Page 2 - WARNING
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 aviolation of Cali...
Page 3 - Introduction; CONGRATULATIONS; on the purchase of your
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefullydesigned and manufactured to give you a maximumamount of dependability and years of trouble-freeoperation. This manual contains operating, maintenance,adjustment, and safety instructions for your Exmark...
Page 4 - Contents; Clean Engine and Exhaust System
Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...
Page 5 - Safety; Safety Alert Symbol; Safe Operating Practices; Training
Safety Safety Safety Alert Symbol This lawn mower meets or exceeds the B71.4specifications of the American National StandardsInstitute in effect at the time of production. Exmark designed and tested this lawn mower to offerreasonably safe service; however, failure to complywith the following instruc...
Page 6 - DANGER; Avoid prolonged breathing of vapors.
Safety • Inspect the area where the equipment is to beused and remove all rocks, toys, sticks, wires,bones, and other foreign objects which can bethrown by the machine and may cause personalinjury to the operator or bystanders. DANGER In certain conditions gasoline is extremelyflammable and vapors a...
Page 7 - Operation; NEVER; Slope Operation; Extreme
Safety Operation WARNING Operating engine parts, especially the muffler,become extremely hot. Severe burns can occuron contact and debris, such as leaves, grass,brush, etc. can catch fire. • Allow engine parts, especially the muffler, tocool before touching. • Remove accumulated debris from mufflera...
Page 8 - Do Not mow slopes when grass is wet.; Drive slowly and carefully.; Maintenance and Storage
Safety DANGER Operating on wet grass or steep slopes can causesliding and loss of control. Wheels dropping overedges, ditches, steep banks, or water can causerollovers, which may result in serious injury,death or drowning. • Do Not mow slopes when grass is wet. • Do Not mow near drop-offs or near wa...
Page 9 - Always shield eyes and face from battery.; Do Not swallow electrolyte.; CAUTION
Safety spark plug wire. Wait for all movement to stopbefore adjusting, cleaning or repairing. • Keep engine and engine area free fromaccumulation of grass, leaves, excessive greaseor oil, and other debris which can accumulatein these areas. These materials can becomecombustible and may result in a f...
Page 11 - Safety and Instructional Decals
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease,dirt and debris from safety signs and instructionallabels. • Replace all worn, damaged, or missing safetysigns. • When replacement components are installed, besure that current safety signs are affixed to there...
Page 15 - Specifications; Model Numbers
Specifications Specifications Model Numbers Serial Nos: 920,000 and Higher PNS20KA443; PNS22KA483; PNS24KA523 Systems Engine • Engine Specifications: See your Engine Owner’sManual • Engine Oil Type: Exmark 4–Cycle PremiumEngine Oil • RPM: Full Speed: 3750 ±50 RPM (PTO notengaged) Idle: 1500 ±100 RPM...
Page 16 - Hydrostatic Ground Drive System; Dimensions
Specifications armrests, integral safety switch, and seat vibrationisolation system. Optional seat accessories for units with standardseats: – Custom ride suspension system to enhance Standard Seat. Adds approximately 3 inches(7.6 cm) to seat height. – Deluxe suspension seat with high back, (dampene...
Page 17 - Torque Requirements
Specifications Overall Length: 44 inchDeck 48 inchDeck 52 inchDeck Roll Bar -Up 78.8 inches(200.2 cm) 77.8 inches(197.6 cm) 77.8 inches(197.6 cm) Roll Bar -Down 79.6 inches(202.2 cm) 78.6 inches(199.6 cm) 78.6 inches(199.6 cm) Overall Height: Roll Bar - Up Roll Bar - Down 71.3 inches (181.1 cm) 48 i...
Page 18 - Product Overview; Determine the left and right sides of the; Controls; Motion Control Levers; Choke Control
Operation Product Overview Figure 4 1. Rollover ProtectionSystem (ROPS) 5. Motion control levers 2. Engine controls (rightconsole) 6. Parking brake 3. Seat belt 7. Height of cut adjustment 4. Fuel cap Operation Note: Determine the left and right sides of the machine from the normal operating positio...
Page 19 - Throttle Control; Pull the lever up and rearward to engage the brake.; Ignition Switch; Brake must be engaged, motion control; Hour Meter; Located by the lower LH ROPS tube mounting.
Operation position. Do Not run a warm engine with choke inthe “ON” position. Figure 6 1. Throttle lever 4. Blade control switch(power take-off) 2. Choke lever 5. Ignition switch 3. Hour meter Throttle Control Located on right console (red lever) (see Figure 6). The throttle is used to control engine...
Page 20 - Drive Wheel Release Valves; PTO Engagement Switch
Operation The fuel shut-off valve is used to shut off the fuelwhen the machine will not be used for a few days,during transport to and from the jobsite, and whenparked inside a building. Align valve handle with the fuel line to open. Rotate90° to close. Drive Wheel Release Valves WARNING Hands may b...
Page 21 - Deck Lift Pedal; Transport Lock; Never use methanol, gasoline; Operating Instructions; The roll bar is an integral and
Operation Deck Lift Pedal Located at the right front corner of the floor pan. Push the pedal forward with your foot to raise thecutting deck. Allow the pedal to move rearward tolower the cutting deck to the cut height that has beenset. Figure 10 1. Transport lock handle 3. Height of cut decal 2. Hei...
Page 22 - Always use the seat belt with the; Open the Fuel Shut-Off Valve; Do Not crank the engine; Engaging the PTO
Operation G014402 1 2 3 4 5 Figure 11 1. Roll bar upper hoop 2. Knob in “latched” position 3. Pull knob to unlatch 4. Rotate 90° to hold unlatched 5. Knob in “unlatched” position 5. Make sure the knobs are fully engaged with the roll bar in the raised position. The upper hoop ofthe roll bar may need...
Page 23 - Operator must be in seat before the; Disengaging the PTO; Use caution when making turns.; Driving Forward
Operation The PTO push-pull switch engages the cutting blades.Be sure that all persons are clear of the mower deckand discharge area before engaging PTO. Important: Operator must be in seat before the PTO can be engaged. 1. Set the throttle midway between the “SLOW” and “FAST” positions. 2. Pull the...
Page 24 - Driving in Reverse; Adjusting the Cutting Height; When changing the cutting height; Adjusting the Anti-Scalp Rollers
Operation Figure 14 1. Front of Unit 3. Neutral 2. Forward 4. Reverse Driving in Reverse 1. Move the motion control levers inward to the neutral operate position. 2. To move rearward in a straight line, move both levers rearward with equal pressure. To turn right, release pressure on the RH motionco...
Page 25 - For Maximum Deck Flotation,; place the rollers; Do; adjust the rollers to support the deck.; Transporting; Transporting a Unit; Do Not drive a unit on a public street or roadway.
Operation Figure 16 For cutting heights above 3.5 inches (90 mm) use the bottom hole. The rollers will still be effective against scalping. 1. Anti-scalp rollermounting bracket 2. Cutting height For Maximum Deck Flotation, place the rollers one hole position lower. Rollers should maintain1/4 inch (6...
Page 26 - Do Not attempt to turn the unit
Operation tipping backward. Having a full width ramp providesa surface for the frame members to contact if theunit starts to tip backward. If it is not possible to useone full width ramp, use enough individual ramps tosimulate a full width continuous ramp. Ramp should be long enough so that the angl...
Page 27 - Maintenance
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING While maintenance or adjustments are beingmade, someone could start the engine.Accidental starting of the engine could seriouslyinjure you or other bystanders. Remove the key f...
Page 28 - Periodic Maintenance; Check Engine Oil Level; Service Interval: Before each use or daily; Check Battery Charge; Service Interval: Monthly; Service Interval: As required
Maintenance Periodic Maintenance Check Engine Oil Level Service Interval: Before each use or daily 1. Stop engine and wait for all moving parts to stop. Make sure unit is on a level surface. 2. Check with engine cold. 3. Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dips...
Page 29 - Do Not lean over the batteries.; Check Mower Blades
Maintenance DANGER Jump starting a weak battery that is cracked,frozen, has low electrolyte level, or anopen/shorted battery cell, can cause anexplosion resulting in serious personal injury. Do Not jump start a weak battery if theseconditions exist. 2. Make sure the booster is a good and fully charg...
Page 31 - Check Seat Belt; Check for Loose Hardware; Service Air Cleaner; Service Interval: Every 250 hours—Replace; Change Engine Oil; Service Interval: After the first 5 hours; Check Hydraulic Oil Level
Maintenance Check that both the mounting hardware and theknobs are in good working condition. Make sure theknobs are fully engaged with the ROPS in the raisedposition. The upper hoop of the roll bar may needto be pushed forward or pulled rearward to get bothknobs fully engaged. Figure 20 1. Engaged ...
Page 32 - Check Tire Pressures; Check Condition Of Belts; Service Interval: Every 50 hours; Lubricate Grease Fittings; See chart for service intervals.; Lubricate Caster Wheel Hubs
Maintenance 2. Wait until the unit cools before checking the hydraulic oil. 3. Check expansion tank and if necessary add Exmark Premium Hydro Oil to the FULL COLDline (see Figure 21). Figure 21 1. Engine 2. Expansion tank Check Tire Pressures Service Interval: Every 50 hours 1. Stop engine, wait for...
Page 33 - To prevent seal and bearing damage,; Check Spark Plugs; Service Interval: Every 200 hours; Change Fuel Filter; Service Interval: After the first 100 hours
Maintenance 5. Pry out seals, and inspect bearings for wear or damage and replace if necessary. 6. Pack the bearings with a NGLI grade #1 multi-purpose grease. 7. Insert one bearing, one new seal into the wheel. Note: Seals (Exmark P/N 103-0063) must be replaced. 8. If the axle assembly has had both...
Page 34 - Check Spark Arrester
Maintenance Hydro Oil Change Interval Exmark Premium HydroOil (Preferred) 500 Hours Mobil 1 15W50 250 Hours Torque plugs to 180 in-lb (244 N-m). Continue toadd oil until it reaches the FULL COLD line onthe expansion reservoir. Figure 23 1. Oil filter 3. Left rear tire 2. Vent plug 6. Raise the rear ...
Page 35 - Thread Locking Adhesives; ROPS spring pin housing.; Check Mower; Dielectric Grease; Adjustments; Deck Leveling; Check the tire pressure in the drive tires. Proper
Maintenance Thread Locking Adhesives Thread locking adhesives such as “Loctite 242”or “Fel-Pro, Pro-Lock Nut Type” are used on thefollowing fasteners: • ROPS spring pin housing. • Sheave and clutch retaining bolt in the end ofengine crankshaft. • Hydro cross member mounting bolts Thread locking adhe...
Page 36 - Adjusting the Blade Slope
Maintenance Figure 25 44 Inch Deck 1. Blades side to side 2. Measure here 7. Set anti-scalp rollers to top holes or remove completely for this adjustment. 8. Set the height-of-cut lever to the 3 inch (76 mm) position. Place two “B” thick blocks (see BlockHeight and Rake Table) under the rear edge of...
Page 37 - Pump Drive Belt Tension; Service Interval: Every 500 hours
Maintenance 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. Loosen the leveling adjust locking nuts (item 1 Figure 26) on all four corners so that the deck issitting securely on all four blocks...
Page 39 - Temporarily
Maintenance with a 1/2 inch wrench allows fine tuning adjustmentsso that the machine does not move in neutral. Anyadjustments should be made for neutral positioningonly. WARNING Engine must be running and drive wheels mustbe turning so adjustments can be performed.Contact with moving parts or hot su...
Page 40 - Electric Clutch Adjustment
Maintenance Figure 32 1. Bolt 3. Nut 2. Spring 4. Additional mountingholes Up to five springs can be secured to the seat box witha nut and bolt, see Figure 32. Refer to the Parts Manual for spring and hardwarepart numbers. Electric Clutch Adjustment Figure 33 1. Armature 5. Brake spacer 2. Field she...
Page 41 - Troubleshooting; Cleaning; Service Interval: Every 100 hours
Maintenance G011733 1 Figure 35 1. Feeler gauge Figure 36 1. Feeler gauge • If the gap is less than 0.010 inch, thenreinstall the shim and reference the Troubleshooting section. • If the gap is sufficient, proceed to thesafety check in step F. F. Perform the following safety check: a. Sit on the sea...
Page 42 - cooling fins and upper surfaces.; Clean Debris From Machine; Park the machine on a level surface and disengage; Clean out any grass build-up from underside of; Waste Disposal; Motor Oil Disposal
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. Clean Debris From Machine Service Interval: Before each use or daily 1. Stop engine,...
Page 43 - condition prior to mower use.
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 causedby an empty fuel tank. The followi...
Page 45 - Schematics; Electrical Diagram
Page 46 - Electrical Logic Schematic
Page 47 - Pioneer S-Series Turf Equipment
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 exerc...
Page 49 - Service Record
Service Record Date: Description of Work Done: Service Done By: 49
Page 52 - M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S; SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS; WALK-BEHIND ACCESSORIES AND OPTIONS
M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS WALK-BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO-MULCH SYSTEM TURF STRIPER STANDON CUSTOM RIDE SEAT SUSPENSION SYSTEM FULL SUSPENSION SEAT DECK LIFT ASSIST KIT HITCH KI...
