Table of Contents
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Table of Contents
Related Manuals for Exmark PIONEER S-SERIES
Summary of Contents for Exmark PIONEER S-SERIES
- Page 1 PIONEER S-SERIES For Serial Nos. 920,000 & Higher Part No. 4500-898 Rev. A...
- Page 2 Replacements may be ordered through the engine manufacturer. Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously.
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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 Adjusting the Seat Ride Suspension....39 Electric Clutch Adjustment......40 Cleaning ............41 Introduction ............3 Clean Engine and Exhaust System Safety ..............5 Area ............41 Safety Alert Symbol ......... 5 Remove Engine Shrouds and Clean Cooling Safe Operating Practices ........5 Fins............ -
Page 5: Safety
English it is the owner’s responsibility to Institute in effect at the time of production. explain this material to them. Exmark designed and tested this lawn mower to offer • Become familiar with the safe operation of the reasonably safe service; however, failure to comply equipment, operator controls, and safety signs. - Page 6 Safety • Inspect the area where the equipment is to be DANGER used and remove all rocks, toys, sticks, wires, In certain conditions during fueling, static bones, and other foreign objects which can be electricity can be released causing a spark thrown by the machine and may cause personal which can ignite gasoline vapors.
- Page 7 Safety Operation damage and make repairs before restarting and operating the mower). WARNING – Before clearing blockages. Operating engine parts, especially the muffler, – Whenever you leave the mower. become extremely hot. Severe burns can occur • Stop engine, wait for all moving parts to stop, and on contact and debris, such as leaves, grass, engage parking brake: brush, etc.
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Page 8: Maintenance And Storage
Safety • Be aware that operating on wet grass, across steep DANGER slopes or downhill may cause the mower to lose Operating on wet grass or steep slopes can cause traction. Loss of traction to the drive wheels may sliding and loss of control. Wheels dropping over result in sliding and a loss of braking and steering. - Page 9 Failure to use original DANGER Exmark parts could cause serious injury or death. Making unauthorized changes to the Charging or jump starting the battery may engine, fuel or venting system, may violate EPA produce explosive gases.
- Page 10 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. •...
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Page 11: 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 12 Safety 109-6014 116-1119 107-2102 116-1121 1. Rotate the drive release 2. Push the machine. knob to loosen, slide the knob, and tighten. 109-3148 116-1496...
- Page 13 Safety 116-3303 116-4465 1. Fast 3. Choke-on 2. Slow 4. Choke-off PTO Switch Symbols 1. PTO–disengage 2. PTO–engage 116-4308 1. Latch 2. Unlatch...
- Page 14 Safety 109-6016 1. Read the instructions before servicing or performing 4. Refer to the Operator’s manual for grease instructions maintenance 2. Time interval 5. Check hydraulic oil level and refer to the Operator’s manual or further instructions 3. Check oil level 6.
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Page 15: Specifications
Manual • Operator must be in seat when PTO is engaged, • Engine Oil Type: Exmark 4–Cycle Premium brake is disengaged, or motion control levers are Engine Oil moved in or engine will stop. -
Page 16: Dimensions
– 48 inch Deck: 3 anti-scalp rollers Hydro Gear ZT3100 – 52 inch Deck: 3 anti-scalp rollers • Hydraulic Oil Type: Exmark Premium Hydro Oil. • Hydraulic Oil Capacity: 7.7 oz (2.3 L) per side • Deck Depth: • Hydraulic Filter: P/N 109-3321 –... -
Page 17: Torque Requirements
Specifications Overall Length: Bolt Location Torque Engine Mounting Bolts 44 inch 48 inch 52 inch (Kawasaki) 27-33 ft-lb (37-45 N-m) Deck Deck Deck Roll Bar - 78.8 inches 77.8 inches 77.8 inches Wheel Lug Nuts 70-90 ft-lb (95-122 N-m) (200.2 cm) (197.6 cm) (197.6 cm) Rollover Protection... -
Page 18: Product Overview
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. -
Page 19: Throttle Control
Operation position. Do Not run a warm engine with choke in The ignition switch is used to start and stop the the “ON” position. engine. The switch has three positions “OFF”, “ON” and “START”. Insert key into switch and rotate clockwise to the “ON”... - Page 20 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°...
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Page 21: Pre-Start
Operation Deck Lift Pedal Make sure you understand the controls, their locations, their functions, and their safety Located at the right front corner of the floor pan. requirements. Push the pedal forward with your foot to raise the Refer to the Maintenance section and perform all the cutting deck. -
Page 22: Starting The Engine
Operation Starting the Engine 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. -
Page 23: Stopping The Engine
Operation Important: To begin movement (forward or The PTO push-pull switch engages the cutting blades. Be sure that all persons are clear of the mower deck backward) the operator must be in the seat, the and discharge area before engaging PTO. brake lever must be disengaged (pushed down) before the motion control levers can be moved in Important: Operator must be in seat before the... -
Page 24: Adjusting The Cutting Height
Operation Figure 15 1. Transport lock handle 3. Height of cut decal 2. Height adjustment pin 4. Deck foot pedal Figure 14 1. Front of Unit 3. Neutral 2. Forward 4. Reverse 5. Insert the height adjustment pin into the hole corresponding to the desired cutting height. -
Page 25: Transporting
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. - Page 26 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.
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Page 27: Maintenance
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 The engine can become very hot. Touching a hot made, someone could start the engine. engine can cause severe burns. -
Page 28: Periodic Maintenance
“FULL” 12.4 – 12.6 75–100% 30 Minutes 16 volts/7 mark on the dipstick. Exmark 4-Cycle Premium amps Engine Oil is recommended; refer to the Engine 12.2 – 12.4 50–75% 1 Hour 16 volts/7 Owner’s manual for an acceptable alternative. -
Page 29: Check Mower Blades
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. -
Page 30: Check Safety Interlock System
Check Safety Interlock Note: If machine does not pass any of these tests, do not operate. Contact your authorized EXMARK System SERVICE DEALER. Service Interval: Before each use or daily... -
Page 31: Check Seat Belt
Before reinstalling new filter, apply a thin coating Service Interval: Before each use or daily of Exmark 4–Cycle Premium Engine Oil on the 1. Stop engine, wait for all moving parts to stop, and surface of the rubber seal. Turn filter clockwise remove key. -
Page 32: Check Tire Pressures
Refer to the following chart for fitting locations hydraulic oil. and lubrication schedule. 3. Check expansion tank and if necessary add Lubrication Chart Exmark Premium Hydro Oil to the FULL COLD line (see Figure 21). Fitting Initial Number of Service... -
Page 33: Check Spark Plugs
Important: To prevent seal and bearing damage, Important: Before reinstalling new filters, check the bearing adjustment often. Spin the apply a thin coat of Exmark Premium Hydro caster tire. The tire should not spin freely Oil on the surface of the filters rubber seal. -
Page 34: Check Spark Arrester (If Equipped)
A. With the bypass valve open and the engine Hydro Oil Change Interval running, slowly move the directional control Exmark Premium Hydro 500 Hours in both forward and reverse (5 or 6 times). Oil (Preferred) B. With the bypass valve closed and the engine... -
Page 35: Thread Locking Adhesives
Maintenance Thread Locking Adhesives Adjustments Thread locking adhesives such as “Loctite 242” Note: Disengage PTO, shut off engine, wait for or “Fel-Pro, Pro-Lock Nut Type” are used on the all moving parts to stop, engage parking brake, and following fasteners: remove key before servicing, cleaning, or making any adjustments to the unit. -
Page 36: Adjusting The Blade Slope
Maintenance Figure 26 Figure 25 44 Inch Deck 1. Leveling adjust locking 3. Deck hanger nuts 1. Blades side to side 2. Measure here 2. Deck lift arm 4. Chain 11. Recheck that blocks fit just snugly under the deck 7. -
Page 37: Pump Drive Belt Tension
Maintenance blocks (see Block Height and Rake Table in Deck or when a brake component has been removed or Leveling) under each side of the front edge of the replaced. deck, but not under the anti-scalp roller brackets. 1. Drive the machine onto a level surface. 7. -
Page 38: Motion Control Handle Adjustment
Maintenance • Adjusting the Brake to Engage: Shorten the 1. Loosen the upper bolt holding the control lever linkage by turning the yoke clockwise. to the control arm shaft. 2. Loosen the lower bolt just enough to pivot the • Adjusting the Brake to Disengage: control lever fore or aft Figure 29. -
Page 39: Adjusting The Seat Ride Suspension
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. -
Page 40: Electric Clutch Adjustment
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. -
Page 41: Cleaning
Maintenance Cleaning Clean Engine and Exhaust System Area G011733 Service Interval: Before each use or daily (May be required more Figure 35 often in dry or dirty conditions.) 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. -
Page 42: Clean Debris From Machine
Maintenance 1. Stop engine, wait for all moving parts to stop, and recycling center or according to your state and local remove key. Engage parking brake. regulations. 2. Slide seat all the way forward. Battery Disposal 3. Remove accumulated debris from the hydro fan cooling fins and upper surfaces. -
Page 43: 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 44 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.
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Page 45: Schematics
Schematics Schematics Electrical Diagram... - Page 46 Schematics Electrical Logic Schematic...
- Page 47 Exmark Service Dealer before obtaining any warranty service. conditions herein, that we will repair, replace or adjust any part on these Contact any Exmark Service Dealer to arrange service at their dealership. products and found by us (in the exercise of our reasonable discretion) to To locate a dealer convenient to you, access our website at be defective in factory materials or workmanship.
- Page 48 Notes:...
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Page 49: Service Record
Service Record Date: Description of Work Done: Service Done By:... - Page 51 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.
- Page 52 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...