PIONEER S-SERIES For Serial Nos. 920,000 & Higher Part No. 4500-898 Rev.
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: The engine in this product is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code (CPRC) Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land as defined in CPRC 4126.
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY. Figure 1 1.
Contents Adjusting the Seat Ride Suspension.................39 Electric Clutch Adjustment.............................40 Cleaning ............................................................41 Clean Engine and Exhaust System Area ...........................................................41 Remove Engine Shrouds and Clean Cooling Fins...............................................41 Clean Hydro Fan Cooling Fins ........................41 Clean Debris From Machine ...........................
Safety Safety Safe Operating Practices Safety Alert Symbol Training • Read the Operator’s Manual and other training material. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them. • Become familiar with the safe operation of the equipment, operator controls, and safety signs. • All operators and mechanics should be trained. The owner is responsible for training the users.
Safety • Inspect the area where the equipment is to be used and remove all rocks, toys, sticks, wires, bones, and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders. DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage.
Safety Operation damage and make repairs before restarting and operating the mower). WARNING – Before clearing blockages. Operating engine parts, especially the muffler, become extremely hot. Severe burns can occur on contact and debris, such as leaves, grass, brush, etc. can catch fire. • Allow engine parts, especially the muffler, to cool before touching. • Remove accumulated debris from muffler and engine area.
Safety • Be aware that operating on wet grass, across steep slopes or downhill may cause the mower to lose traction. Loss of traction to the drive wheels may result in sliding and a loss of braking and steering. • Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope. • Follow the manufacturer’s recommendations for wheel weights or counter weights to improve stability. • Use extreme care with grass catchers or attachments.
Safety • Keep engine and engine area free from accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas. These materials can become combustible and may result in a fire. DANGER Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns. Swallowing electrolyte can be fatal or if it touches skin can cause severe burns.
Safety WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. • If equipped, make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.
Safety Safety and Instructional Decals • New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg. Co. Inc. • Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels. • Replace all worn, damaged, or missing safety signs. • When replacement components are installed, be sure that current safety signs are affixed to the replaced components.
Safety 109-6014 116-1119 107-2102 116-1121 1. Rotate the drive release knob to loosen, slide the knob, and tighten. 2. Push the machine.
Safety 116-3303 116-4465 1. Fast 2. Slow 3. Choke-on 4. Choke-off PTO Switch Symbols 1. PTO–disengage 116-4308 1. Latch 2. Unlatch 13 2.
Safety 109-6016 1. Read the instructions before servicing or performing maintenance 2. Time interval 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 3. Check oil level 116-4430 1. Park brake — engage 4. Neutral 2. Fast 3. Slow 5.
Specifications Specifications Model Numbers Serial Nos: 920,000 and Higher PNS20KA443; PNS22KA483; PNS24KA523 Systems Safety Interlock System • PTO must be disengaged, brake engaged, and motion control levers out (neutral lock) to start engine. (It is not necessary for the operator to be in the seat to start the engine.) • Operator must be in seat when PTO is engaged, brake is disengaged, or motion control levers are moved in or engine will stop.
Specifications – 48 inch Deck: (121.9 cm) armrests, integral safety switch, and seat vibration isolation system. – 52 inch Deck: (132.1 cm) Optional seat accessories for units with standard seats: • Discharge: Side • Blade Size: – Custom ride suspension system to enhance Standard Seat. Adds approximately 3 inches (7.6 cm) to seat height. – Deluxe suspension seat with high back, (dampened, adjustable spring suspension), armrests, and integral safety switch. Adds approximately 1/2 inch (1.
Specifications Overall Length: Bolt Location Torque 44 inch Deck 48 inch Deck 52 inch Deck Engine Mounting Bolts (Kawasaki) 27-33 ft-lb (37-45 N-m) Roll Bar Up 78.8 inches (200.2 cm) 77.8 inches (197.6 cm) 77.8 inches (197.6 cm) Wheel Lug Nuts 70-90 ft-lb (95-122 N-m) Roll Bar Down 79.6 inches (202.2 cm) 78.6 inches (199.6 cm) 78.6 inches (199.
Operation Product Overview Operation Note: Determine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control levers located on each side of the 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.
Operation 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. position. Do Not run a warm engine with choke in the “ON” position. Figure 7 Figure 6 1. Throttle lever 4.
Operation 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. Drive Wheel Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury or death.
Operation tank allows gasoline to expand. Overfilling may result in fuel leakage or damage to the engine or emission system. Switch must be pulled out (up) to engage the blades. Switch is pushed in to disengage the blades. Deck Lift Pedal Located at the right front corner of the floor pan. Make sure you understand the controls, their locations, their functions, and their safety requirements. Push the pedal forward with your foot to raise the cutting deck.
Operation Starting the Engine 1 2 3 1. Move the motion control levers out to the neutral lock position. 2. Pull up and back on the parking brake lever to engage the parking brake. 3. Push down on the PTO switch to the “disengage” position. 4 5 Note: It is not necessary for the operator to be in the seat to start the engine. 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.
Operation Important: To begin movement (forward or backward) the operator must be in the seat, the brake lever must be disengaged (pushed down) before the motion control levers can be moved in or the engine will stop. The PTO push-pull switch engages the cutting blades. Be sure that all persons are clear of the mower deck and discharge area before engaging PTO. Important: Operator must be in seat before the PTO can be engaged.
Operation Figure 15 Figure 14 1. Front of Unit 2. Forward 3. Neutral 4. Reverse 1. Transport lock handle 3. Height of cut decal 2. Height adjustment pin 4. Deck foot pedal 4. Insert the height adjustment pin into the hole corresponding to the desired cutting height. Driving in Reverse See the decal on the side of the deck lift plate for cut heights. 1. Move the motion control levers inward to the neutral operate position. 5.
Operation Transporting Transporting a Unit Use a heavy-duty trailer or truck to transport the machine. Lock brake and block wheels. Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Be sure that the trailer or truck has all necessary lighting and marking as required by law. Secure a trailer with a safety chain. CAUTION Figure 16 For cutting heights above 3.5 inches (90 mm) use the bottom hole. The rollers will still be effective against scalping. 1.
Operation tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward. If it is not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp. Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck Do Not exceed 15°. A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck.
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING WARNING While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders. The engine can become very hot. Touching a hot engine can cause severe burns. Allow the engine to cool completely before service or making repairs around the engine area.
Maintenance Periodic Maintenance the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater. Check Engine Oil Level Important: Make sure the negative battery cable is disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery (see chart for recommended charger settings). Service Interval: Before each use or daily 1.
Maintenance 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.
Maintenance lock position. The operator does not need to be in the seat to start the engine. Try to start with operator in seat, parking brake disengaged, PTO disengaged and motion control levers in the neutral lock position - starter must not crank. Try to start with operator in seat, parking brake engaged, PTO engaged and motion control levers in the neutral lock position - starter must not crank. Figure 19 1. Spindle 2. Blade 3.
Maintenance Check Rollover Protections Systems (Roll Bar) Knobs element; replace if dirty. (May need more often under severe conditions. See the Engine Owner's Manual for additional information.) Service Interval: Before each use or daily Check that both the mounting hardware and the knobs are in good working condition. Make sure the knobs are fully engaged with the ROPS in the raised position.
Maintenance Check Hydraulic Oil Level Lubricate Grease Fittings Service Interval: Before each use or daily Note: See chart for service intervals. 1. Stop engine and wait for all moving parts to stop. Engage parking brake. 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Wait until the unit cools before checking the hydraulic oil. 2. Lubricate fittings with one to two pumps of NGLI grade #2 multi-purpose gun grease. 3.
Maintenance Check Spark Plugs 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.
Maintenance 5. Remove the vent plug on each transmission and fill through expansion reservoir, when oil comes out of vent reinstall plug. WARNING Engine must be running and drive wheels must be turning so adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury. Exmark Premium Hydro Oil is recommended.
Maintenance Adjustments 3. If any breaks in the screen or welds are observed, replace arrester. 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. 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.
Maintenance Figure 26 Figure 25 44 Inch Deck 1. Blades side to side 1. Leveling adjust locking nuts 2. Deck lift arm 2. Measure here 7. Set anti-scalp rollers to top holes or remove completely for this adjustment. Adjusting the Blade Slope Block Height and Rake Table Front Block Height “A” Rear Block Height “B” Rake “R” 44 2.69 inches (6.8 cm) 2.99 inches (7.6 cm) 1/8–3/8 inch (3.2–9.5 mm) 48 & 52 2.77 inches (7.0 cm) 2.81 inches (7.1 cm) 1/16–5/16 inch (1.6–7.9 mm) 4. Chain 11.
Maintenance Check to make sure brake is adjusted properly. This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced. each side of the cutting deck. Place two “A” thick blocks (see Block Height and Rake Table in Deck Leveling) under each side of the front edge of the deck, but not under the anti-scalp roller brackets. 7.
Maintenance • Adjusting the Brake to Engage: Shorten the linkage by turning the yoke clockwise. • Adjusting the Brake to Disengage: Lengthen the linkage by turning the yoke counterclockwise. 8. Reinstall the clevis pin and hair pin and tighten down the jam nut. Repeat step 6 and readjust if necessary. 9. When adjustment is complete, remove the jack stands or equivalent support and lower the machine. 10. Place the machine into the “operating” position.
Maintenance with a 1/2 inch wrench allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only. WARNING Engine must be running and drive wheels must be turning so adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury. Keep fingers, hands, and clothing clear of rotating components and hot surfaces. 1. Prior to starting the engine, push the deck lift pedal and remove the height of cut pin.
Maintenance 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: A. Loosen both brake mounting bolts one-half to one full turn (see Figure 34). Note: Do Not remove the brake pole from the field shell/armature.
Maintenance Cleaning Clean Engine and Exhaust System Area G011733 Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) 1 Figure 35 1. Feeler gauge 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.
Maintenance 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Slide seat all the way forward. 3. Remove accumulated debris from the hydro fan cooling fins and upper surfaces. recycling center or according to your state and local regulations. Battery Disposal DANGER Clean Debris From Machine Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns. Swallowing electrolyte can be fatal or if it touches skin can cause severe burns.
Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of trouble. Do not attempt to service or replace major items or any items that call for special timing of adjustment procedures (such as valves, governor, etc.).
Troubleshooting Problem Engine loses power Possible Cause Corrective Action 1. Engine load is excessive 1. Reduce the ground speed. 2. Air cleaner is dirty. 3. Oil level in the crankcase is low. 4. Cooling fins and air passages for the engine are plugged. 5. Dirt in fuel filter. 6. Dirt, water, or stale fuel is in the fuel system. 2. Clean or replace the air cleaner element. 3. Add oil to the crankcase. 4. Remove the obstructions from the cooling fins and air passages. 5. Replace the fuel filter. 6.
Schematics Schematics Electrical Diagram 45
Schematics Electrical Logic Schematic 46
Pioneer S-Series Turf Equipment 2 Year Limited Commercial Warranty 4 Year or 500 Hours Limited Consumer Warranty General Warranty Conditions and Products Covered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part on these products and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship.
Notes: 48
Service Record Date: Description of Work Done: 49 Service Done By:
G011841 Figure 37 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope indicator to determine the degree of slope of hills before operating. Do Not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3. Example of how to compare slope with folded edge.
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID-MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM (ROPS) DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO-MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM OUT-FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL-TAIL WHEEL SN
