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Exmark STARIS S Series Operator's Manual

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STARIS
S-SERIES
®
For Serial Nos.
408,644,346 & Higher
Part No. 4505-317 Rev. A

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Summary of Contents for Exmark STARIS S Series

  • Page 1 STARIS S-SERIES ® For Serial Nos. 408,644,346 & Higher Part No. 4505-317 Rev. A...
  • Page 2 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.

  • Page 3: Introduction

    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.

  • Page 4: Table Of Contents

    Contents Park Brake Adjustment........41 Electric Clutch Adjustment......41 Motion Control Adjustment ......43 Introduction ............3 Adjust Motion Control Handle Safety ..............5 Position............43 Safety Alert Symbol ......... 5 Caster Pivot Bearings Pre-Load General Safety ..........5 Adjustment ..........44 Safety and Instructional Decals ....... 6 Cleaning ............45 Specifications ............12 Cleaning and Storing Safety......45...

  • Page 5: Safety

    Safety Safety on the machine, engine, and attachments. All operators and mechanics should be trained. If the operator(s) or mechanic(s) can not read this This machine has been designed in conformance with manual, it is the owner’s responsibility to explain the American National Standards Institute–B71.4 this material to them;...

  • Page 6: Safety And Instructional Decals

    Exmark equipment dealer or labels. distributor or from Exmark Mfg. Co. Inc. • Replace all worn, damaged, or missing safety • Safety signs may be affixed by peeling off the signs.
  • Page 7 Safety decal119-6807 119-6807 1. Warning—no step decal116-8253 116-8253 1. Rotate counterclockwise 3. Unlock to push machine. to release. 2. Rotate clockwise to lock. 4. Read the instructions before servicing or performing maintenance. decal126-0898 126-0898 1. Read the Operator’s manual 2. 3/8-16 x 3 3/4 inch bolt. Bolt must be Grade 8. Bolt and spring disc washer must be installed as shown.
  • Page 8 Safety decal126-7875 126-7875 1. Fuse location 4. Auxiliary, 15A 2. Relay location 5. Start relay 3. Main, 20A 6. Not used decal133-8062 decal135-2280 133-8062 135-2280 1. Height of cut decal135-2267 135-2267 Drive Pump Belt Routing decal135-5206 135-5206 1. Unlock 2. Lock decal135-2266 135-2266 1.
  • Page 9 142-3077 1. Read the Operator’s 4. Do Not overfill manual. 2. Hydraulic fluid 5. Warning-Do Not touch the hot surface. Correct fill level when cold decal135-6844 135-6844 1. Read the Operator’s 2. Only use Exmark manual 10W-50 engine oil...
  • Page 10 Safety decal135-6772 135-6772 EFI Models 1. Forward 5. Throttle-slow 9. Engine-start 2. Neutral 6. Continuous variable setting 10. Optional light accessory 3. Reverse 7. Engine-off 4. Throttle-fast 8. Engine-on decal135-6773 135-6773 Non-EFI Models 1. Forward 5. Choke-off 9. Engine-off 2. Neutral 6.
  • Page 11 Safety decal135-2412 135-2412 4. Thrown object hazard-Pick up objects that could be thrown 1. Warning-Read the Operator’s Manual. Do Not operate this machine unless you are trained. Wear hearing protection. by mower. Keep bystanders away. Keep deflector in place. 2. Warning-Stay away from moving parts; keep all guards 5.

  • Page 12: Specifications

    Parker/Ross wheel drive motors. – Do Not add oil to gasoline. • Hydraulic Oil: Use Exmark Premium Hydro Oil. • Fuel Filter: In-line fuel filter • Hydraulic Oil Capacity: 2.4 qt. (2.2 L) • Fuel Shut-Off Valve: 1/4 turn •...

  • Page 13: Dimensions

    Specifications Wheel Drive System • Deck: Full floating deck is attached to support frame, removable for service. Deck design allows Drive wheels are direct coupled to Parker wheel drive for bagging, mulching or side discharge. motors with 1 1/4 inch (31.8 mm) tapered shaft. 60 inch Deck: Anti-scalp rollers provide maximum turf protection.

  • Page 14: Torque Requirements

    Product Overview Curb Weight: Product Overview 48 inch Deck 52 inch Deck 60 inch Deck 960 lb 990 lb 1045 lb (435 kg) (449 kg) (474 kg) Note: Weights will vary slightly depending on engine. Torque Requirements Bolt Location Torque Cutter Housing Spindle 130-160 ft-lb (176-217 N-m)

  • Page 15: Operation

    Operation Operation Choke Control (All Models Except Kohler EFI) Note: Determine the left and right sides of the Located on the LH side of the control console (black machine from the normal operating position. lever) (see Figure 5). The choke is used to aid in starting a cold engine. Controls Moving the choke lever forward will put the choke in the “ON”...
  • Page 16 Operation Hour Meter Note: The LCD indicator appears in the message display on the front console when the park brake is Located in the center of the front control console in engaged (see Figure 7). the message display (see Figure 7). Pull the lever up and rearward to engage the brake.

  • Page 17: Before Operation

    Do not operate the machine unless they are in switch is engaged (see Figure 7). proper working condition. Replace worn or deteriorated parts with genuine Exmark parts Low Voltage Error when necessary. Located on the right console in the message display.

  • Page 18: Operating Instructions

    Operation deteriorating components and replace them with or container opening at all times until fueling the manufacturer’s recommended parts when is complete. Do Not use a nozzle lock open necessary. device. • Do Not overfill the fuel tank. Fill the fuel tank to Fuel Safety the bottom of the filler neck.
  • Page 19 Operation is absolutely necessary. Always look down and WARNING behind you before moving the machine in reverse. Operating engine parts, especially the muffler, • Park the machine on level ground. Stop engine, become extremely hot. Severe burns can occur wait for all moving parts to stop, and remove key. on contact and debris, such as leaves, grass, –...
  • Page 20 Operation – Review and understand the slope instructions Push down on the PTO switch to the “disengage” in the manual and on the machine position. – Evaluate the site conditions of the day to Place the throttle midway between the “SLOW” determine if the slope is safe for machine and “FAST”...
  • Page 21 Operation Move the motion control levers to the center, (pushed forward) before the motion control operate position. levers can be moved or the engine will stop. Pull the PTO switch outward to engage the blades. When the motion control levers are positioned fully outward (apart), the drive system is in the PTO Place the throttle in the “FAST”...
  • Page 22 Operation g009474 Figure 10 To turn left or right, release pressure on the g009473 motion control lever toward the desired turn Figure 9 direction. To stop, position both motion control levers in the neutral operate position. To turn left or right, pull the motion control lever back toward neutral in the desired turn direction.
  • Page 23 Operation Note: When changing the cutting height Note: For Maximum Deck Flotation, place positions, always come to a complete stop rollers one hole position lower. Rollers should and disengage the PTO. maintain 1/4 inch (6.35 mm) clearance to ground. Do Not adjust rollers to support the deck. g265194 Figure 11 g281695...

  • Page 24: After Operation

    Operation After Operation Torque the 3/8-16 nyloc nut. • For the outer anti-scalp rollers, torque to General Safety 50–55 ft-lb (68-75 N-m) (Figure 13). • Park machine on level ground, disengage drives, set parking brake, stop engine, remove key or disconnect spark plug wire.
  • Page 25 Operation WARNING WARNING Driving on the street or roadway without turn Loading a machine on a trailer or truck increases signals, lights, reflective markings, or a slow the possibility of backward tip-over. Backward moving vehicle emblem is dangerous and can tip-over could cause serious injury or death.

  • Page 26: Maintenance

    The use of improper components to the original equipment or failure to use can result in system failure, gasoline leakage original Exmark parts could lead to serious and possible explosion. injury or death. Unauthorized changes to the Use only approved fuel lines and fuel filters machine, engine, fuel or venting system, may for high pressure systems.

  • Page 27: Recommended Maintenance Schedule(S)

    Maintenance • Keep your hands and feet away from moving parts or hot surfaces. If possible, do not make adjustments with the engine running. • Keep all parts in good working condition and all hardware tightened, especially the blade-attachment hardware. Recommended Maintenance Schedule(s) Maintenance Service Maintenance Procedure...

  • Page 28: Periodic Maintenance

    “FULL” • In the event of an accident, flush with water mark on the dipstick. Exmark 4-Cycle Premium and call a doctor immediately. Engine Oil is recommended; refer to the Engine Owner's manual for an appropriate API rating and viscosity.
  • Page 29 Connecting the jumper cables incorrectly approved for use with AGM type batteries with an (wrong polarity) can immediately damage the output of 3.5 amps or less. Exmark recommends electrical and/or EFI system. the use of battery charger P/N 135-7024. Make...

  • Page 30: Check Mower Blades

    Maintenance g006780 Figure 16 g012785 Figure 15 1. Install bushing in blade prior to installing bushing in spindle. 1. Positive (+) cable on discharged battery 2. Positive (+) cable on booster battery 3. Negative (–) cable on the booster battery Install bushing/blade assembly into spindle.
  • Page 31 Always install the original Exmark blades, blade bushings, and blade bolts as shown. Lift the Thigh Pad for Rear...

  • Page 32: Check Safety Interlock System

    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.
  • Page 33 Maintenance 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 Engaged Both levers out (neutral PTO must begin shutdown Running idle (1/3 lock) within 1 second;...

  • Page 34: Check For Loose Hardware

    Stop engine, wait for all moving parts to stop, and the holes in the engine deck. Before the new remove key. Engage parking brake. filter is installed, apply a thin coating of Exmark Visually inspect machine for any loose hardware 10W-50 Premium Engine Oil on the surface of or any other possible problem.

  • Page 35: Check Tire Pressures

    Pivots incorrect if the oil is checked when the unit is hot. If the dipstick oil level does not register on the dipstick, add Exmark Premium Hydro Oil. Do Not overfill. Replace hydraulic reservoir cap and tighten until snug. Do Not overtighten.

  • Page 36: Check Spark Plugs

    Insert the second bearing and new seal into the wheel. Note: Use only Exmark Part No. 109-4180 for Apply a thread locking adhesive to the 2nd spacer Summer use above 32°F (0°C) or P/N 1-523541 for nut and thread onto the axle with the wrench flats Winter use below 32°F (0°C) (Refer to Transmission...
  • Page 37 (together) and move both levers forward with equal pressure, and run for one it with Exmark Premium Hydro oil and apply minute. Shut down the machine, allow the hydros a thin coat of oil on the surface of the rubber to cool and recheck oil level.

  • Page 38: Wheel Hub Nut Torque Specification

    Maintenance 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.

  • Page 39: Thread Locking Adhesives

    Maintenance Adjustments in solvent if necessary). Reinstall arrester on exhaust outlet. Note: Disengage PTO, shut off engine, wait for all moving parts to stop, engage parking brake, and Thread Locking Adhesives remove key before servicing, cleaning, or making any adjustments to the unit. Thread locking adhesives such as “Loctite 242”...
  • Page 40 Maintenance can be utilized to gain more adjustment. The back tips of the side blades should measure 3 1/4 inches (8.3 cm). Re-measure until all four sides are the correct height. Tighten all the nuts on the deck lift arm assemblies.

  • Page 41: Pump Drive Belt Tension

    Maintenance Important: Torque the front and rear height-of-cut plate mounting bolts to 27-33 ft-lb (37-45 N-m). Repeat steps 8 through 12. Pump Drive Belt Tension Self-tensioning - No adjustment necessary. Mower Deck Drive Belt Tension Self-tensioning - No adjustment necessary. Check the Park Brake Park the machine on a level surface.
  • Page 42 Maintenance g011732 Figure 27 g011734 Figure 28 1. Armature 5. Brake spacer 2. Field shell 6. Re-gap shim 1. Brake mounting bolt 2. Shim 3. Rotor 7. Brake pole 4. Brake mounting bolt Using needle nose pliers, or by hand, take hold of the tab and remove the shim (Do Not Removing the Shim: discard the shim until proper clutch function...

  • Page 43: Motion Control Adjustment

    Maintenance Start engine. Brake must be engaged and motion control levers out to start engine. Run engine at full throttle and release brake. Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature.

  • Page 44: Caster Pivot Bearings Pre-Load Adjustment

    Maintenance Note: Adjust the horizontal alignment before the Note: Moving the flat portion of the cam front to back alignment. clockwise lowers the handle, while moving it counterclockwise raises the handle Stop engine, wait for all moving parts to stop, and remove key.

  • Page 45: Cleaning

    Maintenance Cleaning CAUTION Excessive debris around engine cooling air intake and exhaust system area can cause engine, Cleaning and Storing Safety exhaust area, and hydraulic system to overheat • Park machine on level ground, disengage drives, which can create a fire hazard. set parking brake, stop engine, and remove key.

  • Page 46: Waste Disposal

    Maintenance Waste Disposal 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. Battery Disposal DANGER Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns.

  • Page 47: Troubleshooting

    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.
  • Page 48 Troubleshooting Problem Possible Cause Corrective Action Engine loses power 1. Engine load is excessive 1. Reduce the ground speed. 2. Air cleaner is dirty. 2. Clean or replace the air cleaner element. 3. Oil level in the crankcase is low. 3.
  • Page 49 Troubleshooting Problem Possible Cause Corrective Action Clutch will not engage. 1. Fuse is blown. 1. Replace fuse. Check coil resistance, battery charge, charging system, and wiring connections and replace if necessary. 2. Low voltage supply at the clutch. 2. Check coil resistance, battery charge, charging system, and wiring connections and replace if necessary.

  • Page 50: Schematics

    Schematics Schematics Electrical Schematic—Kawasaki g303795...
  • Page 51 Schematics Electrical Schematic–Kohler EFI g303794...
  • Page 52 Schematics Hydraulic Diagram g304191...

  • Page 53: Information

    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...
  • Page 54 Service Record Date: Description of Work Done: Service Done By:...
  • Page 56 Pack) or Fill in Below Engine Model No. and Spec. No. Model No. Engine Serial No. (E/No) Serial No. ©2021 Exmark Mfg. Co., Inc. Part No. 4505-317 Rev. A 415 Industrial Row (402) 223-6375 Beatrice, NE 68310 Fax (402) 223-5489...

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