Exmark Navigator CD48CD User manual

Brand: Exmark

Model: Navigator CD48CD

Category: Lawnmowers

Type: User manual

This manual is also suitable for

CD42CD/CD48CD

ForSerialNos.

790,000&Higher

PartNo.4500-370Rev.A

Exmarkreservestherighttomakechangesor

addimprovementstoitsproductsatanytime

withoutincurringanyobligationtomakesuch

changestoproductsmanufacturedpreviously.

Exmark,oritsdistributorsanddealers,accept

noresponsibilityforvariationswhichmaybe

evidentintheactualspecicationsofitsproducts

andthestatementsanddescriptionscontained

inthispublication.

IndustrialParkBox808

Beatrice,NE68310

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.

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

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.

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.

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

Specications

ModelNumbers

SerialNos:790,000andHigher

CD42CD;CD48CD

Systems

Tires&Wheels

FrontCaster

Semi-Pneumatic

Quantity

Tread

Smooth

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

BoltLocation

Torque

BladeMountingBolt85-110ft-lb(115-149N-m)

GearboxMountingBolts30-35ft-lb(41-47N-m)

GearboxAssemblyBolts50-55ft-lb(68-75N-m)

BladeShearBolts80-100in-lb

(922-1130N-cm)

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).

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.

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).

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)

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.

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

Interval

MaintenanceProcedure

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).

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

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

340Hours

2.Front

Caster

WheelHub

128Hours

3.Deck

Flip-Up

4100Hours

4.Push

ArmTubes

100Hours

5.Front

Caster

Pivots

*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

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.

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.

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.

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.

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