Exmark STARIS S Series Operator'S Manual Download Page 47

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Troubleshooting

Important:

It is essential that all operator safety mechanisms be connected and in proper operating

condition prior to mower use.

When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused
by an empty fuel tank.

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

Engine Service Dealer

Note:

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

Problem

Possible Cause

Corrective Action

1. PTO is engaged.

1. Disengage the PTO.

2. One of the speed control levers are not

in neutral position.

2. Ensure the speed control lever is in the

neutral position.

3. Battery does not have a full charge.

3. Charge the battery. See

Check Battery

Charge

and

Recommended Jump

Starting Procedure

sections in

Maintenance.

4. Electrical connections are corroded, loose

or faulty.

4. Check the electrical connections for

good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.

5. Fuse is blown.

5. Replace the blown fuse.

6. Neutral LCD indicator does not

illuminate.

6. Check reed switch.

Starter does not crank.

7. Relay or switch is defective.

7. Contact an Authorized Service Dealer.

1. Fuel tank is empty.

1. Fill both fuel tanks.

2. Fuel shutoff valve is closed.

2. Open the fuel shutoff valve.

3. The throttle and choke are not in the

correct position.

3. Be sure the throttle control is midway

between the “SLOW” and “FAST”
positions, and the choke is in the “ON”
position for a cold engine or the “OFF”
position for a warm engine.

4. Dirt in fuel filter.

4. Replace the fuel filter.

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

system.

5. Contact an Authorized Service Dealer.

6. Air cleaner is dirty.

6. Clean or replace the air cleaner element.

7. Electrical connections are corroded, loose

or faulty.

7. Check the electrical connections for

good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.

8. Relay or switch is defective.

8. Contact an Authorized Service Dealer.

9. Faulty spark plug.

9. Clean, adjust or replace spark plug.

10. Spark plug wire is not connected.

10. Check the spark plug wire connection.

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

11. MIL illuminates and blinks

11. Contact an Authorized Service Dealer.

Summary of Contents for STARIS S Series

Page 1: ...STARIS S SERIES For Serial Nos 408 644 346 Higher Part No 4505 317 Rev A ...

Page 2: ... is equipped with a spark arrester as defined in Section 4442 maintained in effective working order or the engine is constructed equipped and maintained for the prevention of fire To acquire a spark arrester for your unit see your Engine Service Dealer For all models that do not have Exmark engines please refer to the engine manufacturer s information included with the machine For models with Exma...

Page 3: ...uals If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secu...

Page 4: ...e Grease Fittings 35 Lubricate Caster Wheel Hubs 35 Check Spark Plugs 36 Change Hydraulic System Filter and Fluid 36 Wheel Hub Nut Torque Specification 38 Check Spark Arrester if equipped 38 Thread Locking Adhesives 39 Mobil HTS Grease Or Food Grade Anti seize 39 Copper Based Anti seize 39 Dielectric Grease 39 Adjustments 39 Deck Leveling 39 Pump Drive Belt Tension 41 Mower Deck Drive Belt Tension...

Page 5: ... of amputating hands and feet and of throwing objects Always follow all safety instructions to avoid serious personal injury and death Read understand and follow all instructions and warnings in the Operator s Manual and on the machine engine and attachments All operators and mechanics should be trained If the operator s or mechanic s can not read this manual it is the owner s responsibility to ex...

Page 6: ...ty signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower decal98 1977 98 1977 1 Entanglement hazard belt stay away from moving parts decal106 5517 106 5517 1 Wa...

Page 7: ...727 decal119 6807 119 6807 1 Warning no step 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 3 Nyloc nut torque to 50 55 ft lb 68 75 N m 4 Roller 5 Bushing 6 Mount bracket 7 Spring disc washer decal126 2055 126 2055 1 Wheel lug nut torque to 129 N m 95 ft lb 2 Wheel hub nut torque to 319 N m ...

Page 8: ... Routing decal135 2266 135 2266 1 Read the instructions before servicing or performing maintenance 2 Time interval 3 Check oil level 4 Refer to the Operator s manual for grease instructions 5 Check hydraulic oil level and refer to the Operator s manual or further instructions 6 Check tire pressure decal135 2280 135 2280 1 Height of cut decal135 5206 135 5206 1 Unlock 2 Lock 8 ...

Page 9: ... in place 3 Cutting dismemberment of hand or foot stay away from moving parts keep all guards and shields in place decal142 3077 142 3077 1 Read the Operator s manual 4 Do Not overfill 2 Hydraulic fluid 5 Warning Do Not touch the hot surface 3 Correct fill level when cold decal135 6844 135 6844 1 Read the Operator s manual 2 Only use Exmark 10W 50 engine oil decal142 3157 142 3157 9 ...

Page 10: ...e 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 Throttle fast 10 Engine on 3 Reverse 7 Continuous variable setting 11 Engine start 4 Choke on 8 Throttle slow 12 Optional light accessory 10 ...

Page 11: ...in place Stop engine and remove key before adjusting servicing or cleaning 5 Cutting dismemberment hazard Mow across slopes not up and down Do Not mow wet slopes use extreme caution when operating on slopes 3 Warning Disengage PTO move drive levers out to neutral lock position engage parking brake and stop engine before leaving the operator s position 6 Crushing dismemberment hazard of bystanders ...

Page 12: ...ity Negative Ground Fuses 20 amp charging system fuse 15 amp accessory fuse Safety Interlock System LCD indicators appear for the park brake drive levers and operator presence in the message display on the front control panel Note Because the PTO must be disengaged to start the engine the LCD indicator will not illuminate at this time PTO must be disengaged and motion control levers out neutral lo...

Page 13: ...ll 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 increme...

Page 14: ...m Outer Anti Scalp Roller Nyloc Nut See Figure 13 60 Inch Deck Only 50 55 ft lb 68 75 N m Center Anti Scalp Roller Nyloc Nut See Figure 14 60 Inch Deck Only 30 35 ft lb 41 47 N m Engine Mounting Bolts Kawasaki Kohler 30 35 ft lb 41 47 N m 27 33 ft lb 37 45 N m Wheel Lug Nuts 85 105 ft lb 115 142 N m Wheel Hub Nuts 211 260 ft lb 286 352 N m Wheel Motor Mounting Bolts 67 83 ft lb 91 113 N m Hydro Pu...

Page 15: ...lay Note When the motion control levers are moved inward a LCD indicator appears in the operator presence of the message display Choke Control All Models Except Kohler EFI 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 rea...

Page 16: ...t 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 Hour Meter Located in the center of the front control console in the message display see Figure 7 The hour meter records the number of hours that the engine has run g275343 Figure 7 1 LCD Indicators 2 ...

Page 17: ...he machine and may cause personal injury to the operator or bystanders This mower was designed for one operator only Do Not carry passengers Wear appropriate personal protective equipment such as safety glasses long pants substantial slip resistant footwear and hearing protection Tie back long hair and avoid loose clothing and loose jewelry which may get tangled in moving parts This machine produc...

Page 18: ...sible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle is used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do Not use a nozzle lock open device Do Not overfill the fuel tank Fill the fuel tank to the bottom of the filler neck...

Page 19: ...rfaces other than grass and when transporting the mower to and from the area to be mowed Be alert slow down and use caution when making turns Do Not mow in reverse unless it is absolutely necessary Always look down and behind you before moving the machine in reverse Park the machine on level ground Stop engine wait for all moving parts to stop and remove key Before checking cleaning or working on ...

Page 20: ...e in gear when going down slopes Do not coast downhill Open the Fuel Shut Off Valve Rotate the valve and align with the fuel line to open Starting the Engine 1 Move the motion control levers out to the neutral lock position 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 FA...

Page 21: ...ON Machine can spin very rapidly by positioning one lever too much ahead of the other Operator may lose control of the machine which may cause damage to the machine or injury Use caution when making turns Slow the machine down before making sharp turns Important To begin movement forward or backward the brake lever must be disengaged pushed forward before the motion control levers can be moved or ...

Page 22: ...Bar 1 Insert a 7 32 inch allen wrench through the hole on one side of the control tower panel Place a 9 16 inch wrench on the corresponding nut located underneath the control tower Loosen the bolt and repeat for the opposite side of the front reference bar see Figure 8 2 Rotate the bar forward or rearward limiting the forward travel of the control levers until desired maximum forward speed is achi...

Page 23: ... 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 an...

Page 24: ... engine and engine area free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Frequently check for worn or deteriorating components that could create a hazard Tighten loose hardware Transporting Transporting the Machine Use a heavy duty trailer or truck to transport the mac...

Page 25: ...r near a slope position the trailer or truck so it is on the down side of the slope and the ramps extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible Important Do Not attempt to turn the machine while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing do...

Page 26: ... the machine engine fuel or venting system may violate applicable safety standards such as ANSI OSHA and NFPA and or government regulations such as EPA and CARB WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may resul...

Page 27: ...grass build up from under the deck Every 50 hours Check the hydraulic oil level Check the tire pressures Check the condition of the belts Grease the lift linkage pivots Check spark arrester if equipped Every 80 hours Remove engine shrouds and clean cooling fins Every 100 hours Change the engine oil May need more often under severe conditions Every 160 hours Check the spark plugs Every 250 hours Re...

Page 28: ... 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 DANGER Charging or jump starting the bat...

Page 29: ...ctrolyte 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 ...

Page 30: ...p and remove key Engage parking brake 2 Lift deck and secure in raised position as stated in the Clean Grass Build Up Under Deck section 3 Inspect blades and sharpen or replace as required 4 Reinstall the blades if they were removed in the following order A Install bushing through blade with bushing flange on bottom grass side of blade g006780 Figure 16 1 Install bushing in blade prior to installi...

Page 31: ...will lock in the up position g266465 Figure 18 1 Thigh pad 3 Released position 2 Wireform 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 Removing the Rear Guard Service Interval As required When the cover is removed it allows access to the engine oil and starter EFI fuel system 1 Raise and lock th...

Page 32: ... should crank Up position but blades disengaged Both levers out neutral Starter should crank State of System 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 Starti...

Page 33: ...tion Control Levers Outcome Running idle 1 3 throttle Engaged Both levers out neutral lock PTO must begin shutdown within 1 second engine stays running State of System System Engine Parking Brake Motion Control Levers Outcome Running idle 1 3 throttle Engaged Both levers not in neutral Engine must begin shutdown within 1 second State of System 33 ...

Page 34: ... 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...

Page 35: ...r blade drive belt condition 3 Look under the engine deck to check the pump drive belt condition 4 Check all idler arms to be sure they pivot freely Lubricate Grease Fittings Note See chart for service intervals 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate fittings with NLGI grade 2 multi purpose gun grease Refer to the following chart for fitting...

Page 36: ...e 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 beari...

Page 37: ...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 eng...

Page 38: ...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 leve...

Page 39: ... of contact Dielectric grease should not be applied to sealed connectors Adjustments Note Disengage PTO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit Deck Leveling 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 t...

Page 40: ...3 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 g266542 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 re...

Page 41: ...nt 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 Figu...

Page 42: ...ke 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 g011734 Figure 28 1 Brake mounting bolt 2 Shim B Using needle nose pliers or by hand take hold of the tab and remove the shim Do Not discard the ...

Page 43: ...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...

Page 44: ...ion from the rear of the machine 6 Loosen the nut holding the cam see Figure 33 g267325 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 verti...

Page 45: ...ty conditions CAUTION Excessive debris around engine cooling air intake and exhaust system area can cause engine exhaust area and hydraulic system to overheat which can create a fire hazard Clean all debris from engine and exhaust system area 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 s...

Page 46: ...fety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is being replaced or if the ...

Page 47: ...ctrical contact cleaner apply dielectric grease and reconnect 5 Fuse is blown 5 Replace the blown fuse 6 Neutral LCD indicator does not illuminate 6 Check reed switch Starter does not crank 7 Relay or switch is defective 7 Contact an Authorized Service Dealer 1 Fuel tank is empty 1 Fill both fuel tanks 2 Fuel shutoff valve is closed 2 Open the fuel shutoff valve 3 The throttle and choke are not in...

Page 48: ... 3 Mower deck is not level 3 Level mower deck from side to side and front to rear 4 Underside of mower is dirty 4 Clean the underside of the mower 5 Tire pressure in drive tires not correct 5 Adjust tire pressure in the drive tires 6 Blade spindle bent 6 Contact an Authorized Service Dealer Uneven cutting height 7 Tips of adjacent blades are at an uneven cutting height Blades tips should be even w...

Page 49: ...cessary 2 Low voltage supply at the clutch 2 Check coil resistance battery charge charging system and wiring connections and replace if necessary 3 Damaged coil 3 Replace clutch 4 Inadequate current supply 4 Repair or replace clutch lead wire or electrical system Clean connector contacts Clutch will not engage 5 Rotor armature airgap is too large 5 Remove shim or replace clutch 49 ...

Page 50: ...Schematics Schematics Electrical Schematic Kawasaki g303795 50 ...

Page 51: ...Schematics Electrical Schematic Kohler EFI g303794 51 ...

Page 52: ...Schematics Hydraulic Diagram g304191 52 ...

Page 53: ...estaurants grocery stores hotels schools and hospitals and on a wide variety of products Additionally some online and mail order retailers provide Prop 65 warnings on their websites or in catalogs How do the California warnings compare to federal limits Prop 65 standards are often more stringent than federal and international standards There are various substances that require a Prop 65 warning at...

Page 54: ...Service Record Date Description of Work Done Service Done By 54 ...

Page 55: ...55 ...

Page 56: ...TOM RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB Some accessories and options not available for some models Place Model No and Serial No Label Here Included in the Literature Pack or Fill in...

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