Exmark 4500-996 Rev A manual

PIONEER E-SERIES For Serial Nos. 312,000,000 & Higher Part No. 4500-996 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 PNE651KA482; PNE691KA522 Systems Engine • Engine Specications: See your Engine Owner’ s Manual • Engine Oil T ype: Exmark 4–Cycle Premium Engine Oil • RPM: Full Speed: 3600 ±50 RPM (PTO not engag ed) Idle: 1500 ±100 RPM Fuel System • Capacity: 7.0 gal.[...]

Specications – 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 brake . • Deck Height Adjustment Lever: Sets cutting height to desired position. • Deck Lift[...]

Specications Dimensions Overall Width: 48 inch Deck 52 inch Deck Without Dec k 44.1 inches (112.0 cm) 44.1 inches (112.0 cm) Deector Up 48.0 inches (121.9 cm) 52.8 inches (134.1 cm) Deector Do wn 59.2 inches (150.4 cm) 64.0 inches (162.6 cm) Overall Length: 48 inch Deck 52 inch Deck R oll Bar - Up 77.8 inches (197.6 cm) 77.8 inches (197.6 [...]

Operation Product Overview Figure 4 1. Rollover Protection System (ROPS) 5. Motion control levers 2. Engine Controls (right console) 6. Parking brake 3. Seat belt 7. Height of cut adjustment 4. Fuel cap Operation Note: Deter mine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion co[...]

Operation rear , to the detent, will put the c hoke in the “OFF” position. Do Not r un a w ar m engine with c hoke in the “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 lev er) (see Figure 6). The throttle is us[...]

Operation The fuel shut-off v alv e is used to shut off the fuel when the machine will not be used for a few days , during transport to and from the jobsite, and when parked inside a building . Align v alv e handle with the fuel line to open. R otate 90° to close . Drive Wheel Release V alves W ARNING Hands may become entang led in the rotating dr[...]

Operation Switch must be pulled out (up) to engage the blades . Switch is pushed in to diseng age the blades . Deck Lift Pedal Located at the right front corner of the oor pan. Push the pedal forward with your foot to raise the cutting deck. Allo w the pedal to mo v e rearward to low er the cutting deck to the cut height that has been set. Figur[...]

Operation Figure 1 1 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 eng aged with the roll bar in the raised position. The upper hoop of the roll bar may need to be pushed forward or pulled rearw ard to get both kn[...]

Operation The PTO push-pull switc h engag es the cutting blades . Be sure that all persons are clear of the mo wer deck and disc harge area before engaging PTO . Important: Operator must be in seat before the PTO can be engaged. 1. Set the throttle midway between the “SLO W” and “F AST” positions . 2. Pull the PTO switc h outward to engag e[...]

Operation Figure 14 T o turn left or right, pull the motion control lev er back to ward neutral in the desired turn direction. The machine will mo ve faster the far ther the motion control levers are mo ved from the neutral position. 4. T o stop , position both motion control lev ers in the neutral operate position. Driving in Rev erse 1. Mov e the[...]

Operation Adjusting the Anti-Scalp Rollers It is recommended to change the anti-scalp roller position, when the height of cut has changed. 1. Stop the mac hine and mov e the motion control levers outw ard to the neutral loc ked position. 2. Disengag e the PTO . 3. Engag e the park brake . 4. Stop the engine, remo ve the k ey and w ait for all movin[...]

Operation W ARNING Loading a unit on a trailer or tr uck increases the possibility of backw ard tip-ov er . Backw ard tip-ov er could cause serious injur y or death. • Use extreme caution when operating a unit on a ramp. • Use only a single, full width ramp; Do Not use individual ramps for each side of the unit. • If indi vidual ramps must be[...]

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. Blade drive washer 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 ba[...]

Maintenance Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mo wing . 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 f[...]

Maintenance 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. Engine 2. Expansion tank Check T ire Pressures Service Interval: Ev[...]

Maintenance originally installed at the factor y to keep the fuel line aw ay from components that could cause fuel line damage. Replace Emissions Air Intake Filter Service Interval: Every 500 hours 1. Stop engine, w ait for all moving par ts to stop , and remov e key or spark plug wire(s). Engag e parking brake . 2. R emov e the lter from the ve[...]

Maintenance A. With the bypass v alve open and the engine r unning, slo wly mo ve the directional control in both forward and reverse (5 or 6 times). B . With the bypass valv e closed and the engine r unning, slo wly mo ve the directional control in both forw ard and rev erse directions (5 to 6 times). Chec k the oil level, and add oil as required [...]

Maintenance Adjustments Note: Disengag e PTO , shut off engine, w ait for all moving parts to stop , engage parking brake , and remov e key before ser vicing, cleaning, or making any adjustments to the unit. CAUTION Raising the mower deck for ser vice or maintenance relying solely on mechanical or h ydraulic jacks could be dangerous. The mechanical[...]

Maintenance “R” (see Bloc k Height and Rake T able in Deck Leveling ) lo wer than the rear blade tip , adjust the blade level using the follo wing instr uctions: 2. P ark the mac hine on a lev el surface and disengage the blade control switch. 3. Mov e the motion control levers outward to the neutral position, engag e the parking brak e, stop t[...]

Maintenance CAUTION Raising the mow er deck for ser vice or maintenance rel ying solely on mechanical or h ydraulic jacks could be dangerous. The mechanical or h ydraulic jacks may not be enough suppor t or may malfunction allo wing the unit to fall, which could cause injur y . Do Not rely solely on mechanical or hy draulic jacks for suppor t. Use [...]

Maintenance Full Forward T racking Adjustment If the machine trav els or pulls to one side when the motion control levers are in the full forw ard position, adjust the cov er plates . 1. Loosen the screws on a co v er plate (see Figure 29). 2. Slide the cov er plate backward or forw ard to adjust the tra vel of the lev er and tighten the screws . 3[...]

Maintenance Figure 30 1. Nut 4. Control plate 2. T urnbuckle 5. Return to neutral plate 3. Stationary plate 6. T abs touching return to neutral plate 8. Tighten n uts . 9. Shut off unit. R emov e jumper wire from wire harness and plug connector into seat switch. 10. R emo v e the jack stands . 11. Raise the dec k and re-install the height of cut pi[...]

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 44[...]

Schematics Electrical Logic Schematic 45[...]

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[...]

Notes: 47[...]

Notes: 48[...]

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

50[...]

G01 1841 Figure 32 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[...]