GrassFlap 42B User manual
GrassFlap.com Phone: (502) 594-3546 Rev 10.2021
Parts List
10-99-33
Hinge Plate Exmark
10-99-11
Flap Spring
10-99-31
Low Prole
Spring Mount
10-99-22
Clevis Pin
10-99-34
Exmark Flap
Mount
10-99-28
Bushing Cable Pin
Flap End
10-99-32
Bushing
Spring Bolt
GrassFlap 42B Installation Guide
10-99-52
Bushing Kit for Flap Hex
10-99-51
Bushing Kit for Pedal Hex
10-99-07
Cable 70 Inch 10-99-35
SE Pedal Assembly
10-99-21
Clevis Kit
10-99-07
Cable 70 Inch
10-99-51
Bushing Kit for
Pedal Hex
10-99-13
RE Pedal Assembly 10-99-41
SEL Pedal Assembly
10-99-08
Cable 50 Inch
10-99-21
Clevis Kit
Cable
Tie
Grass
Flap
grassflap.com
Instruction videos available online at
http://www.youtube.com/user/GrassFlap
and at GrassFlap.com
PLEASE READ!
If you are having ANY ISSUES
with assembly or operation.
Please contact us at:
(502) 594-3546
or
david@grassap.com
STEP 1
STEP 2
(2x)
AB
A) Remove factory discharge chute, save bolts for later use.
B) Remove belt cover.
GrassFlap 42B Assembly Instructions
GrassFlap.com Phone: (502)594-3546 3
STEP 3
Exmark No-Drill Mount
10-99-35
2x
Install no drill mount.
Position as shown. Use bolts from step 1 or
(2) 3/8” x 1” bolts provided.
Use hammer to tap mount in place if tight (no drill
mount will be snug on walk-behind mower.)
Tools List
Wrench - 7/16”, 1/2” & 9/16”
Socket
1/2” & 9/16”
Drill Bit - 11/32” & 1/2”
Pliers
Center Punch
Zip Ties
Hammer
Drill
STEP 4
STEP 5
A (2x)
B
Mount ap assembly to no-drill.
A) Use (2) 3/8” x 1“ bolts provided.
B) Make sure the ap is ush with opening
and tighten bolts.
STEP 6
Connect ap spring.
Use a small box end wrench to hook spring over
bushing spring bolt on hinge assembly.
GrassFlap 42B Assembly Instructions
GrassFlap.com Phone: (502)594-3546 4
A
B
Bolt On Spring Mount
A) Place spring mount on ap so large hole on spring
mount ts over nut on pivot bolt (do not loosen pivot
bolt nut).
B) Install spring mount as shown using 5/16-18 x 3/4”
carriage bolt provided through slot and snug.
STEP 7
Install Cable
A)
Pull rubber boot oend of cable with xed clevis.
Remove nut 1 and slip cable wire into slot.
B)
Slip cable into hole and snug jam nuts leaving
minimum thread showing on tting, as shown below.
DO NOT connect clevis to ap at this time.
DO NOT OVERTIGHTEN NUTS.
STEP 8
A
B
A) Reinstall belt cover.
B) Adjust position of spring mount and tighten bolts.
GrassFlap 42B Assembly Instructions
GrassFlap.com Phone: (502)594-3546 5
A
B
BootNut 1 Fixed Clevis
Nut 2
PEDAL END
(Cable Installaon, step 1 and 4, AREAS TO
PAY PARTICULAR ATTENTION TO, Recommended cable roung, WARNINGS)
(Recommended cable roung, SECURE
WITH CABLE CLAMP/ZIP TIE)
Cable Installaon, step 2,
PROPER PEDAL HEIGHT)
(Cable Installaon, step 3, MAINTAINING THE CABLE)
FLAP END
(Cable Installaon, step 1 and 4, AREAS TO
PAY PARTICULAR ATTENTION TO, page 6 installaon guide, WARNING)
ROUTING
(Cable Installaon, step 4, AREAS TO PAY PARTICULAR
ATTENTION TO)
(Cable Installaon, step 5, REFERENCE 6” RADIUS)
(See recommended cable roung)
GrassFlap.com Phone: (502)594-3546 6
GrassFlap Cable Installation
WARNING: PROPER CABLE INSTALLATION AND MAINTENANCE
IS CRITICAL TO LIFE OF CABLE
4) AREAS TO PAY PARTICULAR ATTENTION TO ARE:
1. Do not bend cable wire.
2. Make certain the cable is not in a bind when the deck is raised either manually
or when mowing.
3. Leave enough slack where the cable is tied to mower to keep out of the belts
for the deck to raise and lower without straining the cable.
4. Avoid direct heat on cable, do not route near muer
5. Maintain recommended bend radius of 6 inches for all bends.
3) MAINTAINING THE CABLE:
1. Be sure the rubber boot is in place to keep dirt and water out of cable.
2) PROPER PEDAL HEIGHT:
1. Adjust pedal height so pedal bottoms out with full pressure to
prevent cable from carrying full weight of operator. Start with
cable tting as shown - adjust pedal end to raise pedal, adjust
ap end to lower pedal. Verify pedal height with ap in
balance (half open) position.
DO NOT BEND
1) Improper cable routing WILL cause failure, usually within
the rst month of use. The rst 1/2 inch of cable conduit
(black exible part) must be straight in line with the end tting.
Cable wire near ball must not be bent during installation.
R
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.
5) MINIMUM BEND RADIUS
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How to set
pedal height:
Pedal End
(1 thread showing)
Flap End
(1 thread showing)
this side
this side
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SE Pedal SEL Pedal
Step 4
Step 5
Step 2
Position removable clevis onto cable ball.
Step 1
Pull rubber boot oof cable tting and spin nut 1
oof cable tting. Spin nut 2 onto tting so one
thread is showing.
SE & SEL Pedal Cable Installation
1 thread
Nut 1
Nut 2
For video showing
how to install cable
on pedal scan using
phone camera.
Secure with
cable tie
A) Once pedal is installed on mower attach cable clamp
or zip tie to secure cable.
B) Verify everything is in place and secure.
A) Position removable clevis on pedal with clevis slot
on cut out side of pedal.
B) Insert 1/4 pin with head on same side as clevis slot.
C) Insert cotter pin and wrap around pin to secure.
C
A
B
A) Slip cable wire into slot.
B) Spin nut 1 onto tting to secure cable to pedal.
DO NOT OVERTIGHTEN NUTS.
C) Push rubber boot back onto tting.
Step 3
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SE Pedal Location & Cable Routing
Option 1
Option 2
Option 3
Preferred locations for SE pedal assembly.
WARNING:
First
½” after
tting must
be straight
SE Pedal Cable Routing
on Stand-On
Tie cable
down
WARNING:
First ½” after
tting must
be straight
WARNING:
First ½” after
tting must
be straight
2x
Install Pedal
A) Mark and drill two 11/32” holes, if needed, for pedal
mounting bolts.
B) Tighten two 5/16” x 1” carriage bolts to secure pedal
assembly to mower deck.
Option 1
Secure with
zip-tie Option 2 SE Pedal Cable Routing
on Zero Turn
WARNING:
First
½” after
tting must
be straight
A
B
C
D
FLAP CONNECTION
3/16”
Clevis Pin
10-99-22
Bushing Cable
Pin Flap End
10-99-28
Flap Connection:
A) Place 1/4”bushing in ap.
B) Slip clevis onto ap.
C) Insert 3/16 pin with head
on spring side.
D) Insert cotter pin and bend
around pin.
Cotter Pin
Cotter Pin
WARNING:
First ½” after
tting must
be straight
WARNING:
First ½” after
tting must
be straight
A
B
C
D
FLAP CONNECTION
3/16”
Clevis Pin
10-99-22
Flap Connection:
A) Place 1/4”bushing in ap.
B) Slip clevis onto ap.
C) Insert 3/16” pin with head
on spring side.
D) Insert cotter pin and bend
around pin.
Bushing Cable
Pin Flap End
10-99-28
Zip Tie Cable
to Pedal
2x
Install Pedal
A) Mark and drill two 11/32” holes, if needed, for pedal
mounting bolts.
B) Tighten two 5/16” x 1” hex bolts to secure pedal
assembly to mower deck.
GrassFlap.com Phone: (502)594-3546 10
SEL Pedal Location & Cable Routing
Preferred location for SEL pedal assembly.
WARNING:
First
½” after
tting must
be straight
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RE Pedal Location & Cable Routing
WARNING:
First ½” after
be straight
WARNING:
First ½” after
be straight
A
B
C
D
FLAP CONNECTION
3/16”
Clevis Pin
10-99-22
Bushing Cable
Pin Flap End
10-99-28
PEDAL CONNECTION
A
B
C
1/4” Clevis Kit
10-99-21
1/4” Pin
Preferred locations for RE pedal assembly.
Option 1
Option 2
WARNING:
First
½” after
tting must
be straight
Pedal Connection:
A) Place clevis on cable ball
and squarely seat in
bottom of clevis.
B) Insert 1/4” diameter pin.
C) Insert cotter pin and wrap
around pin.
Flap Connection:
A) Place 1/4”bushing in ap.
B) Slip clevis onto ap.
C) Insert 3/16” pin with head
on spring side.
D) Insert cotter pin and wrap
around pin.
2x
Install Pedal
A) Mark and drill two11/32” holes, if needed, for pedal
mounting bolts.
B) Tighten two 5/16” x 1” hex bolts to secure pedal
assembly to mower deck.
Cotter Pin
Cotter Pin
GrassFlap.com Phone: (502)594-3546 12
l eqently AeQesns
WHAT TO DO IF YOUR CABLE BREAKS
DO NOT REMOVE e coit from the mow this mkes it imossie totermine cuse ofu
FIRST ATTEMPT TO DETERMINE THE CAUSE OF THE FAILURE
1REVIEW THE CABLE INSTALATION USING THE CABLE INSTALLATION CHECKLISTook t eh item on the
from the oriinnston nconrm the ce is sro If ou the set-ne
then most this is the use of theu
IF YOU ARE NOT ABLE TO DETERMINE THE CAUSE OF THE FAILURE AND WOULD LIKE HELP DETERMINING IT
rocefoows
2TAKE PICTURES oe co it is routon the mower withroke wire osie the coit
just wire were run in the co Picture must show oth the centhe coit in smeu
Pictures required for warranty claim
3CIRCLE BROKEN END OF WIRE inure from ste2most ones tou eit the ictur
4EMAIL TOi@som
5INCLUDE ALL ITEMS LISTED BELOW
Pictures ofoken c (from st oe
Picture of Comete“e Inon Chet”(from st1oe
cAroximte rchse te of current
Where urchseme rchner
e uject ine “BR CABL”
If ou nee ct it is sueste ouurch one onine so it is h our w whie we reiew
the informon
MY FLAP ONLY OPENS HALFWAY
The is esinto oen with the fuo Pushier wituse to mo The roer
oon is toush the eown un rohes f oosion then t thtointsure on
shou rse toow to rise the sses the hf oin
CAN THE FLAP BE POSITIONED PARTIALLY OPEN?
Ye the cn h in r ooon usinthe foot im ho the in esire osion
of the nice ftures of is the w the otes to oen cose the without hinto
sh on sre Youre toun re in one smooth moon to it oen the
me moonunreee it ck to the ososionn orer to ock it somewhere etween fu
o fuosewou requseco moon toock ree i
WILL THE FLAP PUSH OPEN?
en enore it wiush oen It i cose with rin the sme srino hos the in the oen
osion the me the sheoen there is t enoehinit th oure no oer
mn oocu
HOW DO I RETURN GRASSFLAP IF I CHANGED MY MIND?
Anoct me return Proct must e inke new coonCost ooct shiinwiefu
Returnois not refun
CAN THE DEFLECTOR ANGLE BE MOUNTED TO THE DECK INSTEAD OF THE FLAP?
The ectohou ewith toeent ciins fromowin ht ins to
oen As it s to oen there is not enoe toect the ciins own so thee uoin oth ws
oithout the nthewio sht on onto the oertorMoun the n to the eck wou
on rieoo when the is fu cos
Safety and Warnings
Thrown objects
Mowing with power equipment involves certain risk including but not limited to thrown objects. Be sure to clean up
the area to be mowed and remove objects that could be thrown by the blades BEFORE you start mowing
Once the grass flap is installed your mower will be equipped with an operator controlled discharge chute (OCDC).
Do not operate the mower if the OCDC is not properly attached. This discharge chute has a variable adjustment
from fully open to fully closed. In the closed position it will serve to keep some of the clipping material under the
mower deck for a longer period of time, in order to enhance the mulching capabilities, as well as function as a
safety shield. The discharge chute should ALWAYS BE IN THE CLOSED POSITION WHEN MOWING WHILE
PEOPLE ARE PRESENT IN THE IMMEDIATE VINCINITY.
Do not allow anyone in the area while mowing. If someone does enter the area, stop mowing immediately until they
leave.
Moving parts
The mower deck has spinning mower blades that can amputate hands and feet. Do not allow anyone near the
mower while it is running! Keep safety devices (guards, shields, and switches) in place and working.
Children
Tragic accidents can occur with children. Do not allow then anywhere near the area of operation. Children are
often attracted to the unit and mowing activity. Never assume that children will remain where you last sat them. If
there is a risk that children may enter the area where you are mowing, have another responsible adult watch them.
General Safety Precautions
1.
Do not mow when children, pets, or others are present. The operator is responsible for the safety of others
within the vicinity of the operation of your mower.
2.
Keep hands, feet, and clothing away from rotating blades or other rotating parts while the engine is
running.
3.
Do not attempt to open or close the flap at the discharge chute while the engine is running, doing so
could result in personal injury including loss of hands, feet or death.
4.
Clear work area of objects (wire, rocks, and debris of any kind) that can be picked up and thrown by the
mower, and possibly damage the equipment or cause personal injury to the operator.
5.
Do not attempt to adjust or repair the mower deck, grass flap, or related components while the engine is
running. You must disengage power to attachments, disengage PTO, set parking brake, set steering
controls to neutral, shut off the engine, and remove the key before making any repairs or adjustments or
attempting any of the following tasks:
a.
Flap connecting linkage adjustment
b.
Flap removal or cleaning
c.
Unclogging the chute
Failure to comply can result in personal injury, loss of limb, or death.
6.
Keep all nuts, bolts, screws, and other fasteners in place and properly secured to be sure
equipment is in safe working condition.
7.
Keep equipment and attachments in good operating condition and keep safety devices, such as guards,
shields and covers in place and working.
8.
Do not operate the mower or attachments if any guards are missing or not functioning.
9.
Stop the mower and attachments, secure the mower, and inspect for damage after striking a foreign
object. Repair any damage before restarting and operating the equipment.
10.
Use personal protective equipment when operating mower of performing maintenance, such as (but not
limited to) protection for eyes, feet, and head. Do not operate or service the mower when barefoot or
wearing open-toed sandals.
11.
Obey all safety decals.
GrassFlap.com Phone: (502)594-3546 13
SAFE OPERATION OF MOWING EQUIPMENT IS THE RESPONSIBILITY OF THE MOWER
OPERATOR! THE GRASS FLAP WHEN CLOSED WILL REDUCE BUT NOT ELIMINATE THE RISK OF
OBJECTS BEING THROWN FROM THE DISCHARGE CHUTE! BE AWARE OF SURRONDINGS AT
ALL TIMES!
WARRANTY
There are no understandings, agreements, representations, or warranties expressed or implied (including
but not limited to any regarding the merchantability or fitness for a particular purpose) not specified herein,
regarding equipment which is the subject of this warranty.
Owner operator Knowledge Responsibility
As a condition of the Grass Flap warranty, the owner operator(s) are fully responsible for having read, and
reasonably understanding the proper operation and care of the Grass Flap unit before attempting to
operate the unit.
Product warranty if for a period of 90 days from date of purchase. Warranty covers defects in workmanship
and materials ONLY.
Limitations of warranty
Proof of purchase including purchase date is required for claim validation. It is the discretion of the
manufacture as to replace or repair a warranted product.
All warranty work must be performed by an authorized Grass Flap servicing dealer ONLY.
This Warranty only covers Grass Flap complete units that have been maintained and operated under
conditions considered normal for turf equipment.
Expressly not covered
a) Damage, defects or deterioration due to normal use, wear, or exposure to the elements.
b) Damage or defects resulting from misuse, neglect, alteration, accident or negligence.
c) Damage or defects resulting from repairs by person(s) other than the manufacturer or a
manufacturer’s representative.
d) Repair or replacements resulting from operation of Grass Flap equipment that has been modified,
or effected with respect to the intended use of the product
e) Repair or replacement as a result of Grass Flap equipment operated in a manner which is not in
accord with the instructions as specified in the operator section or other instructions provided by
Grass Flap.
Grass Flap is not responsible for (nor limited to the following)
f) 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 Grass Flap service dealer.
g) Rental of like or similar equipment during the time of any warranty, or replacement work.
h) Loss, cost or expense relating to transportation of Grass Flap equipment from location of owner
or location where used by owner to or from any authorized Grass Flap dealer
i) Any claims for lost revenue, lost profit or additional cost or expenses incurred as a result of a claim of
breach of warranty.
j) Loss or damage to person or property other than that covered by the terms of this warranty.
k) Losses or damage related to equipment the Grass Flap is mounted on.
l) Any telephone, telegram, travel charges, or attorney’s fees.
Disclaimer
Any and all statements or representations made by seller of this equipment, including those set forth in
any sales literature or made orally by and sales representative are superseded by the terms of this
warranty. There are no representations or warranties, which have been authorized and provided to the
buyer of Grass Flap equipment, other than as set forth in this warranty. Any affirmation of fact or promise
made by Grass Flap or any of its representatives to the buyer which relates to the goods that are the
subject of this warranty shall not be regarded as part of the basis of the bargain and shall not be deemed
to create and express warranty that such goods shall conform to the affirmation or promise
GrassFlap.com Phone: (502)594-3546 14
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