Exmark 4500-996 Rev A manual Recommended Maintenance Schedules

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Maintenance

Maintenance

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

WARNING

While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders.

Remove the key from the ignition switch, engage parking brake, and pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).

WARNING

The engine can become very hot. Touching a hot engine can cause severe burns.

Allow the engine to cool completely before service or making repairs around the engine area.

Recommended Maintenance Schedule(s)

	Maintenance Service	Maintenance Procedure
	Interval	Maintenance Procedure
	Interval

	After the first 5 hours	•	Change the engine oil.

	After the first 100 hours	•	Change the hydraulic filter and fluid.

		• Check the engine oil level.
		•	Check the mower blades.
		• Check the safety interlock system.
		• Check the rollover protections systems (roll bar) knobs.
		• Check the seat belt.
	Before each use or daily	•	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 25 hours	•	Grease the front caster axles.

		• Check the tire pressures.
	Every 50 hours	• Check the condition of the belts.
	Every 50 hours	• Grease the deck and pump idler pivot.
		• Grease the deck and pump idler pivot.
		• Check spark arrester (if equipped).

		• Check the air cleaner; replace if dirty or damaged. (May need more often under severe
	Every 100 hours		conditions. See the Engine Owner's Manual for additional information.)
	Every 100 hours	• Change the engine oil. (May need more often under severe conditions.)

		• Remove the engine shrouds and clean the cooling fins.

	Every 200 hours	•	Check the spark plugs.

		• Replace the emissions air intake filter.
	Every 500 hours	•	Change the hydraulic filter and fluid (Every 250 hours if using Mobil 1 15W50)
		• Check the park brake adjustment.

	Monthly	•	Check the battery charge.

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Contents For Serial Nos 312,000,000 & Higher PIONEER E-SERIESAll Rights Reserved CALIFORNIA Proposition 65 WarningModel No Serial No IntroductionContents ALERT! YOUR SAFETY IS INVOLVED SafetySafety Alert Symbol SafetyKeep away from eyes and skin Never siphon by mouth DANGERAvoid prolonged breathing of vapors Keep face away from nozzle and gas tank/container openingRemove accumulated debris from muffler and engine area OperationSlope Operation Allow engine parts, especially the muffler, to cool before touchingLower the roll bar only when absolutely necessary Using the Rollover Protection System ROPSMaintenance and Storage Do Not mow slopes when grass is wetKeep sparks, flames, or cigarettes away from battery Ventilate when charging or using battery in an enclosed spaceDo Not swallow electrolyte Use cardboard or paper, not your hands, to find hydraulic leaks Safety and Instructional Decals 109-6014 107-2102116-4465 PTO Switch Symbols116-6363 116-4308109-6016 116-4430Reverse Model Numbers SpecificationsSpecifications Safety Interlock SystemCutting Deck Tires & WheelsSeat Hydrostatic Ground Drive SystemOverall Width DimensionsCurb Weight Torque RequirementsMotion Control Levers Product OverviewControls OperationHour Meter Ignition SwitchThrottle Control Brake LeverPTO Engagement Switch Drive Wheel Release ValvesDo Not tow machine Transport Lock Pre-StartOperating Instructions Deck Lift PedalOpen the Fuel Shut-Off Valve Starting the EngineEngaging the PTO Driving the Machine Use caution when making turnsDisengaging the PTO Stopping the EngineDriving in Reverse Adjusting the Cutting HeightDo Not drive a unit on a public street or roadway Adjusting the Anti-Scalp RollersTransporting Transporting a UnitLoading a Unit Use extreme caution when operating a unit on a rampMaintenance Recommended Maintenance SchedulesMaintenance Service Interval Before each use or daily Periodic MaintenanceCheck Battery Charge Recommended Jump Starting ProcedureShield the eyes and face from the batteries at all times Do Not jump start a weak battery if these conditions existCheck Mower Blades Batteries contain acid and produce explosive gases1. Spindle 2. Blade 3. Blade drive washer Check Safety Interlock SystemSERVICE DEALER 4. Blade bolt washer assembly - Torque to 50-60 ft-lbCheck Seat Belt Service Air CleanerService Interval After the first 5 hours Check Rollover Protections Systems Roll Bar KnobsCheck Tire Pressures Service Interval Every 50 hoursNote See chart for service intervals Service Interval Every 200 hoursChange Hydraulic System Filter and Fluid Service Interval Every 500 hoursService Interval After the first 100 hours Replace Emissions Air Intake FilterCopper-Based Anti-seize Do Not refuel or run engine unless spark arrester is installedCheck Spark Arrester if equipped Thread Locking AdhesivesBlade Slope AdjustmentsAdjusting the Blade Slope Deck LevelingAdjusting the Parking Brake Pump Drive Belt TensionDeck Belt Tension Motion Control Handle Adjustment Adjusting the heightAdjusting the Tilt Motion Control Linkage Adjustment Full Forward Tracking Adjustment8. Tighten nuts Adjusting the Seat Ride SuspensionElectric Clutch Adjustment No adjustment necessaryClean Hydro Fan Cooling Fins CleaningClean Engine and Exhaust System Area Remove Engine Shrouds and Clean Cooling Finsrecycling center or according to your state and local regulations Battery DisposalTroubleshooting TroubleshootingCutting blades is/are bent or unbalanced see Drive Wheel Release Valves sectionSchematics SchematicsElectrical Diagram Electrical Logic Schematic General Warranty Conditions and Products Covered Pioneer E-Series Turf Equipment1 Year Limited Commercial Warranty 4 Year or 500 Hours Limited Consumer WarrantyPage Page Description of Work Done Service RecordService Done By DatePage This page may be copied for personal use WALK-BEHIND ACCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONSMID-MOUNT RIDING ACCESSORIES AND OPTIONS OUT-FRONT RIDING ACCESSORIES AND OPTIONS