Exmark 465, 565, 505 User Manual

0 (0)

LAZER Z® HP

465, 505, AND 565 MODELS

For Serial Nos.

720,000 & Higher

Part No. 4500-251 Rev. A

WARNING

CALIFORNIA

Proposition 65 Warning

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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-002 Ce système d’allumage par ètincelle de vèhicule est conforme à la norme NMB-002 du Canada

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously. Exmark, or its distributors and dealers, accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication.

© 1997–2007—Exmark Mfg. Co., Inc.		Contact us at www.Exmark.com.
Industrial Park Box 808		Printed in the USA.
Industrial Park Box 808	2	Printed in the USA.
Beatrice, NE 68310	2	All Rights Reserved

Introduction

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.

This manual contains operating, maintenance, adjustment, and safety instructions for your Exmark mower.

BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.

By following the operating, maintenance, and safety instructions, you will prolong the life of your mower, 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 stations. They carry ample stock of service parts or can secure them promptly for you from the factory.

All Exmark parts are thoroughly tested and inspected before leaving the factory, however, attention is required on your part if you are to obtain the fullest measure of satisfaction and performance.

Whenever you need service, genuine Exmark parts, or additional information, contact an Authorized Service Dealer or Exmark Customer Service and have the model and serial numbers of your product ready.

Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.

Figure 1

1. Model and serial number location

Model No.

Serial No.

Contents
Introduction ...........................................................	3
Safety .....................................................................	5
Safety Alert Symbol.........................................	5
SafeOperatingPractices..................................	5
SafetyandInstructionalDecals .....................	10
Specifications .......................................................	14
Model Numbers............................................	14
Systems.........................................................	14
Dimensions...................................................	16
Torque Requirements ....................................	17
Product Overview ................................................	17
Operation .............................................................	18
Controls........................................................	18
Pre-Start........................................................	19
OperatingInstructions ..................................	19
Transporting .................................................	23
Maintenance .........................................................	25
RecommendedMaintenanceSchedule(s) ...........	25
Periodic Maintenance .......................................	26
CheckEngineOilLevel.................................	26
Check Battery Charge....................................	26
Check Mower Blades.....................................	27
CheckSafetyInterlockSystem.......................	27
Check Rollover Protection System (Roll
Bar) Pins ...................................................	28
Check Seat Belt..............................................	28
CheckforLooseHardware............................	28
Service Air Cleaner........................................	28
Change Engine Oil........................................	28
CheckHydraulicOilLevel.............................	29
Check Tire Pressures .....................................	29
CheckConditionOfBelts..............................	29
LubricateGreaseFittings...............................	29
LubricateCasterWheelHubs ........................	30
LubricateBrakeHandlePivot ........................	31
LubricateBrakeRodBushings.......................	31
Lubricate Motion Control Bronze
Bushings ...................................................	31
LubricateSeatSwitchActuator ......................	31
Check Spark Plugs.........................................	31
ChangeHydraulicSystemFilter .....................	31
Wheel Hub - Slotted Nut Torque
Specification..............................................	32
ThreadLockingAdhesives.............................	32
Mobil HTS Grease (Or Food-Grade
Anti-seize).................................................	32
Copper-BasedAnti-seize ..............................	32
Dielectric Grease...........................................	32
Adjustments .....................................................	33

Deck Leveling ...............................................	33
PumpDriveBeltTension...............................	33
Deck Belt Tension ........................................	33
BrakeLinkAdjustment..................................	34
Brake Adjustment..........................................	34
ElectricClutchAdjustment............................	34
ReverseIndicatorAdjustment........................	34
MotionControlLinkageAdjustment .............	35
Adjust Seat Switch ........................................	36
Caster Pivot Bearings Pre-Load
Adjustment ...............................................	36
Cleaning ...........................................................	37
CleanEngineCoolingSystem........................	37
RemoveEngineShroudsandCleanCooling
Fins...........................................................	37
CleanGrassBuild-UpUnderDeck ................	37
Waste Disposal..............................................	37
Troubleshooting ...................................................	39
Schematics ...........................................................	41

Safety

Safety Alert Symbol

This Safety Alert Symbol (Figure 2) 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!

Figure 2

1.Safety alert symbol

The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER,

WARNING, or CAUTION.

DANGER: White lettering / Red background. Indicates an imminently hazardous situation which, if not avoided, Will result in death or serious injury.

WARNING: Black lettering / Orange background. Indicates a potentially hazardous situation which, if not avoided, Could result in death or serious injury.

CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous situation which, if not avoided, May result in minor or moderate injury.

This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

Safe Operating Practices

Training

•Read the Operator’s Manual and other training material. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them.

•Become familiar with the safe operation of the equipment, operator controls, and safety signs.

•All operators and mechanics should be trained. The owner is responsible for training the users.

•Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

•The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property.

Preparation

•Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by Exmark.

•Wear appropriate clothing including safety glasses, substantial footwear, long trousers, and hearing protection. Do Not operate when barefoot or when wearing open sandals. Long hair, loose clothing or jewelry may get tangled in moving parts.

CAUTION

This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure.

Wear hearing protection when operating this machine.

•Inspect the area where the equipment is to be used and remove all rocks, toys, sticks, wires, bones, and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders.

Safety

DANGER

In certain conditions gasoline is extremely flammable and vapors are explosive.

A fire or explosion from gasoline can burn you, others, and cause property damage.

•Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any gasoline that spills.

•Never refill the fuel tank or drain the machine indoors or inside an enclosed trailer.

•Do Not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1/4 to 1/2 inch (6–13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.

•Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by spark.

•Store gasoline in an approved container and keep it out of the reach of children.

•Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot.

•If fuel is spilled, Do Not attempt to start the engine. Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated.

•Do Not operate without entire exhaust system in place and in proper working condition.

DANGER

In certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage.

•Always place gasoline containers on the ground away from your vehicle before filling.

•Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

•When practical, remove gas-powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

•If this is not possible, 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

Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors has caused cancer in laboratory animals. Failure to use caution may cause serious injury or illness.

•Avoid prolonged breathing of vapors.

•Keep face away from nozzle and gas tank/container opening.

•Keep away from eyes and skin.

•Never siphon by mouth.

•Check that the operator’s presence controls, safety switches, and shields are attached and functioning properly. Do Not operate unless they are functioning properly.

Safety

Operation

WARNING

Operating engine parts, especially the muffler, become extremely hot. Severe burns can occur on contact and debris, such as leaves, grass, brush, etc. can catch fire.

•Allow engine parts, especially the muffler, to cool before touching.

•Remove accumulated debris from muffler and engine area.

•Install and maintain in working order a spark arrester before using equipment on forest-covered, grass-covered, or brush-covered unimproved land.

WARNING

Engine exhaust contains carbon monoxide, which is an odorless deadly poison that can kill you.

Do Not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect.

•Operate only in daylight or good artificial light, keeping away from holes and hidden hazards.

•Be sure all drives are in neutral and parking brake is engaged before starting engine. Use seat belts.

•Never operate the mower with damaged guards, shields, or covers. Always have safety shields, guards, switches and other devices in place and in proper working condition.

•Never mow with the discharge deflector raised, removed or altered unless there is a grass collection system or mulch kit in place and working properly.

•Do Not change the engine governor setting or overspeed the engine.

•Stop engine, wait for all moving parts to stop, remove key and engage parking brake:

–Before checking, cleaning or working on the mower.

–After striking a foreign object or abnormal vibration occurs (inspect the mower for

damage and make repairs before restarting and operating the mower).

–Before clearing blockages.

–Whenever you leave the mower.

•Stop engine, wait for all moving parts to stop, and engage parking brake:

–Before refueling.

–Before dumping the grass catcher.

WARNING

Hands, feet, hair, clothing, or accessories can become entangled in rotating parts. Contact with the rotating parts can cause traumatic amputation or severe lacerations.

•Do Not operate the machine without guards, shields, and safety devices in place and working properly.

•Keep hands, feet, hair, jewelry, or clothing away from rotating parts.

•NEVER carry passengers. DO NOT operate the mower when people, especially children, or pets are in the area.

•Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions.

•Stop the blades, slow down, and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed.

•Be aware of the mower discharge path and direct discharge away from others.

•Do Not operate the mower under the influence of alcohol or drugs.

•Use extreme care when loading or unloading the machine into a trailer or truck.

•Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

Slope Operation

Use Extreme caution when mowing and/or turning on slopes as loss of traction and/or tip-over could occur. The operator is responsible for safe operation on slopes.

Safety

DANGER

Operating on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning.

•Do Not mow slopes when grass is wet.

•Do Not mow near drop-offs or near water.

•Do Not mow slopes greater than 15 degrees.

•Reduce speed and use extreme caution on slopes.

•Avoid sudden turns or rapid speed changes.

•See inside the back cover to determine the approximate slope angle of the area to be mowed.

•Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep banks or water. (Figure 3).

Figure 3
1. Safe Zone-Use the	3. Water
mower here on slopes
less than 15 degrees

2.Danger Zone-Use a walk behind mower and/or hand trimmer near drop-offs and water.

•Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing area. Tall grass can hide obstacles.

•Watch for ditches, holes, rocks, dips and rises that change the operating angle, as rough terrain could overturn the machine.

•Avoid sudden starts when mowing uphill because the 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 and steering.

•Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope.

•Follow the manufacturer’s recommendations for wheel weights or counter weights to improve stability.

•Use extreme care with grass catchers or attachments. These can change the stability of the machine and cause loss of control.

Using the Rollover Protection System (ROPS)

A Rollover Protection System (roll bar) is installed on the unit.

WARNING

There is no rollover protection when the roll bar is down. Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning.

•Keep the roll bar in the raised and locked position and use seat belt.

•Lower the roll bar only when absolutely necessary.

•Do Not wear seat belt when the roll bar is down.

•Drive slowly and carefully.

•Raise the roll bar as soon as clearance permits.

•Check carefully for overhead clearances (i.e. branches, doorways, and electrical wires) before driving under any objects and do not contact them.

Safety

Maintenance and Storage

•Disengage drives, lower implement, set parking brake, stop engine and remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing.

•Keep engine, engine area, and pump drive belt compartment free from accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas. These materials can become combustible and may result in a fire.

•Let engine cool before storing and do not store near flame or any enclosed area where open pilot lights or heat appliances are present.

•Shut off fuel while storing or transporting. Do Not store fuel near flames or drain indoors.

•Park machine on level ground. Never allow untrained personnel to service machine.

•Use jack stands to support components when required.

•Carefully release pressure from components with stored energy.

•Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

•Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

•Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

•Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

•Keep all guards, shields and all safety devices in place and in safe working condition.

•Check all bolts frequently to maintain proper tightness.

•Frequently check for worn or deteriorating components that could create a hazard.

•All replacement parts must be the same as or equivalent to the parts supplied as original equipment.

WARNING

Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.

•Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

•Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid.

•Use cardboard or paper, not your hands, to find hydraulic leaks.

•Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system.

Safety

Safety and Instructional Decals

•Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels.

•Replace all worn, damaged, or missing safety signs.

•When replacement components are installed, be sure that current safety signs are affixed to the replaced components.

•If an attachment or accessory has been installed, make sure current safety signs are visible.

•New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg. Co. Inc.

•Safety signs may be affixed by peeling off the backing to expose the adhesive surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.

•Familiarize yourself with the following safety signs and instruction labels. They are critical to the safe operation of your Exmark commercial mower.

1-303508

1-523552

1-403005

1-513742

1–653147

1-513748

Safety

98-5954

103–2076

103–4930

103–2644

103–6340

103–4892

Safety

107-2102

107-2112

109-0872

109–1196

109–1224

Safety

109-3148

109–7949

109–1399

103–4891

108–5995

1. Fast	2. Slow	3. Neutral	4. Reverse

Specifications

Model Numbers

Serial Nos: 720,000 and Higher

LHP19KA465; LHP19KA465CA; LHP23KA465; LHP23KA505; LHP23KA565; LHP27KC505; LHP27KC505R; LHP27KC565

Systems

Engine

•Engine Specifications: See your Engine Owner’s Manual

•RPM: Full Speed: 3600 ±50 RPM (No Load) Idle: 1500 RPM

Fuel System

•Capacity: 11.2 gal. (42.0 L)

•Type of Fuel: Regular unleaded gasoline, 87 octane or higher.

•Fuel Filter:

–Kohler:

In-line 15 Micron Kohler P/N 2405010.

–Kawasaki:

In-line Kawasaki P/N 49019–7001

•Fuel Shut-Off Valve: 1/4 turn increments (“ON”, “OFF”)

•Fuel gauge in left hand fuel tank.

Electrical System

•Charging System: Flywheel Alternator

•Charging Capacity: 15 amps

•Battery Type: BCI Group U1

•Battery Voltage: 12 Volt

•Polarity: Negative Ground

•Fuses: Two 20 amp blade type

Safety Interlock System

•PTO must 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 is engaged.

Operator Controls

•Steering and Motion Control:

Note: Motion control levers are adjustable to two heights.

–Separate levers, on each side of the console, control speed and direction of travel of the respective drive wheels.

–Steering is controlled by varying the position of the levers relative to each other.

–Moving motion control levers outward (in slots) locks the drive system in neutral.

•PTO Engagement Switch: Engages electric clutch (to drive belt) which engages mower blades.

•Parking Brake Lever: Engages parking brake.

•Deck Height Adjustment Lever: Sets cutting height to desired position.

•Deck Lift Assist Lever: Foot pedal that assists in raising the deck.

Seat

•Type: Standard seat with high back, foam padded (internal suspension) and armrests.

Optional seat accessories:

–Custom ride suspension system to enhance Standard Seat.

–Deluxe suspension seat with high back, low profile foam-in-place cushion (dampened, adjustable spring suspension) and armrests.

Specifications

•Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other components. Held in tilted position with prop rod. Adjustable fore and aft seat track.

•Armrests:

–Standard seat: foam padded flip-up armrests.

–Optional suspension seat: molded adjustable flip-up armrests.

•Seat Safety Switch: Incorporated into the Safety Interlock System. Time delay seat switch eliminates rough ground cut-outs.

Hydrostatic Ground Drive System

•Hydrostatic Pumps: Two Hydro Gear variable displacement piston pumps.

•Wheel Motors: Two Parker with 1 1/4 inch tapered shafts.

•Hydraulic Oil Type: Use Mobil 1 15W-50 Synthetic motor oil.

•Hydraulic Oil Capacity: 2.1 qt. (2.0 L)

•Hydraulic Filter: Replaceable cartridge type.

–Summer use above 32°F (0°C)

P/N 109-4180: 25 microns, 10 psi bypass

–Winter use below 32°F (0°C)

P/N 1-523541: 40 microns, 18 psi bypass

•Speeds:

–0-9.5 mph (15.3 km/hr) forward.

–0-5.5 mph (8.9 km/hr) reverse.

•Drive wheel release valves allow machine to be moved when engine is not running.

Tires & Wheels

Drive

	Pneumatic (Air-Filled)

Model Number	LHP19KA465*;	LHP19KA465**
	LHP19KA465CA;
	LHP23KA465;
	LHP23KA505;
	LHP23KA565;
	LHP27KC505;
	LHP27KC505R;
	LHP27KC565
Quantity	2	2

Tread	“Multi Trac C/S”	Turf Master
Size	24 x 9.50-12	23 x 9.50-12

Ply Rating	4	4

Pressure	13 psi (90 kPa)	13 psi (90 kPa)
Front Caster

	Semi-Pneumatic	Pneumatic
		(Air-Filled)
Model Number	LHP19KA465*;	LHP19KA465**
	LHP19KA465CA;
	LHP23KA465;
	LHP23KA505;
	LHP23KA565;
	LHP27KC505;
	LHP27KC505R;
	LHP27KC565
Quantity	2	2

Tread	Smooth	Smooth

Size	13 x 5.00-6	13 x 5.00-6

Ply Rating		4
Pressure		13 psi (90 kPa)

*For serial numbers 739052 and Lower **For serial numbers 739053 and Higher

Cutting Deck

•Cutting Width:

–46 inch Deck: 46 inches (116.8 cm)

–50 inch Deck: 50 inches (127.0 cm)

–56 inch Deck: 56 inches (142.2 cm)

•Discharge: Side

•Blade Size: (3 ea.)

+ 33 hidden pages