Staris® S-Series

• Engine Specifications: See your Engine Owner’s Manual

• Engine Oil Type: Exmark 10W-50 Premium Synthetic Engine Oil

• RPM: Full Speed: 3650 ±100 RPM (No Load)

• Capacity: 10.0 gal. (37.9 L)Two tanks 5.0 gal (18.9 L) each

• 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.

  • Both tanks must have fuel or air will enter the system and cause poor engine performance or prevent engine from running.

  • Do Not add oil to gasoline.

• Fuel Filter: In-line fuel filter

• Fuel Shut-Off Valve: 1/4 turn

• Charging System: Flywheel Alternator

• Charging Capacity:

  Kawasaki: 15 amps

  Kohler EFI: 20 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

• 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 not illuminate at this time.

• PTO must be disengaged and motion control levers out (neutral lock) 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.

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.

• 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 canister 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:

  • 0-10.0 mph (16 km/hr) forward.

  • 0-4.0 mph (6 km/hr) reverse.

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

Drive wheels are direct coupled to Parker wheel drive motors with 1 1/4 inch (31.8 mm) tapered shaft.

Drive

Front Caster (All Models)

• Cutting Width:

  • 48 inch Deck: 48 inches (121.9 cm)

  • 52 inch Deck: 52 inches (132.1 cm)

  • 60 inch Deck: 60 inches (152.4 cm)

• Discharge: Side

• Blade Size: (3 ea.)

  • 48 inch Deck: 16.25 inches (41.3 cm)

  • 52 inch Deck: 18.00 inches (45.7 cm)

  • 60 inch Deck: 20.50 inches (52.1 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.

  60 inch Deck: Anti-scalp rollers provide maximum turf protection.

• Deck Depth:

  • 48 inch Deck: 5.5 inches (14.0 cm)

  • 52 inch Deck: 5.5 inches (14.0 cm)

  • 60 inch Deck: 5.5 inches (14.0 cm)

• Cutting Height Adjustment:

  Adjusts from 1 1/2 inch (3.8 cm) to 5 inches (12.7 cm) in 1/4 inch (6.4 mm) increments

• Mulching Kit: Optional

• Bagger: Optional

Note: Weights will vary slightly depending on engine.

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).

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 motion control levers are in the neutral lock position, a LCD indicator displays on the message display.

Note: When the motion control levers are moved inward, a LCD indicator appears in the operator presence of the message display.

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.

Figure 5

Non-EFI Model Shown

1. Choke
2. Throttle
3. Rear reference bar
4. LH Motion control lever
5. Message display
6. Front Reference/Speed Control Bar
7. RH Motion control lever
8. PTO engagement switch
9. Ignition

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.

Locate on the left 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 7).

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.

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 6

1. Off
2. On
3. Start

Note: Brake must be engaged, motion control levers out (neutral lock position) and PTO switch disengaged to start engine. (It is not necessary for the operator to be on the platform to start the engine.)

Note: The LCD indicators appear when each control meets the “safe to start” mode (e.g. the indicator turns on when PTO is disengaged).

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.

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.

• Kawasaki Models: Located on the RH side of the machine, towards the rear of the engine.

• Kohler Models: 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.

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.

Turn clockwise to reset the drive system. Torque to 110-130 in-lb (12-15 N-m). Do Not overtighten. Do Not tow machine.

Located in the center of the console control below the Smart Controller (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).

Located on the right console in the message display.

Refer to the Smart Controller User’s Guide for more information.

Located on the RH of the front control panel.

Pull the handle rearward to raise the cutting deck. Allow the handle to move forward to lower the cutting deck to the cut height that has been set.

Pull the handle all the way rearward to latch the cutting deck into the raised transport position. Pull rearward and push the button down, on the top of the lever, to unlatch from transport.

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

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

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 (except Kohler EFI units).

   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.

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.

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.

1. Set the throttle midway between the “SLOW” and “FAST” positions.

2. Push down on the PTO switch to disengage the blades.

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.

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

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

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.

   

   Figure 9

   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 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.

   

   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.

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.

The cutting height of the mower deck is adjusted from 1.5 to 5 inches (3.8 cm to 12.7 cm) in 1/4 inch (6.4 mm) increments.

1. Stop the machine and move the motion control levers outward to the neutral locked position.

2. Disengage the PTO.

3. Raise and lock the deck to the 5 inch (12.7 cm) transport position (Figure 11).

   The deck is raised by pulling the deck lift handle rearward and to the right to place it into the transport lock position

   Note: When changing the cutting height positions, always come to a complete stop and disengage the PTO.

   

   Figure 11

   1. Deck lift handle

4. Insert the height adjustment pin into the hole corresponding to the desired cutting height.

   See the decal on the top of the deck lift plate for cut heights.

5. Pull the deck lift handle rearward, depress the release button and push slowly downward to allow the deck to lower to the cutting height.

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

1. Disengage the PTO.

2. Bring the unit to a full stop.

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

4. Engage the parking brake.

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

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

7. Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of the positions shown in Figure 12. 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.

   

   Figure 12

   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

8. Be sure roller bolts are installed with the spring disc washer between head of the bolt and mounting bracket (outer anti-scalp rollers only).

9. Torque the 3/8-16 nyloc nut.

   • For the outer anti-scalp rollers, torque to 50–55 ft-lb (68-75 N-m) (Figure 13).

     

     Figure 13

     Outer Anti-Scalp Roller

     1. 3/8-16 x 3 3/4 Grade 8 bolt
     2. Spring disc washer (cone towards bolt )
     3. Front right anti-scalp bracket shown
     4. 3/8 nyloc-torque to 50–55 ft-lb (68-75 N-m)

   • For the center anti-scalp rollers, torque to 30-35 ft-lb (41-47 N-m).

     

     Figure 14

     Center Anti-Scalp Roller

     1. 3/8 inch nyloc-torque to 30-35 ft-lb (41-47 N-m)
     2. Anti-scalp rollers
     3. Wheel spacer
     4. 3/8-16 x 7 3/8 inch bolt

Important: Refer to the Engine Owner’s Manual for additional maintenance procedures.

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.

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.

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. This is especially important on Kohler EFI (Electronic Fuel Injection) models. Failure to do so may damage the ECU (Electronic Control Unit).

Important: For Kohler EFI Models: Disconnect the battery and unplug the harness from the engine ECU before performing any welding on the equipment.

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 or EFI 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.

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 and/or EFI system.

   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).

   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.

   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 15.

   

   Figure 15

   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

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).

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:

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

      

      Figure 16

      1. Install bushing in blade prior to installing bushing in spindle.

   2. Install bushing/blade assembly into spindle.

      

      Figure 17

      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.

   3. 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).

   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.

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.

   

   Figure 18

   1. Thigh pad
   2. Wireform
   3. Released position
   4. Locked position

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.

When the cover is removed, it allows access to the engine oil and starter EFI fuel system.

1. Raise and lock the thigh pad.

2. Grab the top of the rear guard and pull rearward.

3. The tabs at the bottom of the rear guard will pop loose from the brake shaft. Lift the guard from the slots in the frame and remove.

   

   Figure 19

   1. Rear guard
   2. Slot

To reinstall the rear guard, insert the three tabs into the slots in the bottom of the frame (see Figure 19). Push the guard forward and snap over the brake shaft.

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

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	Check the safety interlock system.

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

		System
		PTO (Blades)	Motion Control Levers	Outcome
	State of System	Disengaged	Both levers out (neutral)	Starter should crank
		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.

		System
		PTO (Blades)	Motion Control Levers	Outcome
	State of System	Disengaged	Both levers not in neutral	Starter must not crank
		Engaged	Both levers in neutral	Starter must not crank

Check Shutdown Circuit Chart

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

		System
		Engine	PTO (Blades)	Motion Control Levers	Outcome
	State of System	Running idle (1/3 throttle)	Engaged	Both levers out (neutral lock)	PTO must begin shutdown within 1 second; engine stays running.

		System
		Engine	Parking Brake	Motion Control Levers	Outcome
	State of System	Running idle (1/3 throttle)	Engaged	Both levers not in neutral	Engine must begin shutdown within 1 second

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.

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

2. See the Engine Owner's Manual for maintenance instructions.

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

2. Lift and lock the thigh pad. Remove and retain the rear guard.

3. Drain oil while engine is warm from operation.

4. The oil drain hose assembly is located on the left side of the engine.

   Place pan under machine to catch oil. Remove oil drain plug. Allow oil to drain and replace oil drain plug. Torque plug to 20-24 ft-lb (27-33 N-m).

5. 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 10W-50 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.

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

7. 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.

8. Wipe up any spilled oil from engine deck mounting surfaces.

9. Reinstall the rear guard and lower the thigh pad.

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

2. Lift and lock the thigh pad.

3. Clean area around hydraulic reservoir cap and remove cap. Oil level should be 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 20 for oil levels.

   

   Figure 20

   1. Full
   2. Add

   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.

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 13 psi (90 kPa).

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

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.

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

   Fitting Locations	Initial Pumps	Number of Places	Service Interval
   1. Deck Belt Idler Pivot	1	1	Yearly
   2. Front Caster Pivots	*0	2	*Yearly

   * See step 3 for special lubrication instructions on the front caster pivots.

3. Lubricate front caster pivots once a year. Remove hex plug and cap. Thread grease zerk in hole and pump with grease until it oozes out around top bearing. Remove grease zerk and thread plug back in. Place cap back on.

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

   

   Figure 21

   1. Seal guard
   2. Spacer nut with wrench flats

2. Remove caster wheel from caster forks.

3. Remove seal guards from the wheel hub.

4. Remove one of the spacer nuts from the axle assembly in the caster wheel. Note that thread locking adhesive has been applied to lock the spacer nuts to the axle. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly.

5. Pry out seals, and inspect bearings for wear or damage and replace if necessary.

6. Pack the bearings with a NLGI grade #1 multi-purpose grease.

7. Insert one bearing, one new seal into the wheel.

   Note: Seals (Exmark P/N 103-0063) must be replaced.

8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward. Do Not thread spacer nut all of the way onto the end of the axle. Leave approximately 1/8 inch (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut.

9. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.

10. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of NLGI grade #1 multi-purpose grease.

11. Insert the second bearing and new seal into the wheel.

12. Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward.

13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-torque to 20-25 in-lb (2-3 N-m). Make sure axle does not extend beyond either nut.

14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall caster bolt and tighten nut fully.

Important: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster tire. The tire should not spin freely (more than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust torque on spacer nut until there is a slight amount of drag. Reapply thread locking adhesive.

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

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

Note: It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage.

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. Lift and lock the thigh pad. Remove and retain the rear guard.

3. Place a catch pan under the hydro filter which is located near the right rear tire.

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.

   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.

   Turn filter clockwise until rubber seal contacts the filter adapter, then tighten the filter an additional 2/3 to 3/4 turn.

6. Fill reservoir as stated in Check Hydraulic Oil Level.

   Exmark Premium Hydro Oil is recommended. Refer to the chart for an acceptable alternative:

   Hydro Oil	Service Interval
   Exmark Premium Hydro Oil (Preferred)	After first 250 hours*Every 500 hours/Yearly thereafter
   Mobil 1 15W50	After first 250 hours *Every 250 hours/Yearly thereafter

   *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.

   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.

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

9. Start engine and move throttle control ahead to full throttle position. Move RH motion control leversinward (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.

   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 22) may have lost their “prime”. Refer to Hydraulic System Air Purge section.

10. Reinstall the rear guard and lower the thigh pad.

11. Remove the jack stands.

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.

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 22). Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is “primed”.

Figure 22

1. Charge pump cap
2. Loosen 1 1/2 turns only

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 RH motion control lever 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.

   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 22) 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.

Torque the nut on the wheel motor tapered shaft to 175-225 ft-lb (237-305 N-m).

Note: Do Not use anti-seize compound on the wheel hub.

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.

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

• Pump pulley setscrews.

• Pulley retaining bolt in end of engine PTO.

• Clutch retaining bolt in end of crank.

• Caster wheel spacer nuts.

• Platform suspension pivot shaft.

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 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 pulleys.

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.

1. Position the mower on a flat surface.

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

3. Check the tire pressure in drive tires and pneumatic front caster tires (if equipped). Proper inflation pressure for tires is 13 psi (90 kPa). Adjust if necessary.

4. Pull the deck lift handle all the way rearward to latch the cutting deck into the raised transport position.

5. Insert the height adjustment pin into the 3 inch (7.6 cm) cutting height location.

6. Release the transport lock and allow the deck to lower to the cutting height.

7. Raise the discharge deflector.

8. Measure from the level surface to the front tip of the center blade. The measurement should read 3 inches (7.6 cm).

   Note: In most conditions, the back tips on the side blades should be adjusted 1/4 inch (6.4 mm) higher than the front.

   

   Figure 23

   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

9. Adjust the height — to increase, turn the adjuster screw clockwise; to decrease, turn counterclockwise. Fine tune the front deck lift assembly by turning the adjuster screw until it reaches the 3 inch (7.6 cm) height (see Figure 24).

   

   Figure 24

   1. Adjuster screw
   2. Jam nut

10. Measure the back tip height. Fine tune rear adjusters as required; the single point adjustment can be utilized to gain more adjustment. The back tips of the side blades should measure 3 1/4 inches (8.3 cm).

11. Re-measure until all four sides are the correct height. Tighten all the nuts on the deck lift arm assemblies.

12. Lower the discharge deflector.

13. If the four deck adjusters do not have enough adjustment to achieve accurate cut height with the desired rake, the single point adjustment can be utilized to gain more adjustment (see Figure 25).

    

    Figure 25

    1. Front height-of-cut plate mounting bolts
    2. Single point height adjustment bolt
    3. Rear height-of-cut plate mounting bolt

14. To adjust the single point system, first loosen the front and rear height-of-cut plate mounting bolts.

15. If the deck is too low, tighten the single point adjustment bolt by rotating it clockwise. If the deck is too high, loosen the single point adjustment bolt by rotating it counterclockwise.

    Note: Loosen or tighten the single point adjustment bolt enough to move the height-of-cut plate mounting bolts at least 1/3 the length of the available travel in their slots. This will regain some up and down adjustment on each of the four deck links.

16. Re-tighten front and rear height-of-cut plate mounting bolts.

    Important: Torque the front and rear height-of-cut plate mounting bolts to 27-33 ft-lb (37-45 N-m).

17. Repeat steps 8 through 12.

Self-tensioning - No adjustment necessary.

Self-tensioning - No adjustment necessary.

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 snubber should lift off the tires and the hand lever should travel forward. When engaging the brake, lift the handle up and rearward. With the brake disengaged, measure the distance between the snubber teeth and the tire.

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. 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.

4. Disengage the park brake.

5. Remove the rear guard from the machine.

6. Reach inside the oval cutout to loosen the jam nut as shown in Figure 26.

   

   Figure 26

   1. Jam nut
   2. Turnbuckle

7. Rotate the turnbuckle to achieve .50 inch (12.7 mm) clearance between the brake snubber teeth and the tire.

8. To decrease the gap, turn the turnbuckle clockwise (as viewed from the top).

9. Tighten the jam nut once the .50 inch (12.7 mm) is achieved.

10. Check the brake operation again.

No adjustment necessary. However when the clutch brake has worn to the point where the clutch no longer engages consistently, the shim can be removed to extend the clutch life.

Figure 27

1. Armature
2. Field shell
3. Rotor
4. Brake mounting bolt
5. Brake spacer
6. Re-gap shim
7. Brake pole

Removing the Shim:

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. Allow the machine to cool completely before starting these instructions.

2. Using a pneumatic line, blow out any debris from under the brake pole and around the brake spacers.

3. Check the condition of the wire harness leads, connectors, and terminals. Clean or repair as necessary.

4. Verify that 12V is present at the clutch connector when the PTO switch is engaged.

5. Measure the gap between the rotor and armature. If the gap is greater than .04 inch (1 mm), proceed with the following steps:

   1. Loosen both brake mounting bolts one-half to one full turn (see Figure 28).

      Note: Do Not remove the brake pole from the field shell/armature. The brake pole has worn to match the armature and needs to continue to match after the shim is removed to ensure proper brake torque.

      

      Figure 28

      1. Brake mounting bolt
      2. Shim

   2. Using needle nose pliers, or by hand, take hold of the tab and remove the shim (Do Not discard the shim until proper clutch function has been confirmed).

   3. Using a pneumatic line, blow out any debris from under the brake pole and around the brake spacers.

   4. Re-torque each bolt (M6 x 1) to 10 ft-lb (13 N-m) +/-0.5 ft-lb (0.7 N-m).

   5. Using a 0.010 inch thick feeler gauge, verify that a gap is present between the rotor and armature face on both sides of the brake pole as shown. (Due to the way the rotor and armature faces wear (peaks and valleys) it is sometimes difficult to measure the true gap.)

      

      Figure 29

      1. Feeler gauge
      

      Figure 30

      1. Feeler gauge

      • If the gap is less than 0.010 inch, then reinstall the shim and reference the Troubleshooting section.

      • If the gap is sufficient, proceed to the safety check in step 6.

   6. Perform the following safety check:

      1. Start the engine.

      2. Make sure the blades Do Not engage with the PTO switch “off” and the clutch disengaged.

         If the clutch does not disengage, reinstall the shim and reference the Troubleshooting section.

      3. Engage and disengage the PTO switch ten consecutive times to ensure the clutch is functioning properly. If the clutch does not engage properly, reference the Troubleshooting section.

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. Prior to starting the engine, pull the deck lift handle rearward and push the button down, on the top of the lever, to unlatch from transport. Lower deck to the ground.

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

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

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

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

5. Bring the motion control levers into the neutral position. Access the links from the front of the tower (Figure 31). 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 31). 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.

   

   Figure 31

   1. Lower nut
   2. Upper nut
   3. Links

6. Shut off unit.

7. Remove the jack stands.

8. Raise the deck and re-install the height of cut pin.

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

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.

   

   Figure 32

   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

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 33).

   

   Figure 33

   1. Cam nut

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.

Remove dust cap from caster and tighten nyloc nut until washers are flat and back off 1/4 of a turn to properly set the pre-load on the bearings. If disassembled, make sure the spring disc washers are reinstalled as shown in Figure 34.

Figure 34

1. Spring disc washers

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: 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 motors.

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.

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.

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.