cut-outs. 2.7 HYDROSTATIC G...
Page 18 - Drive Wheels; Wheel Base: (center of caster tire to center of drive tire); TORQUE REQUIREMENTS; Bolt Location; ASSEMBLY INSTRUCTIONS; Disassemble roll bar from the crate.
- 13 - 2.10 DIMENSIONS 2.10.1 Overall Width: Without deck Discharge chute up Discharge chute down w/44” Deck 43.9 in. (111.5 cm) 47.4 in. (120.3 cm) 54.7 in. (138.9 cm) w/48” Deck 45.9 in. (116.6 cm) 50.3 in. (122.4 cm) 58.1 in. (147.6 cm) w/52” Deck 47.9 in. (121.7 cm) 54.7 in. (138.9 cm) 63.2 in. ...
Page 19 - LOOSELY
- 14 - 3.2.2 Raise the rear of the unit and support it with jack stands or equivalent support. CAUTION POTENTIAL HAZARD ♦ Raising the rear of the unit for assembly relying solely on mechanical or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enoug...
Page 20 - The machine is shipped with a filled lead acid battery.; Wash hands after handling.
- 15 - c) Locate the upper u-shaped section of the roll bar. Install the upper roll bar section using the two 1/2-13 x 3 1/4 capscrews from step b and two 1/2-13 hex flange lock nuts. Do not over tighten. Make sure upper roll bar can pivot freely. Notes: • Make sure the capscrew and nuts are install...
Page 21 - cable; INSTALL DRIVE WHEELS
- 16 - 3.3.2 Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater. IMPORTANT: Make sure the negative battery ca...
Page 22 - bottom of the seat. Retain for use later.; INSTALL MOTION CONTROL LEVERS; outside; of the control arm shaft and secure with; FIGURE; POSITION DISCHARGE CHUTE
- 17 - b) Remove the four 5/16-18 whizlock nuts from the seat track studs at the bottom of the seat. Retain for use later. c) Align the seat track studs on the bottom of the seat with the holes in the seat frame. Place seat on top of the frame and secure with the four 5/16-18 whizlock nuts remove in...
Page 23 - SERVICE HYDRAULIC OIL; OPERATION INSTRUCTIONS; FIGURE 6
- 18 - 3.10 SERVICE HYDRAULIC OIL The machine is shipped with hydraulic oil in the reservoir. Run the machine for approximately 15 minutes to allow any extra air to purge out of the hydraulic system. Check hydraulic reservoir and if necessary fill the reservoir to the appropriate level with Mobil 1 ...
Page 24 - ROTATE
- 19 - Pulling the levers back from the neutral position will cause the respective drive wheels to rotate in a reverse direction (spring tension can be felt when moving into reverse from neutral). To turn to the left while backing, move the left lever forward toward neutral. To turn to the right whi...
Page 25 - Do Not; MOWING
- 20 - Brake must be engaged, motion control levers out (neutral lock position) and PTO switch “OFF” to start engine. (It is not necessary for the operator to be in the seat to start the engine.) 4.1.9 Hour Meter: Located on the right fuel tank. The hour meter is connected to a pressure switch insta...
Page 26 - crank the engine continuously for more than ten (10); IMPORTANT: Operator must be in seat before the PTO can be engaged.
- 21 - 4.3.3 Starting Engine: Brake must be engaged , the PTO switch disengaged , and the motion control levers out (neutral lock position). (The operator does not need to be in the seat to start the engine.) On a cold engine, place the throttle midway between the “SLOW” and “FAST” positions and pus...
Page 27 - TRANSPORTING
- 22 - 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 engine. Rotate ignition switch to “OFF” position. Remove the key to prevent children or other unauthorized persons from startin...
Page 28 - PERIODIC MAINTENANCE; Service Interval: Daily
- 23 - 4.4.2 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 of the unit. The lower rear section of the tractor frame extends back between th...
Page 29 - operate the engine with the oil level below the; Service Interval: Daily or more often in dry conditions; Service Interval: Monthly
- 24 - d) If the oil level is low, add oil to bring the oil level up to the “FULL” mark on the dipstick. Use oil as specified in the Engine Owner’s Manual. DO NOT overfill. IMPORTANT : DO NOT operate the engine with the oil level below the “LOW” (or “ADD”) mark on the dipstick, or over the “FULL” ma...
Page 30 - Service Interval: Daily; FIGURE 7
- 25 - b) Raise deck to the transport (4.5” (11.4cm) cutting height) position. Lift the front of unit and support unit using jack stands or equivalent support. CAUTION POTENTIAL HAZARD ♦ Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be danger...
Page 31 - pass any of these tests, do not operate.
- 26 - CAUTION POTENTIAL HAZARD ♦ Operating a mower deck with loose or weakened blade bolts can be dangerous. WHAT CAN HAPPEN ♦ A loose or weakened blade bolt could allow a blade rotating at a high speed to come out from under the deck, causing serious injury or property damage. HOW TO AVOID THE HAZ...
Page 32 - Use
- 27 - 5.1.8 Check for loose hardware. Service Interval: Daily a) Stop engine, wait for all moving parts to stop, and remove key. b) Visually inspect machine for any loose hardware or any other possible problem. Tighten hardware or correct the problem before operating. 5.1.9 Service air cleaner. Ser...
Page 33 - Service; LUBRICATION CHART
- 28 - 5.1.12 Check tire pressures: Service Interval: 40 hrs. a) Stop engine, wait for all moving parts to stop, and remove key. b) Check tire pressure in drive tires. c) Inflate drive tires to 13 psi (90 kPa). d) Semi-pneumatic caster tires do not need to be inflated. NOTE: Do not add any type of t...
Page 34 - Service Interval: Once Yearly; NOTE
- 29 - 5.1.15 Lubricate caster wheel hubs: Service Interval: Once Yearly a) Stop engine, wait for all moving parts to stop, and remove key. b) Remove caster wheel from caster forks. c) Remove seal guards from the wheel hub. d) Remove one of the spacer nuts from the axle assembly in the caster wheel....
Page 36 - Changing oil unnecessarily
- 31 - IMPORTANT : Before reinstalling new filter, fill it with Mobil 1 15W-50 and apply a thin coat of oil on the surface of the rubber seal. Turn the filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 2/3 to 3/4 turn. e) Fill reservoir as stated in...
Page 37 - ADJUSTMENTS
- 32 - 5.1.28 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact. 5.2 ADJUSTMENTS IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop, and remove key before servicing, cleaning or making adjustments to the unit. 5.2.1 ...
Page 38 - ANTI-SCALP ROLLER ADJUSTMENT; Position mower on a flat surface.
- 33 - FIGURE 10 ANTI-SCALP ROLLER ADJUSTMENT 5.2.2 Deck Leveling: a) Position mower on a flat surface. b) Stop engine, wait for all moving parts to stop, and remove key. c) Check tire pressure in drive tires. Proper inflation pressure for tires is 13 psi (90 kPa). Adjust if necessary. Semi-Pneumati...
Page 39 - Pump Drive Belt Tension.
- 34 - j) On left side, adjust front swivel using the locking nut behind the swivel until the front chain is tight and all slack is removed from linkage. Do not lift front of deck off 1-1/8” (2.9 cm) block. Secure front swivel using locking nut in front of swivel. Repeat for right side. FIGURE 11 SW...
Page 40 - BRAKE ADJUSTMENT; Adjust Throttle Lever Tension.; THROTTLE; Electric Clutch Adjustment:
- 35 - b) Measure the length of the spring. Measurement should be 2.75” (7.0 cm) between washers (see Figure 12). c) If adjustment is necessary, tighten the lock nut directly below the yoke and loosen the two nuts jammed together below the spring. Turn the nut directly below the washer until the cor...
Page 41 - Temporarily
- 36 - c) Begin with either the left or right motion control lever. Move lever to the neutral position and pull lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginning to put pressure on spring), See Figure 14. d) Check where lever is relative to notch...
Page 42 - RH MOTION CONTROL ADJUSTMENT; Brake must be engaged and motion control levers out to; LH MOTION CONTROL ADJUSTMENT
- 37 - NOTE: The nuts to the rear of the unit on each rod have left-hand threads. FIGURE 14 RH MOTION CONTROL ADJUSTMENT f) Start engine. Brake must be engaged and motion control levers out to start engine. Operator does not have to be in the seat because of the jumper wire being used. Run engine at...
Page 43 - CASTER ADJUSTMENT
- 38 - j) Shut off unit. Remove jumper wire from wire harness connector and plug connector into seat switch. 5.2.12 Caster pivot bearings pre-load adjustment. a) 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 be...
Page 45 - ENGINE TROUBLESHOOTING TABLE
- 40 - 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 Will not start 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 ...
Page 47 - ELECTRICAL DIAGRAM – KOHLER UNITS
Page 50 - SERVICE RECORD; Date
- 45 - SERVICE RECORD Date Description of Work Done Service Done By
Page 52 - RIDING ACCESSORIES; INDUSTRIAL PARK BOX 808; Check us out on the Web:
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