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,NE68310

Contactusatwww.Exmark.com.

2

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.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready .

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

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.

•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.

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.

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

SafetyandInstructionalDecals

Safety

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

1-403005

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

103-8425

103-8797

68-8340

103-8798

98–5954

103-8799

103-6230

7

Specications

Specications

ModelNumbers

SerialNos:790,000andHigher

CD42CD;CD48CD

Systems

Tires&Wheels

Quantity

Tread

Size8x3.00–4

PlyRating

Pressure

CuttingDeck

•ModelNumbers:

–CD42CD

–CD48CD

•CuttingWidth:

–42inchDeck:42inch(106.7cm)

–48inchDeck:48inch(121.9cm)

–48inchDeck:45/8inches(11.7cm)

•CuttingHeightAdjustment:

Adjustsfrom1inch(2.5cm)to4inches(10.2cm)

FrontCaster

Semi-Pneumatic

2

Smooth

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:

•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)

42inchDeck48inchDeck

13.1inches(33.3cm)13.1inches(33.3cm)

CurbWeight:

42inchDeck48inchDeck

295lb(134kg)325lb(147kg)

TorqueRequirements

BoltLocation

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

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

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

BladeShearBolts80-100in-lb

8

Torque

(922-1130N-cm)

Setup

WARNING

OperatingaNavigatortractorwithoutan
approvedExmarkfrontmountattachment
increasesthepossibilityofoperator
entanglementindrivewheelsorforwardtip
over.Entanglementortip-overcouldcause
seriousinjuryordeath.

WhenoperatingaNavigatortractor
withoutanapprovedExmarkfrontmount
attachment,observethefollowing:

•Keepfeetandclothingawayfromtires.

•Limitoperationtominimumrequiredto
installadifferentfrontmountattachment.

•Minimizespeedanduseextremecaution.

•Onlyoperateonaatlevelsurface.

•DoNotoperateupordownatrailerramp.

Setup

Figure3

1.Jackshaft2.Driveshaft

4.Aligndeckpusharmtubestotractorpusharms
andpushdeckrearward.Securepusharmswith
lynchpinsonleftandrightsidesoftheunit(see
Figure4).

•Avoidsuddenaccelerationordeceleration.

AssembleDecktoNavigator

Important:DoNottransportNavigatortractor

withoutandapprovedExmarkfrontmount
attachment.

1.Stopengine,waitforallmovingpartstostopand
removekey.Engageparkingbrake.

2.RollthemowerdeckuptotheNavigatortractor
withthedischargetubedown,makingsurethe
deckspringsarelocatedabovethedrivewheel
andbelowtheconsoleoneachside.

3.Raiseseatandinstalldriveshaftontojackshaft
(seeFigure3)

Figure4

1.Slidethepusharmintothedeckpusharmtube

2.Securethepushpinarmwithlynchpin

5.AlignupperportionofthePTOrubberguardto
thetabsonthefrontoftheconsoleandsecure
withaclevispinandhairpinoneachside(see
Figure5).

9

Setup

DeckRemoval

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Raisemowerdeckupandlatchwithdecklocking
pinsperRaisingtheMowerDecktothe
ServicePositionsectioninOperation.

3.Removehairpinsandwashersatthetopofthe
deckliftassistspringoneachsideoftheunit(see
Figure6).

Figure5

1.SecurePTOguardwithclevispinandhairpin

6.Releasethedecklockingpinsoneachside,raise
mowerdecktotheservicepositionandsecure
decklatchontohook.SeeRaisingtheDeckto
theServicePositionsectioninOperation.

7.Installspringsontothespringanchorpinsunder
theleftandrightconsolesandsecurewitha
washerandhairpin(seeFigure6).

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.

Figure6

1.Springanchorpinunderconsole

2.Securespringswithawasherandhairpin

3.Slidespringontospringanchorpin

8.Un-latchdeckfromraisedposition,slowlylower
decktogroundandlockdecklockingpinson
eachsideLoweringtheDecktotheOperation
PositionsectioninOperation.

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.

WARNING

Operatingthemowerdeckintheraised
servicepositioncanbedangerous.Engaging
thePTOwithadeckintheraisedposition
canresultinaseriousinjuryorproperty
damage.

Alwayslowerandlockmowerdeckinthe
operationpositionbeforeengagingthePTO.

LoweringtheMowerDecktothe
OperatingPosition

1.Whilermlyholdingontodecklifthandle,
unhookdecklatchfromtractorsectionandslowly
lowerdecktoground(seeFigure9).

2.Pushdecklockingpinsinwardandrotateforward
tosecurelylockdeckinloweredposition(see
Figure8).

3.Usingdecklifthandle,liftdeckupandlatchin
“up”position(latchislocatedatfrontcenterof
seat)(seeFigure9).

Figure9

1.Securethedeckin
theraisedpositionby
securingthedecklatch
ontothehook.

2.Hook

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

ToadjusttheFRSbafes:

1.Stopengine,waitforallmovingpartstostopand
removekey.Engageparkingbrake.

2.Removehairpinsandclevispinsfrombothsides
ofthePTOguard(seeFigure5).Foldguard
forward.

3.LoosennylocnutsontherearstudsoftheFRS
bafes.

Operation

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

Interval

Aftertherst50hours

Beforeeachuseordaily

Every40hours

Every100hours

Yearly

MaintenanceProcedure

•Changeoilinallthreegearboxhousings.Addoilasneededuntillevelwithoildrainplug.

•Checkthemowerblades.

•Checkforloosehardware.

•Greasethefrontcasterwheelhub.

•Cleanthegrassanddebrisbuild-upfromthecuttingdeck.

•Cleanthegrassbuild-upfromunderthedeck.

•Checktheconditionofthebelts.

•Greasethedriveshaft.

•Changeoilinallthreegearboxhousings.Addoilasneededuntillevelwithoildrainplug.
thereafter

•Greasethedeckip-up.

•Greasethepivotarmtubes.

•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).

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.

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

2.Placeunitonalevelsurface.

3.Removethegearboxanddriveshaftassembly
fromthemowerdeck.Retainhardwareforre-use.

4.Removethelargeoildrainplugonthefrontof
eachofthethreegearboxsectionsanddrainoil
(Figure13).

Figure13

1.Smallmagneticplugs
(frontandback)

2.Largeoildrain/llplug

3.Smallmagneticplug
(frontonly)

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

1.Drive
Shaft

2.Front
Caster
WheelHub

3.Deck
Flip-Up

4.Push
ArmTubes

5.Front
Caster
Pivots

Initial

Pumps

1

128Hours

1

12

*0

Numberof

Places

340Hours

4100Hours

2

Service

Interval

100Hours

*Yearly

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.

*Seestep3forspeciallubricationinstructionson
thefrontcasterpivotsandtheLubricateCaster
WheelHubssectionforspeciallubrication
instructionsonthefrontcasterswheelhubs.

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.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242”
or“Fel-Pro,Pro-LockNutType”areusedonthe
followingfasteners:

Casterwheelspacernuts.

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.

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).

Figure16

1.Springdiscwashers

DeckLockingPinStop
Adjustment

Figure15

RightHandSideShown

1.Hairpin3.Decksupportpin

2.Spacer

5.Shorten/lengtheneachdecksupportpintoobtain
bladetipheightof3inchesatthefrontofthe
deckand31/4inchesattherearofthedeck.

1.Slidedecklockingpinsinonbothsidesandrotate
tolockthedeckinthe“operation”position.

2.Loosenthejamnutandturnthestopscrew
clockwiseuntilthelockingpinsistightandcannot
berotatedbyhand(Figure17).

Figure17

1.Rotatestopscrewclockwiseuntillockingpinistight,
thenbackoff1/2turn.

2.Loosenjamnut

CasterPivotBearings
Pre-loadAdjustment

Removedustcapfromcasterandtightennylocnut
untilwashersareat.Backthenylocoff1/4ofa
turntoproperlysetthepre-loadonthebearings.

Note:Ifdisassembled,makesurethespringwashers
arereinstalledasshowninFigure16.

3.Loosenthestopscrewcounterclockwise1/2
turnandtightenthejamnut

4.Testthelockingpintomakesureitslidesfreely .
Readjustifnecessary.

18

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.

Maintenance

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

Unevencuttingheight.

Abnormalvibration.

BladesDoNotrotate.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Spacersareinwronglocation.

7.Tipsofadjacentbladesareatanuneven
cuttingheight.Bladestipsshouldbeeven
within3/16inchwhichisapproximately
onebladethickness.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Enginepulleyisdamaged.4.ContactanAuthorizedServiceDealer.

5.Bladespindleisbent.5.ContactanAuthorizedServiceDealer.

1.PTObeltisworn,loose,orbroken.1.Checkbelttensionorreplacebelt

2.PTOshaftisnotconnected.

3.PTObeltisoffpulley .3.Checkbeltfordamage.Installbeltand

2.Installnewcuttingblade(s).

front-to-rear.

6.Positionspacersunderhairpins.

7.Replaceblades,spindlesand(or)check
fordamagetomowerdeck.

1.Installnewcuttingblade(s).

2.ConnectPTOshaft.

checkadjustingshaftsandbeltguidesfor
correctposition.

20

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

• Bags, Belts and Tires 90 days

• 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:

• Pickup and delivery charges to and from any authorized 
 Exmark Service Dealer.

• 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.

• 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.

• 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.

If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:

 Exmark Customer Service Department
 The Exmark Warranty Company
 2101 Ashland Avenue
 Beatrice, NE 68310
 402-223-6375 or
 [e-mail]

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:

• Expenses related to gasoline, oil or lubricants.

• 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.

• Rental of like or similar replacement equipment during the 
 period of any warranty, repair or replacement work.

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that 
 covered by the terms of this warranty.

• Any claims for lost revenue, lost profit or additional cost as 
 a result of a claim of breach of warranty.

• 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.

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-425

21

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

22

23

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

12

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRO NT RIDING ACCESSORI ES AND OPTI ONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.

SerialNo.

©2009ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
AllRightsReserved

DatePurchased

PartNo.4500-370Rev.A
[phone]
Fax[phone]
PrintedintheUSA

www.exmark.com