Exmark STARIS E Series Operator's Manual


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Exmark STARIS E Series Operator's Manual | Manualzz

STARIS

®

E-SERIES

For Serial Nos.

406,294,345 & Higher

Part No. 4504-758 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.

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of

California to cause cancer and reproductive harm. Wash hands after handling.

Use of this product may cause exposure to chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

Important:

It is a violation of California Public

Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire.

To acquire a spark arrester for your unit, see your

Engine Service Dealer.

For all models that do not have Exmark engines, please refer to the engine manufacturer's information included with the machine.

For models with Exmark engines, refer to this manual for information.

The gross or net horsepower (or torque) of this engine was laboratory rated by the engine manufacturer in accordance with the Society of Automotive Engineers (SAE) J1940 or J2723.

As configured to meet safety, emission, and operating requirements, the actual engine horsepower (or torque) on this class of mower will be significantly lower.

©2019 Exmark Mfg. Co., Inc.

2101 Ashland Ave

Beatrice, NE 68310

2

Contact us at www.Exmark.com.

Printed in the USA

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.

Important:

To maximize safety, performance, and proper operation of this machine, it is essential that all operators carefully read and fully understand the contents of the Operator’s manual provided with the product. Safe operation of Exmark equipment is essential.

Failure to comply with the operating instructions or receive proper training may result in injury.

Go to https://www.Exmark.com for additional safe operation information, such as safety tips, training materials, and Operator’s manuals.

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.

For complete warranty details, see https://www.Exmark.com. You may also call us 402-223-6375 to request a written copy of the product’s warranty.

g303949

3

Contents

Introduction ........................................................... 3

Safety ..................................................................... 5

Safety Alert Symbol ......................................... 5

General Safety ................................................. 5

Safety and Instructional Decals ....................... 6

Specifications ........................................................11

Systems ..........................................................11

Dimensions....................................................12

Torque Requirements .....................................12

Product Overview .................................................13

Operation ..............................................................14

Controls .........................................................14

Before Operation ...........................................16

Pre-Start.........................................................16

During Operation Safety.................................18

Operating Instructions ...................................19

After Operation..............................................24

Transporting ..................................................25

Maintenance ..........................................................26

Maintenance Safety.............................................26

Recommended Maintenance Schedule(s) ............27

Periodic Maintenance ........................................28

Check Engine Oil Level ..................................28

Check Mower Blades ......................................30

Check Safety Interlock System ........................32

Check for Loose Hardware .............................34

Service Air Cleaner .........................................34

Change Engine Oil .........................................34

Check Hydraulic Oil Level ..............................34

Check Tire Pressures ......................................35

Check Condition Of Belts...............................35

Lubricate Grease Fittings................................35

Check Spark Plugs ..........................................35

Change Hydraulic System Filter and

Fluid ..........................................................36

Wheel Hub Nut Torque Specification..............37

Check Spark Arrester (if equipped)..................37

Thread Locking Adhesives..............................38

Mobil HTS Grease (Or Food-Grade

Anti-seize)..................................................38

Copper-Based Anti-seize ................................38

Dielectric Grease............................................38

Adjustments ......................................................39

Deck Leveling ................................................39

Pump Drive Belt Tension................................39

Mower Deck Drive Belt Tension .....................40

Park Brake Adjustment ...................................40

Motion Control Tracking Adjustment .............40

Adjust Motion Control Handle

Position......................................................41

Cleaning ............................................................42

Clean Debris From Machine ...........................42

Clean Engine and Exhaust System

Area ...........................................................42

Remove Engine Shroud Access Panels and

Clean Cooling Fins .....................................42

Clean Grass Build-Up Under Deck .................42

Waste Disposal ...............................................42

Troubleshooting ....................................................44

Schematics ............................................................47

California Proposition 65 Warning

Information ...............................................49

4

Safety

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

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

: Indicates an imminently hazardous situation which, if not avoided,

Will

result in death or serious injury.

WARNING

: Indicates a potentially hazardous situation which, if not avoided,

Could

result in death or serious injury.

CAUTION

: 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.

g000502 be trained. If the operator(s) or mechanic(s) can not read this manual, it is the owner’s responsibility to explain this material to them; other languages may be available on our website.

• Only allow trained, responsible, and physically capable operators that are familiar with the safe operation, operator controls, and safety signs and instructions to operate the machine. Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

• Do Not operate the machine near drop-offs, ditches, embankments, water, or other hazards.

• Do Not put your hands or feet near moving components of the machine.

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

• Stop the machine, shut off the engine, and remove the key before servicing, fueling, or unclogging the machine.

General Safety

This machine is capable of amputating hands and feet and of throwing objects. Exmark designed and tested this lawn mower to offer reasonably safe service; however, failure to comply with safety instructions may result in injury or death.

• Read, understand, and follow all instructions and warnings in the Operator’s Manual and other training material, on the machine, engine, and attachments. All operators and mechanics should

5

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.

decal98-1977

98-1977

1.

Entanglement hazard, belt—stay away from moving parts.

106-5517

1.

Warning—do not touch the hot surface.

decal106-5517

1.

Parking brake—disengaged decal115-9625

115-9625

2.

Parking brake—engaged decal112-9028

112-9028

1.

Warning—stay away from moving parts; keep all guards in place.

3.

Parking brake

116-7912

1.

Interval

2.

Power Take-off (PTO)

4.

Neutral

5.

Operator presence control

6.

Battery decal116-7912

6

Safety

decal116-8253

116-8253

1.

Rotate counterclockwise to release.

3.

Unlock to push machine.

2.

Rotate clockwise to lock.

4.

Read the instructions before servicing or performing maintenance.

decal126-2056

126-2056

1.

Wheel lug nut torque 95 ft-lb (129 N-m) (4x)

2.

Wheel hub nut torque 125 ft-lb (169 N-m)

3.

Read and understand the Operator’s manual before performing any maintenance, check torque after first

100 hours then every 500 hours thereafter.

decal133-8062

133-8062

decal116-8283

116-8283

1.

Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 55-60 ft-lb (75-81 N-m).

135-2267

Drive Pump Belt Routing decal135-2267 decal116-8559

116-8559

1.

Warning–stay away from moving parts; keep all guards in place.

decal135-2562

135-2562

1.

Read Operator’s Manual.

2.

Remove the ignition key and read the instructions before servicing or performing maintenance.

3.

Height of cut

7

Safety

decal135-2563

135-2563

1.

Read the instructions before servicing or performing maintenance

2.

Time interval

3.

Check oil level

4.

Refer to the Operator's manual for grease instructions

5.

Check hydraulic oil level and refer to the Operator's manual or further instructions

6.

Check tire pressure decal135-5210

135-5210

1.

Thrown objects hazard - keep bystanders away.

2.

Thrown objects hazard, mower - do not operate without the deflector, discharge cover or grass collection system in place.

3.

Cutting/dismemberment of hand or foot - stay away from moving parts; keep all guards and shields in place.

1.

Read the Operator’s manual

135-6844

2.

Only use Exmark

10W-50 engine oil decal135-6844

135-3004

decal135-3004

136-1672

1.

Warning-Do Not step; no riders.

Lock Symbol

decal136-1672 g224590

8

Safety

decal142-3077

1.

Read the Operator’s manual.

2.

Hydraulic fluid

142-3077

4.

Do Not overfill

5.

Warning-Do Not touch the hot surface.

3.

Correct fill level when cold decal135-2412

135-2412

1.

Warning-Read the Operator’s Manual. Do Not operate this machine unless you are trained. Wear hearing protection.

2.

Warning-Stay away from moving parts; keep all guards in place. Stop engine and remove key before adjusting, servicing, or cleaning.

3.

Warning-Disengage PTO, move drive levers out to neutral lock position, engage parking brake, and stop engine before leaving the operator’s position.

4.

Thrown object hazard-Pick up objects that could be thrown by mower. Keep bystanders away. Keep deflector in place.

5.

Cutting/dismemberment hazard-Mow across slopes not up and down. Do Not mow wet slopes–use extreme caution when operating on slopes.

6.

Crushing/dismemberment hazard of bystanders - Do Not carry passengers, look forward and down when operating the machine, look behind and down when reversing.

9

Safety

1.

Forward

2.

Neutral

3.

Reverse

4.

Choke-on

135-6773

5.

Choke-off

6.

Throttle-fast

7.

Continuous variable setting

8.

Throttle-slow

9.

Engine-off

10.

Engine-on

11.

Engine-start

12.

Optional light accessory decal135-6773

10

Specifications

Specifications

Systems

Engine

• Engine Specifications: See your Engine Owner’s

Manual

• Engine Oil Type: Exmark 10W-50 Premium

Engine Oil

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

Fuel System

• Capacity: 5.0 gal. (19 L)

• Fuel Recommendations:

– For best results, use only clean, fresh, unleaded gasoline with an octane rating of 87 or higher

((R+M)/2 rating method).

– Oxygenated fuel with up to 10% ethanol or

15% MTBE by volume is acceptable.

Do Not

use ethanol blends of gasoline (such as E15 or E85) with more than 10% ethanol by volume. Performance problems and/or engine damage may result which may not be covered under warranty.

Do Not

use gasoline containing methanol.

Do Not

store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used.

Do Not

add oil to gasoline.

• Fuel Filter: Replaceable In-line

• Fuel Shut-Off Valve: 1/4 turn

Electrical System

• Charging System: Flywheel Alternator

• Charging Capacity: Kawasaki: 15 amps

• Battery Type: Exmark 12V Non-Spillable, AGM,

Maintenance Free Battery Part No. 135-4421

• Battery Voltage: 12 Volt

• Polarity: Negative Ground

• Fuses:

– 20 amp charging system fuse

– 15 amp accessory fuse

Safety Interlock System

• LCD indicators appear for the park brake, drive levers, and operator presence in the message display on the front control panel.

Note:

Because the PTO must be disengaged to start the engine, the LCD indicator will illuminate at this time.

• PTO must be disengaged and motion control levers in neutral to start engine. (It is not necessary for the operator to be on the platform to start the engine.)

• Mower blades will stop if both motion control levers are moved or released into the neutral position.

• Engine will stop if the motion control levers are moved from the neutral position with the park brake engaged.

• The Operator presence and neutral LCD indicators will not appear at the same time.

When the levers are out in the neutral position, the neutral LCD indicator will appear, but the

Operator Presence will not. When either lever is moved inward from the neutral position, the neutral LCD indicator will disappear and the

Operator Presence indicator will appear.

Operator Controls

Steering Control: Fingertip drive control levers provide independent speed control, braking and neutral to each drive wheel for moving forward or reverse, stopping, and power turning.

Transmission

• Two Hydro Gear variable displacement high efficiency pumps independently coupled to two high efficiency Parker/Ross wheel drive motors.

• Hydraulic Oil: Use Exmark Premium Hydro Oil.

• Hydraulic Oil Capacity: 2.4 qt. (2.2 L)

• Hydraulic Filter is replaceable cartridge type.

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

(Summer use above 32°F (0°C))

P/N 1-523541: 40 microns, 18 psi bypass (Winter use below 32°F (0°C))

• Speeds:

– 0-7.5 mph (12 km/hr) forward.

11

Specifications

– 0-3.5 mph (6 km/hr) reverse.

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

Wheel Drive System

Drive wheels are direct coupled to Parker wheel drive motors with 1 inch (25.4 mm) tapered shaft.

Tires & Wheels

Front Caster–All Models

Quantity

Tread

Size

Drive Tires

Semi-

Pneumatic

2

Smooth

9 x 4.50-5

Quantity

Tread

Size

Ply Rating

Pressure

32 Inch Models

Pneumatic

(Air-Filled)

2

Kenda K500

21 x 7.00–10

4

13 psi

(90 kPa)

36 Inch Models

Pneumatic

(Air-Filled)

2

Kenda K500

21 x 8.50–10

4

13 psi

(90 kPa)

Cutting Deck

• Cutting Width:

– 32 inches (81.3 cm)

– 36 inches (91.4 cm)

• Discharge: Side

• Blade Size: (2 ea.):

– 32 Inch Models: 16.25 inches (41.3 cm)

– 36 Inch Models: 18.00 inches (45.7 cm)

• Blade Spindles: Solid steel spindles with 1.00 inch

(25.4 mm) I.D. bearings.

• Deck Drive:

– Electric clutch mounted on engine shaft.

– Blades driven by one belt (w/self-tensioning idlers).

• Deck: Full floating deck is attached to support frame, removable for service. Deck design allows for bagging, mulching or side discharge.

• Deck Depth: 5.0 inches (12.7 cm)

• Cutting Height Adjustment:

Adjusts from 1 inch (2.5 cm) to 5 inches (12.7 cm) in 1/2 inch (12.7 mm) increments

• Mulching Kit: Optional

• Bagger: Optional

Dimensions

Overall Width:

32 Inch Models 36 Inch Models

Deflector Up 33.7 inches (85.6

cm)

Deflector Down 44.9 inches

(114.0 cm)

36.6 inches (93.0

cm)

48.0 inches

(121.9 cm)

Overall Length:

32 and 36 Inch Models

58.1 inches (147.6 cm)

Overall Height:

47.3 inches (120.1 cm)

Tread Width: (Outside to Outside of

Tires, Widthwise)

32 Inch Models

33.2 inches (84.3 cm)

36 Inch Models

36.2 inches (91.9 cm)

Curb Weight:

737 lb (334 kg)

Note:

Weights will vary slightly depending on deck size.

Torque Requirements

Bolt Location

Cutter Housing Spindle

Nut

Blade Mounting Bolt

(lubricate with anti-seize)

Torque

130-160 ft-lb

(176-217 N-m)

50-60 ft-lb (68-81 N-m)

12

Bolt Location

Engine Mounting Bolts

Wheel Lug Nuts

Wheel Hub Nuts

Wheel Motor Mounting

Bolts

Torque

30-35 ft-lb (41-47 N-m)

85-105 ft-lb (115-142

N-m)

115-135 ft-lb

(156-183 N-m)

30-35 ft-lb (41-47 N-m)

Product Overview

Product Overview

1.

Height of cut pins

2.

Park brake lever

Figure 3

3.

Controls

4.

Motion controls g260634

13

Operation

Operation

Note:

Determine the left and right sides of the machine from the normal operating position.

Controls

Note:

Become familiar with all the controls before starting the engine and operating the machine.

Motion Control Levers

The motion control levers, located on each side of the top console, control the forward and reverse motion of the machine.

Moving the levers forward or backward turns the wheel on the same side forward or reverse respectively. Wheel speed is proportional to the amount the lever is moved.

Moving the levers outward, from the center position into the notch, locks them in the neutral position

(see Figure 4).

Choke Control

Located on the LH side of the control console (black

lever) (see Figure 5).

The choke is used to aid in starting a cold engine.

Moving the choke lever forward will put the choke in the “ON” position and moving the choke lever to the rear, to the detent, will put the choke in the “OFF” position. Do Not run a warm engine with choke in the “ON” position.

g260686

Figure 5

1.

Choke

2.

Throttle

3.

Rear reference bar

6.

Front Reference/Speed

Control Bar

7.

RH Motion control lever

8.

PTO engagement switch

4.

LH Motion control lever 9.

Ignition

5.

Message display g224633

Figure 4

1.

Neutral lock position

(handles out)

2.

Neutral operate position

(handles in)

3.

Front of machine

4.

Reverse

5.

Rear reference bar

6.

Front reference/Speed control bar

7.

Forward

8.

Adjustment hole

Note:

When the levers are out in the neutral position, the neutral LCD indicator will appear, but the Operator Presence will not.

Note:

When either lever is moved inward from the neutral position, the neutral LCD indicator will disappear and the Operator Presence indicator will appear.

Throttle Control

Located on the LH side of the control console (red lever).

The throttle is used to control engine speed. Moving the throttle lever forward will increase engine speed and moving the throttle lever to the rear will decrease engine speed. Moving the throttle forward into the detent is full throttle.

Park Brake Lever

Located on the right side of the machine.

The brake lever engages a parking brake on the drive wheels.

Note:

The LCD indicator appears in the message display on the front console when the park brake is

engaged (see Figure 5 and Figure 7).

14

Operation

Pull the lever up and rearward to engage the brake.

Push the lever forward and down to disengage the brake.

When parking on a steep slope, the wheels must be chocked or blocked in addition to the brake being engaged. The machine must be tied down and brake engaged when transporting.

Park brake must be disengaged before moving motion control out of neutral or engine must begin shutdown.

g275343

Ignition Switch

Located on the RH side of the control console.

The ignition switch is used to start and stop the engine. The switch has three positions “OFF”, “ON” and “START”. Insert key into switch and rotate clockwise to the “ON” position. Rotate clockwise to the next position to engage the starter (key must be held against spring pressure in this position). Allow the key to return to the “ON” position immediately after the engine starts.

Figure 7

1.

LCD Indicators

2.

Low voltage indicator light

3.

Hour/Voltage display

The hour meter is recording when the decimal point is flashing in Hour/Voltage display.

Hours are displayed when the key is off or when the machine is running.

Note:

If the ignition key is turned to the “ON” position for a few seconds before cranking the engine, the battery voltage will display in the area where the hours are normally displayed.

Note:

The LCD indicators appear when each control meets the “safe to start” mode.

1.

Off

2.

On

Figure 6

3.

Start g219837

Fuel Shut-Off Valve

Located on the LH side of the machine, towards the rear of the engine.

The fuel shut-off valve is used to shut off the fuel when the machine will not be used for a few days, during transport to and from the jobsite, and when parked inside a building.

Align valve handle with the fuel line to open. Rotate

90° to close.

Note:

To start the engine, place the motion control levers in neutral and disengage the PTO switch (it is not necessary for the operator to be on the platform).

Hour Meter

Located in the center of the front control console in

the message display (see Figure 7).

The hour meter records the number of hours that the engine has run.

Drive Wheel Release Valves

Located on the right rear corner of the hydrostatic pumps.

Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be moved by hand without the engine running.

With a 5/8 wrench, turn both valves one turn counterclockwise to release the drive system.

15

Operation

Turn clockwise to reset the drive system. Torque to

110-130 in-lb (12-15 N-m).

Do Not overtighten.

Do Not tow machine.

PTO Engagement Switch

Located in the center of the console control below

the hour meter (reference Figure 5).

Switch must be pulled out (up) to engage the blades.

Switch is pushed in to disengage the blades.

The LCD indicator will disappear when the PTO

switch is engaged (see Figure 7).

Before Operation

functioning properly. Do Not operate unless they are functioning properly.

• Do Not operate the mower when people, especially children, or pets are in the area. Stop the machine and attachment(s) if anyone enters the area.

• Do Not operate the machine without the entire grass collection system, discharge deflector, or other safety devices in place and in proper working condition. Grass catcher components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check for worn or deteriorating components and replace them with the manufacturer’s recommended parts when necessary.

Before Operation Safety

• 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.

• Always shut off the engine, and remove the key. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning, storing, or repairing it.

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

• Wear appropriate personal protective equipment such as safety glasses, substantial slip-resistant footwear, and hearing protection. Tie back long hair and avoid loose clothing and loose jewelry which 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.

• Check that the operator presence controls, safety switches, and shields are attached and

Pre-Start

Fill fuel tank on level ground. See

Fuel

Recommendations

in the Specifications section for additional gasoline information.

Do Not

add oil to gasoline.

Do Not

overfill fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows gasoline to expand. Overfilling may result in fuel leakage or damage to the engine or emission system.

Make sure you understand the controls, their locations, their functions, and their safety requirements.

Refer to the Maintenance section and perform all the necessary inspection and maintenance steps.

Fuel Safety

Use extreme care when handling fuel.

16

Operation

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 on level ground, 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. Fill the fuel tank to the bottom of the filler neck.

The empty space in the tank allows gasoline to expand. Overfilling may result in fuel leakage or damage to the engine or emission system.

• 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. Do Not use a nozzle lock open device.

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.

To help prevent fires:

• Keep engine and engine area free from accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas.

• Clean up oil and fuel spills and remove fuel soaked debris.

• Allow the machine to cool before storing the machine in any enclosure. Do Not store near

17

Operation

flame or any enclosed area where open pilot lights or heat appliances are present.

During Operation Safety

General Safety

The operator must use their full attention when operating the machine.

Do Not

engage in any activity that causes distractions; otherwise, injury or property damage may occur.

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.

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.

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

• This mower was designed for one operator only.

Do not carry passengers and keep all others away from machine during operation.

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

• Operate only in daylight or good artificial light.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area,

Do Not operate the machine; seek shelter.

• Use extra care while operating with accessories or attachments, such as grass collection systems.

These can change the stability of the machine and cause a loss of control. Follow directions for counter weights if required.

• Keep away from holes, ruts, bumps, rocks, and other hidden hazards. Use care when approaching blind corners, shrubs, trees, tall grass or other objects that may hide obstacles or obscure vision.

Uneven terrain could overturn the machine or cause the operator to lose their balance or footing.

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

• Start the engine carefully according to instructions with feet well away from the blades.

• 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.

• Keep clear of the discharge opening at all times. Never mow with the discharge door raised, removed or altered unless there is a grass collection system or mulch kit in place and working properly.

• Keep hands and feet away from moving parts.

If possible, Do Not make adjustments with the engine running.

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 raise the deck with blades running.

• Be aware of the mower discharge path and direct discharge away from others. Avoid discharging material against a wall or obstruction as the material may ricochet back toward the operator.

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 alert, slow down and use caution when making turns. Look behind and to the side before changing directions. Do Not mow in reverse unless absolutely necessary.

18

Operation

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

• Park the machine on level ground. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s).

– 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. Do Not leave a running machine unattended.

• Stop engine, wait for all moving parts to stop:

– Before refueling.

– Before dumping the grass catcher.

– Before making height adjustments.

• Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.

– Keep children out of the mowing area and under the watchful care of another responsible adult, not the operator.

– Be alert and turn the machine off if children enter the area.

– Before and while backing or changing direction, look behind, down, and side-to-side for small children.

– Never allow children to operate the machine.

– Do Not carry children, even with the blades shut off. Children could fall off and be seriously injured or interfere with the safe operation of the machine. Children that have been given rides in the past could suddenly appear in the working area for another ride and be run over or backed over by the machine.

– Review and understand the slope instructions in the manual and on the machine

– Evaluate the site conditions of the day to determine if the slope is safe for machine operation. Use common sense and good judgment when performing this evaluation.

Changes in the terrain, such as moisture, can quickly affect the operation of the machine on a slope.

• Operate across slopes, never up and down. Avoid operation on excessively steep or wet slopes. Poor footing could cause a slip and fall accident.

• Identify hazards at the base of the slope. Do not operate the machine near drop offs, ditches, embankments, water or other hazards. The machine could suddenly roll over if a wheel goes over the edge or the edge collapses. Keep a safe distance between the machine and any hazard.

Use a hand held tool to operate in these areas.

• Avoid starting, stopping or turning the machine on slopes. Avoid making sudden changes in speed or direction; turn slowly and gradually.

• Do not operate a machine under any conditions where traction, steering or stability is in question.

Be aware that operating the machine on wet grass, across slopes or downhill may cause the machine to lose traction. Loss of traction to the drive wheels may result in sliding and a loss of braking and steering. The machine can slide even if the drive wheels are stopped.

• Remove or mark obstacles such as ditches, holes, ruts, bumps, rocks or other hidden hazards. Tall grass can hide obstacles. Uneven terrain could overturn the machine.

• If you lose control of the machine, step away from the direction of travel of the machine.

• Always keep the machine in gear when going down slopes. Do not coast downhill.

Operating Instructions

Slope Safety

• Slopes are a major factor related to loss of control and rollover accidents, which can result in severe injury or death. The operator is responsible for safe slope operation. Operating the machine on any slope requires extra caution. Before using the machine on a slope, the operator must:

Open the Fuel Shut-Off Valve

Rotate the valve and align with the fuel line to open.

Starting the Engine

1.

Move the motion control levers out to the neutral lock position.

19

Operation

2.

Pull the parking brake up and rearward to engage the parking brake.

3.

Push down on the PTO switch to the “disengage” position.

4.

Place the throttle midway between the “SLOW” and “FAST” positions.

5.

On a cold engine, push the choke lever forward into the “ON” position.

On a warm engine, leave the choke in the “OFF” position.

6.

Turn ignition switch to the “START” position.

Release the switch as soon as the engine starts.

Important:

Do Not crank the engine continuously for more than ten seconds at a time. If the engine does not start, allow a 60 second cool-down period between starting attempts. Failure to follow these guidelines can burn out the starter motor.

7.

If the choke is in the “ON” position, gradually return choke to the “OFF” position as the engine warms up.

PTO Engagement

DANGER

The rotating blades under the mower deck are dangerous. Blade contact can cause serious injury or kill you.

Do Not put hands or feet under the mower or mower deck when the blades are engaged.

DANGER

An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also, contact with the blade could occur. Thrown objects or blade contact can cause serious injury or death.

2.

Release the parking brake.

3.

Move the motion control levers to the center, operate position.

4.

Pull the PTO switch outward to engage the blades.

5.

Place the throttle in the “FAST” position to begin mowing.

Disengaging the PTO

1.

Set the throttle midway between the “SLOW” and

“FAST” positions.

2.

Push down on the PTO switch to disengage the blades.

Stopping the Engine

1.

Bring the unit to a full stop.

2.

Move the motion control levers out to the neutral lock position.

3.

Place the throttle midway between the “SLOW” and “FAST” positions.

4.

Push down on the PTO switch to disengage the blades.

5.

Engage the parking brake.

6.

Allow the engine to run for a minimum of 15 seconds, then turn the ignition switch to the

“OFF” position to stop the engine.

7.

Remove the key to prevent children or other unauthorized persons from starting engine.

8.

Close the fuel shut-off valve when the machine will not be in use for a few days, when transporting, or when the unit is parked inside a building.

Driving the Machine

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

The PTO switch engages the cutting blades. Be sure all persons are clear of mower deck and discharge area before engaging the PTO.

1.

Set throttle to “MIDWAY” position.

CAUTION

Machine can spin very rapidly by positioning one lever too much ahead of the other. Operator may lose control of the machine, which may cause damage to the machine or injury.

• Use caution when making turns.

• Slow the machine down before making sharp turns.

Important:

To begin movement (forward or backward), the brake lever must be disengaged

20

Operation

(pushed forward) before the motion control levers can be moved or the engine will stop.

When the motion control levers are positioned fully outward (apart), the drive system is in the PTO

disengage position (Figure 8).

Note:

The “N” LCD indicator appears when both levers are in the neutral lock position.

When the motion control levers are moved directly inward (together) the drive system is in the neutral operate position.

g014656

Figure 9

g224633

Figure 8

1.

Neutral lock position

(handles out)

2.

Neutral operate position

(handles in)

3.

Front of machine

4.

Reverse

5.

Rear reference bar

6.

Front reference/Speed control bar

7.

Forward

8.

Front reference bar adjustment hole

To turn left or right, pull the motion control lever back toward neutral in the desired turn direction.

The machine will move faster the farther the motion control levers are moved from the neutral position.

4.

To stop, position both motion control levers in the neutral operate position.

Driving Forward

1.

Make sure the motion control levers are in the neutral position.

2.

Release the parking brake.

3.

To move forward in a straight line, move both levers forward with equal pressure.

Driving in Reverse

1.

Move the motion control levers to the neutral operate position.

2.

To move rearward in a straight line, slowly move both levers rearward with equal pressure.

21

Operation

The cutting height of the mower deck is adjusted from 1 to 5 inches (25 mm to 127 mm) in 1/2 inch increments.

Figure 10

To turn left or right, release pressure on the motion control lever toward the desired turn direction.

3.

To stop, position both motion control levers in the neutral operate position.

g014657

Note:

Mowing for extended periods of time at 1 inch height of cut may result in reduced deck belt life due to increased belt operating angle.

1.

Stop the machine and move the drive levers to the neutral locked position.

2.

Disengage the PTO.

3.

Engage the park brake.

4.

Stop the engine, remove the key and wait for all moving parts to stop.

5.

Lift the cutting deck using the handle as shown in

Figure 11(handle position varies with deck size)

to the highest position possible. Engage deck height change assist lever by rotating forward until

contact with the deck support rod (see Figure 11).

While the lever is manually engaged, lower the deck to rest on the lever.

Adjusting the Front Reference Bar

1.

Insert a 7/32 inch allen wrench through the hole on one side of the control tower panel. Place a 9/16 inch wrench on the corresponding nut located underneath the control tower. Loosen the bolt and repeat for the opposite side of the front

reference bar (see Figure 8).

2.

Rotate the bar forward or rearward, limiting the forward travel of the control levers until desired maximum forward speed is achieved.

3.

Tighten bolts to lock reference bar in place.

1.

Deck height change assist lever

Figure 11

2.

Handle g303934

Adjusting the Cutting Height

WARNING

When the two front support rod hairpins are removed from the mower deck, the weight of the tractor section may cause the front frame of the machine to rise suddenly. If the machine rises suddenly, injury may occur.

Securely hold down the front of the machine when raising the mower deck for hairpin repositioning.

6.

Install hairpin clips in the holes for the desired

cutting height. See Figure 12.

Important:

To maintain correct cutting height and rake, check the following for proper adjustment.

A.

The front and rear hairpins are in the same holes with the proper spacers under the hair

pins. See Figure 12.

Note:

All deck pins have a groove at the 3 inch (76 mm) cut height for ease of identification.

22

Operation

g224810

1.

Deck support pin

Figure 12

2.

Cutting Height

B.

Check tire pressure in drive tires and inflate to

12-14 psi (83-97 kPa) if necessary.

Measure the circumference of each drive tire.

Adjust tire pressures within the above range to try to make tire circumferences match as closely as possible.

C.

The length of the rear deck support link assemblies average 6.38 inches (162 mm) from the center of the balljoint to the center of the

farthest hole; see Figure 13.

Note:

All four pins must equally support the weight of the deck. Adjustment in the length of the rear deck support assemblies may be necessary. If one side is longer than 6.38

inches (162 mm), than the opposite side must be shorter by the same amount.

Figure 13

Left Hand Side Shown

1.

3/8 inch (9.5 mm)

2.

1/4 inch (6.4 mm)

3.

6.38 inches (162 mm)

4.

Deck support rod g303985

7.

Repeat steps 5 and 6 for the opposite side.

8.

Lift deck to unlatch (Figure 14 ).

Note:

Deck height change assist levers are not intended to be used as cut height positions.

During operation, vibration and jerky movements could lift the cutting deck enough to allow disengagement of levers. This will result in sudden drop of the cutting deck, causing possible damage. Levers can be used to hold the deck up for loading and unloading from a trailer.

23

Operation

1.

Deck height change assist lever

Figure 14

2.

Handle g303981 g224809

Figure 15

For cutting heights above 3.5 inches (38 mm) use the bottom hole. The rollers will still be effective against scalping.

1.

Anti-scalp roller mounting bracket

2.

Cutting height

Adjusting the Anti-Scalp Rollers

It is recommended to change the anti-scalp roller position when the height of cut has changed.

1.

Stop the machine and move the drive levers to the neutral lock position.

2.

Disengage the PTO.

3.

Engage the park brake.

4.

Stop the engine, remove the key and wait for all moving parts to stop.

5.

After adjusting the height of cut, adjust the anti-scalp rollers by removing the nyloc nut, spring disc washer, axle roller, and bolt.

6.

Adjust anti-scalp rollers for normal operating conditions. Place rollers in one of the positions

shown in Figure 15. Rollers will maintain 3/4

inches (19 mm) clearance to the ground to minimize gouging and roller wear or damage.

Note:

For Maximum Deck Flotation

, place rollers one hole position lower. Rollers should maintain 1/4 inch (6.35 mm) clearance to ground.

Do Not adjust rollers to support the deck.

Note:

Roller may need to be removed when mowing at 1 inch (25 mm).

7.

Be sure roller bolts are installed with the spring disc washer between head of the bolt and mounting bracket.

8.

Torque the 3/8-16 nyloc nut to 50–55 ft-lb (68-75

N-m) (Figure 16).

g304045

1.

Anti-scalp roller

Figure 16

2.

3/8 nyloc-torque to

50–55 ft-lb (68-75 N-m)

3.

Axle roller

4.

3/8-16 x 3 3/4 Grade 8 bolt

5.

Spring disc washer

(cone towards bolt)

After Operation

General Safety

• Park machine on level ground, disengage drives, set parking brake, stop engine, remove key or disconnect spark plug wire. Wait for all movement

24

Operation

to stop and allow the machine to cool before adjusting, cleaning, repairing, or storing. Never allow untrained personnel to service machine.

• Clean the machine as stated in the Maintenance section. Keep engine and engine area 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.

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

Transporting

Transporting the Machine

Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law.

Thoroughly read all of the safety instructions.

Knowing this information could help you, your family, pets, or bystanders avoid injury.

To transport the machine:

• Use full width ramps when loading the machine.

• Be sure the fuel shut-off valve is closed.

• Engage the park brake, then block the wheels. Do

Not rely solely on the parking brake to hold the machine on the trailer.

• Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. If possible, both front and rear straps should be directed down and outward from the machine.

• Secure a trailer to the towing vehicle with safety chains.

WARNING

Driving on the street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury.

Do not drive machine on a public street or roadway.

Loading the Machine

Use extreme caution when loading machines 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 machine. A full width ramp provides a surface to walk on behind the machine. If it is not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp.

A steep ramp angle may cause components to get caught as the machine moves from ramp to trailer or truck. Steeper angles may also cause the machine to tip backward. If loading on or near a slope, position the trailer or truck so it is on the down side of the slope and the ramps extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible.

Important:

Do Not attempt to turn the machine while on the ramp, you may lose control and drive off the side.

Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp. Both maneuvers can cause the machine to tip backward.

WARNING

Loading a machine on a trailer or truck increases the possibility of backward tip-over. Backward tip-over could cause serious injury or death.

• Use extreme caution when operating a machine on a ramp.

• Use only a single, full width ramp; Do Not use individual ramps for each side of the machine.

• If individual ramps must be used, use enough ramps to create an unbroken ramp surface wider than the machine.

• Avoid sudden acceleration while driving machine up a ramp to avoid tipping backward.

• Avoid sudden deceleration while backing machine down a ramp to avoid tipping backward.

25

Maintenance

Maintenance

Note:

Determine the left and right sides of the machine from the normal operating position.

Maintenance Safety

WARNING

While maintenance or adjustments are being made, someone could start the engine.

Accidental starting of the engine could seriously injure you or other bystanders.

Remove the key from the ignition switch, engage parking brake, and pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).

WARNING

Removal or modification of original equipment, parts and/or accessories may alter the warranty, controllability, and safety of the machine. Unauthorized modifications to the original equipment or failure to use original Exmark parts could lead to serious injury or death. Unauthorized changes to the machine, engine, fuel or venting system, may violate applicable safety standards such as:

ANSI, OSHA and NFPA and/or government regulations such as EPA and CARB.

WARNING

The engine can become very hot. Touching a hot engine can cause severe burns.

Allow the engine to cool completely before service or making repairs around the engine area.

• Park machine on level ground, disengage drives, set parking brake, stop engine, remove key or disconnect spark plug wire. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning or repairing. Never allow untrained personnel to service machine.

• 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.

• Keep the machine, guards, shields and all safety devices in place and in safe working condition. Frequently check for worn or deteriorating components and replace them with the manufacturer’s recommended parts when necessary.

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.

• If equipped, 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.

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

• Use jack stands to support the machine and/or components when required.

26

Maintenance

CAUTION

Raising the machine for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the machine to fall, which could cause injury.

Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

• Carefully release pressure from components with stored energy.

• Keep hands and feet away from moving parts.

If possible, Do Not make adjustments with the engine running. If the maintenance or adjustment procedure requires the engine to be running and components moving, use extreme caution.

WARNING

Contact with moving parts or hot surfaces may cause personal injury.

Keep your fingers, hands, and clothing clear of rotating components and hot surfaces.

• Check all bolts frequently to maintain proper tightness.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the first 5 hours

After the first 100 hours

After the first 250 hours

Before each use or daily

Every 25 hours

Every 50 hours

Every 80 hours

Every 100 hours

Every 160 hours

Every 200 hours

Every 500 hours

Yearly

Maintenance Procedure

• Change the engine oil.

• Check the wheel hub torque specification.

• Check the wheel lug nuts.

• Change the hydraulic filter and fluid.

• Check the engine oil level.

• Check the mower blades.

• Check the safety interlock system.

• Check for loose hardware.

• Clean the grass and debris build-up from the machine and cutting deck.

• Clean the engine and exhaust system area.

• Clean the grass build-up from under the deck.

• Service the foam element. (May need more often under severe conditions. See the Engine

Owner's manual for additional information.)

• Check the hydraulic oil level.

• Check the tire pressures.

• Check the condition of the belts.

• Check spark arrester (if equipped).

• Remove engine shrouds and clean cooling fins.

• Service the paper element. (May need more often under severe conditions. See the Engine

Owner's manual for additional information.)

• Change the engine oil. (May need more often under severe conditions.)

• Check the spark plugs.

• Replace the paper element.

• Change the hydraulic filter and fluid (Every 250 hours/Yearly if using Mobil 1 15W50)

• Check the wheel hub torque specification.

• Check the wheel lug nuts.

• Grease the deck belt idler pivot.

27

Maintenance

Periodic Maintenance

Lift the Thigh Pad for Rear

Access

Service Interval: As required

The pad can be locked open to allow access to the hydro oil, pumps, ground drive belt, rotating screen, oil dipstick, and the fuel shut-off valves.

1.

Lower the platform.

2.

Lift the thigh pad all the way up. The pad will lock in the “up” position.

g271490

1.

Rear guard

Figure 18

2.

Slot

1.

Thigh pad

2.

Wireform

Figure 17

3.

Released position

4.

Locked position g271810

Installing the Rear Guard

Service Interval: As required

To reinstall the rear guard, insert the three tabs into

the slots in the bottom of the frame (see Figure 18).

Push the guard forward and snap over the brake shaft.

3.

Perform any maintenance or adjustment on the machine.

4.

Lift up on the wireform on the right side under the pad and lower the pad.

Removing the Rear Guard

Service Interval: As required

1.

Raise and lock the thigh pad.

2.

Grab the top of the rear guard and pull rearward.

3.

The top of the rear guard will pop loose from the brake shaft. Lift the guard from the slots in the frame and remove.

Check Engine Oil Level

Service Interval: Before each use or daily

1.

Stop engine and wait for all moving parts to stop.

Make sure unit is on a level surface.

2.

Check with engine cold.

3.

Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick according to the engine manufacturer's recommendations.

Remove the dipstick and read the oil level.

4.

If the oil level is low, wipe off the area around the oil fill cap, remove cap and fill to the “FULL” mark on the dipstick. Exmark 4-Cycle Premium

Engine Oil is recommended; refer to the Engine

Owner's manual for an appropriate API rating and viscosity.

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” mark.

28

Maintenance

Check Battery Charge

Service Interval: As required

Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries in storage when the open circuit voltage drops to 12.4

volts.

Note:

To prevent damage due to freezing, battery should be fully charged before putting away for winter storage.

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.

CAUTION

If the ignition is in the “ON” position there is potential for sparks and engagement of components. Sparks could cause an explosion or moving parts could accidentally engage causing personal injury.

Be sure ignition switch is in the “OFF” position before charging the battery.

Check the voltage of the battery with a digital voltmeter or with the message display When the ignition is set to the accessory mode, the module will display the battery voltage. If the voltage is less than

12.4 volts, the battery may need to be charged.

Important:

In order to prevent damage to the battery, use an automatic 12 volt smart charger approved for use with AGM type batteries with an output of 3.5 amps or less. Exmark recommends the use of battery charger P/N 135-7024. Make sure the negative battery cable is disconnected before charging and that the charger is set to the correct mode for 12V AGM batteries.

DANGER

Charging or jump starting the battery may produce explosive gases. Battery gases can explode causing serious injury.

• Keep sparks, flames, or cigarettes away from battery.

• Ventilate when charging or using battery in an enclosed space.

• Make sure venting path of battery is always open once battery is filled with acid.

• Always shield eyes and face from battery.

DANGER

Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns.

Swallowing electrolyte can be fatal or if it touches skin can cause severe burns.

• Wear safety glasses to shield eyes, and rubber gloves to protect skin and clothing when handling electrolyte.

• Do Not swallow electrolyte.

• In the event of an accident, flush with water and call a doctor immediately.

Recommended Jump

Starting Procedure

Service Interval: As required

1.

Check the weak battery for terminal corrosion

(white, green, or blue “snow”), it must be cleaned off prior to jump starting. Clean and tighten connections as necessary.

CAUTION

Corrosion or loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure.

Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine may occur.

DANGER

Jump starting a weak battery that is cracked, frozen, has low electrolyte level, or an open/shorted battery cell, can cause an explosion resulting in serious personal injury.

Do Not jump start a weak battery if these conditions exist.

29

Maintenance

2.

Make sure the booster is a good and fully charged lead acid battery at 12.6 volts or greater. Use properly sized jumper cables (4 to 6 AWG) with short lengths to reduce voltage drop between systems. Make sure the cables are color coded or labeled for the correct polarity.

CAUTION

Connecting the jumper cables incorrectly

(wrong polarity) can immediately damage the electrical system.

g012785

Figure 19

Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries.

Note:

The following instructions are adapted from the SAE J1494 Rev. Dec. 2001 – Battery

Booster Cables – Surface Vehicle Recommended

Practice (SAE – Society of Automotive

Engineers).

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

WARNING

Batteries contain acid and produce explosive gases.

• Shield the eyes and face from the batteries at all times.

• Do Not lean over the batteries.

4.

Connect the other end of the positive cable to the positive terminal of the booster battery.

5.

Connect the black negative (–) cable to the other terminal (negative) of the booster battery.

6.

MAKE THE FINAL CONNECTION ON

THE ENGINE BLOCK OF THE STALLED

VEHICLE (NOT TO THE NEGATIVE POST)

AWAY FROM THE BATTERY. STAND BACK.

7.

Start the vehicle and remove the cables in the reverse order of connection (the engine block

(black) connection is the first to disconnect).

Note:

Be sure the vent caps are tight and level.

Place a damp cloth, if available, over any vent caps on both batteries. Be sure the vehicles do not touch and that both electrical systems are off and at the same rated system voltage. These instructions are for negative ground systems only.

3.

Connect the positive (+) cable to the positive (+) terminal of the discharged battery that is wired to

the starter or solenoid as shown in Figure 19.

Check Mower Blades

Service Interval: Before each use or daily

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Lift deck and secure in raised position as stated in the

Clean Grass Build-Up Under Deck

section.

3.

Inspect blades and sharpen or replace as required.

4.

Reinstall the blades (if they were removed) in the following order:

A.

Install bushing through blade with bushing flange on bottom (grass) side of blade.

30

Figure 20

1.

Install bushing in blade prior to installing bushing in spindle.

g006780

B.

Install bushing/blade assembly into spindle.

Maintenance

WARNING

Incorrect installation of the blade or components used to retain the blade can be dangerous. Failure to use all original components and assembled as shown could allow a blade or blade component to be thrown out from under the deck resulting in serious personal injury or death.

Always install the original Exmark blades, blade bushings, and blade bolts as shown.

Figure 21

1.

Use wrench here for blade installation. This nut has been torqued to 130-160 ft-lb (176–217 N-m)

2.

Torque to 50-60 ft-lb (68-81 N-m) Apply lubricant to threads as needed to prevent seizing. Copper-based anti-seize preferable. Grease acceptable substitute.

g014914

C.

Apply lubricant to threads of blade bolt as needed to prevent seizing. Copper-based anti-seize preferable. Grease acceptable substitute. Install blade bolt finger tight. Place wrench on the top spindle nut then torque the blade bolts to 50-60 ft-lb (68-81 N-m).

31

Maintenance

Check Safety Interlock System

Important:

It is essential that operator safety mechanisms be connected and in proper operating condition prior to use.

Note:

If machine does not pass any of these tests,

Do Not

operate. Contact an Authorized Service Dealer.

Check the Normal Engine Starting Chart

Service Interval: Before each use or daily

Note:

It is not necessary for the operator to be on the platform to start the engine.

PTO (Blades)

Disengaged

System

Motion Control Levers

Both levers out (neutral)

Outcome

Starter should crank

State of System

Up position, but blades disengaged*

Both levers out (neutral) Starter should crank

*Note:

The starter will crank with the PTO switch in the “ON” (pulled up) position; however, the system will disengage the PTO and a reset PTO error will occur. Engaging the PTO will require the operator to reset the

PTO switch by turning it “OFF” (pushed down) and then turning it “ON”.

Check Engine Starting Circuit Chart

Note:

In the

Check Engine Starting Circuit Chart

, the state of system item that is bold is being checked in each scenario.

PTO (Blades)

Disengaged

System

Motion Control Levers

Both levers not in neutral

Outcome

Starter must not crank

State of System

Engaged

Both levers in neutral Starter must not crank

32

Maintenance

Check Shutdown Circuit Chart

Note:

The state of system item(s) that is bold is being checked in each scenario.

Engine

Running idle (1/3 throttle)

PTO (Blades)

Engaged

System

Motion Control Levers

Both levers out (neutral lock)

Outcome

PTO

must begin shutdown within 1 second; engine stays running.

State of

System

State of

System

Engine

Running idle (1/3 throttle)

Parking Brake

Engaged

System

Motion Control Levers Outcome

Both levers not in neutral

Engine must begin shutdown within 1 second

33

Maintenance

Check for Loose Hardware

Service Interval: Before each use or daily

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Visually inspect machine for any loose hardware or any other possible problem. Tighten hardware or correct the problem before operating.

Service Air Cleaner

Service Interval: Every 25 hours—Service the foam element. (May need more often under severe conditions. See the Engine Owner's manual for additional information.)

1.

Air deflector

Figure 22

2.

Knob and washer g271831

6.

The oil drain valve is located on the left side of the engine.

Every 100 hours—Service the paper element. (May need more often under severe conditions. See the

Engine Owner's manual for additional information.)

Every 200 hours/Yearly

(whichever comes first)—Replace the paper element.

Place the pan under the machine to catch the oil.

Loosen the oil drain valve and allow the oil to drain. Tighten the oil drain valve.

7.

Replace the oil filter per the Engine Owner's

Manual. Clean around the oil filter and carefully remove the filter by unscrewing it. Make sure no oil drains onto the belt drive or clutch through the holes in the engine deck. Before the new filter is installed, apply a thin coating of Exmark

4–Cycle Premium Engine Oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts the filter adapter, then tighten filter an additional 2/3 to 3/4 turn.

1.

Stop engine, wait for all moving parts to stop, and remove key or spark plug wire(s). Engage parking brake.

2.

See the Engine Owner's Manual for maintenance instructions.

Change Engine Oil

8.

Clean around oil fill cap and remove cap. Fill to specified capacity and replace cap.

9.

Use oil recommended in the

Check Engine Oil

Level

section.

Do Not

overfill. Start the engine and check for leaks. Stop engine and recheck oil level.

Service Interval: After the first 5 hours

Every 100 hours (May need more often under severe conditions.)

10.

Wipe up any spilled oil from engine deck mounting surfaces.

11.

Reinstall the air deflector and rear guard.

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

12.

Lower the thigh pad.

2.

Drain oil while engine is warm from operation.

Check Hydraulic Oil Level

3.

Lift and lock the thigh pad.

Service Interval: Every 50 hours

4.

Remove and retain the rear guard.

1.

Stop engine and wait for all moving parts to stop, and remove key. Engage parking brake.

5.

Remove and retain the knob, washer, and air deflector located under the machine.

2.

Lift and lock the thigh pad.

34

Maintenance

3.

Clean area around hydraulic reservoir cap and remove cap. Oil level should be to in the cross hatch on the dipstick when cold. If not, add oil. Use Exmark Premium Hydro Oil. Replace hydraulic reservoir cap and tighten until snug. Do

Not overtighten.

4.

Wipe the dipstick clean and re-insert the cap back into the hydro. Lightly tighten the cap.

5.

Remove the cap again and check the level of the

oil on the dipstick. See Figure 23 for oil levels.

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Look on the top side of the cutting deck to check the mower blade drive belt condition.

3.

Look under the engine deck to check the pump drive belt condition.

4.

Check all idler arms to be sure they pivot freely.

Lubricate Grease Fittings

Note:

See chart for service intervals.

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Lubricate fittings with NLGI grade #2 multi-purpose gun grease.

Refer to the following chart for fitting locations and lubrication schedule.

Lubrication Chart

1.

Full

Figure 23

2.

Add g008606

Fitting

Locations

1. Deck Belt

Idler Pivot

Initial

Pumps

1

Number of

Places

1

Service

Interval

Yearly

Note:

The oil level on the dipstick will be incorrect if the oil is checked when the unit is hot.

6.

If the dipstick oil level does not register on the dipstick, add Exmark Premium Hydro Oil.

Do

Not overfill.

7.

Replace hydraulic reservoir cap and tighten until snug.

Do Not overtighten.

8.

Lower the thigh pad.

Check Tire Pressures

Service Interval: Every 50 hours

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Check tire pressure in drive tires.

3.

Inflate drive tires to 12–14 psi (83–97 kPa).

4.

Semi-pneumatic caster tires do not need to be inflated.

Check Condition Of Belts

Service Interval: Every 50 hours

Check Spark Plugs

Service Interval: Every 160 hours

Remove spark plugs, check condition and reset gaps, or replace with new plugs. See Engine Owner's

Manual.

Change Fuel Filter

Service Interval: As required

A fuel filter is installed in the fuel line between the fuel tank and the engine. Replace when necessary.

35

Maintenance

Change Hydraulic System

Filter and Fluid

6.

Fill reservoir as stated in

Check Hydraulic Oil

Level.

Exmark Premium Hydro Oil is recommended.

Refer to the chart for an acceptable alternative:

Service Interval: After the first 250 hours

Every 500 hours/Yearly

(whichever comes first) thereafter.

(Every 250 hours/Yearly if using Mobil 1 15W50 thereafter)

Hydro Oil

Exmark Premium Hydro

Oil (Preferred)

Mobil 1 15W50

Service Interval

After first 250 hours

*Every 500 hours/Yearly thereafter

After first 250 hours

*Every 250 hours/Yearly thereafter

Note:

Use only Exmark Part No. 109-4180 for

Summer use above 32°F (0°C) or P/N 1-523541 for

Winter use below 32°F (0°C) (Refer to

Transmission

section in Specifications for filter specifications).

1.

Stop engine, wait for all moving parts to stop, and remove key or spark plug wire(s). Engage parking brake.

2.

Remove the RH side guard.

*May need more often under severe conditions.

7.

Loosen filter 1/2 turn and allow a small amount of oil to leak from the oil filter (this allows air to be purged from the oil filter and supply hose from the hydraulic reservoir). Turn filter clockwise until rubber seal contacts the filter adapter. Then tighten the filter an additional 2/3 to 3/4 turn.

8.

Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely.

g271949

CAUTION

Raising the mower for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury.

Figure 24

1.

RH side guard

Do Not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

3.

Place a catch pan under the hydro filter.

4.

Carefully clean area around filter. It is important that no dirt or contamination enter hydraulic system.

5.

Unscrew filter to remove and allow oil to drain from reservoir.

9.

Start engine and move throttle control ahead to full throttle position. Move motion control levers inward (together) and move both levers forward with equal pressure, and run for one minute. Shut down the machine, allow the hydros to cool and recheck oil level.

Important:

Before reinstalling new filter, fill it with Exmark Premium Hydro oil and apply a thin coat of oil on the surface of the rubber seal.

If either drive wheel does not rotate, one or both of the charge pumps (located on the top of the

main pump as shown in Figure 25) may have lost

their “prime”. Refer to

Hydraulic System Air

Purge

section.

Turn filter clockwise until rubber seal contacts the filter adapter, then tighten the filter an additional

2/3 to 3/4 turn.

10.

Reinstall the RH side guard.

11.

Remove the jack stands.

36

Maintenance

Note:

Do Not change hydraulic system oil (except for what can be drained when changing filter), unless it is felt the oil has been contaminated or been extremely hot.

Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system.

Hydraulic System Air Purge

Service Interval: As required

Air must be purged from the hydraulic system when any hydraulic components, including oil filter, are removed or any of the hydraulic lines are disconnected.

The critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable

displacement pump (Figure 25). Air in other parts of

the hydraulic system will be purged through normal operation once the charge pump is “primed”.

g012852

Note:

It is necessary to lightly touch the charge pump cap with your hand to check the pump temperature. If the cap is too hot to touch, turn off engine. The pumps may be damaged if the pump becomes too hot.

If either drive wheel still does not rotate continue

with step 4.

4.

Thoroughly clean the area around each of the charge pump housings.

5.

To “prime” charge pump, loosen two hex socket

head capscrews (shown in Figure 25)

1 1/2 turns only. Make sure engine is not running.

Lift the charge pump housing upward and wait for a steady flow of oil to flow out from under the housing. Retighten the capscrews. Do this for both pumps.

Note:

Hydraulic reservoir can be pressurized up to 5 psi to speed this process.

6.

If either drive wheel still does not rotate, stop

and repeat steps 4 and 5 above for the respective

pump. If wheels rotate slowly, the system may prime after additional running. Check oil level as stated in

Check the Hydraulic Oil Level

section.

7.

Allow unit to run several minutes after the charge pumps are “primed” with drive system in the full speed position. Check oil level as stated in

Check the Hydraulic Oil Level

section.

8.

Check hydro drive linkage adjustment as stated in

Hydro Drive Linkage Adjustment

section in

Adjustments.

Figure 25

1.

Charge pump cap 2.

Loosen 1 1/2 turns only

Wheel Hub Nut Torque

Specification

Service Interval: After the first 100 hours

Every 500 hours thereafter

1.

Stop engine and wait for all moving parts to stop.

Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off the ground.

2.

Check oil level as stated in

Check Hydraulic Oil

Level

section.

3.

Start engine and move throttle control ahead to full throttle position. Move motion control levers inward (together) and move both levers forward with equal pressure.

If either drive wheel does not rotate, it is possible to assist the purging of the charge pump by carefully rotating the tire in the forward position.

Torque the nut on the wheel motor tapered shaft to

115-135 ft-lb (156-183 N-m).

Note:

Do

Not

use anti-seize compound on the wheel hub.

Check Spark Arrester

(if equipped)

Service Interval: Every 50 hours

37

Maintenance

WARNING

Hot exhaust system components may ignite gasoline vapors even after the engine is stopped.

Hot particles exhausted during engine operation may ignite flammable materials. Fire may result in personal injury or property damage.

Do Not refuel or run engine unless spark arrester is installed.

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Wait for muffler to cool.

3.

If any breaks in the screen or welds are observed, replace arrester.

4.

If plugging of the screen is observed, remove arrester and shake loose particles out of the arrester and clean screen with a wire brush (soak in solvent if necessary). Reinstall arrester on exhaust outlet.

Dielectric Grease

Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact.

Dielectric grease should not be applied to sealed connectors.

Thread Locking Adhesives

Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type” are used on the following fasteners:

• Pump sheave setscrews.

• Sheave retaining bolt in end of engine crankshaft.

Mobil HTS Grease (Or

Food-Grade Anti-seize)

Mobil HTS grease (or food-grade anti-seize) is used in the following locations:

—Between splines of the cutter housing spindle and sheave.

Copper-Based Anti-seize

Copper-based anti-seize is used in the following locations:

• On threads of Blade Bolts. See

Check Mower

Blades

section.

• Between engine crankshaft, PTO shaft, and PTO pulley.

• Between pump shafts and sheaves.

38

Maintenance

Adjustments

Note:

Disengage PTO, shut off engine, wait for all moving parts to stop, engage parking brake, and remove key before servicing, cleaning, or making any adjustments to the unit.

Deck Leveling

Note:

Small adjustments can be accomplished by increasing the tire pressure in the tire on the low side.

1.

Park the machine on a level surface and disengage the blade control switch.

2.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

3.

Check the air pressure in the drive tires. If needed, adjust to the recommended inflation; refer to

Checking the Tire Pressure

in Drive System

Maintenance section.

4.

Set the height of cut pins to the 3 inch (7.6 cm) position.

5.

Raise the discharge deflector.

6.

Carefully rotate the blades front to rear. Measure from the tip of the front blade to the level surface

(Figure 26). The blades should measure 3 inches

(7.6 cm) ±1/8 inch (.3 cm).

Note:

In most conditions, the back tips should be adjusted 3/16 –1/4 inch (4.6–6.4 mm) higher than the front.

Figure 26

1.

3 1/4 inches (8.3 cm)

2.

Back blade tip

3.

Front blade tip

4.

3 inches (7.6 cm)

5.

Level surface g014790

7.

Use the fine adjustments on the rear deck lift pins to adjust the height of the rear blade tips.

Loosen the jam nut on the rear pin. Fine tune the rear blade tip by rotating the pin. To increase the height, turn the pin clockwise; to decrease, turn

counterclockwise (see Figure 27).

39

Figure 27

1.

Jam nut

8.

Tighten the jam nut.

9.

Lower the discharge deflector.

Pump Drive Belt Tension

Self-tensioning - No adjustment necessary.

g271523

Maintenance

Mower Deck Drive Belt

Tension

Self-tensioning - No adjustment necessary.

and counterclockwise to increase the gap (see

Figure 28).

5.

Reinstall the rod into the brake lever and secure with the washer and hairpin.

Park Brake Adjustment

If the parking brake does not hold securely, an adjustment is required.

1.

Park the machine on a level surface.

2.

Shut off engine and wait for all moving parts to stop.

3.

When the park brake is released, the brake bars should lift off the tires and the hand lever should travel forward. When the brake is disengaged, the gap between the brake snubber teeth and drive tire should measure 1/2–5/8 inch (13–16 mm)

(see Figure 28).

Figure 28

Motion Control Tracking

Adjustment

Located in the front inside the tower. Rotating the pump linkage with a 9/16 inch wrench allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only.

1.

Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely.

2.

Start engine. Brake must be engaged and motion control levers out to start engine. Run engine at full throttle and release brake.

3.

Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature.

g271524

Note:

The motion control lever needs to be in neutral while making any necessary adjustments.

4.

Bring the motion control levers into the neutral position. Access the links from the front of the

tower (Figure 29). Adjust pump control rod

lengths by loosening the bottom nuts on each and rotating the turn buckle until the wheels slightly

creep in reverse (Figure 29). Pumps have a return

to neutral arms and will return to neutral when the control levers are released. If the levers do not fold out, adjust the links until the lever folds out in the middle of the neutral lock notch. Move the levers to the full forward and reverse. If the levers fold out, tighten the jam nuts on the links.

1.

Hairpin and washer

2.

4.69–4.81 inch

(11.9–12.2 cm)

3.

1/2–5/8 inch (13–16 mm)

4.

If the parking brake does not hold securely an adjustment is required. To adjust the brake, remove and retain the hairpin and washer on the brake linkage rod. Turn the brake linkage rod clockwise to decrease the gap

40

Maintenance

1.

Lower nut

2.

Upper nut

Figure 29

3.

Links g267312

Figure 30

1.

LH Motion control lever

2.

RH Motion control lever

3.

RH Motion control lever in PTO disengage position

4.

Check the horizontal alignment here g012878

5.

Shut off unit.

6.

Remove the jack stands.

7.

Check that the machine does not creep in neutral with the park brakes disengaged.

4.

To adjust the right motion control lever horizontally, the cam needs to be adjusted.

5.

Release the cushion from the rear of the machine.

6.

Loosen the nut holding the cam (see Figure 31).

Adjust Motion Control

Handle Position

If the motion control levers do not align horizontally, adjust one or both levers.

Note:

Adjust the horizontal alignment before the front to back alignment.

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Push the right motion control lever down out of the PTO disengage position.

3.

Check if the right motion control lever aligns horizontally with the left motion control lever.

1.

Cam nut

Figure 31

g267325

7.

Adjust the cam until it aligns with the left motion control lever and tighten the nut for the cam.

Note:

Moving the flat portion of the cam clockwise lowers the handle, while moving it counterclockwise raises the handle

Important:

Make sure the flat portion of the cam does not go above a vertical position

(right or left), or damage may occur to the switch.

8.

Tighten the switch screws.

41

Maintenance

Cleaning

Clean Debris From Machine

Remove Engine Shroud

Access Panels and Clean

Cooling Fins

Service Interval: Before each use or daily

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Clean off any oil, debris, or grass build-up on the machine and cutting deck, especially under deck belt shields, around the fuel tank, around engine and exhaust area.

Important: motors.

You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, around the engine, hydraulic pumps, and

Service Interval: Every 80 hours

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Remove cooling shroud access panels from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine which can cause improper cooling.

3.

Make sure cooling shroud access panels are properly reinstalled. Operating the engine without cooling shroud access panels will cause engine damage due to overheating.

Clean Grass Build-Up Under

Deck

Clean Engine and Exhaust

System Area

Service Interval: Before each use or daily

(May be required more often in dry or dirty conditions.)

CAUTION

Excessive debris around engine cooling air intake and exhaust system area can cause engine, exhaust area, and hydraulic system to overheat which can create a fire hazard.

Service Interval: Before each use or daily

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Raise deck to the transport (maximum cutting height) position. Lift the front of unit and support machine using jack stands or equivalent support.

3.

Clean out any grass build-up from underside of deck and in discharge deflector.

Waste Disposal

Clean all debris from engine and exhaust system area.

Motor Oil Disposal

Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at a certified recycling center or according to your state and local regulations.

1.

Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2.

Clean all debris from rotating engine air intake screen, around engine shrouding, and exhaust system area.

3.

Wipe up any excessive grease or oil around the engine and exhaust system area.

4.

Clean oil coolers (if equipped) of all debris, dirt, and oil.

42

Battery Disposal

DANGER

Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns.

Swallowing electrolyte can be fatal or if it touches skin can cause severe burns.

• Wear safety glasses to shield eyes, and rubber gloves to protect skin and clothing when handling electrolyte.

• Do Not swallow electrolyte.

• In the event of an accident, flush with water and call a doctor immediately.

Federal law states that batteries should not be placed in the garbage. Management and disposal practices must be within relevant federal, state, or local laws.

If a battery is being replaced or if the unit containing the battery is no longer operating and is being scrapped, take the battery to a local certified recycling center. If no local recycling is available return the battery to any certified battery reseller.

Maintenance

43

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 caused by an empty fuel tank.

The following table lists some of the common causes of trouble. Do Not attempt to service or replace major items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have this work done by your

Engine Service Dealer

.

Note:

When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.

Problem

Starter does not crank.

Engine will not start, starts hard, or fails to keep running

Engine loses power

Possible Cause

1. PTO is engaged.

2. One of the speed control levers are not in neutral position.

3. Battery does not have a full charge.

4. Electrical connections are corroded, loose or faulty.

Corrective Action

1. Disengage the PTO.

2. Ensure the speed control lever is in the neutral position.

3. Charge the battery. See

Check Battery

Charge

and

Recommended Jump

Starting Procedure

sections in

Maintenance.

4. Check the electrical connections for good contact. Clean connector terminals thoroughly with electrical contact cleaner, apply dielectric grease and reconnect.

5. Replace the blown fuse.

6. Check reed switch.

5. Fuse is blown.

6. Neutral LCD indicator does not illuminate.

7. Relay or switch is defective.

1. Fuel tank is empty.

2. Fuel shutoff valve is closed.

3. The throttle and choke are not in the correct position.

4. Dirt in fuel filter.

5. Dirt, water, or stale fuel is in the fuel system.

6. Air cleaner is dirty.

7. Electrical connections are corroded, loose or faulty.

7. Contact an Authorized Service Dealer.

1. Fill the fuel tank.

2. Open the fuel shutoff valve.

3. Be sure the throttle control is midway between the “SLOW” and “FAST” positions, and the choke is in the “ON” position for a cold engine or the “OFF” position for a warm engine.

4. Replace the fuel filter.

5. Contact an Authorized Service Dealer.

8. Relay or switch is defective.

9. Faulty spark plug.

10. Spark plug wire is not connected.

1. Engine load is excessive

2. Air cleaner is dirty.

3. Oil level in the crankcase is low.

4. Cooling fins and air passages for the engine are plugged.

5. Vent system filter plugged.

6. Dirt in fuel filter.

7. Dirt, water, or stale fuel is in the fuel system.

6. Clean or replace the air cleaner element.

7. Check the electrical connections for good contact. Clean connector terminals thoroughly with electrical contact cleaner, apply dielectric grease and reconnect.

8. Contact an Authorized Service Dealer.

9. Clean, adjust or replace spark plug.

10. Check the spark plug wire connection.

1. Reduce the ground speed.

2. Clean or replace the air cleaner element.

3. Add oil to the crankcase.

4. Remove the obstructions from the cooling fins and air passages.

5. Inspect vent filter; replace if dirty.

6. Replace the fuel filter.

7. Contact an Authorized Service Dealer.

44

Troubleshooting

Engine overheats

Problem

Mower pulls left or right (with levers fully forward).

Machine does not drive.

Uneven cutting height.

Abnormal vibration

Blades do not rotate.

Possible Cause

1. Engine load is excessive

2. Oil level in the crankcase is low.

3. Cooling fins and air passages for the engine are plugged.

1. Tire pressure in drive tires not correct.

2. Tracking needs adjustment.

Corrective Action

1. Reduce the ground speed.

2. Add oil to the crankcase.

3. Remove the obstructions from the cooling fins and air passages.

1. Adjust tire pressure in the drive tires.

2. Adjust the tracking by turning turnbuckle on the LH turnbuckle in the direction that the mower needs to be adjusted to. Rotate the turnbuckle in 1/4 turn increments until the mower tracks correctly.

1. Bypass valve is not closed tight.

2. Drive or pump belt is worn, loose or broken.

3. Drive or pump belt is off a pulley.

1. Blade(s) not sharp.

2. Cutting blade(s) is/are bent.

3. Mower deck is not level.

4. Underside of mower is dirty.

5. Tire pressure in drive tires not correct.

6. Blade spindle bent.

7. Tips of adjacent blades are at an uneven cutting height. Blades tips should be even within 3/16 inch which is approximately one blade thickness.

1. Tighten the bypass valve.

2. Change the belt.

3. Change the belt.

1. Sharpen the blade(s).

2. Install new cutting blade(s).

3. Level mower deck from side-to-side and front-to-rear.

4. Clean the underside of the mower.

5. Adjust tire pressure in the drive tires.

6. Contact an Authorized Service Dealer.

7. Replace blades, spindles and (or) check for damage to mower deck.

1. Cutting blade(s) is/are bent or unbalanced.

1. Install new cutting blade(s).

2. Blade mounting bolt is loose.

3. Engine mounting bolts are loose.

4. Loose engine pulley, idler pulley, or blade pulley.

5. Engine pulley is damaged.

6. Blade spindle is bent.

7. Belt is damaged.

2. Tighten the blade mounting bolt.

3. Tighten the engine mounting bolts.

4. Tighten the appropriate pulley.

5. Contact an Authorized Service Dealer.

6. Contact an Authorized Service Dealer.

7. Install new belt.

1. Drive belt is off pulley.

2. Deck belt is worn, loose or broken.

3. Deck belt is off pulley.

4. Broken or missing idler spring.

5. Damaged electric clutch.

1. Check belt for damage; replace if necessary. Install drive belt and check adjusting shafts and belt guides for correct position.

2. Install new deck belt.

3. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function.

4. Replace the spring.

5. Contact an Authorized Service Dealer.

45

Troubleshooting

Problem

Clutch will not engage.

Possible Cause

1. Fuse is blown.

2. Low voltage supply at the clutch.

3. Damaged coil.

4. Inadequate current supply.

5. Rotor/armature airgap is too large.

Corrective Action

1. Replace fuse. Check coil resistance, battery charge, charging system, and wiring connections and replace if necessary.

2. Check coil resistance, battery charge, charging system, and wiring connections and replace if necessary.

3. Replace clutch.

4. Repair or replace clutch lead wire or electrical system. Clean connector contacts.

5. Remove shim or replace clutch.

46

Schematics

Electrical Diagram

30A FUSE

J7001

J7002

Schematics

47 g271561

Schematics

Hydraulic Diagram

g270319

48

California Proposition 65 Warning Information

What is this warning?

You may see a product for sale that has a warning label like the following:

WARNING:

Cancer and Reproductive Harm—www.p65Warnings.ca.gov.

What is Prop 65?

Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California. It mandates that the Governor of California maintain and publish a list of chemicals known to cause cancer, birth defects, and/or other reproductive harm. The list, which is updated annually, includes hundreds of chemicals found in many everyday items. The purpose of Prop 65 is to inform the public about exposure to these chemicals.

Prop 65 does not ban the sale of products containing these chemicals but instead requires warnings on any product, product packaging, or literature with the product.

Moreover, a Prop 65 warning does not mean that a product is in violation of any product safety standards or requirements. In fact, the California government has clarified that a Prop 65 warning “is not the same as a regulatory decision that a product is ‘safe’ or ‘unsafe.’” Many of these chemicals have been used in everyday products for years without documented harm. For more information, go to https://oag.ca.gov/prop65/faqs-view-all .

A Prop 65 warning means that a company has either (1) evaluated the exposure and has concluded that it exceeds the “no significant risk level”; or (2) has chosen to provide a warning based on its understanding about the presence of a listed chemical without attempting to evaluate the exposure.

Does this law apply everywhere?

Prop 65 warnings are required under California law only. These warnings are seen throughout California in a wide range of settings, including but not limited to restaurants, grocery stores, hotels, schools, and hospitals, and on a wide variety of products. Additionally, some online and mail order retailers provide Prop 65 warnings on their websites or in catalogs.

How do the California warnings compare to federal limits?

Prop 65 standards are often more stringent than federal and international standards. There are various substances that require a Prop 65 warning at levels that are far lower than federal action limits. For example, the Prop 65 standard for warnings for lead is 0.5 μg/day, which is well below the federal and international standards.

Why don’t all similar products carry the warning?

Products sold in California require Prop 65 labelling while similar products sold elsewhere do not.

A company involved in a Prop 65 lawsuit reaching a settlement may be required to use Prop 65 warnings for its products, but other companies making similar products may have no such requirement.

The enforcement of Prop 65 is inconsistent.

Companies may elect not to provide warnings because they conclude that they are not required to do so under Prop 65; a lack of warnings for a product does not mean that the product is free of listed chemicals at similar levels.

Why does Exmark include this warning?

Exmark has chosen to provide consumers with as much information as possible so that they can make informed decisions about the products they buy and use. Exmark provides warnings in certain cases based on its knowledge of the presence of one or more listed chemicals without evaluating the level of exposure, as not all the listed chemicals provide exposure limit requirements. While the exposure from Exmark products may be negligible or well within the “no significant risk” range, out of an abundance of caution, Exmark has elected to provide the Prop 65 warnings. Moreover, if Exmark does not provide these warnings, it could be sued by the State of California or by private parties seeking to enforce Prop 65 and subject to substantial penalties.

49

Date:

Service Record

Description of Work Done: Service Done By:

50

51

EXMARK ACCESSORIES AND OPTIONS*

MID-MOUNT RIDING ACCESSORIES AND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

12

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OUT-FRONT RIDING ACCESSORIES AND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

*Some accessories and options not available for some models.

Place Model No. and Serial No.

Label Here (Included in the Literature

Pack) or Fill in Below

Model No.

Serial No.

Date Purchased

Engine Model No. and Spec. No.

Engine Serial No. (E/No)

©2019 Exmark Mfg. Co., Inc.

2101 Ashland Ave

Beatrice, NE 68310

All Rights Reserved

Part No. 4504-758 Rev. A

(402) 223-6375

Fax (402) 223-5489

Printed in the USA www.exmark.com

*4504-758* A

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Key Features

  • Powerful engine for superior cutting performance
  • Durable construction for long-lasting use
  • Innovative features for enhanced efficiency and ease of use
  • Versatile design for a variety of applications
  • Comfortable operation for extended use
  • Easy maintenance for minimal downtime
  • Compact size for easy storage
  • Lightweight design for easy maneuverability

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Frequently Answers and Questions

What is the difference between the STARIS E Series and other mowers?
The STARIS E Series is different from other mowers in its class due to its superior cutting performance, durable construction, innovative features, versatile design, comfortable operation, easy maintenance, compact size, and lightweight design.
What types of applications is the STARIS E Series suitable for?
The STARIS E Series is suitable for a variety of applications, including professional landscaping, large yards, and even small yards.
How long does the STARIS E Series typically last?
The STARIS E Series is built to last with its durable construction and high-quality components.