Exmark 4500-370 User's Manual
Contents
1. 42 inch Deck 13 1 inches 33 3 cm 48 inch Deck 13 1 inches 33 3 cm Curb Weight 42 inch Deck 295 Ib 134 kg 48 inch Deck 325 Ib 147 kg Torgue Reguirements Blade Mounting Bolt 85 110 ft Ib 115 149 N m Gearbox Mounting Bolts 30 35 ft lb 41 47 N m Gearbox Assembly Bolts 50 55 ft lb 68 75 N m Blade Shear Bolts 80 100 in Ib 922 1130 N cm Setup Setup A WARNING Operating a Navigator tractor without an approved Exmark front mount attachment increases the possibility of operator entanglement in drive wheels or forward tip over Entanglement or tip over could cause serious injury or death 1 ZA o Leh When operating a Navigator tractor without an approved Exmark front mount attachment observe the following Keep feet and clothing away from tires Figure 3 Limit operation to minimum required to fa pos la 22 Driveshaft install a different front mount attachment 4 Align deck push arm tubes to tractor push arms and push deck rearward Secure push arms with Only operate on a flat level surface lynch pins on left and right sides of the unit see Do Not operate up ot down a trailer ramp Figure 4 Minimize speed and use extreme caution Avoid sudden acceleration or deceleration Assemble Deck to Navigator Important Do Not transport Navigator tractor without and approved Exmark front mount attachment 1 Stop engine wait for all moving parts to sto2. damage and replace if necessary 6 Pack the bearings with a NGLI grade 1 multi purpose grease Caster wheel spacer nuts 7 Insert one bearing one new seal into the wheel Note Seals Exmark PN 103 0063 must be replaced 8 If the axle assembly has had both spacer nuts removed or broken loose apply a thread locking adhesive to one spacer nut 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 inch 3 mm from the outer surface of the spacer nut to the end of the axle inside the nut 9 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing 10 With the open end of the wheel facing up fill the atea inside the wheel around the axle full of NGLI grade 1 multi purpose grease 11 Insert the second bearing and new seal into the wheel 12 Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward 13 Torque the nut to 75 80 in Ib 8 9 N m loosen then re torque to 20 25 in lb 2 3 N m Make sure axle does not extend beyond either nut 14 Reinstall the seal guards over the wheel hub 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
3. nyloc nuts 3 Bolt clarity 4 Washer 5 Baffles Raise deck as stated in Raising the Mower Deck to th Service Positi n sechon 6 Lower deck per Lowering the Mower Deck to the Operating Position section Remove bolt and washer at the front of each of the FRS baffles Rotate baffles into desired a OE ft Seo PRA position and reinstall bolt and washer baffles These nuts may be left slightly loose if frequent baffle adjustment is anticipated 8 Reinstall PTO guard using clevis pins and hair pins removed in step 2 13 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position A 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 Recommended Maintenance Schedule s Maintenance Service g Maintenance Procedure Interval After the first 50 hours e Change oil in all three gearbox housings Add oil as needed until level with oil drain plug heck the mower blades heck for loose hardware Before each use or daily rease the front caster wheel hub ean the grass and debris build up from the cutting deck ean
4. or herself other people or property Preparation Do Not modify the Navigator cutting deck Only use on machines approved by Exmark Wear appropriate clothing including safety glasses substantial footwear long trousers and hearing protection Do Not operate when barefoot or when wearing open sandals A CAUTION This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders Operation Operate only in daylight or good artificial light keeping away from holes and hidden hazards Never raise deck with blades running Stop engine wait for all moving parts to stop remove key and engage parking 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 Safety A WARNING Hands feet hair clothing or accessories can become entangled in rotating parts Contact with the rotating parts can cause traumatic amputation or severe lace
5. 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 17 Maintenance Adjustments Note Disengage PTO 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 Deck Leveling 1 Position mower on a flat surface 2 Stop engine wait for all moving parts to stop and remove key Engage parking brake 3 Inflate drive tires to 15 psi 103 kPa Verify all hairpins are in the 3 inch deck height holes with the spacers under the hair pins Figure 15 6007580 Figure 15 Right Hand Side Shown 1 Hairpin 3 Deck support pin 2 Spacer 5 Shorten lengthen each deck support pin to obtain blade tip height of 3 inches at the front of the deck and 3 1 4 inches at the rear of the deck Caster Pivot Bearings Pre load Adjustment Remove dust cap from caster and tighten nyloc nut until washers are flat Back the nyloc off 1 4 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 16 OZE Figure 16 1 Spring disc washers Deck Locking Pin Stop Adjustment 1 Slide deck locking pins in on both sides and rotate to lock the deck in the operation position 2 Loose
6. the replaced components e Ifan attachment or accessory has been installed make sure current safety signs are visible KEEP HANDS and FEET AWAY 1 403005 A CAUTION BLADE RETAINING BOLTS MUST BE TORQUED TO 85 110 ft Ibs CHECK BLADE BOLT TORQUE AFTER New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc 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 ait bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower ROTATING DRIVELINE Can cause serious injury or death Keep all driveline shields in place e Securely attach both ends of the driveline Ko 103 8425 103 8425 A WARNING FOLDING DECK Can cause serious injury Do NOT operate with pivot joint unlocked 103 8797 103 8797 STRIKING ANY SOLID OBJECT 68 8340 68 8340 A DANGER THIS UNIT WHEN COVER IS NOT IN PLACE avoid serious injury or death Do NOT operate with deck in tilt up postion 103 8798 103 8798 98 5954 A WARNING DISENGAGE BLADE CLUTCH SHUT OFF ENGINE AND REMOVE KEY BEFORE MAKING ADJUSTMENTS SERVICING OR CLEANING DECK CUTTING HEIGHT ADJUSTMENT DECK SUPPORT PIN 4 CUTTING A WARNING SPRING LOADED MECHA
7. the grass build up from under the deck EE e Check the condition of the belts vety ours Grease the drive shaft e Change oil in all three gearbox housings Add oil as needed until level with oil drain plug thereafter e Grease the deck flip up e Grease the pivot arm tubes earl Grease the front caster pivots early y e Lubricate the caster wheel hubs Every 100 hours Periodic Main tenance 3 Inspect blades and sharpen or replace as required 4 To remove blade use a block of wood or locking Check Mower Blades pliers to hold blade in place and remove the f f 1 2 20 x 2 1 4 inch blade bolt that secures the Service Interval Before each use or daily bladeand blide driver 1 Stop engine wait for all moving parts to stop and 5 Re install the blade driver with new blades by remove key Engage parking brake using a block of wood or locking pliers to hold 2 Lift deck and secure in raised position as stated the blade in place and torque the blade bolts to in section Raising the Mower Deck to the 85 110 ft lb 115 149 N m Service Position Maintenance Note Blade driver flats must be aligned with the flats on the shaft when installing blade on the mowet deck Lower the mower deck to the operation position see section Lowering the Mower Deck to the Operation Position A WARNING Operating a mower deck with loose or weakened blade bolts can be dangerous A loose or weakened blade bolt could allo
8. 1 3 40 Hours Shaft 2 Front 1 2 8 Hours Caster Wheel Hub 3 Deck 1 4 100 Hours Flip Up 4 Push 1 2 100 Hours Arm Tubes csc Caster Pivots See step 3 for special lubrication instructions on the front caster pivots and the Lubricate Caster Wheel Hubs section for special lubrication instructions on the front casters wheel hubs V G007582 3 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 Lubricate Caster Wheel Hubs Service Interval Yearly 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Os G006115 2 Figure 14 1 Seal guard 2 Spacer nut with wrench flats 2 Remove caster wheel from caster forks Remove seal guards from the wheel hub 4 Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has been applied to lock the Maintenance spacer nuts to the axle Remove the axle with Thread Locking Adhesives the other spacer nut still assembled to it from the wheel assembly Thread locking adhesives such as Loctite 242 ot Fel Pro Pro Lock Nut Type are used on the 5 Pry out seals and inspect bearings for wear or following fasteners
9. ETE LINE OF ACCESSORIES AND OPTIONS MID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12V POWER PORT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SUN SHADE TRASH CONTAINER TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC GUICK DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC GUICK DISPOSAL SYSTEM ROLL OVER PROTECTION SYSTEM ROPS WEATHER CAB WALK BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO MULCH SYSTEM Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Model No Serial No 2009 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 All Rights Reserved TURF STRIPER STANDON Date Purchased Part No 4500 370 Rev A 402 223 6300 ANAK Fax 402 223 5489 M Printed in the USA www exmark com
10. NISM Can cause serious injury e Remove spring from tractor section only e See operator s manual for disassembly procedure 103 8799 103 8799 aie HEIGHT Fie o 4 0 102 INCHES mm 103 6230 103 6230 Specifications Specifications Model Numbers Serial Nos 790 000 and Higher CD42CD CD48CD Systems Tires 8 Wheels II ie Pressure Cutting Deck e Model Numbers CD42CD CD48CD e Cutting Width 42 inch Deck 42 inch 106 7 cm 48 inch Deck 48 inch 121 9 cm e Discharge Center e Blade Size 2 ea 42 inch Deck 22 00 inches 55 9 cm 48 inch Deck 25 00 inches 63 5 cm e Deck Drive Clutching belt on horizontal engine shaft Dual A section hexagon belt with spring tensioned idler to jackshaft and blower Heavy duty cast iron spiral bevel gearbox is final drive to blades e Deck Full floating deck is attached to out front support frame Deck design allows for bagging or mulching e Deck Depth 42 inch Deck 4 5 8 inches 11 7 cm 48 inch Deck 4 5 8 inches 11 7 cm Cutting Height Adjustment Adjusts from 1 inch 2 5 cm to 4 inches 10 2 cm in 1 4 inch 64 cm increments Mulching Kit Optional Dimensions Overall Width 42 inch Deck 43 2 inches 109 7 cm 48 inch Deck 49 2 inches 125 0 cm Overall Length 42 inch Deck 37 2 inches 94 4 cm 48 inch Deck 39 9 inches 101 3 cm Overall Height
11. cD42CD CD48CD E at ja A the D Ca O For Serial Nos 790 000 amp Higher Part No 4500 370 Rev A Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 2009 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PARTS___ am OVERNIGHT FREE 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 Some restrictions apply See your participating Exmark Dealer for details Contact us at www Exmark com Printed in the USA All Rights Reserved Introduction CONGRATULATIONS on the purchase of your Exmark Cutting Deck This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation This manual contains operating maintenance adjustment and safety instructions for your Exmark mower BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your m
12. delivery charges to and from any authorized Exmark Service Dealer e Any damage or deterioration due to normal use wear and tear or exposure 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 Any 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 operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage All warranty work must 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 www exmark com U S or Canada customers may also call 402 223 6375 21 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 A
13. e 2 Place unit on a level surface Remove the gearbox and drive shaft assembly from the mower deck Retain hardware for re use 4 Remove the large oil drain plug on the front of each of the three gearbox sections and drain oil Figure 13 Figure 13 1 Small magnetic plugs front and back 2 Large oil drain fill plug 3 Small magnetic plug front only 15 Maintenance 5 Remove small magnetic plugs and wipe away any material accumulated on the plugs 6 Apply a Teflon pipe sealant to all small magnetic plugs and re install into the gearbox 7 Re install the gearbox and drive shaft assembly to the mower deck 8 Fill gearbox with Mobil SHC synthetic 75W 90 gear lube oil until level with oil drain fill plug Each of the gearbox sections must be filled separately 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 9 Apply a Teflon pipe sealant to the 3 large oil plugs and re install into the gearbox Lubricate Grease Fittings Note See chart for service intervals 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate fittings with NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule Lubrication Chart Fitting Initial Number of Service Locations Pumps Places Interval 1 Drive
14. e unhook deck latch from tractor section and slowly lower deck to ground see Figure 9 Push deck locking pins inward and rotate forward to securely lock deck in lowered position see Figure 8 A WARNING Operating mower without locking pins securely latched can result in the mower deck folding up unexpectedly The mower deck folding up unexpectedly can cause serious injury Always operate mower with locking pins securely latched Adjusting Fill Reduction System FRS Baffles The Navigator s exclusive Fill Reduction System has been designed to allow you to reduce the amount of clippings collected by varying degrees Advantages include less frequent emptying of the hopper and return of nutrients to the soil Possible Configurations 1 Baffles open standard blades Maximum collection Baffles closed standard blades Partial mulching Baffles closed mulch blades Intermediate mulching Mulch plug installed mulch blades Complete mulching requires mulch kit Operation To adjust the FRS baffles 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake G007577 Remove hair pins and clevis pins from both sides of the PTO guard see Figure 5 Fold guard forward Loosen nyloc nuts on the rear studs of the FRS baffles Figure 11 3 1 Baffles shown in closed position Figure 10 2 Baffles shown in open position PTO guard removed for 2 Loosen
15. e mounting bolt Tighten the engine mounting bolts Contact an Authorized Service Dealer Contact an Authorized Service Dealer Check belt tension or replace belt Connect PTO shaft Check belt for damage Install belt and check adjusting shafts and belt guides for correct position Exmark Commercial Turf Eguipment 2 Year Limited 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 exercise of our reasonable discretion to be defective in factory materials or workmanship for a period of two years This warranty applies to Exmark commercial turf equipment sold in the U S 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 Warranty Exceptions Warranty Period e Bags Belts and Tires 90 days e Battery 1 Year Prorated Engine 2 years The Engine warranty is covered by the engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following e Pickup and
16. ired Deck Raising and Lowering Raising the Mower Deck into Service Position 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake A WARNING Incorrectly raising or lowering a mower deck can be dangerous A dropped mower deck can result in a serious injury or property damage e 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 2 Release the deck locking pins on each side Figure 8 Operation Figure 8 a Deck lift handle 2 Rotate the deck locking pin toward the rear and pull outward to unlock 3 Push the deck locking pin in and rotate toward the front to lock 3 Using deck lift handle lift deck up and latch in up position latch is located at front center of seat see Figure 9 Figure 9 2 Hook 1 Secure the deck in the raised position by securing the deck latch onto the hook A WARNING Operating the mower deck in the raised service position can be dangerous Engaging the PTO with a deck in the raised position can result in a serious injury or property damage Always lower and lock mower deck in the operation position before engaging the PTO Lowering the Mower Deck to the Operating Position 1 While firmly holding onto deck lift handl
17. k 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 adjustments 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 Uneven cutting height Abnormal vibration Blades Do Not rotate Blade s not sharp Cutting blade s is are bent Mower deck is not level Underside of mower is dirty Tire pressure in drive tires not correct Spacers are in wrong location Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is approximately one blade thickness Cutting blade s is are bent or unbalanced Blade mounting bolt is loose Engine mounting bolts are loose Engine pulley is damaged Blade spindle is bent PTO belt is worn loose or broken PTO shaft is not connected PTO belt is off pulley 20 Sharpen the blade s Install new cutting blade s Level mower deck from side to side and front to reat Clean the underside of the mower Adjust tire pressure in the drive tires Position spacers under hairpins Replace blades spindles and or check for damage to mower deck Install new cutting blade s Tighten the blad
18. 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 All implied warranties of merchantability that the product is fit for ordinary use and fitness for use that the product is fit for a particular purpose are limited to the duration of the express 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 G4500 425 Service Record Date Description of Work Done Service Done By 22 This is a5 slope No Slope Example Compare slope with a tree building fence post pole etc ry Align this edge with a vertical surface u it 1 1 i y Aa J U i I ii t AE iM PA v i No g x pat We rush vy A ye yl OA SNA vt A adhe 1 i w anit dary Ani ay Ay i de it caine jy ve radu vu sd faubo nt b Hi htt VA wdy yu VA vodn ao Nuh he 7 G000503 23 SEE EXMARK S COMPL
19. mbol 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 potentially hazardous situation which if not avoided May result in minor or moderate injury This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safe Operating Practices Training e Read the tractor and cutting deck Operator s Manuals and other training material If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them e Become familiar with the safe operation of the equipment operator controls and safety signs e All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate or service the equipment Local regulations may restrict the age of the operator The ownet user can prevent and is responsible for accidents or injuries occurring to himself
20. n the jam nut and turn the stop screw clockwise until the locking pins is tight and cannot be rotated by hand Figure 17 G007581 Figure 17 1 Rotate stop screw clockwise until locking pin is tight then back off 1 2 turn 2 Loosen jam nut 3 Loosen the stop screw counter clockwise 1 2 turn and tighten the jam nut Test the locking pin to make sure it slides freely Readjust if necessary 18 Maintenance Cleaning Clean Debris From Cutting Deck 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 build up on the cutting deck especially under deck belt shields Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise mower deck and secure in latched position see Raising the Mower Deck to the Service Position section in Operation 3 Clean out any grass build up from underside of deck and in discharge chute 4 Lower deck to cutting position and lock deck locking pins see Lowering the Mower Deck to the Operation Position section in Operation 19 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 overloo
21. ns 4 silne stds estes Hien a 8 Torque Requirements ifn cath ie matvcsctenatiectas 8 SETUD dasa s O I 9 Assemble Deck to Navigator oo oonsoonnonnviu 9 Deck Rem Oval a 10 Product OW EL VIEW asioin kel o odv dobi 11 OPEO eraa eE o OE EEEE TA 11 Adjusting the Cutting Nleiehts s bipees 11 Deck Raising and Lowering zdar ten 11 Adjusting Fill Reduction System FRS S 12 MALA SNA r 14 Recommended Maintenance Schedule s 14 Periodic Maintenance zru OD 14 Check Mower Blades icine atmavceineraness 14 Check for Loose Hardware sonics sovsndehscevseestives 15 Check Tire Press teS ma O 15 Change Gearbox 01l a 15 Lubricate Grease PIABS zisiel 16 Lubricate Caster Wheel Fabs isos ory desgurteines 16 Thread Locking Adhesives cceeeceeeeees 17 PLUS ERIE TIES seter E A E E E RG 18 Deck Leveling tsis irigis 18 Caster Pivot Bearings Pre load Adj stme t eiennenn n 18 Deck Locking Pin Stop Adjustment 18 Clean a E E A E a RETAS 19 Clean Debris From Cutting Deck 19 Clean Grass Build Up Under Deck 19 Troubleshooting sa sy A a vo 20 Safety Safety Safety Alert Symbol This Safety Alert Symbol Figure Z is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A Figure 2 1 Safety alert symbol The safety alert sy
22. ower 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 Whenever you need service genuine Exmark parts ot additional information contact an Authorized Service Dealer or Exmark Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided 1 Figure 1 Model and serial number location Model No Serial No Contents Tntrod chO Nyss rinane bl a on 3 SATE u e e ra A ko vn ne 5 Safety Alert Symbol scccasiiesssansdenreaaiyeacswimavestes 5 Safe Operating Practices sists ctacdatestieadatectase tas 5 Safety and Instructional Decals wee 7 SUECHICATONS pust meanness 8 Model Nambels sute cdak al a 8 SE S AAE uiared Sevan v 8 Dimensio
23. p and remove key Engage parking brake 2 Roll 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 3 Raise seat and install drive shaft onto jackshaft see Figure 3 Figure 4 1 Slide the push arm into the deck push arm tube 2 Secure the push pin arm with lynch pin 5 Align upper portion of the PTO rubber guard to the tabs on the front of the console and secure with a clevis pin and hairpin on each side see Figure 5 1 Figure 5 Secure PTO guard with clevis pin and hairpin Release the deck locking pins on each side raise mower deck to the service position and secure deck latch onto hook See Raising the Deck to the Service Position section in Operation Install springs onto the spring anchor pins under the left and right consoles and secure with a washer and hairpin see Figure 6 Figure 6 Spring anchor pin under console Secure springs with a washer and hairpin Slide spring onto spring anchor pin Un latch deck from raised position slowly lower deck to ground and lock deck locking pins on each side Lowering the Deck to the Operation Position section in Operation 10 Deck Removal f Stop engine wait for all moving parts to stop and remove key Engage parking brake Raise mower deck up and latch with deck locking pins per Raising the Mower Deck to
24. rations e Do Not operate the machine without guards shields and safety devices in place and working properly Keep hands feet hair jewelry or clothing away from rotating parts Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed Be alert slow down and use caution when making turns Look behind and to the side before changing directions Maintenance and Storage Disengage PTO set parking brake stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Use care when checking blades Wrap the blade s ot wear gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep all guards shields and all safety devices in place and in safe working condition Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard All replacement parts must be the same as ot equivalent to the parts supplied as original equipment Safety Safety and Instructional Decals e Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels e Replace all worn damaged or missing safety signs e When replacement components are installed be sure that current safety signs are affixed to
25. shland Avenue Beatrice NE 68310 402 223 6375 or service exmark com 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 read the operator s manual You must also 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 General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein Neither Exmark nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage Such damages include but are not limited to e Expenses related to gasoline oil or lubricants e Travel time overtime after hours time or other extraordinary repair charges or charges 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 Loss or damage to person or property other than that covered by the terms of this warranty e Any claims for lost revenue
26. the Service Position section in Operation Remove hairpins and washers at the top of the deck lift assist spring on each side of the unit see Figure 6 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 Lowering the Mower Deck to the Operation Position section in Operation 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 4 Remove hairpin and clevis from both sides of the PTO guard see Figure 5 Raise seat and disconnect drive shaft using quick coupler at jackshaft see Figure 3 Pull mower deck forward to remove from unit Important Do Not transport Navigator tractor without an approved Exmark front mount attachment Operation Product Overview 1 Cut height adjustment 2 Caster wheel 6007574 Figure 7 3 Deck lift handle 11 Operation Adjusting the Cutting Height The cutting height of the mower deck is adjusted from 1 to 4 inches 2 5 cm to 10 2 cm in 1 4 inch 63 cm increments 1 Stop the machine and move the speed control levers to the neutral position 2 Disengage the PTO 3 Engage the park brake 4 Stop the engine remove the key and wait for all moving parts to stop 5 Move cotter pins on four deck support pins to proper hole for height of cut des
27. w a blade rotating at a high speed to come out from under the deck causing serious injury or property damage e Replace the blade bolt after striking a foreign object Use only genuine Exmark replacement parts Do Not lubricate the threads of the bolt or spindle before assembly Torque the blade bolt to 85 110 ft lb 115 149 N m Torque the shear bolts to 80 100 in Ib 922 1130 N cm Figure 12 1 2 20 x 2 1 4 blade bolt torque to 85 110 ft lb 115 149 N m Washer Shear bolts torque to 80 100 in Ib 922 1130 N cm Blade driver 1 4 20 nyloc nuts ak wn Check for Loose Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Check Tire Pressures Service Interval Every 40 hours 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 Change Gearbox Oil Service Interval After the first 50 hours Every 100 hours thereafter 1 Stop engine wait for all moving parts to stop and remove key Engage parking brak
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