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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. Do not attempt to service or replace major
items or any items that call for special timing of adjustment procedures (such as valves, governor, etc.). Have
this work done by your

Engine Service Dealer

Note:

When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.

Problem

Possible Cause

Corrective Action

1. PTO is engaged.

1. Disengage the PTO.

2. Parking brake is not engaged.

2. Set the parking brake.

3. Drive levers are not in neutral lock

position.

3. Ensure the drive levers are in the neutral

lock position.

4. Battery does not have a full charge.

4. Charge the battery. See

Check Battery

Charge

and

Recommended Jump

Starting Procedure

sections in

Maintenance.

5. Electrical connections are corroded, loose

or faulty.

5. Check the electrical connections for

good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply 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 in the

correct position.

4. Be sure the throttle control is midway

between the “SLOW” and “FAST”
positions, and the choke is in the “ON”
position for a cold engine or the “OFF”
position for a warm engine.

5. Dirt in fuel filter.

5. Replace the fuel filter.

6. Dirt, water, or stale fuel is in the fuel

system.

6. Contact an Authorized Service Dealer.

7. Air cleaner is dirty.

7. Clean or replace the air cleaner element.

8. Seat switch is not functioning properly.

8. Check the seat switch indicator. Replace

seat if needed.

9. Electrical connections are corroded, loose

or faulty.

9. Check the electrical connections for

good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.

10. Relay or switch is defective.

10. Contact an Authorized Service Dealer.

11. Faulty spark plug.

11. Clean, adjust or replace spark plug.

12. Spark plug wire is not connected.

12. Check the spark plug wire connection.

Engine will not start, starts hard, or fails to
keep running

13. Faulty module.

13. Replace module.

Содержание PIONEER S-SERIES Operators

Страница 1: ...PIONEER S SERIES For Serial Nos 315 000 000 Higher Part No 4502 317 Rev A ...

Страница 2: ... 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 manufacturer L...

Страница 3: ...com for additional safe operation information such as safety tips training materials and Operator s manuals If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficien...

Страница 4: ...lic Oil Level 35 Check Tire Pressures 35 Check Condition Of Belts 35 Lubricate Grease Fittings 35 Check Spark Plugs 36 Change Hydraulic System Filter and Fluid 36 Check Spark Arrester if equipped 37 Thread Locking Adhesives 38 Copper Based Anti seize 38 Dielectric Grease 38 Adjustments 38 Deck Leveling 38 Adjusting the Blade Slope 39 Pump Drive Belt Tension 40 Deck Belt Tension 40 Adjusting the Pa...

Страница 5: ...s or mechanic s can not read this manual it is the owner s responsibility to explain this material to them other languages may be available on our website 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 operate or service t...

Страница 6: ...ot 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 Not fill gasoline ...

Страница 7: ...king 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 Hands f...

Страница 8: ...t grass 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 ...

Страница 9: ...from moving parts If possible Do Not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools DANGER Charging or jump starting the battery may produce explosive gases Battery gases can explode causing serious injury Keep sparks ...

Страница 10: ...re 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 If equipped make sure all hydraulic 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 f...

Страница 11: ... clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower 93 7316 1 Thrown object hazard keep bystanders a safe distance from the machine 2 Thrown object hazard mower keep the deflector in place 3 Cutting dismemberment of hand or foot stay away from moving p...

Страница 12: ...ns before servicing or performing maintenance 3 Height of cut 112 9028 1 Warning stay away from moving parts keep all guards in place 116 1496 126 4363 1 Cutting dismemberment hazard fan and entanglement hazard belt Stop engine and remove key before adjusting servicing or cleaning 116 4465 1 Fast 3 Choke on 2 Slow 4 Choke off 12 ...

Страница 13: ...knob to loosen slide the knob and tighten 3 Push the machine 117 3848 1 Thrown object hazard keep bystanders a safe distance from the machine 2 Thrown object hazard mower do not operate without the deflector discharge cover or grass collection system in place 3 Cutting dismemberment of hand or foot stay away from moving parts keep all guards and shields in place 126 0768 Rear Discharge Units Only ...

Страница 14: ...ge 2 PTO engage 109 6016 1 Read the instructions before servicing or performing maintenance 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 14 ...

Страница 15: ...own object hazard Pick up objects that could be thrown by mower Do Not operate when people and pets are in the area Keep discharge deflector in place 6 Reverse 12 Crushing dismemberment hazard of bystanders do not carry passengers look forward and down when operating the machine look behind and down when reversing 127 0335 1 Tipping hazard do not turn at high speeds make slow wide turns do not use...

Страница 16: ...lter Kohler Kohler P N 24 050 13 Kawasaki Kawasaki P N 49019 0014 Fuel Shut Off Valve All Units 1 4 turn ON OFF Electrical System Charging System Flywheel Alternator Charging Capacity 15 amps Battery Type BCI Group U1 Recommended Minimum Battery CCA 260 CCA Battery Voltage 12 Volt Polarity Negative Ground Fuses All units 25 amp main fuse 20 amp charging system fuse 10 amp PTO fuse 15 amp accessory...

Страница 17: ...djustable fore and aft on seat tracks Armrests Molded flip up armrests Seat Safety Switch Integrated seat switch Time delay seat switch eliminates rough ground cut outs Hydrostatic Ground Drive System Two unitized hydrostatic transmissions Units with 48 or 52 inch decks Hydro Gear ZT3100 Units with 60 inch deck Hydro Gear ZT3400 Hydraulic Oil Type Exmark Premium Hydro Oil Hydraulic Oil Capacity 77...

Страница 18: ... Deck 3 anti scalp rollers 52 inch Deck 3 anti scalp rollers 60 inch Deck 4 anti scalp rollers Deck Depth 48 inch Deck 5 0 inches 12 7 cm 52 inch Deck 5 0 inches 12 7 cm 60 inch Deck 5 5 inches 14 0 cm Cutting Height Adjustment Foot activated lever is used to adjust the cutting height from 1 1 2 inch 3 8 cm to 5 inches 12 7 cm in 1 4 inch 6 4 mm increments Mulching Kit Optional Dimensions Overall ...

Страница 19: ...7 kg PNS710GKC483A4 835 lb 379 kg PNS720GKC52300 828 lb 376 kg PNS720GKC523A4 842 lb 382 kg PNS740GKC60RA3 980 lb 445 kg PNS730GKA604A3 952 lb 432 kg PNS740GKC60400 900 lb 408 kg PNS740GKC604A4 949 lb 430 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 60 ft lb 68 81 N m Anti Scalp Roller Nyloc N...

Страница 20: ...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...

Страница 21: ...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...

Страница 22: ...oned in front of the slots 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 knob clockwise to tighten 7 E...

Страница 23: ...ormation 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 and perform all t...

Страница 24: ...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...

Страница 25: ...when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machine CAUTION 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 Importan...

Страница 26: ...sting the Cutting Height The cutting height of the mower deck is adjusted from 1 1 2 to 5 inches 3 8 cm to 12 7 cm in 1 4 inch 6 4 mm increments 1 Stop the machine and move the motion control levers outward to the neutral locked position 2 Disengage the PTO 3 Raise and lock the deck to the 5 inch 12 7 cm transport position Figure 16 The deck is raised by pushing the foot operated deck lift pedal f...

Страница 27: ...ng height For Maximum Deck Flotation place the rollers one hole position lower Rollers should maintain 1 4 inch 6 4 mm clearance to the ground Do Not adjust the rollers to support the deck 7 Reinstall the mounting hardware Side Discharge Units A Be sure the roller bolts are installed with the spring disc washer between the head of the bolt and the mounting bracket see Figure 18 B Torque the 3 8 ny...

Страница 28: ... injury To transport the machine Lock the brake and block the wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Secure a trailer to the towing vehicle with safety chains WARNING Driving on the street or roadway without turn signals lights reflective markings or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury Do ...

Страница 29: ...en the ramp and the trailer or truck Ensure the length of ramp is at least four times 4X as long as the height of the trailer or truck bed to the ground This will ensure that ramp angle does not exceed 15 degrees on flat ground Back up ramps and drive forward down ramps Avoid sudden acceleration or deceleration while driving the machine on a ramp as this could cause a loss of control or a tip over...

Страница 30: ...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...

Страница 31: ...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...

Страница 32: ...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 23 Figure 23 1 Positive cable on discharged battery 2 Positive cable on booster battery 3 Negative cable on the booster battery 4 Negati...

Страница 33: ...at parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must 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 ...

Страница 34: ...s Replace the secondary air cleaner element May need more often under severe conditions See the Engine Owner s Manual for 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 ne...

Страница 35: ... Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Remove left and right belt shields on deck and lower the deck to inspect deck drive belt 3 Check under machine to inspect the pump drive belt Note No adjustments 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 k...

Страница 36: ... and insert wheel into caster fork Reinstall caster bolt and tighten nut fully Important To prevent seal and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side 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 ...

Страница 37: ... cause personal injury Keep fingers hands and clothing clear of rotating components and hot surfaces A With the bypass valve open and the engine running slowly move the directional control in both forward and reverse 5 or 6 times B With the bypass 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 ...

Страница 38: ...TO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to 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...

Страница 39: ...all four blocks Make sure that the slack is removed from the deck hangers and the deck lift foot lever is pushed back against the stop then tighten the four leveling adjust locking nuts Figure 31 1 Leveling adjust locking nuts 3 Deck hanger 2 Deck lift arm 4 Chain 12 Recheck that blocks fit just snugly under the deck skirt Make sure all attachment bolts are tight 13 Continue leveling the deck by c...

Страница 40: ...g height position B Slowly loosen the adjusting screw on the lift assist spring until the screw can be removed see Figure 30 Save the screw for reinstallation 10 Measure from the tip of the front blade to the flat surface and the tip of the rear blade to the flat surface Figure 32 If the front blade tip is not R see Block Height and Rake Table in Deck Leveling lower than the rear blade tip adjust ...

Страница 41: ...horten the linkage by turning the yoke clockwise Adjusting the Brake to Disengage Lengthen the linkage by turning the yoke counterclockwise 8 Reinstall the clevis pin and hair pin and tighten down the jam nut Repeat step 6 and readjust if necessary 9 When adjustment is complete remove the jack stands or equivalent support and lower the machine 10 Place the machine into the operating position Refer...

Страница 42: ... hot surfaces 1 Prior to starting the engine push the deck lift pedal and remove the height of cut pin Lower deck to the ground 2 Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely 3 Remove the electrical connection from the seat safety switch located under the bottom cushion of the seat The switch is a part of the ...

Страница 43: ...springs should be used with heavier operators and on rough terrain Fewer springs should be used with lighter operators and when mowing smooth well established lawns Always keep the number of springs on the left and right side the same when adding and removing springs Figure 37 1 Bolt 3 Nut 2 Spring 4 Additional mounting holes Up to five springs can be secured to the seat box with a nut and bolt se...

Страница 44: ...function has been confirmed C Using a pneumatic line blow out any debris from under the brake pole and around the brake spacers D Re torque each bolt M6 x 1 to 10 ft lb 13 N m 0 5 ft lb 0 7 N m E Using a 0 010 inch thick feeler gauge verify that a gap is present between the rotor and armature face on both sides of the brake pole as shown Due to the way the rotor and armature faces wear peaks and v...

Страница 45: ...hydro system 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 wait for all moving parts to stop and remove key Engage parking brake 2 Clean off any oil debris or grass bui...

Страница 46: ...thing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is being replaced or if the unit containing the battery is no longer operating and is being scrap...

Страница 47: ... 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...

Страница 48: ...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...

Страница 49: ...Schematics Schematics Electrical Diagram 49 ...

Страница 50: ...Schematics Electrical Logic Schematic 50 ...

Страница 51: ...st be performed by an authorized 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 ...

Страница 52: ...Notes 52 ...

Страница 53: ...Service Record Date Description of Work Done Service Done By 53 ...

Страница 54: ...54 ...

Страница 55: ...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 55 ...

Страница 56: ... 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 Some accessories and options not available for some models Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Be...

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