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PIONEER S-SERIES For Serial Nos. 312,000,000 & Higher Part No. 4501-000 Rev . A[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals known to the State of Califor nia to cause cancer , bir th defects, or other reproductiv e har m. Important: The engine in this product is not equipped with a spark arr ester mufer . It is a violation of Califor nia Public Resource Code (CPRC) Se[...]

Introduction CONGRATULATIONS on the purchase of your Exmark Mo wer . This product has been carefully designed and manufactured to giv e you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for y our Exmark mow er . BEFORE OPERATING Y OUR MO WER, [...]

Contents Introduction . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . 3 Safety .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. 5 Safety Alert Symbol . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. .[...]

Safety Safety Safety Alert Symbol This lawn mow er meets or ex ceeds the B71.4 specications of the American National Standards Institute in effect at the time of production. Exmark designed and tested this lawn mo wer to offer reasonably safe ser vice; how ev er , failure to comply with the following instr uctions ma y result in personal injur y[...]

Safety • Inspect the area where the equipment is to be used and remov e all rocks , to ys , stic ks , wires , bones , and other foreign objects whic h can be thrown b y the machine and ma y cause personal injur y to the operator or bystanders . DANGER In cer tain conditions gasoline is extremely ammable and v apors are explosi ve. A re or e[...]

Safety Operation W ARNING Operating engine par ts, especially the mufer , become extremely hot. Sev ere bur ns can occur on contact and de bris, such as leav es, grass, br ush, etc. can catch re. • Allow engine parts, especially the muf er , to cool before touching . • Remo ve accumulated debris from muf er and engine area. • Inst[...]

Safety DANGER Operating on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping o v er edges, ditches, steep banks, or w ater can cause rollov ers, which may result in serious injur y , death or drowning . • Do Not mo w slopes when grass is wet. • Do Not mow near drop-of fs or near w ater . • Do Not mow slopes grea[...]

Safety • Keep engine and engine area free from accumulation of g rass , leav es , ex cessiv e g rease or oil, and other debris whic h can accum ulate in these areas . These materials can become combustible and may result in a re . • Let engine cool before storing and Do Not store near ame or any enclosed area where open pilot lights or he[...]

Safety W ARNING Hydraulic uid escaping under pressure can penetrate skin and cause injur y . Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this for m of injur y or gangrene may result. • If equipped, make sure all hy draulic uid hoses and lines are in good condition and all[...]

Safety Safety and Instructional Decals • Keep all safety signs legible. R emo v e all grease, dirt and debris from safety signs and instr uctional labels . • R eplace all w orn, damaged, or missing safety signs . • When replacement components are installed, be sure that cur rent safety signs are afx ed to the replaced components . • If a[...]

Safety 107-2102 109-3148 109-6014 1 16-1 1 19 1 16-1496 1 16-3303 12[...]

Safety 1 16-4308 1. Latch 2. Unlatch 1 16-4465 1. Fast 3. Choke-on 2. Slow 4. Choke-off 1 16-6363 1. Rotate the drive release knob to loosen, slide the knob, and tighten. 2. Push the machine. PTO Switch Symbols 1. PTO–disengage 2. PTO–engage 13[...]

Safety 109-6016 1. Read the instructions before servicing or performing maintenance 4. Refer to the Operator's manual for grease instructions 2. T ime interval 5. Check hydraulic oil level and refer to the Operator's manual or further instructions 3. Check oil level 6. Check tire pressure 1 16-4430 1. Park brake — engage 4. Neutral 2. F[...]

Specications Specications Model Numbers Serial Nos: 312,000,000 and Higher PNS600KA443; PNS651KA483; PNS680K C523; PNS740K C604 Systems Engine • Engine Specications: See your Engine Owner’ s Manual • Engine Oil T ype: Exmark 4–Cycle Premium Engine Oil • RPM: Full Speed: K a wasaki: 3750 ±50 RPM (PTO not eng aged) Idle: 1500 ±10[...]

Specications – Steering is controlled b y v arying the position of the levers relativ e to eac h other . – Moving motion control lev ers outward (in slots) loc ks the dri v e system in neutral. • PTO Engagement Switch: Engag es electric clutc h (to driv e belt) whic h eng ages mow er blades . • P arking Brake Lev er : Engag es parking br[...]

Specications – 44 inch Dec k: 22.25 inches (56.5 cm) – (2 ea.) – 48 inch Dec k: 16.25 inches (41.3 cm) – (3 ea.) – 52 inch Dec k: 18.00 inches (45.7 cm) – (3 ea.) – 60 inch Dec k: 20.50 inches (52.1 cm) – (3 ea.) • Blade Spindles: Solid steel spindles with .98 inch (25 mm) I.D . bearings . • Deck Dri ve: “B” Section belt [...]

Product Overview Wheel Base: (Center of Caster T ire to Center of Drive Tire) 44 inch Deck 48 inch Deck 52 inch Deck 60 inch Deck 49.7 inches (126.2 cm) 48.7 inches (123.7 cm) 48.7 inches (123.7 cm) 49.7 inches (126.2 cm) Curb Weight: 44 inch Deck 48 inch Deck 52 inch Deck 60 inch Deck K a wasaki Units 822 lb (373 kg) 862 lb (391 kg) 873 lb (396 kg[...]

Operation Operation Note: Deter mine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control lev ers located on each side of the console control the forward and rev erse motion of the mac hine. Moving the lev ers forward or backw ard turns the wheel on the same side forward or re[...]

Operation The ignition switc h is used to star t and stop the engine. The switch has three positions “OFF”, “ON” and “ST AR T”. Insert key into switc h and rotate clockwise to the “ON” position. R otate clockwise to the next position to eng age the star ter (key must be held against spring pressure in this position). Allo w the key [...]

Operation 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 knob clockwise to tighten 7. Release lever T o release the dri ve system (see item 1 in[...]

Operation Make sure y ou understand the controls , their locations , their functions , and their safety requirements . R efer to the Maintenance section and perfor m all the necessar y inspection and maintenance steps . Operating Instructions Raise the Rollover Protection System (ROPS) Important: The roll bar is an integral and effective safety dev[...]

Operation Starting the Engine 1. Mov e the motion control lev ers out to the neutral lock position. 2. Pull up and back on the parking brake lev er to engag e the parking brak e. 3. Push down on the PTO switch to the “disengag e” position. Note: It is not necessary for the operator to be in the seat to star t the engine . 4. Place the throttle [...]

Operation Important: T o begin mov ement (forw ard or backw ard) the operator must be in the seat, the brake lever must be disengaged (pushed down) before the motion control levers can be mo v ed in or the engine will stop. When the motion control levers are positioned fully outward (apart) in the T -slot, the driv e system is in the neutral lock p[...]

Operation T o turn right, release pressure on the RH motion control lev er and the rear of the machine will mov e towards the rear and to the right. T o turn left, release pressure on the LH motion control lev er and the rear of the machine will mov e towards the rear and to the left. 3. T o stop , position both motion control lev ers in the neutra[...]

Operation 8. T or que the 3/8–16 whizlock n ut to 27-33 ft-lb (37-45 N-m) (Figure 18). 9. T or que the 3/8 nyloc nut to 27-33 ft-lb (37-45 N-m). Figure 18 1. Spring disc washer (cone towards nut ) 3. 3/8 nyloc-torque to 27-33 ft-lb (37-45 N-m) 2. Front right anti-scalp bracket shown 4. 3/8-16 whizlock nut torque to 27-33 ft-lb (37-45 N-m) T ransp[...]

Maintenance Maintenance Note: Deter mine the left and right sides of the mac hine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental star ting of the engine could seriously injure y ou or other bystander s. Remo ve the k ey from the ignition switch, engage parki[...]

Maintenance Periodic Maintenance Check Engine Oil Level Service Interval: Before each use or daily 1. Stop engine and w ait for all moving parts to stop . Make sure unit is on a lev el surface . 2. Check with engine cold. 3. Clean area around dipstic k. R emo v e dipstic k and wipe oil off . Reinsert the dipstick according to the engine manufacture[...]

Maintenance DANGER J ump star ting a w eak batter y that is crack ed, frozen, has low electrolyte level, or an open/shor ted batter y cell, can cause an explosion resulting in serious personal injur y . Do Not jump star t a weak batter y if these conditions exist. 2. Make sure the booster is a good and fully c harged lead acid batter y at 12.6 v ol[...]

Maintenance Figure 20 1. Spindle 2. Blade 3. Splined bushing 4. Blade bolt washer assembly — T orque to 50-60 ft-lb (68-81 N-m) Apply lubricant to threads as needed to prevent seizing. Copper-based anti-seize preferable. Grease acceptable substitute. B . Apply lubricant to the threads of the blade bolt as needed to prev ent seizing . Copper based[...]

Maintenance Check Rollover Protections Systems (Roll Bar) Knobs Service Interval: Before each use or daily Check that both the mounting hardware and the knobs are in good w orking condition. Mak e sure the knobs are fully engag ed with the R OPS in the raised position. The upper hoop of the roll bar ma y need to be pushed forward or pulled rearw ar[...]

Maintenance Check Hydraulic Oil Level Service Interval: Before each use or daily 1. Stop engine and w ait for all moving parts to stop . Engag e parking brake . 2. W ait until the unit cools before c hecking the hy draulic oil. 3. Check expansion tank and if necessar y add Exmark Premium Hy dro Oil to the FULL COLD line (see Figure 22). Figure 22 1[...]

Maintenance 2. R emov e caster wheel from caster forks . 3. R emov e seal guards from the wheel hub . 4. R emov e one of the spacer nuts from the axle assembly in the caster wheel. Note that thread locking adhesiv e has been applied to lock the spacer nuts to the axle . R emov e the axle (with the other spacer nut still assembled to it) from the wh[...]

Maintenance 5. R emov e the vent plug on each transmission and ll through expansion reser v oir , when oil comes out of vent reinstall plug . Exmark Premium Hydro Oil is recommended. R efer to the chart for an acceptable alternativ e: Hydro Oil Change Inter val Exmark Premium Hydro Oil (Prefer red) 500 Hours Mobil 1 15W50 250 Hours T or que plug[...]

Maintenance 3. If any breaks in the screen or welds are obser v ed, replace arrester . 4. If plugging of the screen is obser ved, remov e ar rester and shake loose particles out of the ar rester and clean screen with a wire br ush (soak in solv ent if necessar y). Reinstall ar rester on exhaust outlet. Thread Locking Adhesives Thread loc king adhes[...]

Maintenance Figure 26 44 Inch Deck 1. Blades side to side 2. Measure here 7. Set anti-scalp rollers to top holes or remo v e completely for this adjustment. 8. Set the height-of-cut lever to the 3 inch (76 mm) position. Place tw o “B” thick bloc ks (see Block Height and Rake T able) under the rear edge of the cutting deck skirt; one on each sid[...]

Maintenance each side of the cutting dec k. Place tw o “ A ” thick blocks (see Bloc k Height and Rake T able in Deck Leveling ) under eac h side of the front edge of the deck, but not under the anti-scalp roller brac kets . 7. Loosen the leveling adjust loc king nuts (item 1 Figure 27) on all four corners so that the deck is sitting securely on[...]

Maintenance Figure 29 1. Hairpin 3. Y oke 2. Clevis pin 4. Jam nut • Adjusting the Brak e to Eng age: Shor ten the linkage by turning the yok e cloc kwise . • Adjusting the Brake to Disengag e: Lengthen the linkag e by tur ning the yok e counterclockwise . 8. R einstall the clevis pin and hair pin and tighten down the jam n ut. R epeat step 6 a[...]

Maintenance Figure 31 1. Control arm shaft 3. T racking plate 2. T racking plate screw Motion Control Linkage Adjustment Located on either side of the unit, below the seat are the pump control linkages . R otating the turnbuckle with a 1/2 inch wrenc h allo ws ne tuning adjustments so that the machine does not mov e in neutral. Any adjustments s[...]

Maintenance 11. Raise the dec k and re-install the height of cut pin. 12. Chec k that the mac hine does not creep in neutral with the park brake disengaged. Adjusting the Seat Ride Suspension The n umber of seat springs can be c hanged to maximize rider comfort. More springs should be used with hea vier operators and on rough ter rain. F ew er spri[...]

Maintenance Figure 35 1. Brake mounting bolt 2. Shim B . Using needle nose pliers , or by hand, tak e hold of the tab and remov e the shim (Do Not discard the shim until proper clutch function has been conr med). C. Using a pneumatic line, blow out any debris from under the brake pole and around the brake spacers . D . R e-torque eac h bolt (M6 [...]

Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) CAUTION Excessi v e de bris around engine cooling air intake and exhaust system area can cause engine, exhaust area, and h ydraulic system to o verheat which can create a re hazard. Clean a[...]

Maintenance recycling center or according to y our state and local regulations . Battery Disposal DANGER Batter y electrolyte contains sulfuric acid, which is poisonous and can cause sev ere bur ns. Sw allowing electrol yte can be fatal or if it touches skin can cause sev ere bur ns. • W ear safety g lasses to shield eyes, and r ub ber glo ves to[...]

T roubleshooting T roubleshooting 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 ov erlook the simple causes . F or example: star ting problems could be caused by an empty fuel tank. The following table lists some of the common causes o[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e 1. Reduce the ground speed. 2. Air cleaner is dirty . 2. Clean or replace the air cleaner element. 3. Oil lev el in the crankcase is lo w . 3. Add oil to the crankcase. 4. Cooling ns and air passages for the engine are plug ged. 4. Remov e the obstructions [...]

Schematics Schematics Electrical Diagram 46[...]

Schematics Electrical Logic Schematic 47[...]

General Warranty Conditions and Pr oducts Covered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty 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 defec[...]

Service Record Date: Description of W ork Done: Service Done By: 49[...]

50[...]

G01 1841 Figure 38 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.[...]

MID-MOUNT RIDING A CCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF A CCESSORIES AND OPTIONS W ALK-BEHIND A CCESSORIES AND OPTIONS GRASS CA TCHER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM FULL SUSPENSION SEA T DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V PO WER PORT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED[...]