Exmark PIONEER PNS20KA443, Operator'S Manual

Page 1: ...PIONEER S SERIES For Serial Nos 920 000 Higher Part No 4500 898 Rev A ...

Page 2: ...du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manuf...

Page 3: ...lable online at http www exmark com manuals htm 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 secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before l...

Page 4: ...lic Oil Level 31 Check Tire Pressures 32 Check Condition Of Belts 32 Lubricate Grease Fittings 32 Check Spark Plugs 33 Change Hydraulic System Filter and Fluid 33 Check Spark Arrester if equipped 34 Thread Locking Adhesives 35 Copper Based Anti seize 35 Dielectric Grease 35 Adjustments 35 Deck Leveling 35 Adjusting the Blade Slope 36 Pump Drive Belt Tension 37 Deck Belt Tension 37 Adjusting the Pa...

Page 5: ...d 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 Never let children or untrained people oper...

Page 6: ...ve dissipated Do Not operate without entire exhaust system in place and in proper working condition 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 Always place gasoline containers on the ground away from your vehicle before filling Do ...

Page 7: ...parking brake Before checking cleaning or working on the mower After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage parking brake Before refueling Before dumping the grass catcher WARNING Hand...

Page 8: ...ss 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 e...

Page 9: ...sive gases Battery gases can explode causing serious injury Keep sparks flames or cigarettes away from battery Ventilate when charging or using battery in an enclosed space Make sure venting path of battery is always open once battery is filled with acid Always shield eyes and face from battery DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowi...

Page 10: ...c fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutra...

Page 11: ...essory has been installed make sure current safety signs are visible New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety 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 in...

Page 12: ...Safety 107 2102 109 3148 109 6014 116 1119 116 1121 1 Rotate the drive release knob to loosen slide the knob and tighten 2 Push the machine 116 1496 12 ...

Page 13: ...Safety 116 3303 116 4308 1 Latch 2 Unlatch 116 4465 1 Fast 3 Choke on 2 Slow 4 Choke off PTO Switch Symbols 1 PTO disengage 2 PTO engage 13 ...

Page 14: ...intenance 4 Refer to the Operator s manual for grease instructions 2 Time interval 5 Check hydraulic oil level and refer to the Operator s manual or further instructions 3 Check oil level 6 Check tire pressure 116 4430 1 Park brake engage 4 Neutral 2 Fast 5 Reverse 3 Slow 14 ...

Page 15: ...eat 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 Engine will stop if either the left the right or both levers are moved from neutral lock position while brake is engaged Operator Controls Steering and Motion Control Note Motion control levers are adjustable to three heights Separate levers on each sid...

Page 16: ... 4 Pressure 13 psi 90 kPa 13 psi 90 kPa Cutting Deck Cutting Width 44 inch Deck 111 8 cm 48 inch Deck 121 9 cm 52 inch Deck 132 1 cm Discharge Side Blade Size 44 inch Deck 22 25 inches 56 5 cm 2 ea 48 inch Deck 16 25 inches 41 3 cm 3 ea 52 inch Deck 18 00 inches 45 7 cm 3 ea Blade Spindles Solid steel spindles with 98 inch 25 mm I D bearings Deck Drive B Section belt with self tensioning idler Ele...

Page 17: ...ter of Caster Tire to Center of Drive Tire 44 inch Deck 48 inch Deck 52 inch Deck 49 7 inches 126 2 cm 48 7 inches 123 7 cm 48 7 inches 123 7 cm Curb Weight 44 inch Deck 48 inch Deck 52 inch Deck Kawasaki Units 822 lb 373 kg 862 lb 391 kg 873 lb 396 kg Torque Requirements Bolt Location Torque Blade Drive Sheave Mounting Nut 130 160 ft lb 176 217 N m Blade Mounting Bolt lubricate with anti seize 50...

Page 18: ...rward or backward turns the wheel on the same side forward or reverse respectively Wheel speed is proportional to the amount the lever is moved Moving the levers outward from the center position into the T slot locks them in the neutral position Figure 5 Figure 5 1 Neutral lock position handles out 4 Forward 2 Neutral operate position handles in 5 Neutral operate 3 Front of unit 6 Reverse Choke Co...

Page 19: ...ed down and brake engaged when transporting Ignition Switch Located on right console see Figure 6 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...

Page 20: ...rive wheel release valves are positioned horizontally If the machine has to be pushed by hand the valves must be in the released position see Figure 9 Figure 9 1 Front of the machine 2 Rotate bypass release knob counterclockwise to loosen 3 Lever position for operating the machine 4 Pull lever in this direction to push the machine 5 Lever position for pushing the machine 6 Rotate bypass release kn...

Page 21: ... system could be damaged Do Not add oil to gasoline Do Not overfill fuel tank Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system Make sure you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section a...

Page 22: ...hrottle midway between the SLOW and FAST positions 5 On a cold engine push the choke lever forward into the ON position On a warm engine leave the choke in the OFF position 6 Turn ignition switch to the START position Release the switch as soon as the engine starts Important Do Not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second cool...

Page 23: ... 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 operator must be in the seat the brake lever must be disengaged pushed down before the motion con...

Page 24: ...l is located at the front right corner of the floor pan Note When changing the cutting height positions always come to a complete stop and disengage the PTO Figure 15 1 Transport lock handle 3 Height of cut decal 2 Height adjustment pin 4 Deck foot pedal 5 Insert the height adjustment pin into the hole corresponding to the desired cutting height See the decal on the side of the deck lift plate for...

Page 25: ...g vehicle emblem Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and or fines Do Not drive a unit on a public street or roadway WARNING Loading a unit on a trailer or truck increases the p...

Page 26: ...se mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip backward If loading on or near a slope position the trailer or truck so it is on the down side of the slope and the ramp 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 un...

Page 27: ...eck the rollover protections systems roll bar knobs Check the seat belt Check for loose hardware Check the hydraulic oil level in the expansion tank Clean the engine and exhaust system area Clean the hydro fan cooling guards Clean the grass and debris build up from the machine and cutting deck Clean the grass build up from under the cutting deck Every 50 hours Check the tire pressures Check the co...

Page 28: ...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 Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in 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 great...

Page 29: ...oth electrical systems are off and at the same rated system voltage These instructions are for negative ground systems only 3 Connect the positive cable to the positive terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 18 Figure 18 1 Positive cable on discharged battery 2 Positive cable on booster battery 3 Negative cable on the booster battery 4 Negati...

Page 30: ...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 Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat again with the right lever in then with both levers in starter must not crank 2 Check the kill circuits ...

Page 31: ...or additional information 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 See the Engine Owner s Manual for maintenance instructions Change Engine Oil Service Interval After the first 5 hours Every 100 hours Yearly whichever comes first May need more often under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking bra...

Page 32: ...djustments are required for belt tension 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 one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule Lubrication Chart Fitting Locations Initial Pumps Nu...

Page 33: ... play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Reapply thread locking adhesive Check Spark Plugs Service Interval Every 200 hours Remove spark plugs check condition and reset gaps or replace with new plugs See Engine Owner s Manual Change Fuel Filter Service Interval As required A fuel filter is installed between the fuel tank and the engine Repl...

Page 34: ...ypass valve closed and the engine running slowly move the directional control in both forward and reverse directions 5 to 6 times Check the oil level and add oil as required after stopping the engine C It may be necessary to repeat steps A and B until all the air is completely purged from the system When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal...

Page 35: ...the unit CAUTION Raising the mower deck 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 Deck Leveling 1 Position ...

Page 36: ...Chain 11 Recheck that blocks fit just snugly under the deck skirt Make sure all attachment bolts are tight 12 Continue leveling the deck by checking the front to rear blade slope refer to Adjusting the Blade Slope 13 Recheck blades for levelness and repeat deck leveling procedure if necessary Adjusting the Blade Slope 1 Check the front to rear blade level any time you install the mower If the fron...

Page 37: ...justing the Parking Brake Service Interval Every 500 hours 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 1 Drive the machine onto a level surface 2 Disengage the blade control switch PTO move the motion control levers to the neutral locked position and set the parking brake 3 Stop the e...

Page 38: ...rdware 3 Repeat the adjustment for the opposite control lever Adjusting the Tilt The motion control levers can be tilted fore or aft for maximum operator comfort 1 Loosen the upper bolt holding the control lever to the control arm shaft 2 Loosen the lower bolt just enough to pivot the control lever fore or aft Figure 29 Tighten both bolts to secure the control in the new position 3 Repeat the adju...

Page 39: ...ture Note The motion control lever needs to be in neutral while making any necessary adjustments 7 Bring the motion control levers into the neutral position The control plate tabs should touch the return to neutral plates on the hydros Adjust pump control rod lengths by loosening the nuts and rotating the turnbuckle in the appropriate direction until the wheels slightly creep in reverse Figure 31 ...

Page 40: ...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 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 Figure...

Page 41: ...t 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 shrouding and exhaust system area 3 Wipe up any excessive grease or oil around the ...

Page 42: ...port 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 4 Clean out any grass build up from underside of deck and in discharge deflector Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certif...

Page 43: ... dielectric grease and reconnect 6 Fuse is blown 6 Replace the blown fuse 7 Relay or switch is defective 7 Contact an Authorized Service Dealer Starter does not crank 8 Faulty module 8 Replace module 1 Fuel tank is empty 1 Fill the fuel tank 2 Fuel shutoff valve is closed 2 Open the fuel shutoff valve 3 Oil level in the crankcase is low 3 Add oil to the crankcase 4 The throttle and choke are not i...

Page 44: ...w cutting blade s 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...

Page 45: ...Schematics Schematics Electrical Diagram 45 ...

Page 46: ...Schematics Electrical Logic Schematic 46 ...

Page 47: ... Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S or Canada cus...

Page 48: ...Notes 48 ...

Page 49: ...Service Record Date Description of Work Done Service Done By 49 ...

Page 50: ...50 ...

Page 51: ...se 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 51 ...

Page 52: ...DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM 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 Place Model No and Serial No Label Here Included in the Literature Pack or Fill i...