Exmark 4500-370 User manual

CD42CD/CD48CD
ForSerialNos.
790,000&Higher
PartNo.4500-370Rev.A

Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2009—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE683102
Contactusatwww.Exmark.com.
PrintedintheUSA
AllRightsReserved

Introduction
CONGRATULATIONSonthepurchaseofyour
ExmarkCuttingDeck.Thisproducthasbeen
carefullydesignedandmanufacturedtogiveyou
amaximumamountofdependabilityandyearsof
trouble-freeoperation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.
Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
3

Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals.......................7
Specications.........................................................8
ModelNumbers..............................................8
Systems...........................................................8
Dimensions.....................................................8
TorqueRequirements......................................8
Setup......................................................................9
AssembleDecktoNavigator...........................9
DeckRemoval...............................................10
ProductOverview................................................11
Operation.............................................................11
AdjustingtheCuttingHeight.........................11
DeckRaisingandLowering...........................11
AdjustingFillReductionSystem(FRS)
Bafes.......................................................12
Maintenance.........................................................14
RecommendedMaintenanceSchedule(s)...........14
PeriodicMaintenance.......................................14
CheckMowerBlades.....................................14
CheckforLooseHardware............................15
CheckTirePressures.....................................15
ChangeGearboxOil......................................15
LubricateGreaseFittings...............................16
LubricateCasterWheelHubs........................16
ThreadLockingAdhesives.............................17
Adjustments.....................................................18
DeckLeveling...............................................18
CasterPivotBearingsPre-load
Adjustment...............................................18
DeckLockingPinStopAdjustment...............18
Cleaning...........................................................19
CleanDebrisFromCuttingDeck...................19
CleanGrassBuild-UpUnderDeck................19
Troubleshooting...................................................20
4

Safety
Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
1.Safetyalertsymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
•ReadthetractorandcuttingdeckOperator’s
Manualsandothertrainingmaterial.Ifthe
operator(s)ormechanic(s)cannotreadEnglish
itistheowner’sresponsibilitytoexplainthis
materialtothem.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
•DoNotmodifytheNavigatorcuttingdeck.
•OnlyuseonmachinesapprovedbyExmark.
•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.
CAUTION
Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.
Wearhearingprotectionwhenoperatingthis
machine.
•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
Operation
•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
•Neverraisedeckwithbladesrunning.
•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.
5

Safety
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.
•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.
MaintenanceandStorage
•DisengagePTO,setparkingbrake,stopengine
andremovekeyordisconnectsparkplugwire.
Waitforallmovementtostopbeforeadjusting,
cleaningorrepairing.
•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.
•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
•Checkallboltsfrequentlytomaintainproper
tightness.
•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.
6

Safety
SafetyandInstructionalDecals
•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
•Replaceallworn,damaged,ormissingsafety
signs.
•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
1-403005
68-8340
98–5954
103-6230
103-8425
103-8797
103-8798
103-8799
7

Specications
Specications
ModelNumbers
SerialNos:790,000andHigher
CD42CD;CD48CD
Systems
Tires&Wheels
FrontCaster
Semi-Pneumatic
Quantity2
TreadSmooth
Size8x3.00–4
PlyRating
Pressure
CuttingDeck
•ModelNumbers:
–CD42CD
–CD48CD
•CuttingWidth:
–42inchDeck:42inch(106.7cm)
–48inchDeck:48inch(121.9cm)
•Discharge:Center
•BladeSize:(2ea.)
–42inchDeck:22.00inches(55.9cm)
–48inchDeck:25.00inches(63.5cm)
•DeckDrive:
–Clutchingbeltonhorizontalengineshaft.
Dual“ A”sectionhexagonbeltwithspring
tensionedidlertojackshaftandblower.
–Heavy-dutycastiron,spiralbevelgearboxis
naldrivetoblades.
•Deck:
Fulloatingdeckisattachedtoout-frontsupport
frame.Deckdesignallowsforbaggingor
mulching.
•DeckDepth:
–42inchDeck:45/8inches(11.7cm)
–48inchDeck:45/8inches(11.7cm)
•CuttingHeightAdjustment:
Adjustsfrom1inch(2.5cm)to4inches(10.2cm)
in1/4inch(.64cm)increments.
•MulchingKit:Optional
Dimensions
OverallWidth:
42inchDeck48inchDeck
43.2inches(109.7cm)49.2inches(125.0cm)
OverallLength:
42inchDeck48inchDeck
37.2inches(94.4cm)39.9inches(101.3cm)
OverallHeight:
42inchDeck48inchDeck
13.1inches(33.3cm)13.1inches(33.3cm)
CurbWeight:
42inchDeck48inchDeck
295lb(134kg)325lb(147kg)
TorqueRequirements
BoltLocationTorque
BladeMountingBolt85-110ft-lb(115-149N-m)
GearboxMountingBolts30-35ft-lb(41-47N-m)
GearboxAssemblyBolts50-55ft-lb(68-75N-m)
BladeShearBolts80-100in-lb
(922-1130N-cm)
8

Setup
Setup
WARNING
OperatingaNavigatortractorwithoutan
approvedExmarkfrontmountattachment
increasesthepossibilityofoperator
entanglementindrivewheelsorforwardtip
over.Entanglementortip-overcouldcause
seriousinjuryordeath.
WhenoperatingaNavigatortractor
withoutanapprovedExmarkfrontmount
attachment,observethefollowing:
•Keepfeetandclothingawayfromtires.
•Limitoperationtominimumrequiredto
installadifferentfrontmountattachment.
•Minimizespeedanduseextremecaution.
•Onlyoperateonaatlevelsurface.
•DoNotoperateupordownatrailerramp.
•Avoidsuddenaccelerationordeceleration.
AssembleDecktoNavigator
Important:DoNottransportNavigatortractor
withoutandapprovedExmarkfrontmount
attachment.
1.Stopengine,waitforallmovingpartstostopand
removekey.Engageparkingbrake.
2.RollthemowerdeckuptotheNavigatortractor
withthedischargetubedown,makingsurethe
deckspringsarelocatedabovethedrivewheel
andbelowtheconsoleoneachside.
3.Raiseseatandinstalldriveshaftontojackshaft
(seeFigure3)
Figure3
1.Jackshaft2.Driveshaft
4.Aligndeckpusharmtubestotractorpusharms
andpushdeckrearward.Securepusharmswith
lynchpinsonleftandrightsidesoftheunit(see
Figure4).
Figure4
1.Slidethepusharmintothedeckpusharmtube
2.Securethepushpinarmwithlynchpin
5.AlignupperportionofthePTOrubberguardto
thetabsonthefrontoftheconsoleandsecure
withaclevispinandhairpinoneachside(see
Figure5).
9

Setup
Figure5
1.SecurePTOguardwithclevispinandhairpin
6.Releasethedecklockingpinsoneachside,raise
mowerdecktotheservicepositionandsecure
decklatchontohook.SeeRaisingtheDeckto
theServicePositionsectioninOperation.
7.Installspringsontothespringanchorpinsunder
theleftandrightconsolesandsecurewitha
washerandhairpin(seeFigure6).
Figure6
1.Springanchorpinunderconsole
2.Securespringswithawasherandhairpin
3.Slidespringontospringanchorpin
8.Un-latchdeckfromraisedposition,slowlylower
decktogroundandlockdecklockingpinson
eachsideLoweringtheDecktotheOperation
PositionsectioninOperation.
DeckRemoval
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Raisemowerdeckupandlatchwithdecklocking
pinsperRaisingtheMowerDecktothe
ServicePositionsectioninOperation.
3.Removehairpinsandwashersatthetopofthe
deckliftassistspringoneachsideoftheunit(see
Figure6).
4.Removethespringfromthespringanchor.
Repeatforothersideofunit.
5.Un-latchdeckfromraisedpositionandslowly
lowerdecktogroundperLoweringtheMower
DecktotheOperationPositionsectionin
Operation.
Note:Deckwillbecomeheavieroncespringsare
removedfromtheanchors.Lowerdeckcarefully.
6.Removelynchpinsatfrontofpusharmsonboth
sidesoftheunit(seeFigure4).
7.Removehairpinandclevisfrombothsidesofthe
PTOguard(seeFigure5).
8.Raiseseatanddisconnectdriveshaftusingquick
coupleratjackshaft(seeFigure3).
9.Pullmowerdeckforwardtoremovefromunit.
Important:DoNottransportNavigator
tractorwithoutanapprovedExmarkfront
mountattachment.
10

Operation
ProductOverview
Figure7
1.Cutheightadjustment3.Decklifthandle
2.Casterwheel
Operation
AdjustingtheCuttingHeight
Thecuttingheightofthemowerdeckisadjusted
from1to4inches(2.5cmto10.2cm)in1/4inch
(.63cm)increments.
1.Stopthemachineandmovethespeedcontrol
leverstotheneutralposition.
2.DisengagethePTO.
3.Engagetheparkbrake.
4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.
5.Movecotterpinsonfourdecksupportpinsto
properholeforheightofcutdesired.
DeckRaisingandLowering
RaisingtheMowerDeckintoService
Position
1.Stopengine,waitforallmovingpartstostopand
removekey.Engageparkingbrake.
WARNING
Incorrectlyraisingorloweringamowerdeck
canbedangerous.Adroppedmowerdeck
canresultinaseriousinjuryorproperty
damage.
•Alwaysraiseandlowerdeckonat,dry
ground,freeofanyobstructions.
•Firmlygraspthedecklifthandleand
lowerinaslowcontrolledmanner.
•Alwaysmakesurethedeckissecurely
latchedinthe“up”or“down”position.
2.Releasethedecklockingpinsoneachside
(Figure8).
11

Operation
Figure8
1.Decklifthandle
2.Rotatethedecklockingpintowardtherearandpull
outwardtounlock.
3.Pushthedecklockingpininandrotatetowardthefront
tolock.
3.Usingdecklifthandle,liftdeckupandlatchin
“up”position(latchislocatedatfrontcenterof
seat)(seeFigure9).
Figure9
1.Securethedeckin
theraisedpositionby
securingthedecklatch
ontothehook.
2.Hook
WARNING
Operatingthemowerdeckintheraised
servicepositioncanbedangerous.Engaging
thePTOwithadeckintheraisedposition
canresultinaseriousinjuryorproperty
damage.
Alwayslowerandlockmowerdeckinthe
operationpositionbeforeengagingthePTO.
LoweringtheMowerDecktothe
OperatingPosition
1.Whilermlyholdingontodecklifthandle,
unhookdecklatchfromtractorsectionandslowly
lowerdecktoground(seeFigure9).
2.Pushdecklockingpinsinwardandrotateforward
tosecurelylockdeckinloweredposition(see
Figure8).
WARNING
Operatingmowerwithoutlockingpins
securelylatchedcanresultinthemowerdeck
foldingupunexpectedly.Themowerdeck
foldingupunexpectedlycancauseserious
injury.
Alwaysoperatemowerwithlockingpins
securelylatched.
AdjustingFillReduction
System(FRS)Bafes
TheNavigator’sexclusiveFillReductionSystemhas
beendesignedtoallowyoutoreducetheamountof
clippingscollectedbyvaryingdegrees.
Advantagesincludelessfrequentemptyingofthe
hopperandreturnofnutrientstothesoil.
PossibleCongurations:
1.Bafesopen,standardblades–Maximum
collection
2.Bafesclosed,standardblades–Partialmulching
3.Bafesclosed,mulchblades–Intermediate
mulching
4.Mulchpluginstalled,mulchblades–Complete
mulching(requiresmulchkit)
12

Operation
ToadjusttheFRSbafes:
1.Stopengine,waitforallmovingpartstostopand
removekey.Engageparkingbrake.
2.Removehairpinsandclevispinsfrombothsides
ofthePTOguard(seeFigure5).Foldguard
forward.
3.LoosennylocnutsontherearstudsoftheFRS
bafes.
Figure10
1.PTOguardremovedfor
clarity
2.Loosennylocnuts
4.RaisedeckasstatedinRaisingtheMowerDeck
totheServicePositionsection.
5.Removeboltandwasheratthefrontofeach
oftheFRSbafes.Rotatebafesintodesired
positionandreinstallboltandwasher.
Figure11
1.Bafesshowninclosedposition
2.Bafesshowninopenposition
3.Bolt
4.Washer
5.Bafes
6.LowerdeckperLoweringtheMowerDeckto
theOperatingPositionsection.
7.SnugnylocnutsontherearstudsoftheFRS
bafes.Thesenutsmaybeleftslightlylooseif
frequentbafeadjustmentisanticipated.
8.ReinstallPTOguardusingclevispinsandhair
pinsremovedinstep2.
13

Maintenance
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
WARNING
Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.
Removethekeyfromtheignitionswitch,
engageparkingbrake,andpullthewire(s)
offthesparkplug(s)beforeyoudoany
maintenance.Alsopushthewire(s)aside
soitdoesnotaccidentallycontactthespark
plug(s).
RecommendedMaintenanceSchedule(s)
MaintenanceService
IntervalMaintenanceProcedure
Aftertherst50hours•Changeoilinallthreegearboxhousings.Addoilasneededuntillevelwithoildrainplug.
Beforeeachuseordaily
•Checkthemowerblades.
•Checkforloosehardware.
•Greasethefrontcasterwheelhub.
•Cleanthegrassanddebrisbuild-upfromthecuttingdeck.
•Cleanthegrassbuild-upfromunderthedeck.
Every40hours•Checktheconditionofthebelts.
•Greasethedriveshaft.
Every100hours
•Changeoilinallthreegearboxhousings.Addoilasneededuntillevelwithoildrainplug.
thereafter
•Greasethedeckip-up.
•Greasethepivotarmtubes.
Yearly•Greasethefrontcasterpivots.
•Lubricatethecasterwheelhubs.
PeriodicMaintenance
CheckMowerBlades
ServiceInterval:Beforeeachuseordaily
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Liftdeckandsecureinraisedpositionasstated
insectionRaisingtheMowerDecktothe
ServicePosition.
3.Inspectbladesandsharpenorreplaceasrequired.
4.Toremoveblade,useablockofwoodorlocking
plierstoholdbladeinplaceandremovethe
1/2-20x21/4inchbladeboltthatsecuresthe
bladeandbladedriver.
5.Re-installthebladedriver(withnewblades)by
usingablockofwoodorlockingplierstohold
thebladeinplaceandtorquethebladeboltsto
85-110ft-lb(115-149N-m).
14

Maintenance
Note:Bladedriveratsmustbealignedwiththe
atsontheshaftwheninstallingbladeonthe
mowerdeck.
6.Lowerthemowerdecktotheoperationposition
(seesectionLoweringtheMowerDecktothe
OperationPosition).
WARNING
Operatingamowerdeckwithlooseor
weakenedbladeboltscanbedangerous.A
looseorweakenedbladeboltcouldallowa
bladerotatingatahighspeedtocomeout
fromunderthedeck,causingseriousinjury
orpropertydamage.
•Replacethebladeboltafterstrikinga
foreignobject.
•UseonlygenuineExmarkreplacement
parts.
•DoNotlubricatethethreadsofthebolt
orspindlebeforeassembly.
•Torquethebladeboltto85-110ft-lb
(115-149N-m).
•Torquetheshearboltsto80-100in-lb
(922-1130N-cm).
Figure12
1.1/2-20x21/4bladebolt—torqueto85-110ft-lb
(115-149N-m).
2.Washer
3.Shearbolts—torqueto80–100in-lb(922-1130N-cm)
4.Bladedriver
5.1/4-20nylocnuts
CheckforLooseHardware
ServiceInterval:Beforeeachuseordaily
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.
CheckTirePressures
ServiceInterval:Every40hours
Thefrontcastertiresaresemi-pneumaticandDo
Notneedtobeinated.
Note:DoNotaddanytypeoftirelinerorfoam
llmaterialtothetires.Excessiveloadscreatedby
foamlledtiresmaycausefailurestothehydrodrive
system,frame,andothercomponents.Foamlling
tireswillvoidthewarranty.
ChangeGearboxOil
ServiceInterval:Aftertherst50hours
Every100hoursthereafter
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Placeunitonalevelsurface.
3.Removethegearboxanddriveshaftassembly
fromthemowerdeck.Retainhardwareforre-use.
4.Removethelargeoildrainplugonthefrontof
eachofthethreegearboxsectionsanddrainoil
(Figure13).
Figure13
1.Smallmagneticplugs
(frontandback)
3.Smallmagneticplug
(frontonly)
2.Largeoildrain/llplug
15

Maintenance
5.Removesmallmagneticplugsandwipeawayany
materialaccumulatedontheplugs.
6.ApplyaTeonpipesealanttoallsmallmagnetic
plugsandre-installintothegearbox.
7.Re-installthegearboxanddriveshaftassembly
tothemowerdeck.
8.FillgearboxwithMobilSHC(synthetic)75W-90
gearlubeoiluntillevelwithoildrain/llplug.
Eachofthegearboxsectionsmustbelled
separately.
Note:Mowerdeckshouldremainleveltothe
groundwhenllinggearboxwithoil.DoNotll
gearboxwithdeckraisedintheserviceposition.
9.ApplyaTeonpipesealanttothe3largeoilplugs
andre-installintothegearbox.
LubricateGreaseFittings
Note:Seechartforserviceintervals.
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.LubricatettingswithNGLIgrade#2
multi-purposegungrease.
Refertothefollowingchartforttinglocations
andlubricationschedule.
LubricationChart
Fitting
Locations
Initial
Pumps
Numberof
Places
Service
Interval
1.Drive
Shaft
1340Hours
2.Front
Caster
WheelHub
128Hours
3.Deck
Flip-Up
14100Hours
4.Push
ArmTubes
12100Hours
5.Front
Caster
Pivots
*02*Yearly
*Seestep3forspeciallubricationinstructionson
thefrontcasterpivotsandtheLubricateCaster
WheelHubssectionforspeciallubrication
instructionsonthefrontcasterswheelhubs.
3.Lubricatecasterpivotsonceayear.Removehex
plugandcap.Threadgreasezerkinholeand
pumpwithgreaseuntilitoozesoutaroundtop
bearing.Removegreasezerkandthreadplugback
in.Placecapbackon.
LubricateCasterWheelHubs
ServiceInterval:Yearly
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
Figure14
1.Sealguard2.Spacernutwithwrench
ats
2.Removecasterwheelfromcasterforks.
3.Removesealguardsfromthewheelhub.
4.Removeoneofthespacernutsfromtheaxle
assemblyinthecasterwheel.Notethatthread
lockingadhesivehasbeenappliedtolockthe
16

Maintenance
spacernutstotheaxle.Removetheaxle(with
theotherspacernutstillassembledtoit)from
thewheelassembly.
5.Pryoutseals,andinspectbearingsforwearor
damageandreplaceifnecessary.
6.PackthebearingswithaNGLIgrade#1
multi-purposegrease.
7.Insertonebearing,onenewsealintothewheel.
Note:Seals(ExmarkPN103-0063)mustbe
replaced.
8.Iftheaxleassemblyhashadbothspacernuts
removed(orbrokenloose),applyathreadlocking
adhesivetoonespacernutandthreadontothe
axlewiththewrenchatsfacingoutward.Do
Notthreadspacernutallofthewayontotheend
oftheaxle.Leaveapproximately1/8inch(3mm)
fromtheoutersurfaceofthespacernuttothe
endoftheaxleinsidethenut.
9.Inserttheassemblednutandaxleintothewheel
onthesideofthewheelwiththenewsealand
bearing.
10.Withtheopenendofthewheelfacingup,ll
theareainsidethewheelaroundtheaxlefullof
NGLIgrade#1multi-purposegrease.
11.Insertthesecondbearingandnewsealintothe
wheel.
12.Applyathreadlockingadhesivetothe2ndspacer
nutandthreadontotheaxlewiththewrenchats
facingoutward.
13.Torquethenutto75-80in-lb(8-9N-m),loosen,
thenre-torqueto20-25in-lb(2-3N-m).Make
sureaxledoesnotextendbeyondeithernut.
14.Reinstallthesealguardsoverthewheelhuband
insertwheelintocasterfork.Reinstallcasterbolt
andtightennutfully.
Important:Topreventsealandbearingdamage,
checkthebearingadjustmentoften.Spinthe
castertire.Thetireshouldnotspinfreely
(morethan1or2revolutions)orhaveanyside
play.Ifthewheelspinsfreely,adjusttorqueon
spacernutuntilthereisaslightamountofdrag.
Reapplythreadlockingadhesive.
ThreadLockingAdhesives
Threadlockingadhesivessuchas“Loctite242”
or“Fel-Pro,Pro-LockNutType”areusedonthe
followingfasteners:
Casterwheelspacernuts.
17

Maintenance
Adjustments
Note:DisengagePTO,shutoffengine,waitfor
allmovingpartstostop,engageparkingbrake,and
removekeybeforeservicing,cleaning,ormakingany
adjustmentstotheunit.
DeckLeveling
1.Positionmoweronaatsurface.
2.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
3.Inatedrivetiresto15psi(103kPa).
4.Verifyallhairpinsareinthe3inchdeckheight
holeswiththespacersunderthehairpins
(Figure15).
Figure15
RightHandSideShown
1.Hairpin3.Decksupportpin
2.Spacer
5.Shorten/lengtheneachdecksupportpintoobtain
bladetipheightof3inchesatthefrontofthe
deckand31/4inchesattherearofthedeck.
CasterPivotBearings
Pre-loadAdjustment
Removedustcapfromcasterandtightennylocnut
untilwashersareat.Backthenylocoff1/4ofa
turntoproperlysetthepre-loadonthebearings.
Note:Ifdisassembled,makesurethespringwashers
arereinstalledasshowninFigure16.
Figure16
1.Springdiscwashers
DeckLockingPinStop
Adjustment
1.Slidedecklockingpinsinonbothsidesandrotate
tolockthedeckinthe“operation”position.
2.Loosenthejamnutandturnthestopscrew
clockwiseuntilthelockingpinsistightandcannot
berotatedbyhand(Figure17).
Figure17
1.Rotatestopscrewclockwiseuntillockingpinistight,
thenbackoff1/2turn.
2.Loosenjamnut
3.Loosenthestopscrewcounterclockwise1/2
turnandtightenthejamnut
4.Testthelockingpintomakesureitslidesfreely.
Readjustifnecessary.
18

Maintenance
Cleaning
CleanDebrisFromCutting
Deck
ServiceInterval:Beforeeachuseordaily
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Cleanoffanyoil,debris,orgrassbuild-uponthe
cuttingdeck,especiallyunderdeckbeltshields.
CleanGrassBuild-UpUnder
Deck
ServiceInterval:Beforeeachuseordaily
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Raisemowerdeckandsecureinlatchedposition
(seeRaisingtheMowerDecktotheService
PositionsectioninOperation).
3.Cleanoutanygrassbuild-upfromundersideof
deckandindischargechute.
4.Lowerdecktocuttingpositionandlockdeck
lockingpins(seeLoweringtheMowerDeckto
theOperationPositionsectioninOperation.
19

Troubleshooting
Troubleshooting
Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating
conditionpriortomoweruse.
Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused
byanemptyfueltank.
Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor
itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have
thisworkdonebyyourEngineServiceDealer.
Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.
ProblemPossibleCauseCorrectiveAction
1.Blade(s)notsharp.1.Sharpentheblade(s).
2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).
3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand
front-to-rear.
4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.
5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.
6.Spacersareinwronglocation.6.Positionspacersunderhairpins.
Unevencuttingheight.
7.Tipsofadjacentbladesareatanuneven
cuttingheight.Bladestipsshouldbeeven
within3/16inchwhichisapproximately
onebladethickness.
7.Replaceblades,spindlesand(or)check
fordamagetomowerdeck.
1.Cuttingblade(s)is/arebentorunbalanced.1.Installnewcuttingblade(s).
2.Blademountingboltisloose.2.Tightentheblademountingbolt.
3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.
4.Enginepulleyisdamaged.4.ContactanAuthorizedServiceDealer.
Abnormalvibration.
5.Bladespindleisbent.5.ContactanAuthorizedServiceDealer.
1.PTObeltisworn,loose,orbroken.1.Checkbelttensionorreplacebelt
2.PTOshaftisnotconnected.2.ConnectPTOshaft.
BladesDoNotrotate.
3.PTObeltisoffpulley.3.Checkbeltfordamage.Installbeltand
checkadjustingshaftsandbeltguidesfor
correctposition.
20