Exmark PIONEER S-SERIES Operators User manual

PIONEER®S-SERIES
ForSerialNos.
315,000,000&Higher
PartNo.4502-317Rev.A

WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemical
orchemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:Theengineinthisproductisnot
equippedwithasparkarrestermufer.Itisa
violationofCaliforniaPublicResourceCode
(CPRC)Section4442touseoroperatethis
engineonanyforest-covered,brush-covered,
orgrass-coveredlandasdenedinCPRC4126.
Otherstatesorfederalareasmayhavesimilar
laws.
Toacquireasparkarresterforyourunit,seeyour
EngineServiceDealer.
Thissparkignitionsystemcomplieswiththe
CanadianstandardICES-002.Cesystèmed’allumage
parètincelledevèhiculeestconformeàlanorme
NMB-002duCanada.
TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.
KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.
Labeledpowerratingsaresuppliedbytheengine
manufacturerinaccordancewithSAEtesting
andgross/netpowerratingstandards(J1940,
J1995,J1349).
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2014ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE683102
Contactusatwww.Exmark.com.
PrintedintheUSA
AllRightsReserved

Introduction
CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.
Important:Tomaximizesafety,performance,
andproperoperationofthismachine,itis
essentialthatalloperatorscarefullyreadand
fullyunderstandthecontentsoftheOperator’s
manualprovidedwiththeproduct.Safe
operationofExmarkequipmentisessential.
Failuretocomplywiththeoperatinginstructions
orreceivepropertrainingmayresultininjury.
Gotohttp://www.Exmark.comforadditional
safeoperationinformation,suchassafetytips,
trainingmaterials,andOperator’smanuals.
Ifadditionalinformationisneeded,orshould
yourequiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
3

Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals......................11
Specications........................................................16
ModelNumbers.............................................16
Systems..........................................................16
Dimensions....................................................18
TorqueRequirements.....................................19
ProductOverview.................................................20
Operation..............................................................20
Controls.........................................................20
Pre-Start.........................................................23
OperatingInstructions...................................23
Transporting..................................................28
Maintenance..........................................................30
RecommendedMaintenanceSchedule(s)............30
PeriodicMaintenance........................................31
CheckEngineOilLevel..................................31
CheckBatteryCharge.....................................31
CheckMowerBlades......................................32
CheckSafetyInterlockSystem........................33
CheckRolloverProtectionsSystems(Roll
Bar)Knobs.................................................34
CheckSeatBelt...............................................34
CheckforLooseHardware.............................34
ServiceAirCleaner.........................................34
ChangeEngineOil.........................................34
CheckHydraulicOilLevel..............................35
CheckTirePressures......................................35
CheckConditionOfBelts...............................35
LubricateGreaseFittings................................35
CheckSparkPlugs..........................................36
ChangeHydraulicSystemFilterand
Fluid..........................................................36
CheckSparkArrester(ifequipped)..................37
ThreadLockingAdhesives..............................38
Copper-BasedAnti-seize...............................38
DielectricGrease............................................38
Adjustments......................................................38
DeckLeveling................................................38
AdjustingtheBladeSlope...............................39
PumpDriveBeltTension................................40
DeckBeltTension..........................................40
AdjustingtheParkingBrake............................40
MotionControlHandleAdjustment...............41
FullForwardTrackingAdjustment..................42
MotionControlLinkageAdjustment..............42
AdjustingtheSeatRideSuspension.................43
ElectricClutchAdjustment.............................43
Cleaning............................................................45
CleanEngineandExhaustSystem
Area...........................................................45
RemoveEngineShroudsandClean
CoolingFins...............................................45
CleanHydroFanCoolingFins........................45
CleanDebrisFromMachine...........................45
CleanGrassBuild-UpUnderDeck.................45
WasteDisposal...............................................45
Troubleshooting....................................................47
Schematics............................................................49
4

Safety
Safety
SafetyAlertSymbol
ThislawnmowermeetsorexceedstheB71.4
specicationsoftheAmericanNationalStandards
Instituteineffectatthetimeofproduction.
Exmarkdesignedandtestedthislawnmowertooffer
reasonablysafeservice;however,failuretocomply
withthefollowinginstructionsmayresultinpersonal
injury.
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents.
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
SafetyAlertSymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Indicatesanimminentlyhazardous
situationwhich,ifnotavoided,Willresultindeathor
seriousinjury.
WARNING:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Couldresultindeath
orseriousinjury.
CAUTION:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Mayresultinminor
ormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readthismanual,itistheowner’sresponsibilityto
explainthismaterialtothem;otherlanguagesmay
beavailableonourwebsite.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
•Onlyadultsandmatureteenagersshouldoperate
amower,andevenmatureteenagersshouldhave
adultsupervision.Besureateenager:
1.hasreadandunderstandstheOperator's
Manualandrecognizestherisksinvolved;
2.issufcientlymaturetousecaution;and
3.isofsufcientsizeandweighttooperate
thecontrolscomfortablyandtomanagethe
mowerwithouttakingrisks.
•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,andhearingprotection.Do
Notoperatewhenbarefootorwhenwearingopen
sandals.Longhair,looseclothingorjewelrymay
gettangledinmovingparts.
CAUTION
Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.
Wearhearingprotectionwhenoperatingthis
machine.
5

Safety
•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
DANGER
Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.
Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.
•Fillthefueltankoutdoorsonlevelground,
inanopenarea,whentheengineiscold.
Wipeupanygasolinethatspills.
•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.
•DoNotllthefueltankcompletelyfull.
Fillthefueltanktothebottomoftheller
neck.Theemptyspaceinthetankallows
gasolinetoexpand.Overllingmayresult
infuelleakageordamagetotheengine
oremissionsystem.
•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyspark.
•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.
•Addfuelbeforestartingtheengine.Never
removethecapofthefueltankoradd
fuelwhenengineisrunningorwhenthe
engineishot.
•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
DANGER
Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.
•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.
•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.
•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.
•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.
•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.Do
Notuseanozzlelockopendevice.
WARNING
Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgas
tank/containeropening.
•Keepawayfromeyesandskin.
•Neversiphonbymouth.
•Checkthattheoperatorpresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
6

Safety
Operation
WARNING
Operatingengineparts,especiallythemufer,
becomeextremelyhot.Severeburnscanoccur
oncontactanddebris,suchasleaves,grass,
brush,etc.cancatchre.
•Allowengineparts,especiallythemufer,to
coolbeforetouching.
•Removeaccumulateddebrisfrommuferand
enginearea.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcankill
you.
DoNotrunengineindoorsorinasmallconned
areawheredangerouscarbonmonoxidefumes
cancollect.
•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,
DoNotoperatethemachine;seekshelter.
•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.Useseatbelts
withtherollbarintheraisedandlockedposition.
•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly.
•DoNotchangetheenginegovernorsettingor
overspeedtheengine.
•Parkmachineonlevelground.Stopengine,wait
forallmovingpartstostop,removekeyand
engageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.
•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:
–Beforerefueling.
–Beforedumpingthegrasscatcher.
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesinplace
andworkingproperly.
•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
•NEVERcarrypassengers.DONOToperate
themowerwhenpeople,especiallychildren,or
petsareinthearea.
•Bealert,slowdownandusecautionwhen
makingturns.Lookbehindandtothesidebefore
changingdirections.
•Stoptheblades,slowdown,andusecaution
whencrossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.
•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.
7

Safety
DANGER
Operatingonwetgrassorsteepslopescancause
slidingandlossofcontrol.Wheelsdroppingover
edges,ditches,steepbanks,orwatercancause
rollovers,whichmayresultinseriousinjury,
deathordrowning.
•DoNotmowslopeswhengrassiswet.
•DoNotmowneardrop-offsornearwater.
•DoNotmowslopesgreaterthan15degrees.
•Reducespeedanduseextremecautionon
slopes.
•Avoidsuddenturnsorrapidspeedchanges.
•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.
•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
•Useawalkbehindmowerand/orahandtrimmer
neardrop-offs,ditches,steepbanksorwater.
(Figure3).
Figure3
1.SafeZone-Usethemowerhereonslopeslessthan15
degrees
2.DangerZone-Useawalkbehindmowerand/orhand
trimmeronslopesgreaterthan15degrees,near
drop-offsandwater.
3.Water
•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.
•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandalossofbrakingandsteering.
•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.
UsingtheRolloverProtectionSystem
(ROPS)
ARolloverProtectionSystem(rollbar)isinstalled
ontheunit.
WARNING
Thereisnorolloverprotectionwhentherollbar
isdown.Wheelsdroppingoveredges,ditches,
steepbanks,orwatercancauserollovers,which
mayresultinseriousinjury,deathordrowning.
•DoNotremovetheROPS.
•Keeptherollbarintheraisedandlocked
positionanduseseatbelt.
•Lowertherollbaronlywhenabsolutely
necessary.
•DoNotwearseatbeltwhentherollbaris
down.
•Driveslowlyandcarefully.
•Raisetherollbarassoonasclearance
permits.
•Becertainthattheseatbeltcanbereleasedquickly
intheeventofanemergency.
•Checkcarefullyforoverheadclearances(i.e.
branches,doorways,andelectricalwires)before
drivingunderanyobjectsandDoNotcontact
them.
•Intheeventofarollover,taketheunittoan
AuthorizedServiceDealertohavetheROPS
inspected.
8

Safety
•ReplaceadamagedROPS.DoNotrepairor
revise.
•Anyaccessories,alterations,orattachmentsadded
totheROPSmustbeapprovedbyExmark.
MaintenanceandStorage
•Disengagedrives,setparkingbrake,stopengine
andremovekeyordisconnectsparkplugwire.
Waitforallmovementtostopbeforeadjusting,
cleaningorrepairing.
•Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.
•LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.
•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.
•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.
•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.
•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.
DANGER
Chargingorjumpstartingthebatterymay
produceexplosivegases.Batterygasescan
explodecausingseriousinjury.
•Keepsparks,ames,orcigarettesaway
frombattery.
•Ventilatewhenchargingorusingbattery
inanenclosedspace.
•Makesureventingpathofbatteryis
alwaysopenoncebatteryislledwith
acid.
•Alwaysshieldeyesandfacefrombattery.
DANGER
Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.
•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.
•DoNotswallowelectrolyte.
•Intheeventofanaccident,ushwith
waterandcalladoctorimmediately.
CAUTION
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagementof
components.Sparkscouldcauseanexplosion
ormovingpartscouldaccidentallyengage
causingpersonalinjury.
Besureignitionswitchisinthe“OFF”
positionbeforechargingthebattery.
•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
•Checkallboltsfrequentlytomaintainproper
tightness.
•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
9

Safety
WARNING
Removalormodicationoforiginalequipment,
partsand/oraccessoriesmayalterthewarranty,
controllability,andsafetyofthemachine.
Unauthorizedmodicationstotheoriginal
equipmentorfailuretouseoriginalExmark
partscouldleadtoseriousinjuryordeath.
Unauthorizedchangestothemachine,engine,
fuelorventingsystem,mayviolateapplicable
safetystandardssuchas:ANSI,OSHAand
NFPAand/orgovernmentregulationssuchas
EPAandCARB.
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbyadoctor
familiarwiththisformofinjuryorgangrenemay
result.
•Ifequipped,makesureallhydraulicuid
hosesandlinesareingoodconditionandall
hydraulicconnectionsandttingsaretight
beforeapplyingpressuretohydraulicsystem.
•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
•Usecardboardorpaper,notyourhands,to
ndhydraulicleaks.
•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrollevers
inneutralandshuttingofftheenginebefore
performinganyworkonthehydraulicsystem.
10