Exmark STARIS S Series User manual

STARIS®S-SERIES
ForSerialNos.
408,644,346&Higher
PartNo.4505-317Rev.A

WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Batteryposts,terminals,andrelated
accessoriescontainleadandlead
compounds,chemicalsknowntotheStateof
Californiatocausecancerandreproductive
harm.Washhandsafterhandling.
Useofthisproductmaycauseexposure
tochemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:ItisaviolationofCaliforniaPublic
ResourceCodeSection4442or4443touse
oroperatetheengineonanyforest-covered,
brush-covered,orgrass-coveredlandunlessthe
engineisequippedwithasparkarrester,as
denedinSection4442,maintainedineffective
workingorderortheengineisconstructed,
equipped,andmaintainedforthepreventionof
re.
Toacquireasparkarresterforyourunit,seeyour
EngineServiceDealer.
ForallmodelsthatdonothaveExmarkengines,
pleaserefertotheenginemanufacturer's
informationincludedwiththemachine.
FormodelswithExmarkengines,refertothis
manualforinformation.
Thegrossornethorsepower(ortorque)of
thisenginewaslaboratoryratedbytheengine
manufacturerinaccordancewiththeSociety
ofAutomotiveEngineers(SAE)J1940orJ2723.
Asconguredtomeetsafety,emission,and
operatingrequirements,theactualengine
horsepower(ortorque)onthisclassofmower
willbesignicantlylower.
©2021ExmarkMfg.Co.,Inc.
415IndustrialRow
Beatrice,NE683102
Contactusatwww.Exmark.com.
PrintedintheUSA
AllRightsReserved

Introduction
CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.
Tomaximizesafety,performance,andproper
operationofthismachine,itisessentialthatall
operatorscarefullyreadandfullyunderstandthe
contentsoftheOperator’smanualprovidedwith
theproduct.Failuretocomplywiththeoperating
instructionsorreceivepropertrainingmayresult
ininjury.Gotohttps://www .Exmark.comfor
additionalsafeoperationinformation,suchassafety
tips,trainingmaterials,andOperator’smanuals.
Ifadditionalinformationisneeded,orshould
yourequiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
g304193
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Forcompletewarrantydetails,see
https://www.Exmark.com.Youmayalsocall
us402-223-6375torequestawrittencopyofthe
product’swarranty.
3

Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
GeneralSafety.................................................5
SafetyandInstructionalDecals.......................6
Specications........................................................12
Systems..........................................................12
Dimensions....................................................13
TorqueRequirements.....................................14
ProductOverview.................................................14
Operation..............................................................15
Controls.........................................................15
BeforeOperation...........................................17
OperatingInstructions...................................18
DuringOperationSafety.................................18
AfterOperation..............................................24
Transporting..................................................24
Maintenance..........................................................26
MaintenanceSafety.............................................26
RecommendedMaintenanceSchedule(s)............27
PeriodicMaintenance........................................28
EngineMaintenance.......................................28
EngineSafety.................................................28
CheckEngineOilLevel..................................28
CheckMowerBlades......................................30
CheckSafetyInterlockSystem........................32
CheckforLooseHardware.............................34
ServiceAirCleaner.........................................34
ChangeEngineOil.........................................34
CheckHydraulicOilLevel..............................34
CheckTirePressures......................................35
CheckConditionOfBelts...............................35
LubricateGreaseFittings................................35
LubricateCasterWheelHubs.........................35
CheckSparkPlugs..........................................36
ChangeHydraulicSystemFilterand
Fluid..........................................................36
WheelHubNutTorqueSpecication..............38
CheckSparkArrester(ifequipped)..................38
ThreadLockingAdhesives..............................39
MobilHTSGrease(OrFood-Grade
Anti-seize)..................................................39
Copper-BasedAnti-seize................................39
DielectricGrease............................................39
Adjustments......................................................39
DeckLeveling................................................39
PumpDriveBeltTension................................41
MowerDeckDriveBeltTension.....................41
ChecktheParkBrake......................................41
ParkBrakeAdjustment...................................41
ElectricClutchAdjustment.............................41
MotionControlAdjustment...........................43
AdjustMotionControlHandle
Position......................................................43
CasterPivotBearingsPre-Load
Adjustment................................................44
Cleaning............................................................45
CleaningandStoringSafety.............................45
CleanDebrisFromMachine...........................45
CleanEngineandExhaustSystem
Area...........................................................45
RemoveEngineShroudAccessPanelsand
CleanCoolingFins.....................................45
CleanGrassBuild-UpUnderDeck.................45
WasteDisposal...............................................46
Troubleshooting....................................................47
Schematics............................................................50
CaliforniaProposition65Warning
Information...............................................53
4

Safety
Safety
Thismachinehasbeendesignedinconformancewith
theAmericanNationalStandardsInstitute–B71.4
forCommercialTurfCareEquipment–Safety
Specications.
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents.
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
g000502
Figure2
SafetyAlertSymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Indicatesanimminentlyhazardous
situationwhich,ifnotavoided,Willresultindeathor
seriousinjury.
WARNING:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Couldresultindeath
orseriousinjury.
CAUTION:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Mayresultinminor
ormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
GeneralSafety
Thismachineiscapableofamputatinghandsand
feetandofthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriouspersonalinjuryand
death.
•Read,understand,andfollowallinstructions
andwarningsintheOperator’sManualand
onthemachine,engine,andattachments.All
operatorsandmechanicsshouldbetrained.If
theoperator(s)ormechanic(s)cannotreadthis
manual,itistheowner’sresponsibilitytoexplain
thismaterialtothem;otherlanguagesmaybe
availableonourwebsite.
•Onlyallowtrained,responsible,andphysically
capableoperatorsthatarefamiliarwiththesafe
operation,operatorcontrols,andsafetysignsand
instructionstooperatethemachine.Neverlet
childrenoruntrainedpeopleoperateorservice
theequipment.Localregulationsmayrestrictthe
ageoftheoperator.
•DoNotoperatethemachineneardrop-offs,
ditches,embankments,water,orotherhazards.
•Keepbystandersandchildrenoutoftheoperating
area.
•DoNotputyourhandsorfeetnearmovingparts.
•DoNotoperatethemachinewithoutallsafety
shields,guards,switches,andotherdevicesin
placeandinproperworkingcondition.
•Parkmachineonlevelground,disengagedrives,
setparkingbrake,stopengine,removekey,or
disconnectsparkplugwire.Waitforallmoving
partstostopbeforeleavingtheoperator’s
position.Allowthemachinetocoolbefore
servicing,adjusting,fueling,cleaning,orstoring.
5

Safety
SafetyandInstructionalDecals
•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
•Replaceallworn,damaged,ormissingsafety
signs.
•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
decal98-1977
98-1977
1.Entanglementhazard,belt—stayawayfrommoving
parts.
decal106-5517
106-5517
1.Warning—donottouchthehotsurface.
decal112-9028
112-9028
1.Warning—stayawayfrommovingparts;keepallguards
andshieldsinplace.
decal116-5988
116-5988
1.Parkingbrake—engaged2.Parking
brake—disengaged
decal116-7912
116-7912
1.Interval4.Neutral
2.PowerT ake-off(PTO)5.Operatorpresence
control
3.Parkingbrake6.Battery
6

Safety
decal116-8253
116-8253
1.Rotatecounterclockwise
torelease.
3.Unlocktopushmachine.
2.Rotateclockwisetolock.4.Readtheinstructions
beforeservicingor
performingmaintenance.
decal116-8283
116-8283
1.Warning—readtheOperator'sManualforinstructions
ontorquingthebladebolt/nutto55-60ft-lb(75-81N-m).
decal116-8727
116-8727
decal119-6807
119-6807
1.Warning—nostep
decal126-0898
126-0898
1.ReadtheOperator’smanual
2.3/8-16x33/4inchbolt.BoltmustbeGrade8.Boltand
springdiscwashermustbeinstalledasshown.
3.Nylocnut-torqueto50-55ft-lb(68-75N-m)
4.Roller
5.Bushing
6.Mountbracket
7.Springdiscwasher
decal126-2055
126-2055
1.Wheellugnut—torqueto129N∙m(95ft-lb).
2.Wheelhubnut—torqueto319N∙m(235ft-lb).
3.ReadtheOperator’sManualbeforeperforming
maintenance;checkthetorqueaftertherst100hours
andevery500hoursafter.
7

Safety
decal126-7875
126-7875
1.Fuselocation4.Auxiliary,15A
2.Relaylocation5.Startrelay
3.Main,20A6.Notused
decal133-8062
133-8062
decal135-2267
135-2267
DrivePumpBeltRouting
decal135-2266
135-2266
1.Readtheinstructionsbeforeservicingorperforming
maintenance
2.Timeinterval
3.Checkoillevel
4.RefertotheOperator'smanualforgreaseinstructions
5.CheckhydraulicoillevelandrefertotheOperator's
manualorfurtherinstructions
6.Checktirepressure
decal135-2280
135-2280
1.Heightofcut
decal135-5206
135-5206
1.Unlock2.Lock
8

Safety
decal135-5210
135-5210
1.Thrownobjectshazard-keepbystandersaway.
2.Thrownobjectshazard,mower-donotoperatewithout
thedeector,dischargecoverorgrasscollectionsystem
inplace.
3.Cutting/dismembermentofhandorfoot-stayawayfrom
movingparts;keepallguardsandshieldsinplace.
decal142-3077
142-3077
1.ReadtheOperator’s
manual.
4.DoNotoverll
2.Hydraulicuid5.Warning-DoNottouch
thehotsurface.
3.Correctlllevelwhen
cold
decal135-6844
135-6844
1.ReadtheOperator’s
manual
2.OnlyuseExmark
10W-50engineoil
decal142-3157
142-3157
9

Safety
decal135-6772
135-6772
EFIModels
1.Forward5.Throttle-slow9.Engine-start
2.Neutral6.Continuousvariablesetting10.Optionallightaccessory
3.Reverse7.Engine-off
4.Throttle-fast8.Engine-on
decal135-6773
135-6773
Non-EFIModels
1.Forward5.Choke-off9.Engine-off
2.Neutral6.Throttle-fast10.Engine-on
3.Reverse7.Continuousvariablesetting11.Engine-start
4.Choke-on8.Throttle-slow12.Optionallightaccessory
10

Safety
decal135-2412
135-2412
1.Warning-ReadtheOperator’sManual.DoNotoperatethis
machineunlessyouaretrained.Wearhearingprotection.
4.Thrownobjecthazard-Pickupobjectsthatcouldbethrown
bymower.Keepbystandersaway.Keepdeectorinplace.
2.Warning-Stayawayfrommovingparts;keepallguards
inplace.Stopengineandremovekeybeforeadjusting,
servicing,orcleaning.
5.Cutting/dismembermenthazard-Mowacrossslopesnotup
anddown.DoNotmowwetslopes–useextremecaution
whenoperatingonslopes.
3.Warning-DisengagePTO,movedriveleversouttoneutral
lockposition,engageparkingbrake,andstopengine
beforeleavingtheoperator’sposition.
6.Crushing/dismembermenthazardofbystanders-DoNot
carrypassengers,lookforwardanddownwhenoperating
themachine,lookbehindanddownwhenreversing.
11

Specications
Specications
Systems
Engine
•EngineSpecications:SeeyourEngineOwner’s
Manual
•EngineOilType:Exmark10W-50Premium
SyntheticEngineOil
•RPM:FullSpeed:3650±100RPM(NoLoad)
FuelSystem
•Capacity:10.0gal.(37.9L)
Twotanks5.0gal(18.9L)each
•FuelRecommendations:
–Forbestresults,useonlyclean,fresh,unleaded
gasolinewithanoctaneratingof87orhigher
((R+M)/2ratingmethod).
–Oxygenatedfuelwithupto10%ethanolor
15%MTBEbyvolumeisacceptable.
–DoNotuseethanolblendsofgasoline(such
asE15orE85)withmorethan10%ethanol
byvolume.Performanceproblemsand/or
enginedamagemayresultwhichmaynotbe
coveredunderwarranty.
–DoNotusegasolinecontainingmethanol.
–DoNotstorefueleitherinthefueltankor
fuelcontainersoverthewinterunlessafuel
stabilizerisused.
–Bothtanksmusthavefuelorairwillenterthe
systemandcausepoorengineperformanceor
preventenginefromrunning.
–DoNotaddoiltogasoline.
•FuelFilter:In-linefuellter
•FuelShut-OffValve:1/4turn
ElectricalSystem(ElectricStart)
•ChargingSystem:FlywheelAlternator
•ChargingCapacity:
Kawasaki:15amps
KohlerEFI:20amps
•BatteryType:Exmark12VNon-Spillable,AGM,
MaintenanceFreeBatteryPartNo.135-4421
•BatteryVoltage:12Volt
•Polarity:NegativeGround
•Fuses:
–20ampchargingsystemfuse
–15ampaccessoryfuse
SafetyInterlockSystem
•LCDindicatorsappearfortheparkbrake,drive
levers,andoperatorpresenceinthemessage
displayonthefrontcontrolpanel.
Note:BecausethePTOmustbedisengaged
tostarttheengine,theLCDindicatorwillnot
illuminateatthistime.
•PTOmustbedisengagedandmotioncontrol
leversout(neutrallock)tostartengine.(Itisnot
necessaryfortheoperatortobeontheplatform
tostarttheengine.)
•Mowerbladeswillstopifbothmotioncontrol
leversaremovedorreleasedintotheneutral
position.
•Enginewillstopifthemotioncontrolleversare
movedfromtheneutralpositionwiththepark
brakeengaged.
OperatorControls
SteeringControl:Fingertipdrivecontrollevers
provideindependentspeedcontrol,brakingand
neutraltoeachdrivewheelformovingforwardor
reverse,stopping,andpowerturning.
Transmission
•TwoHydroGearvariabledisplacementhigh
efciencypumpsindependentlycoupledtotwo
highefciencyParker/Rosswheeldrivemotors.
•HydraulicOil:UseExmarkPremiumHydroOil.
•HydraulicOilCapacity:2.4qt.(2.2L)
•HydraulicFilterisreplaceablecanistertype.
P/N109-4180:25microns,10psibypass
(Summeruseabove32°F(0°C))
P/N1-523541:40microns,18psibypass(Winter
usebelow32°F(0°C))
•Speeds:
–0-10.0mph(16km/hr)forward.
–0-4.0mph(6km/hr)reverse.
•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
12

Specications
WheelDriveSystem
DrivewheelsaredirectcoupledtoParkerwheeldrive
motorswith11/4inch(31.8mm)taperedshaft.
Tires&Wheels
Drive
48Inch52Inch60Inch
Pneumatic
(Air-Filled)
Pneumatic
(Air-Filled)
Pneumatic
(Air-Filled)
Quantity222
TreadTurfMasterTurfMasterTurfMaster
Size23x8.5–1223x9.5–1223x
10.5–12
PlyRating444
Pressure13psi
(90kPa)
13psi
(90kPa)
13psi
(90kPa)
FrontCaster(AllModels)
FrontCaster
Semi-
Pneumatic
Quantity2
TreadSmooth
Size12x6.00–6
CuttingDeck
•CuttingWidth:
–48inchDeck:48inches(121.9cm)
–52inchDeck:52inches(132.1cm)
–60inchDeck:60inches(152.4cm)
•Discharge:Side
•BladeSize:(3ea.)
–48inchDeck:16.25inches(41.3cm)
–52inchDeck:18.00inches(45.7cm)
–60inchDeck:20.50inches(52.1cm)
•BladeSpindles:Solidsteelspindleswith1.00inch
(25.4mm)I.D.bearings.
•DeckDrive:
–Electricclutchmountedonengineshaft.
–Bladesdrivenbyonebelt(w/self-tensioning
idlers).
•Deck:Fulloatingdeckisattachedtosupport
frame,removableforservice.Deckdesignallows
forbagging,mulchingorsidedischarge.
60inchDeck:Anti-scalprollersprovide
maximumturfprotection.
•DeckDepth:
–48inchDeck:5.5inches(14.0cm)
–52inchDeck:5.5inches(14.0cm)
–60inchDeck:5.5inches(14.0cm)
•CuttingHeightAdjustment:
Adjustsfrom11/2inch(3.8cm)to5inches(12.7
cm)in1/4inch(6.4mm)increments
•MulchingKit:Optional
•Bagger:Optional
Dimensions
OverallWidth:
48inch
Deck
52inch
Deck
60inch
Deck
Deector
Up
51.8inches
(131.6cm)
56.3inches
(143.0cm)
63.9inches
(162.3cm)
Deector
Down
59.6inches
(151.4cm)
64.8inches
(164.6cm)
72.8inches
(184.9cm)
OverallLength:
48inch
Deck
52inch
Deck
60inch
Deck
Platform
Up
64.0inches
(162.5cm)
64.0inches
(162.5cm)
65.2inches
(165.6cm)
Platform
Down
69.3inches
(176.0cm)
69.3inches
(176.0cm)
70.5inches
(179.1cm)
OverallHeight:
48inchDeck52inchDeck60inchDeck
46.7inches
(118.6cm)
46.7inches
(118.6cm)
46.7inches
(118.6cm)
TreadWidth:(OutsidetoOutsideof
Tires,Widthwise)
48inchDeck52inchDeck60inchDeck
48.8inches
(124.0cm)
52.2inches
(132.61cm)
52.9inches
(134.4cm)
13

ProductOverview
CurbWeight:
48inchDeck52inchDeck60inchDeck
960lb
(435kg)
990lb
(449kg)
1045lb
(474kg)
Note:Weightswillvaryslightlydependingonengine.
TorqueRequirements
BoltLocationTorque
CutterHousingSpindle
Nut
130-160ft-lb
(176-217N-m)
BladeMountingBolt
(lubricatewithanti-seize)
50-60ft-lb(68-81N-m)
OuterAnti-Scalp
RollerNylocNut(See
Figure13)–60InchDeck
Only
50-55ft-lb(68-75N-m)
CenterAnti-Scalp
RollerNylocNut(See
Figure14)–60InchDeck
Only
30-35ft-lb(41-47N-m)
EngineMountingBolts
Kawasaki
Kohler
30-35ft-lb(41-47N-m)
27-33ft-lb(37-45N-m)
WheelLugNuts85-105ft-lb(115-142
N-m)
WheelHubNuts211-260ft-lb
(286-352N-m)
WheelMotorMounting
Bolts
67-83ft-lb(91-113N-m)
HydroPumpRelease
Valves
110-130in-lb(12-15N-m)
ProductOverview
g268259
Figure3
1.Deckliftlever3.Motioncontrols
2.Controls
14

Operation
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
Note:Becomefamiliarwithallthecontrolsbefore
startingtheengineandoperatingthemachine.
MotionControlLevers
Themotioncontrollevers,locatedoneachsideofthe
topconsole,controltheforwardandreversemotion
ofthemachine.
Movingtheleversforwardorbackwardturns
thewheelonthesamesideforwardorreverse
respectively.Wheelspeedisproportionaltothe
amounttheleverismoved.
Movingtheleversoutward,fromthecenterposition
intothenotch,locksthemintheneutralposition
(seeFigure4).
g224633
Figure4
1.Neutrallockposition
(handlesout)
5.Rearreferencebar
2.Neutraloperateposition
(handlesin)
6.Frontreference/Speed
controlbar
3.Frontofmachine7.Forward
4.Reverse8.Adjustmenthole
Note:Whenthemotioncontrolleversareinthe
neutrallockposition,aLCDindicatordisplayson
themessagedisplay.
Note:Whenthemotioncontrolleversaremoved
inward,aLCDindicatorappearsintheoperator
presenceofthemessagedisplay.
ChokeControl(AllModelsExcept
KohlerEFI)
LocatedontheLHsideofthecontrolconsole(black
lever)(seeFigure5).
Thechokeisusedtoaidinstartingacoldengine.
Movingthechokeleverforwardwillputthechokein
the“ON”positionandmovingthechokelevertothe
rear,tothedetent,willputthechokeinthe“OFF”
position.DoNotrunawarmenginewithchokein
the“ON”position.
g268307
Figure5
Non-EFIModelShown
1.Choke6.FrontReference/Speed
ControlBar
2.Throttle7.RHMotioncontrollever
3.Rearreferencebar8.PTOengagementswitch
4.LHMotioncontrollever9.Ignition
5.Messagedisplay
ThrottleControl
LocatedontheLHsideofthecontrolconsole(red
lever).
Thethrottleisusedtocontrolenginespeed.Moving
thethrottleleverforwardwillincreaseenginespeed
andmovingthethrottlelevertotherearwilldecrease
enginespeed.Movingthethrottleforwardintothe
detentisfullthrottle.
ParkBrakeLever
Locateontheleftsideofthemachine.
Thebrakeleverengagesaparkingbrakeonthedrive
wheels.
15

Operation
Note:TheLCDindicatorappearsinthemessage
displayonthefrontconsolewhentheparkbrakeis
engaged(seeFigure7).
Pulltheleverupandrearwardtoengagethebrake.
Pushtheleverforwardanddowntodisengagethe
brake.
Whenparkingonasteepslope,thewheelsmustbe
chockedorblockedinadditiontothebrakebeing
engaged.Themachinemustbetieddownandbrake
engagedwhentransporting.
Parkbrakemustbedisengagedbeforemovingmotion
controloutofneutralorenginemustbeginshutdown.
IgnitionSwitch
LocatedontheRHsideofthecontrolconsole.
Theignitionswitchisusedtostartandstopthe
engine.Theswitchhasthreepositions“OFF”,“ON”
and“START”.Insertkeyintoswitchandrotate
clockwisetothe“ON”position.Rotateclockwiseto
thenextpositiontoengagethestarter(keymustbe
heldagainstspringpressureinthisposition).Allow
thekeytoreturntothe“ON”positionimmediately
aftertheenginestarts.
g219837
Figure6
1.Off3.Start
2.On
Note:Brakemustbeengaged,motioncontrol
leversout(neutrallockposition)andPTOswitch
disengagedtostartengine.(Itisnotnecessaryforthe
operatortobeontheplatformtostarttheengine.)
Note:TheLCDindicatorsappearwheneachcontrol
meetsthe“safetostart”mode(e.g.theindicator
turnsonwhenPTOisdisengaged).
HourMeter
Locatedinthecenterofthefrontcontrolconsolein
themessagedisplay(seeFigure7).
Thehourmeterrecordsthenumberofhoursthat
theenginehasrun.
g275343
Figure7
1.LCDIndicators
2.Lowvoltageindicatorlight
3.Hour/Voltagedisplay
Thehourmeterisrecordingwhenthedecimalpoint
isashinginHour/Voltagedisplay.
Hoursaredisplayedwhenthekeyisofforwhenthe
machineisrunning.
Note:Iftheignitionkeyisturnedtothe“ON”
positionforafewsecondsbeforecrankingtheengine,
thebatteryvoltagewilldisplayintheareawherethe
hoursarenormallydisplayed.
Note:TheLCDindicatorsappearwheneach
controlmeetsthe“safetostart”mode.
FuelShut-OffValve
•KawasakiModels:LocatedontheRHsideof
themachine,towardstherearoftheengine.
•KohlerModels:LocatedontheLHsideofthe
machine,towardstherearoftheengine.
Thefuelshut-offvalveisusedtoshutoffthefuel
whenthemachinewillnotbeusedforafewdays,
duringtransporttoandfromthejobsite,andwhen
parkedinsideabuilding.
Alignvalvehandlewiththefuellinetoopen.Rotate
90°toclose.
16

Operation
DriveWheelReleaseValves
Locatedontherightrearcornerofthehydrostatic
pumps.
Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
movedbyhandwithouttheenginerunning.
Witha5/8wrench,turnbothvalvesoneturn
counterclockwisetoreleasethedrivesystem.
Turnclockwisetoresetthedrivesystem.Torqueto
110-130in-lb(12-15N-m).DoNotovertighten.
DoNottowmachine.
PTOEngagementSwitch
Locatedinthecenteroftheconsolecontrolbelow
theSmartController(referenceFigure5).
Switchmustbepulledout(up)toengagetheblades.
Switchispushedintodisengagetheblades.
TheLCDindicatorwilldisappearwhenthePTO
switchisengaged(seeFigure7).
LowVoltageError
Locatedontherightconsoleinthemessagedisplay.
RefertotheSmartControllerUser’sGuidefor
moreinformation.
DeckLiftHandle
LocatedontheRHofthefrontcontrolpanel.
Pullthehandlerearwardtoraisethecuttingdeck.
Allowthehandletomoveforwardtolowerthe
cuttingdecktothecutheightthathasbeenset.
Pullthehandleallthewayrearwardtolatchthe
cuttingdeckintotheraisedtransportposition.Pull
rearwardandpushthebuttondown,onthetopof
thelever,tounlatchfromtransport.
BeforeOperation
BeforeOperationSafety
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
•Inspecttheareawherethemachineistobeused
andremoveallrocks,toys,sticks,wires,bones,
andotherforeignobjects.Thesecanbethrown
orinterferewiththeoperationofthemachine
andmaycausepersonalinjurytotheoperatoror
bystanders.
•Thismowerwasdesignedforoneoperatoronly.
DoNotcarrypassengers.
•Wearappropriatepersonalprotectiveequipment
suchassafetyglasses,longpants,substantial
slip-resistantfootwear,andhearingprotection.
Tiebacklonghairandavoidlooseclothingand
loosejewelrywhichmaygettangledinmoving
parts.
•Thismachineproducessoundlevelsinexcessof
85dBAattheoperator’searandcancausehearing
lossthroughextendedperiodsofexposure.Wear
hearingprotectionwhenoperatingthismachine.
•Checkthatthefollowingitemsareinplaceandin
properworkingcondition:theoperatorpresence
controls,safetyswitches,guards,shields,discharge
deectorand/ortheentiregrasscatchersystem.
Donotoperatethemachineunlesstheyarein
properworkingcondition.Replacewornor
deterioratedpartswithgenuineExmarkparts
whennecessary.
DANGER
Itisessentialthatoperatorsafetymechanisms
beconnectedandinproperoperating
conditionpriortouse.Contactingtheblade
canresultinseriouspersonalinjury.
Shutofftheengine,removethekey,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.Whenthekeyisturnedto
the“OFF”position,theengineshouldshut
offandthebladeshouldstop.Ifnot,stop
usingthemachineimmediatelyandcontact
anAuthorizedServiceDealer.
•DoNotoperatethemowerwhenpeople,
especiallychildren,orpetsareinthearea.Shut
offthemachineandattachment(s)ifanyone
entersthearea.
•DoNotoperatethemachinewithouttheentire
grasscollectionsystem,dischargedeector,
orothersafetydevicesinplaceandinproper
workingcondition.Grasscatchercomponents
aresubjecttowear,damageanddeterioration,
whichcouldexposemovingpartsorallowobjects
tobethrown.Frequentlycheckforwornor
17

Operation
deterioratingcomponentsandreplacethemwith
themanufacturer’srecommendedpartswhen
necessary.
FuelSafety
DANGER
Gasolineisextremelyammableandvaporsare
explosive.
Areorexplosionfromgasolinecanburnyou,
others,andcausepropertydamage.
•Fillthefueltankoutdoorsonlevelground,
inanopenarea,whentheengineiscold.If
fuelisspilled,DoNotattempttostartthe
engine.Moveawayfromtheareaofthespill
andavoidcreatinganysourceofignitionuntil
fuelvaporshavedissipated.
•DoNotrellthefueltankordrainthe
machineindoorsorinsideanenclosedtrailer.
•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyspark.
•Addfuelbeforestartingtheengine.Never
removethecapofthefueltankoraddfuel
whenengineisrunningorwhentheengine
ishot.
•Storegasolineinanapprovedcontainerand
keepitoutofthereachofchildren.
•DoNotoperatewithoutentireexhaustsystem
inplaceandinproperworkingcondition.
•Incertainconditionsduringfueling,static
electricitycanbereleasedcausingasparkwhich
canignitegasolinevapors.
–DoNotllcontainersinsideavehicleorona
truckortrailerbedwithaplasticliner.Always
placecontainersonthegroundandawayfrom
yourvehiclebeforelling.
–Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelsonthe
ground.Ifthisisnotpossible,thenrefuel
suchequipmentonatruckortrailerfroma
portablecontainer,ratherthanfromagasoline
dispensernozzle.
–Ifagasolinedispensernozzleisused,keepthe
nozzleincontactwiththerimofthefueltank
orcontaineropeningatalltimesuntilfueling
iscomplete.DoNotuseanozzlelockopen
device.
•DoNotoverllthefueltank.Fillthefueltankto
thebottomofthellerneck.Theemptyspacein
thetankallowsgasolinetoexpand.Overlling
mayresultinfuelleakageordamagetotheengine
oremissionsystem.
•Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporsmaycauseserious
injuryandillness.
–Avoidprolongedbreathingofvapors.
–Keepfaceawayfromnozzleandgas
tank/containeropening.
–Keepawayfromeyesandskin.
•Tohelppreventres:
–Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.
–Cleanupoilandfuelspillsandremovefuel
soakeddebris.
–Allowthemachinetocoolbeforestoringthe
machineinanyenclosure.DoNotstorethe
machineorfuelcontainer,orrefuel,where
thereisanopename,spark,orpilotlight
suchasonawaterheaterorotherappliance.
•Fillbothtankstothesamelevel;whenthe
machineisinuse,thefueltankswilldrawequally.
Ifonetankisnotlledtothesameleveland
emptiessooner,itwillpullairandtheenginewill
notrunproperly.
OperatingInstructions
DuringOperationSafety
GeneralSafety
Theoperatormustusetheirfullattentionwhen
operatingthemachine.DoNotengageinanyactivity
thatcausesdistractions;otherwise,injuryorproperty
damagemayoccur.
18

Operation
WARNING
Operatingengineparts,especiallythemufer,
becomeextremelyhot.Severeburnscanoccur
oncontactanddebris,suchasleaves,grass,
brush,etc.cancatchre.
CleanthemachineasstatedintheMaintenance
section.Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.
•Operatetheengineonlyinwell-ventilatedareas.
Exhaustgasescontaincarbonmonoxide,whichis
anodorlessdeadlypoison.
•Donotoperatethemachinewhileill,tired,or
undertheinuenceofalcoholordrugs.
•Operatethemachineonlyingoodvisibilityand
appropriateweatherconditions.DoNotoperate
themachinewhenthereistheriskoflightning.
•Keepawayfromholes,ruts,bumps,rocks,and
otherhiddenhazards.Usecarewhenapproaching
blindcorners,shrubs,trees,tallgrassorother
objectsthatmayhideobstaclesorobscurevision.
Uneventerraincouldoverturnthemachineor
causetheoperatortolosetheirbalanceorfooting.
•Starttheenginewithyourfeetwellawayfrom
theblades.
•DoNotoperatethemachinewithoutallsafety
shields,guards,switches,andotherdevicesin
placeandinproperworkingcondition.
•Keepyourhandsandfeetawayfromthemoving
parts.Keepclearofthedischargeopening.
•DoNotmowwiththedischargedeector
raised,removed,oralteredunlessthereisa
grass-collectionsystemormulchkitinplaceand
workingproperly.
•Neverraisethedeckwithbladesrunning.
•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.Avoiddischarging
materialagainstawallorobstructionasthe
materialmayricochetbacktowardtheoperator.
Stoptheblades,slowdown,andusecaution
whencrossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
•Bealert,slowdownandusecautionwhen
makingturns.DoNotmowinreverseunlessit
isabsolutelynecessary.Alwayslookdownand
behindyoubeforemovingthemachineinreverse.
•Parkthemachineonlevelground.Stopengine,
waitforallmovingpartstostop,andremovekey.
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.DoNotleave
arunningmachineunattended.
•Stopengine,waitforallmovingpartstostop:
–Beforerefueling.
–Beforedumpingthegrasscatcher.
–Beforemakingheightadjustments.
•Tragicaccidentscanoccuriftheoperatorisnot
alerttothepresenceofchildren.Childrenare
oftenattractedtothemachineandthemowing
activity.Neverassumethatchildrenwillremain
whereyoulastsawthem.
–Keepchildrenoutofthemowingareaand
underthewatchfulcareofanotherresponsible
adult,nottheoperator.
–Bealertandturnthemachineoffifchildren
enterthearea.
–Beforeandwhilebackingorchanging
direction,lookbehind,down,andside-to-side
forsmallchildren.
–Neverallowchildrentooperatethemachine.
–DoNotcarrychildren,evenwiththeblades
shutoff.Childrencouldfalloffandbe
seriouslyinjuredorinterferewiththesafe
operationofthemachine.Childrenthathave
beengivenridesinthepastcouldsuddenly
appearintheworkingareaforanotherrideand
berunoverorbackedoverbythemachine.
SlopeSafety
•Slopesareamajorfactorrelatedtolossofcontrol
androlloveraccidents,whichcanresultinsevere
injuryordeath.Theoperatorisresponsiblefor
safeslopeoperation.Operatingthemachineon
anysloperequiresextracaution.Beforeusingthe
machineonaslope,theoperatormust:
19

Operation
–Reviewandunderstandtheslopeinstructions
inthemanualandonthemachine
–Evaluatethesiteconditionsofthedayto
determineiftheslopeissafeformachine
operation.Usecommonsenseandgood
judgmentwhenperformingthisevaluation.
Changesintheterrain,suchasmoisture,can
quicklyaffecttheoperationofthemachine
onaslope.
•Operateacrossslopes,neverupanddown.Avoid
operationonexcessivelysteeporwetslopes.Poor
footingcouldcauseaslipandfallaccident.
•Identifyhazardsatthebaseoftheslope.Do
notoperatethemachineneardropoffs,ditches,
embankments,waterorotherhazards.The
machinecouldsuddenlyrolloverifawheelgoes
overtheedgeortheedgecollapses.Keepasafe
distancebetweenthemachineandanyhazard.
Useahandheldtooltooperateintheseareas.
•Avoidstarting,stoppingorturningthemachine
onslopes.Avoidmakingsuddenchangesinspeed
ordirection;turnslowlyandgradually.
•Donotoperateamachineunderanyconditions
wheretraction,steeringorstabilityisinquestion.
Beawarethatoperatingthemachineonwetgrass,
acrossslopesordownhillmaycausethemachine
tolosetraction.Lossoftractiontothedrive
wheelsmayresultinslidingandalossofbraking
andsteering.Themachinecanslideevenifthe
drivewheelsarestopped.
•Removeormarkobstaclessuchasditches,holes,
ruts,bumps,rocksorotherhiddenhazards.Tall
grasscanhideobstacles.Uneventerraincould
overturnthemachine.
•Ifyoulosecontrolofthemachine,stepawayfrom
thedirectionoftravelofthemachine.
•Alwayskeepthemachineingearwhengoing
downslopes.Donotcoastdownhill.
OpentheFuelShut-OffValve
Rotatethevalveandalignwiththefuellinetoopen.
StartingtheEngine
1.Movethemotioncontrolleversouttotheneutral
lockposition.
2.Pulltheparkingbrakeupandrearwardtoengage
theparkingbrake.
3.PushdownonthePTOswitchtothe“disengage”
position.
4.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.
5.Onacoldengine,pushthechokeleverforward
intothe“ON”position(exceptKohlerEFIunits).
Onawarmengine,leavethechokeinthe“OFF”
position.
6.Turnignitionswitchtothe“START”position.
Releasetheswitchassoonastheenginestarts.
Important:DoNotcranktheengine
continuouslyformorethantensecondsata
time.Iftheenginedoesnotstart,allowa60
secondcool-downperiodbetweenstarting
attempts.Failuretofollowtheseguidelines
canburnoutthestartermotor.
7.Ifthechokeisinthe“ON”position,gradually
returnchoketothe“OFF”positionastheengine
warmsup.
PTOEngagement
DANGER
Therotatingbladesunderthemowerdeckare
dangerous.Bladecontactcancauseserious
injuryorkillyou.
DoNotputhandsorfeetunderthemoweror
mowerdeckwhenthebladesareengaged.
DANGER
Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryordeath.
Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunlessthere
isagrasscollectionsystemormulchkitinplace
andworkingproperly.
ThePTOswitchengagesthecuttingblades.Besure
allpersonsareclearofmowerdeckanddischarge
areabeforeengagingthePTO.
1.Setthrottleto“MIDWAY”position.
2.Releasetheparkingbrake.
20