Exmark CD42CD User's Manual
Contents
1. 2 25 103 8504 Decal Navigator 1 26 103 8667 Pad Anti Skid 427 1 103 8630 Pad Anti Skid 48 1 Exmark red touch up paint spray paint P N 1 850337 6 liquid bottle P N 103 9140 Includes frame weldment plus items 7 13 14 19 21 25 37 38 and Decals Include zerk item 30 Includes 2 nyloc nuts item 38 15 5 2 FRONT FRAME GROUP 0900000 16 5 3 GEARBOX COMPONENTS FOR 103 3460 amp 103 3387 T 14 TORQUE TO ws 55 60 FT LBS 9 6 60361 Description Qty Item Part No Description Qty 1 109 0188 Asm Input Pinion 42 1 A 109 0198 Asm Connector Tube 48 Short 1 109 0189 Asm Input Pinion 48 1 109 0199 Asm Connector Tube 42 Long 1 24 109 0190 Center Housing 5 1 A 109 0200 Asm Connector Tube 48 Long 1 109 0191 End Housing W Plugs amp 2 9 109 0201 Kit Output 2 4 109 0192 Output Shaft Gear amp Brgs 42 LH 1 10 109 0202 Seal aieea epe des Ka2. 4 13 103 4118 Wid Deck Lock _ 1 39 3296 45 Nut Nyloc 1 2 13 2 14 103 4119 Wid Deck Lock 1 40 3296 51 Nut 3 4 10 2 15 103 9482 Asm Deck Lift Handle W Decal 1 41 32120 33 Ring Retaining 2 16 103 4284 Wld Spring Tensioner 42 32121 3 Rollpin 3 16 3 4 2 17 103 4285 Mount Deck Lift 2 43 614672 Screw Shoulder 3 8 16 x 1 295 2 18 103 4588 Bearing Roller 2 44 103 3655 01 Fork amp 19 103 4882 Cap Grease 45 103 4324 Asm Wheel amp Tire 8x3 00 4 Sp 20 103 7353 Pin Cut Height 46 103 9481 Asm Front Frame W Decals 42 21 103 7436 Bushing Deck 2 A 103 9480 Asm Front Frame W Decals 48 1 22 103 7448 2 47 103 4281 Spring 2 23 103 7865 Spring 2 48 103 9495 Asm Caster Wheel W Axle 1 24 103 7971 Cover Deck 2 49 103 4280 Asm Spring Lift
3. 1 103 3387 Gearbox 48 1 21 103 4230 Spacer 2 59 103 9479 Asm Deck W Decals 42 1 22 103 4974 FING 1 103 9478 Asm Deck W Decals 48 1 23 103 5868 01 Wd Spring 1 60 103 4209 Blade LH 42 1 24 103 5979 Guard nade 1 103 4207 Blade LH 48 1 1 25 103 6183 03 Bracket PTO Guard 1 61 103 4210 Blade RH 42 Red 26 103 6230 Decal Cutting Height Adjustment 2 103 4208 Blade RH 48 Red 27 103 6290 03 Plate Drive Line 1 620 103 9497 Asm Gearbox Cover W Decal 42 1 28 103 7353 Hairpin Cut 4 103 9496 Asm Gearbox Cover W Decal 48 1 29 103 7705 Driver 2 63 103 8556 01 Wid Baffle Discharge LH 42 30 103 7994 Balljoint a 1 103 8590 01 Wid Baffle Discharge LH 48 31 103 8307 Latch 1 64 103 8557 01 Wid Baffle Discharge 42 32 103 8363 Asm Deck 1 103 8591 01 Wild Baffle Discharge RH 48 33 103 8425 Decal
4. 1 65 103 8626 Pad Anti Skid 42 1 34 103 8496 Nut 7 8 9 2 103 8629 Pad Anti Skid 48 1 35 103 8610 Stand Off 1 2 2 66 103 8667 Pad Anti Skid 42 1 36 103 8841 1 103 8630 Pad Anti Skid 48 1 37 321 2 Screw 1 4 20 1 2 2 67 3296 42 Nut Nyloc 1 4 20 4 38 322 3 Screw 5 16 18 3 4 7 68 3256 23 Washer 5 16 3 Exmark red touch up paint spray paint P N 1 850337 6 oz liquid bottle P N 103 9140 13 Use Pro Lock Nut P N 1 840022 5ml tube on setscrew item 45 Deck assembly includes anti skid pad item 66 Gearbox cover assembly includes anti skid pad item 62 Deck latch assembly includes nyloc nut item 52 Rear deck height adj assembly includes 1 whizlock nut Item 48 5 1 DECK GROUP TORQUE TO y 30 35 FT LBS 1 48 REAR DECK HEIGHT ADJUSTMENT PINS TORQUE 11 85 110 FT LBS TORQUE 11 85 110 FT LBS 14 5 2 FRONT FRAME GROUP Item Part No Description Qty Item Part No Description Qty 1
5. 2 48 3290 357 Nut Whizlock 3 8 16 6 12 98 5954 Decal 2 49 3296 2 Nut Nyloc 10 24 15 13 99 0283 Bolt Shear 1 4 20 7 8 4 50 3296 29 Nut Nyloc 5 16 18 3 14 1 808280 Pin Clevis 5 16 1 2 51 3296 39 Nut Nyloc 3 8 16 1 15 103 9487 Asm Discharge Tube 1 52 3296 6 Nut Nyloc 3 8 24 1 16 109 0321 Asm Front Deck Height 2 53 32128 20 Nut Whizlock 5 16 18 4 17 103 3698 03 Guard Plenum ae 54 32128 49 18 103 3700 Roller 55 114439 19 109 0322 Asm Rear Deck Height Adj 42 2 56 103 9024 Decal Commercial 42 1 109 0323 Asm Rear Deck Height Adj 48 2 1 403131 Decal Commercial 48 1 20 103 9485 Asm Drive Shaft 1 57 106 5620 Spacer 42 103 9327 Asm Cross U Joint sae 106 5597 Spacer 48 103 9328 Yoke Keyed 58 103 3460 Gearbox 42 Std 103 9329 Yoke Quick
6. g Install springs onto the spring anchor pins under the left and right consoles and secure with a washer and hairpin See Figure 5 h SPRING ANCHOR PIN a UNDER CONSOLE g SLIDE SPRING ONTO SPRING ANCHOR PIN S 2 N SECURE SPRINGS WITH A WASHER AND HAIRPIN G0377 FIGURE 5 DECK SPRING INSTALLATION Un latch deck from raised position slowly lower deck to ground and lock deck locking pins on each side per section 4 1 2 Lowering the Deck to the Operation Position 3 4 DECK REMOVAL a b Stop engine wait for all moving parts to stop and remove key Raise mower deck up and latch with deck locking pins per section 4 1 1 Raising the Mower Deck to the Service Position Remove hairpins and washers at the top of the deck lift assist spring on each side of the unit See Figure 5 Remove the spring from the spring anchor Repeat for other side of unit Un latch deck from raised position and slowly lower deck to ground per section 4 1 2 Lowering the Mower Deck to the Operation Position NOTE Deck will become heavier once springs are removed from the anchors Lower deck carefully Remove lynch pins at front of push arms on both sides of the unit See Figure 3 Remove hairpin and clevis from both sides of the PTO guard See Figure 4 Raise seat and disconnect drive shaft using quick coupler at jackshaft See Figure 2 Pull mower deck forward to remove from unit 4 MAINTENANCE amp AD
7. DISENGAGE BLADE CLUTCH SHUT OFF ENGINE AND REMOVE KEY BEFORE MAKING ADJUSTMENTS SERVICING OR CLEANING DECK CUTTING HEIGHT ADJUSTMENT DECK SUPPORT PIN CUTTING HEIGHT INCHES mm 103 6230 PART NO 103 6230 LOCATION On Top of Deck Centered on Each Side 2 SPECIFICATIONS 2 1 MODEL NUMBER CD42CD CD48CD 2 2 DIMENSIONS 42 Deck 48 Deck Overall Width 43 2 109 7 cm 49 2 125 0 cm Overall Height 13 1 33 3 cm 13 1 33 3 cm Overall Length 37 2 94 4 cm 39 9 101 3 cm Weight 295 Ibs 134 kg 325 Ibs 147 kg 2 3 TORQUE REQUIREMENTS Bolt Location Torque Blade Mounting 85 110 ft lbs 115 149 N m Gearbox Mounting Bolts 30 35 ft lbs 41 47 N m Gearbox Assembly 50 55 ft lbs 68 75 N m 3 ASSEMBLY INSTRUCTIONS 3 1 UNCRATE DECK a Remove flat hairpins from under front frame and discard See Figure 1 3 2 ASSEMBLE DISCHARGE CHUTE a Locate the 3 holes at the rear of the mower deck shown in Figure 1 and remove the 3 10 24 x 3 4 truss head screws and 3 10 24 nyloc nuts b Assemble the discharge tube to the mower deck as shown using the hardware removed in 3 2 1 with hinge positioned on top of mower deck c Locate the discharge tube spring on the mower deck and hook onto the discharge tube spr
8. lift deck up and latch in up position latch is located at front center of seat See Figure 6 WARNING POTENTIAL HAZARD Operating the mower deck in the raised service position can be dangerous WHAT CAN HAPPEN Engaging the PTO with a deck in the raised position can result in a serious injury or property damage HOW TO AVOID THE HAZARD Always lower and lock mower deck in the operation position before engaging the PTO 4 1 2 Lowering the Mower Deck to the Operation Position a While firmly holding onto deck lift handle unhook deck latch from tractor section and slowly lower deck to ground b POTENTIAL HAZARD Operating mower without locking pins securely latched can result in the mower deck folding up unexpectedly Push deck locking pins inward and rotate forward to securely lock deck in lowered position See Figure 6 WARNING WHAT CAN HAPPEN The mower deck folding up unexpectedly can cause serious injury HOW TO AVOID THE HAZARD Always operate mower with locking pins securely latched 4 2 PERIODIC MAINTENANCE Clean grass build up under deck 4 2 1 4 2 2 Service Interval Daily Stop engine wait for all moving parts to stop and remove key Raise mower deck and secure in latched position See section 4 1 1 Raising the Mower Deck to the Service Position Clean out any grass build up from underside of deck and in discharge chute Lower d
9. 1 303334 Washer Spring Disk 5 16 2 27 103 8797 Decal Folding 2 2 1 513810 Bushing see A 28 103 8798 Decal Danger 3 1 543508 Cup Bearing Tapered Roller 4 29 103 8799 Decal 4 1 543509 Cone Bearing Tapered Roller 4 30 302 19 Zerk 1 4 28 5 4 5 1 543511 Seal 2 31 302 61 Zerk 45 1 4 28 4 6 1 633508 Washer Spring 0 6 32 322 4 Screw 5 16 18 7 8 2 7 1 811010 tev day 2 33 325 38 Screw 1 2 13 4 3 4 2 103 3729 01 Wid Deck Pivot 1 34 3218 3 Nut 3 8 16 2 103 3732 01 Wid Deck Pivot LH 1 35 3243 5 Setscrew 3 8 16 1 2 10 103 3772 Plug Spring 2 36 3256 28 Washer 3 4 2 11 103 3773 Shaft Spring 2 37 3296 29 Nut 5 16 18 2 12 103 4017 Spacer Front 2 38 3296 39 Nut Nyloc 3 8 16
10. be shipped via UPS next day or Second Day Air Exmark Manufacturing stocks a limited supply of parts for transaxles pumps and wheel motors These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program WARNING POTENTIAL HAZARD e This product is a piece of power equipment WHAT CAN HAPPEN e Failure to follow safe operating practices can result in serious operator injury or even death HOW TO AVOID THE HAZARD Keep all shields guards and safety devices especially the grass discharge system in place and in proper working condition Stop engine and wait for all moving parts to stop Remove spark plug wire s or remove key before adjusting servicing or performing maintenance If mower deck becomes clogged stop engine and wait for all moving parts to stop Remove spark plug wire s or remove key before cleaning blockage Keep hands feet and clothing away from power driven parts Keep off mower unless seat platform is provided Keep others off mower CONGRATULATIONS on the purchase of your Exmark Navigator Cutting Deck This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation OPERATOR S MANUAL This manual contains assembly operating maintenance adjustment and safety instructions for your Navigator Cutting Deck BEFORE OPERATING YOUR MOWER CAREFULL
11. by customer the dealer contacts his distributor by 1 00 p m local time and requests Exmark Parts Plus shipment of six 6 line items or less Distributor ships part s to dealer or customer as requested by dealer same day overnight UPS E X M A R R aT L U 5 Distributor bills dealer for part and freight charges where applicable If distributor does not have the part s in stock to satisfy Exmark Parts Plus order he contacts Exmark by 3 00 p m central time with an Exmark Parts Plus order of six 6 line items or less order is received by 3 00 p m central time Exmark ships part s direct to dealer or customer as requested by distributor same day overnight UPS Exmark bills the distributor for parts and shipping charges where applicable The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the program Who pays for the part and freight if it fails to arrive overnight in accordance to the program A Under any circumstance the customer does not pay If the part does not arrive overnight due to 1 The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1 00 p m the dealer pays for the part and freight 2 The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and
12. freight 3 Exmark being unable to ship the part and the Exmark parts order is received by 3 00 p m central time Exmark pays for the part and freight 4 If the part does not arrive overnight due to the shipper UPS the shipper pays for the freight and Exmark pays for the part The following restrictions apply The Exmark Parts Plus Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday Parts Plus service is available only in the 48 contiguous United States UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday The next day air charge plus the Saturday delivery fee will be the responsibility of the purchaser Exmark Mfg will assume no responsibility for Saturday delivery shipments To qualify all Exmark Parts Plus orders must be received by Exmark by 3 00 p m central time Orders must be six 6 line items or less Exclusions from the Exmark Parts Plus Program are Any wholegood or accessory in its entirety engines and engine replacement parts 5 speed Peerless transmissions and 5 speed transaxles hydraulic or hydrostatic wheel motors cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions Due to UPS restrictions aerosol spray paint is considered a hazardous material and cannot
13. For Serial Nos 510 000 amp Higher ark MFG CO INC NAVIGATOR CD42CD CD48CD CONGRATULATIONS on the purchase of your new Exmark equipment This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor If you need to order replacement parts from your dealer always give the model number and serial number of your equipment as well as the part number description and quantity of the part needed The Serial No plate is located on the top of the deck in front of the right spindle For ease of ordering and reference we suggest that you record the information requested in the following identification table Place Model No and Serial No Label Here Included in Literature Pack or Fill in Below Date Purchased Model No R gt Serial No Part No 103 8614 Rev A EXMARK PARTS PLUS PROGRAM EFFECTIVE DATE September 1 1995 Program If your Exmark dealer does not have the Exmark part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed How the Program Works 1 If dealer does not have part in stock for a down unit at the time of request
14. JUSTMENTS WARNING POTENTIAL HAZARD e While maintenance or adjustments are being made someone could start the engine WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or other bystanders HOW TO AVOID THE HAZARD Remove the key from the ignition switch 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 4 1DECK RAISING AND LOWERING 4 1 1 Raising the Mower Deck into Service Position a Stop engine wait for all moving parts to stop and remove key WARNING POTENTIAL HAZARD Incorrectly raising or lowering a mower deck be dangerous WHAT CAN HAPPEN mower deck can result in a serious injury or property damage HOW TO AVOID THE HAZARD Always raise and lower deck on flat dry ground free of any obstructions Firmly grasp the deck lift handle and lower in a slow controlled manner Always make sure the deck is securely latched in the up or down position b Release the deck locking pins on each side See Figure 6 SECURE DECK IN RAISED POSITION BY SECURING DECK LATCH ONTO HOOK DECK LOCKING PIN 1 ROTATE TOWARD REAR AND PULL OUTWARD TO UNLOCK 2 PUSH IN AND ROTATE TOWARD FRONT TO LOCK rl DECK LIFT HANDLE G0369 FIGURE 6 RAISING THE DECK deck lift handle
15. Y READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your equipment maintain its maximum efficiency and promote safe operation 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 efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance TABLE OF CONTENTS SAFETY PAGE 1 1 Safety Alert Symbol 123 1 2 1242 Operation 1 5 Maintenance amp Storage 1 2 3 SPECIFICATIONS 2 1 Model 2 2 IDIMENSION 2 3 ASSEMBLY INSTRUCTIONS 3 1 Uncrate Deck reri a 3 2 Assemble Dis
16. ZARD Wear hearing protection when operating this machine 1 3 3 1 3 4 While mowing always wear substantial footwear and long trousers Do not operate equipment when barefoot or when wearing open sandals Thoroughly inspect the area where the equipment is to be used and remove all stones sticks wires bones and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders 1 4 OPERATION Although hazard control and accident prevention are partially dependent upon the design and configuration of the equipment these factors are also dependent upon the awareness concern prudence and proper training of the personnel involved in the operation transport maintenance and storage of the equipment It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD not operate the machine without guards shields and safety devices in place and working Keep hands feet hair jewelry clothing away from rotating parts 1 4 1 Give complete undivided attention to the job at hand 1 4 2 Mow only in daylight or good artificial light
17. al instructions provided by Exmark All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service 1 Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S Customers may also call 402 223 6375 2 Bring the product and your proof of purchase sales receipt to the Exmark Service Dealer If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com 18 Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense As acondition to this warranty customer shall have read the operator s manual and shall have completed and submitted to Exmark Warranty Company within the prescribed time the Exmark warranty registration General Conditions The sole liability of Exmark and Ex
18. ally hazardous situation which if not avoided MAY result in minor or moderate injury 1 2 TRAINING 1 2 1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit 1 2 2 Before operating your mower read the Navigator tractor and cutting deck manual instructions carefully Familiarize yourself with the controls and the proper use of the equipment If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 1 2 4 Avoid mowing while people especially children or pets are nearby Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property 1 3 PREPARATION 1 3 1 Do not modify the Navigator cutting deck and only use on approved Exmark machines 1 3 2 The use of personal protective equipment such as but not limited to protection for the eyes ears feet and head is recommended CAUTION POTENTIAL HAZARD This machine produces sound levels in excess of 85 dBA at the operator s ear when in operation WHAT CAN HAPPEN Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss HOW TO AVOID THE HA
19. and thread onto the axle with the wrench flats facing outward Do not thread spacer nut all of the way onto the end of the axle Leave approximately 1 8 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing With the open end of the wheel facing up fill the area inside the wheel around the axle full of NGLI grade 1 multi purpose grease Insert the second bearing and new seal into the wheel Apply a thread locking adhesive to the 2 spacer nut and thread onto the axle with the wrench flats facing outward Torque the nut to 75 80 in lbs 8 9 N m loosen then re torque to 20 25 in lbs 2 3 N m Make sure axle does not extend beyond either nut n _ Re install the seal guards over the wheel hub and insert wheel into caster fork Re install 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 Re apply thread locking adhesive c Lubricate switch actuator rod with spray type lubricant or light oil 42 7 Change gearbox oil Change oil in all 3 gearbox housings after first 50 hrs of operation Check every 100 hours thereafter Ad
20. charge 3 3 Assemble Deck to 4 6 SA Deck Removal ei ere ne Reread aS MAINTENANCE amp ADJUSTMENTS 4 1 Deck Raising and Lowering eee 6 8 4 2 Maintenance EERE 8 11 Ais 11 12 PARTS LIST 5 1 eee 13 14 5 2 Eront Frame E 15 16 5 3 Gearbox Components 17 18 1 SAFETY 1 1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL A is used both in this manual and on the unit to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION DANGER White lettering Red background Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION Black lettering Yellow background Indicates a potenti
21. d oil as needed until level with oil drain plug a Stop engine wait for all moving parts to stop and remove key b Place unit on a level surface Remove the gearbox and drive shaft assembly from the mower deck Retain hardware for re use d Remove the large oil drain plug on the front of each of the 3 gearboxes and drain oil See Figure 9 Remove small magnetic plugs and wipe away any material accumulated on the plugs See Figure 9 SMALL MAGNETIC PLUGS FRONT AND BACK LARGE OIL DRAIN PLUG D LARGE OIL DRAIN PLUG SMALL MAGNETIC PLUG 7 gt FRONT ONLY LARGE OIL DRAIN PLUG SMALL MAGNETIC PLUGS 60381 FIGURE 9 GEARBOX OIL DRAIN LOCATIONS f Apply a Teflon pipe sealant to all small magnetic plugs and re install into the gearbox g Re install the gearbox and drive shaft assembly to the mower deck h gearbox with Mobil 1 75W 90 gear lube oil until level with oil drain plug NOTE Mower deck should remain level to the ground when filling gearbox with oil Do not fill gearbox with deck raised in the service position i Apply a Teflon pipe sealant to the 3 large oil plugs and re install into the gearbox 4 2 8 Thread locking adhesives such as Loctite 242 or Fel Pro Pro Lock Nut Type are used on the following fasteners a Caster wheel spacer nuts 4 3 ADJUSTMENTS IMPORTANT Disengage PTO shut off engine wait for all moving parts to stop and remove key before serv
22. de bolt after striking a foreign object Use only the following replacement parts Blade bolt 92 5816 Washer 86 1990 e DO NOT lubricate the threads of the bolt or spindle before assembly Torque the blade bolt to 85 110 ft Ibs 115 149 N m 114 20 X 2 1 4 WASHER BLADE BOLT lt SHEAR PINS 2 TORQUE BLADE BOLT 1 4 20 NYLOC NUTS gt 4 2 3 4 2 4 4 2 5 G0366 FIGURE 7 BLADE BOLT INSTALLATION Check for loose hardware Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Visually inspect machine for any loose hardware or any other possible Check tire pressures The front caster tires are semi pneumatic and do not need to be inflated NOTE Do not add any type of tire liner or foam fill material to the tires Excessive loads created by foam filled tires may cause failures to the hydro drive system frame and other components Foam filling tires will void the warranty Lubricate grease fittings Service Interval Refer to chart a Stop engine wait for all moving parts to stop and remove key b Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule GREASE FITTING LUBRICATION CHART 5 FITTING INITIAL NO of SERVICE 2 2 LOCATIONS PUMPS PLACES INTERVAL 1 Drive Shaft 220 2 Front Caster Wheel Hub 3 3 4 1 Se
23. e Section 4 2 5 for special lubrication instructions on the front caster pivots and Section 5 2 6 for special lubrication instructions on the rear caster wheel hub Lubricate caster pivots once a year Remove hex plug and cap Thread grease zerk in hole and pump with grease until it oozes out around top bearing Remove grease zerk and thread plug back in Place cap back on G0368 4 2 6 Lubricate caster wheel hub Service Interval Once Yearly Stop engine wait for all moving parts to stop and remove key N Remove caster wheel from caster forks Remove seal guards from the wheel hub A SEN Remove one of the spacer nuts from the GUARD A axle assembly the caster wheel Note that thread locking adhesive has been a applied to lock the spacer nuts to the axle Se SPACER NUT WITH Remove the axle with the other spacer coss WRENCH FLATS nut still assembled to it from the wheel FIGURE 8 assembly CASTER WHEEL ASSEMBLY Pry out seals and inspect bearings for wear or damage and replace if necessary Pack the bearings with a NGLI grade 1 multi purpose grease Insert 1 bearing 1 new seal into the wheel NOTE Seals Exmark PN 103 0063 must be replaced If the axle assembly has had both spacer nuts removed or broken loose apply a thread locking adhesive to 1 spacer nut
24. eck to cutting position and lock deck locking pins See section 4 1 2 Lowering the Mower Deck to the Operation Position Check mower blades Service Interval Daily Stop engine wait for all moving parts to stop and remove key Lift deck and secure in raised position as stated in Section 4 1 1 Raising the Mower Deck to the Service Position Inspect blades and sharpen or replace as required To remove blade use a block of wood or locking pliers to hold blade in place and remove the 1 2 20 x 2 1 4 blade bolt that secures the blade and blade driver If blade is worn or damaged remove the shear pins that secure the blade driver to the blade Re install a new blade to the blade driver and secure with the shear pins Re install the blade driver with new blades by using a block of wood or locking pliers to hold the blade in place and torque the blade bolts to 85 110 ft lbs 115 149 N m NOTE Blade driver flats must be aligned with the flats on the shaft when installing blade on the mower deck Lower the mower deck to the operation position See section 4 1 2 Lowering the Mower Deck to the Operation Position CAUTION POTENTIAL HAZARD Operating a mower deck with loose or weakened blade bolts can be dangerous WHAT CAN HAPPEN A loose or weakened blade bolt could allow a blade rotating at a high speed to come out from under the deck causing serious injury or property damage HOW TO AVOID THE HAZARD Replace the bla
25. els They are critical to the safe operation of your Exmark commercial mower A WARNING FOLDING DECK Can cause serious injury Do NOT operate with pivot joint unlocked N P PART NO 103 8797 LOCATION On Top RH and LH Sides of Front Frame A DANGER COVER 1 MISSING DO NOT OPERATE 985554 THIS UNIT WHEN COVER IS NOT IN PLACE PART NO 98 5954 LOCATION On Top of Deck Under Gear Box Cover On LH Frame Under PTO Shield On RH Lower Frame behind fuel tank To avoid serious injury or death Do NOT operate with deck in tilt up postion 103 8798 PART NO 103 8798 LOCATION Front RH Surface of Front Frame ROTATING DRIVELINE Can cause serious injury or death Keep driveline shields in place Securely attach both ends of the driveline 103 8425 PART NO 103 8425 LOCATION On Driveshaft A WARNING SPRING LOADED MECHANISM Can cause serious injury e Remove spring from tractor section only e See operator s manual for disassembly procedure 103 8799 PART NO 103 8799 LOCATION On Top of Front Frame Near Deck Springs CAUTION BLADE RETAINING BOLTS MUST BE TORQUED TO 85 110 ft lbs CHECK BLADE BOLT TORQUE AFTER STRIKING ANY SOLID OBJECT 68 8340 PART NO 68 8340 LOCATION On Top of Deck LH amp RH Sides KEEP HANDS and FEET AWAY PART NO 1 403005 LOCATION On Top of Mower Deck LH amp RH Sides A WARNING
26. h is the subject of this warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state SEE EXMARK S COMPLETE LINE OF ACCESSORIES RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SUN SHADE TRASH CONTAINER TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER E Z RIDER Check us out on the Web www exmark com 2005 EXMARK MFG CO INC PART NO 103 8614 Rev A INDUSTRIAL PARK BOX 808 402 223 6300 BEATRICE NE 68310 ALL RIGHTS RESERVED FAX 402 223 5489 ark MFG CO INC PRINTED IN U S A
27. icing cleaning or making any adjustments to the unit 4 3 1 Cutting Height Adjustment a Stop engine wait for all moving parts to stop and remove key Move cotter pins on four deck support pins to proper hole for height of cut desired 11 4 3 2 Deck Leveling a Position mower on a flat surface b Stop engine wait for all moving parts to stop and remove key c Inflate drive tires to 15 psi 103 kPa d Verify all hairpins are the 3 deck height holes with the spacers under the hair pins See Figure 10 Shorten lengthen each deck support pin to obtain blade tip height of 3 0 at the front of the deck and 3 25 at the rear of the deck RIGHT HAND SIDE SHOWN 60342 FIGURE 10 DECK SUPPORT PIN ASSEMBLY 4 3 3 Caster pivot bearings pre load adjustment a Remove dust cap from caster and tighten nyloc nut until washers are flat Back the nyloc off 1 4 181 of a turn to properly set the pre load on the bearings Note If disassembled make sure the spring washers are reinstalled as shown in Figure 11 60091 FIGURE 11 4 3 4 Deck Locking pin stop adjustment CASTER ADJUSTMENT a Slide deck locking pins in on both sides and rotate to lock the deck in the operation position b Loosen the jam nut and turn the stop screw clockwise until the locking pins is tight and cannot be rotated by hand See Figure 12 c Loosen the stop screw co
28. ing bracket See Figure 1 ASSEMBLE DISCHARGE TUBE ee TO REAR OF MOWER DECK S A REMOVE AND DISCARD FLAT _ HOOK SPRING ON HAIRPIN FROM UNDER FRONT DISCHARGE TUBE FRAME ON EACH SIDE SPRING BRACKET G0372 FIGURE 1 DISCHARGE TUBE ASSEMBLY 3 3 ASSEMBLE DECK TO NAVIGATOR a Stop engine wait for all moving parts to stop and remove key b the mower deck up to the Navigator tractor with the discharge tube down making sure the deck springs are located above the drive wheel and below the console on each side Raise seat and install drive shaft onto jackshaft See Figure 2 JACKSHAFT Se _ DRIVE SHAFT FIGURE 2 JACKSHAFT AND DRIVE SHAFT CONNECTION d Align deck push arm tubes to tractor push arms and push deck rearward Secure push arms with lynch pins on left and right sides of the unit See Figure 3 60356 SECURE PUSH ARM WITH LYNCH PIN SLIDE PUSH ARM INTO DECK PUSH ARM TUBE Qo G0378 FIGURE 3 PUSH ARM INSTALLATION Align upper portion of the PTO rubber guard to the tabs the front of the console and secure with a clevis pin and hairpin on each side See Figure 4 SECURE GUARD WITH CLEVIS PIN AND HAIRPIN FIGURE 4 PTO GUARD INSTALLATION f Release the deck locking pins on each side raise mower deck to the service position and secure deck latch onto hook See section 4 1 1 Raising the Deck to the Service Position
29. kani ainet 1 109 0193 Output Shaft Gear amp Brgs 48 LH 1 11 109 0203 OPNO 7 5 109 0194 Output Shaft Gear amp Brgs 42 RH 1 12 109 0204 Washer 1 109 0195 Output Shaft Gear amp Brgs 48 RH 1 13 109 0205 1 6 109 0196 Output 2 14 93 3987 Screw 3 8 24 1 1 4 8 28 109 0197 Asm Connector Tube 42 Short 1 Exmark red touch up paint spray paint P N 1 850337 6 liquid bottle P N 103 9140 Includes o rings item 11 Includes 1 output seal assembly item 9 Apply bead of Mobil HTS grease P N 103 5217 1 5 oz packet between seal item 10 and v ring item 13 Does not include screw item 14 Ttor 17 6 2 Year Limited Warranty Exmark Turf Equipment For units purchased on or after October 1 2004 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 manufactured by Exmark and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship for a period of two years This warranty applies to Exmark turf equipment purcha
30. keeping away from holes and hidden hazards NEVER carry passengers 1 4 3 Use EXTREME caution when backing up LOOK BEHIND YOU 1 4 4 Stop the blades when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed 1 4 5 Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition 1 5 MAINTENANCE AND STORAGE 1 5 1 1 5 2 1 5 3 1 5 4 Check all bolts frequently to maintain proper tightness Keep all guards shields and all safety devices in place and in safe working condition Frequently check for worn or deteriorating components that could create a hazard All replacement parts must be the same as or equivalent to the parts supplied as original equipment 1 6 SAFETY SIGNS 1 6 1 1 6 2 1 6 3 1 6 4 Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels Safety signs must be replaced if they are missing or illegible When new components are installed be sure that current safety signs are affixed to the replaced components New safety signs may be obtained from Exmark Mfg Co Inc 1 6 5 Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles 1 6 6 Familiarize yourself with the following safety signs and instruction lab
31. mark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein Neither Exmark nor Exmark Warranty Company shall have any liability for any other cost loss or damage including but not limited to any incidental or consequential loss or damage In particular we shall have no liability or responsibility for e Expenses related to gasoline oil or lubricants e Travel time overtime after hours time or other extraordinary repair charges or charge relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark service dealer e Rental of like or similar replacement equipment during the period of any warranty repair or replacement work e Any telephone or telegram charges or travel charges e 05 or damage to person or property other than that covered by the terms of this warranty e claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty e Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower There are no understandings agreements representations or warranties express or implied including but not limited to any regarding the merchantability that product is fit for ordinary use or fitness for use that product is fit for a particular purpose not specified herein respecting the equipment whic
32. sed on or after October 1 2004 sold in the US or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Products Warranty Period e All Products except as noted below 2 years e All Attachments and Accessories 1 year e Metro 21 Series 1 year e Belts and Tires 90 days 1 Year Prorated Warranty is covered by engine manufacturer e Battery e Engine Please refer to the engine manufacturer s warranty statement that is included in the literature packet We are not authorized to handle warranty adjustments on engines This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following e and delivery charges to and from any authorized Exmark Service Dealer e damage or deterioration due to normal use wear and tear or exposure e Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments e Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance e repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operation
33. unter clockwise 1 2 turn and tighten the jam nut d Test the locking pin to make sure it slides freely Readjust if necessary 57 ROTATE STOP SCREW CLOCKWISE UNTIL LOCKING PIN IS TIGHT THEN BACK OFF 1 2 TURN LOOSEN JAM NUT FIGURE 12 DECK LOCKING PIN ADJUSTMENT 12 5 PARTS LIST 5 1 DECK GROUP Item Part No Description Qty Item Part No Description Qty 1 1 403005 Danger Decal 39 322 5 Screw 5 16 18 1 3 2 1 413425 Spacer Deck Support 40 323 11 Screw HH 3 8 16 x 2 1 4 42 2 3 1 513690 Clip Deck Holdup Rod 323 8 Screw 3 8 16 1 1 2 48 2 4 1 523420 Bumper 41 323 7 Screw HH 3 8 16 x 1 1 4 5 1 613204 Balljoint 42 323 9 Screw HH 3 8 16 x 1 3 4 6 1 803075 Screw Truss Head 10 24 x 3 4 14 43 325 14 Screw 1 2 13 1 2 2 7 1 806003 Hairpin 2 44 3219 3 Nut 3 8 24 3 8 30 8770 Washes 2 45 3247 2 Setscrew 3 8 16 3 8 1 9 67 7490 Key Machine 1 4 1 4 1 1 2 1 46 3256 14 Washer 10 51 9 10 68 8340 Decal Blade Bolt Torque 2 47 3290 134 Screw HH Machine 10 24 x 5 8 1 11 92 5816 Bolt Blade 1 2 20 2 1 4
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