Exmark CD42CD, Cd48cd User Manual

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For Serial Nos.

510,000 & Higher

Part No. 103-8614 Rev. A

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995 Program

If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

2. Distributor ships part(s) to dealer or customer, as

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by

5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus® and if it arrives in

6. Who pays for the part and freight if it fails to arrive overnight in accordance to the program? A. Under any circumstance the customer does not pay. B. If the part does not arrive overnight due to:

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus® order

3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,

4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark

the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus

shipment of six (6) line items or less.

requested by dealer, same day, overnight UPS Distributor bills dealer for part and freight charges where applicable.

order, he contacts Exmark by 3:00 p.m.,

central time, with an Exmark Parts Plus

order of six (6) line items or less.

distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.

accordance to the program.

1. The dealer not submitting the Exmark Parts Plus

order to his Exmark distributor by 1:00 p.m., the dealer

pays for the part and freight.

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

Exmark pays for the part and freight.

pays for the part.

The following restrictions apply

-- The Exmark Parts Plus® Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus

Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating pr actices can result in serious

HOW TO AVOID THE HAZARD

♦ Keep all shields, guards, and safety devices (especially the grass ♦ Stop engine and wait for all moving parts to stop. Remove spark

♦ If mower deck becomes clogged, stop engine and wait for all

♦ Keep hands, feet, and clothing away from power driven parts . ♦ Keep off mower unless seat platf o r m is pr ovided. ♦ Keep others off mower.

WARNING

operator injury or even death.

discharge system) in place and in proper working condit ion. plug wire(s) or remove key before adjust ing, servicing, or

performing maint enance. moving parts to stop. Remove spark plug wire(s) or r em ove k ey

before cleaning blockage.

iii

CONGRATULATIONS on the purchase of your Exmark Navigat or Cut ting Deck. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble- free operation.

OPERATOR'S MANUAL

This manual contains assembly, operating, maintenance, adjustment, and safety instructions for your Navigator Cutting Deck.

BEFORE OPERATING YOUR MOWER,

CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.

By following the operating, maint enance, and safety instructions, you will prolong the life of your equipment , maintain its maximum eff iciency, and pr om ot e safe operation.

If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor.

All Exmark equipment dealers and distribut or s are kept informed of the latest methods of servicing and are equipped t o pr ovide prom pt and efficient service in the field or at their service stations. T hey carr y ample stock of service parts or can secure them promptly for you fr om the factory.

All Exmark parts are thoroug hly test ed and inspect ed before leaving the factory, however, attention is required on your part if you are t o obt ain the fullest measure of satisfaction and performance.

TABLE OF CONTENTS

1. SAFETY PAGE

1.1 Safety Alert Symbol....................................................................................... 1

1.2 Training.........................................................................................................1

1.3 Preparation.................................................................................................1-2

1.4 Operation ......................................................................................................2

1.5 Maintenance & Storage................................................................................. 2

1.6 Safety Signs...............................................................................................2-3

2. SPECIFICATIONS

2.1 Model Number...............................................................................................4

2.2 Dimensions.................................................................................................... 4

2.3 Torque Requirements.................................................................................... 4

3. ASSEMBLY INSTRUCTIONS

3.1 Uncrate Deck.................................................................................................4

3.2 Assemble Discharge Chute...........................................................................4

3.3 Assemble Deck to Navigator......................................................................4-6

3.4 Deck Removal............................................................................................... 6

4. MAINTENANCE & ADJUSTMENTS

4.1 Deck Raising and Lowering........................................................................6-8

4.2 Maintenance.............................................................................................8-11

4.3 Adjustments ...........................................................................................11-12

5. PARTS LIST

5.1 Deck Group............................................................................................13-14

5.2 Front Frame Group.................................................................................15-16

5.3 Gearbox Components ................................................................................17

6. WARRANTY.......................................................................................................... 18

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is used both in this manual and on the unit to identify

important safety messages which must be followed to avoid accidents. This symbol means:

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

The safety alert symbol appears above information which alerts you to unsafe actions or

situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White lett e r ing / Red background. Indicates an im minently hazardous situation

which, if not avoided, WILL result in death or serious injur y.

WARNING: Black lettering / O r ange background. Indicates a pot ent ially hazardous situat ion

which, if not avoided, COULD result in death or ser ious inj ur y.

CAUTION: Black lettering / Yellow backgr ound. Indicates a potentially hazardous situation

which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

1.2.1 Regard the Exmark mower as a piece of power eq uipm ent and teach this regard to all who operate this unit.

1.2.2 Before operating your mower, read the Navigator tractor and cutting deck manual instructions carefully. Familiarize yourself with the cont r ols and the proper use of the equipment. If t he oper at or(s) or mechanic(s) can not read Eng lish, it is the owner’s responsibility to explain this material to them.

1.2.3 Do not allow operation of this machine by untrained personnel. Never allow children, teenagers, or people unfamiliar with these instructions to use the mower. Local regulations may restrict the age of the operator.

1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

1.3 PREPARATION

1.3.1 Do not modif y the Navigat or cutting deck and only use on approved Exmark machines.

1.3.2 The use of personal protective equipment, such as (but not lim it ed to) protection for the eyes, ears, feet, and head is recomm ended.

CAUTION

POTENTIAL HAZARD ♦ This machine produces sound levels in excess of 85

dBA at the operator’s ear when in operation.

WHAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or above for

extended periods of time can cause hearing loss.

HOW TO AVOID THE HAZARD ♦ Wear hearing protection when operating this

machine.

1.3.3 While mowing, always wear substantial footwear and long trousers. Do not operate equipment when barefoot or when wearing open sandals.

1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operat or or bystander s.

1.4 OPERATION

Although hazard control and accident prevention are partially dependent upon the

design and configuration of the equipment, t hese f act ors are al so dependent upon the awareness, concern, prudence, and proper training of the personnel i nvolved in the operation, transport, maintenance, and st orage of t he equi pment. It is essential that all Operator Safety Mechanisms be connected and in operating condit i on prior to use for mowing.

WARNING

POTENTIAL HAZARD ♦ Hands, feet, hair, clothing, or accessories can become

entangled in rotating part s.

WHAT CAN HAPPEN ♦ Contact with rotating parts can cause traum at ic am putation

or severe lacerations.

HOW TO AVOID THE HAZARD ♦ Do not operate the machine without guards, shields, and

safety devices in place and working.

♦ Keep hands, feet, hair, je welry, or clot hing away from

rotating parts.

1.4.1 Give complete, undivided attention to the job at hand.

1.4.2 Mow only in daylight or good artif icial light, keeping away from holes and hidden hazards. NEVER carry passengers.

1.4.3 Use EXTREME caution when backing up. LOOK BEHI ND YO U!

1.4.4 Stop the blades when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed.

1.4.5 Never operate the mower with damaged g uards, shields, or covers. Always have safety shields, guards, switches, and other devices in place and in proper work ing condition.

1.5 MAINTENANCE AND STORAGE

1.5.1 Check all bolts frequently to maint ain proper tightness.

1.5.2 Keep all g uar ds, shields, and all safety devices in place and in safe working condition.

1.5.3 Frequently check for worn or deteriorating components that could create a hazard.

1.5.4 All replacement part s m ust be the same as or equivalent to the parts supplied as original equipment.

1.6 SAFETY SIGNS

1.6.1 Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels.

1.6.2 Safety signs must be replaced if they are missing or illegible.

1.6.3 When new components are installed, be sure that current saf et y sig ns ar e affixed to the replaced components.

1.6.4 New safety signs may be obtained from Exmark Mfg. Co. Inc.

1.6.5 Safety signs may be affixed by peeling off the backing t o expose the adhesive surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.

1.6.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They are critical to the safe operation of your Exmark commercial mower.

PART NO. 103-8797 LOCATION: On Top RH and LH Sides of

PART NO. 98-5954 LOCATION: - On Top of Deck, Under Gear Box Cover

- On LH Frame, Under PTO Shield

- On RH Lower Frame, behind fuel tank

PART NO. 103-8798 LOCATION: Front RH Surface of Front Frame

Front Frame

PART NO. 68-8340 LOCATION: On Top of Deck LH & RH Sides

PART NO. 1-403005 LOCATION: On Top of Mower Deck

LH & RH Sides

PART NO. 103-8425 LOCATION: - On Driveshaft

PART NO. 103-8799 LOCATION: On Top of Front Frame, Near Deck

Springs

PART NO. 103-6230 LOCATION: On Top of Deck,

Centered on Each Side

2. SPECIFICATIONS

2.1 MODEL NUMBER: CD42CD; CD48CD

2.2 DIMENSIONS

Overall Width 43.2” (109.7 cm) 49.2” (125.0 cm) Overall Height 13.1” (33.3 cm) 13.1 (33.3 cm) Overall Length 37.2” (94.4 cm) 39.9” (101.3 cm) Weight 295 lbs. (134 kg) 325 lbs. (147 kg)

2.3 TORQUE REQUIREMENTS Bolt Location

Blade Mounting Bolt.....................................................85-110 ft-lbs. (115-149 N-m)

Gearbox Mounting Bolts....................................................30-35 ft-lbs. (41-47 N-m)

Gearbox Assembly Bolts....................................................50-55 ft-lbs. (68-75 N-m)

Torque

42” Deck 48” Deck

3. ASSEMBLY INSTRUCTIONS

3.1 UNCRATE DECK a) Remove flat hairpins from under front fr am e and discard. See Figure 1.

3.2 ASSEMBLE DISCHARGE CHUTE

a) Locate the 3 holes at the rear of t he m ower deck shown in Figur e 1 and r em ove the 3

#10-24 x 3/4 truss head screws and 3 #10-24 nyloc nuts.

b) Assemble the discharge tube to the mower deck as shown using the har dware rem oved in

3.2.1., with hinge positioned on top of m ower deck .

c) Locat e t he dischar ge tube spring on the mower deck and hook onto t he dischar ge tube

spring bracket. See Figur e 1.

FIGURE 1

DISCHARGE TUBE ASSEMBLY

3.3 ASSEMBLE DECK TO NAVIGATOR

a) Stop engine, wait for all moving parts to stop and remove key.

b) Roll the mower deck up to the Navigator tr act or with the discharge tube down, making sure

the deck springs are located above the drive wheel and below the console on each side.

c) Raise seat and install dr ive shaft onto jackshaft ( See Figure 2).

FIGURE 2

JACKSHAFT AND DRIVE SHAFT CONNECTION

d) Align deck push arm tubes to tractor push arms and push deck rearward. Secure push

arms with lynch pins on left and right sides of t he unit. See Figure 3.

FIGURE 3

PUSH ARM INSTALLATION

e) Align upper portion of the PTO r ubber guard to the tabs on the fr ont of the console and

secure with a clevis pin and hairpin on each side. See Figure 4.

FIGURE 4

PTO GUARD INSTALLATION

f) Release the deck locking pins on each side, r aise m ower deck to the service position and

secure deck latch onto hook. See sect ion 4. 1. 1, Raising the Deck to the Service Position.

g) Install springs onto the spring anchor pins under the left and right consoles and secure with

a washer and hairpin. See Figure 5.

FIGURE 5

DECK SPRING INSTALLATION

h) Un-latch deck from raised position, slowly lower deck to gr ound and lock deck locking pins

on each side per section 4.1.2, Lowering the Deck t o t he Operation Position.

3.4 DECK REMOVAL

a) Stop eng ine, wait for all moving parts to stop, and r emove key. b) Raise mower deck up and latch with deck locking pins per section 4.1. 1, Raising the

Mower Deck to the Service Position.

c) Remove hairpins and washers at the top of the deck lift assist spr ing on each side of the

unit. See Figure 5. d) Remove the spring from the spring anchor . Repeat for other side of unit. e) Un-latch deck from raised position and slowly lower deck to ground per sect ion 4. 1.2,

Lowering the Mower Deck to the Operation Position. NOTE: Deck will become heavier once springs are removed from the anchors. Lower

deck carefully. f) Remove lynch pins at front of push ar m s on both sides of the unit. See Figure 3. g) Remove hairpin and clevis from both sides of the PTO guard. See Figure 4. h) Raise seat and disconnect drive shaft using quick coupler at jackshaft. See Fig ur e 2. i) Pull mower deck forward to remove from unit.

4. MAINTENANCE & ADJUSTMENTS

WARNING

POTENTIAL HAZARD ♦ While maintenance or adjustments are being made,

someone could start the engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could seriously injure

you or other bystanders. HOW TO AVOID THE HAZARD ♦ Remove the key from the ig nit ion switch and pull the

wire(s) off the spark plug(s) before you do any

maintenance. Also push the wire(s) aside so it does

not accidentally contact the spark plug( s) .

4.1 DECK RAISING AND LOWERING

4.1.1 Raising the Mower Deck into Service Position:

a) Stop engine, wait for all moving par ts to stop and remove key.

WARNING

POTENTIAL HAZARD ♦ Incorrectly raising or lowering a mower deck can be

dangerous. WHAT CAN HAPPEN ♦ A dropped mower deck can result in a serious injury or

property damage. HOW TO AVOID THE HAZARD ♦ Always raise and lower deck on flat, dry ground, free

of any obstructions. ♦ Firmly grasp the deck lift handle and lower in a slow

controlled manner. ♦ Always make sure the deck is securely latched in the

“up” or “down” position.

b) Release t he deck locking pins on each side. See Figure 6.

FIGURE 6

RAISING THE DECK

c) Using deck lift handle, lift deck up and latch in “ up” position (latch is located at

front center of seat). See Figure 6.

WARNING

POTENTIAL HAZARD ♦ Operating the mower deck in the r aised ser vice

position can be dangerous. WHAT CAN HAPPEN ♦ Engaging the PTO with a deck in t he raised position

can result in a serious injury or property damage. HOW TO AVOID THE HAZARD ♦ Always lower and lock mower deck in the operation

position before engaging the PTO.

4.1.2 Lowering t he Mower Deck to t he O per ation Position: a) While firm ly holding ont o deck lift handle, unhook deck latch from tractor section

and slowly lower deck to ground.

b) Push deck locking pins inward and rotate for ward to secur ely lock deck in

lowered position. See Figure 6.

WARNING

POTENTIAL HAZARD ♦ Operating mower without locking pins securely latc hed

can result in the mower deck folding up unexpectedly. WHAT CAN HAPPEN ♦ The mower deck folding up unexpectedly can cause

serious injury. HOW TO AVOID THE HAZARD ♦ Always operate mower with locking pins securely

latched.

4.2 PERIODIC MAINTENANCE

4.2.1 Clean grass build-up under deck. Service Interval: Daily a) St op engine, wait for all moving parts to st op, and remove key. b) Raise mo wer deck and secur e in latched position. See section 4.1.1, Raising

the Mower Deck to the Service Position. c) Clean out any grass build- up from underside of deck and in dischar ge chute. d) Lower deck to cutting position and lock deck locking pins. See section 4.1.2,

Lowering the Mower Deck to the Operation Position.

4.2.2 Check mower blades Service Interval: Daily a) Stop engine, wait for all moving parts to stop, and r em ove k ey. b) Lift deck and secure in raised position as stated in Section 4.1.1, Raising the

Mower Deck to the Service Position. c) Inspect blades and sharpen or replace as required. d) To remove blade, use a block of wood or locking pliers to hold blade in place and

remove the 1/2-20 x 2 1/4 blade bolt that secures the blade and blade driver. e) If blade is worn or damaged, remove the shear pins that secure the blade dr iver

to the blade. Re-install a new blade to the blade driver and secure with the

shear pins. f) Re-install the blade driver (with new blades) by using a block of wood or locking

pliers to hold the blade in place and torque the blade bolt s to 85-110 ft-lbs. (115-

149 N-m).

NOTE: Blade driver flats must be aligned with the flats on the shaft when

installing blade on the mower deck. g) Lower the mower deck to the operation position. See section 4.1.2, Lowering

the Mower Deck to the Operation Position.

CAUTION

POTENTIAL HAZARD ♦ Operating a mower deck with loose or weakened blade

bolts can be dangerous. WHAT CAN HAPPEN ♦ A loose or weakened blade bolt could allow a blade

rotating at a high speed to come out from under the deck,

causing serious injury or property damage. HOW TO AVOID THE HAZARD ♦ Replace the blade bolt after striking a foreign object.

Use only the following replacement parts:

Blade bolt – 92-5816

Washer – 86-1990 ♦ DO NOT lubricate the threads of the bolt or spindle before

assembly. ♦ Torque the blade bolt to 85-110 ft. lbs. (115-149 N-m)

FIGURE 7

BLADE BOLT INSTALLATION

4.2.3 Check for loose hardware Service Interval: Daily a) St op engine, wait for all moving parts to st op, and remove key. b) Visually inspect machine for any loose hardware or any other possible

4.2.4 Check tire pressur es The front caster tires are semi-pneumatic and do not need to be inflated.

NOTE: Do not add any type of tire liner or foam fill material to the tires.

Excessive loads created by foam filled tires may cause failures to the hydro drive system, frame, and other components. Foam filling tires will void the warranty.

4.2.5 Lubricate grease fittings Service Interval: Refer to chart. a) St op engine, wait for all moving parts to st op, and remove key. b) Lubricate fittings with one to two pumps of NGLI grade #2 multi-purpose gun

grease.

Refer to t he following chart for fit t ing locations and lubrication schedule.

GREASE FITTING LUBRICATION CHART

FITTING

LOCATIONS

1. Drive Shaft 1 3 40 hours

2. Front Caster Wheel Hub 1 2 8 hours

3. Deck Flip-Up

4. Push Arm Tubes

5. Caster Pivots *0 3 *yearly

∗ See Section 4.2.5 c) for special lubrication instructions on

the front caster pivots and Section 5. 2. 6 for special lubrication instructions on the rear caster wheel hub.

c) Lubricate caster pivots once a year. Remove hex plug

and cap. Thread grease zerk in hole and pump with grease until it oozes out around top bearing. Remove grease zerk and thread plug back in. Place cap back on.

INITIAL

PUMPS

1 4 100 hours 1 2 100 hours

NO. of

PLACES

SERVICE

INTERVAL

4.2.6 Lubricat e cast er wheel hub:

Service Interval: Once Yearly a) Stop engine, wait for all moving parts t o stop,

and remove key. b) Remove caster wheel from caster forks. c) Remove seal guards from the wheel hub. d) Remove one of the spacer nuts from the

axle assembly in the caster wheel. Note

that thread locking adhesive has been

applied to lock the spacer nuts to the axle.

Remove the axle (with the other spacer

nut still assembled to it) f r om the wheel

assembly.

CASTER WHEEL ASSEMBLY

e) Pry out seals, and inspect bearings for wear or

damage and replace if necessary. f) Pack the bearings with a NGLI gr ade #1 m ulti-purpose grease. g) Insert (1) bearing, (1) new seal into the wheel. NOTE: Seals (Exmark PN 103-0063) must be r eplaced. h) If the axle assembly has had both spacer nuts removed (or broken loose), apply

a thread locking adhesive to (1) spacer nut and thread onto the axle with the

wrench flats facing outward. Do not t hr ead spacer nut all of the way onto the

end of the axle. Leave approximately 1/8” (3 mm) from the outer surface of the

spacer nut to the end of the axle inside the nut. i) Insert t he assem bled nut and axle into the wheel on the side of the wheel with

the new seal and bearing. j) With the open end of the wheel facing up, fill the area inside the wheel around

the axle full of NGLI g r ade #1 multi-purpose grease. k) Insert the second bearing and new seal into the wheel.

l) Apply a thread locking adhesive to the 2

spacer nut and thread onto the axle

with the wrench flats facing outward. m) Torque the nut to 75-80 in-lbs. (8-9 N-m), loosen, then re-torque to 20-25 in-lbs.

(2-3 N-m). Make sure axle does not extend beyond either nut.

FIGURE 8

n) Re-install the seal guards over the wheel hub and insert wheel into caster fork.

Re-install caster bolt and tighten nut fully.

IMPORTANT: To prevent seal and bearing damage, check the bearing

adjustment often. Spin t he caster tire. The tire should not spin freely (more

than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust

torque on spacer nut until there is a slight amount of drag. Re- apply thr ead

locking adhesive. c) Lubricate switch actuator rod with spray type lubricant or light oil.

4.2.7 Change gearbox oil: Change oil in all 3 gearbox housings after first 50 hrs of operation. Check

every 100 hours thereafter. Add oil as needed until level with oil drain plug.

a) Stop engine, wait for all moving parts to st op, and remove key. b) Place unit on a level surface. c) Remove the gearbox and drive shaft assembly from the mower deck. Retain

hardware for re-use. d) Remove the large oil drain plug on the front of each of the 3 gearboxes and drain

oil. See Figure 9. e) Remove small magnetic plugs and wipe away any material accumulated on the

plugs. See Figure 9.

f ) Apply a Teflon pipe sealant to all small magnetic plugs and re-install into the

gearbox. g) Re-install the gearbox and drive shaft assembly to the mower deck. h) Fill gearbox with Mobil 1 75W-90 gear lube oil unt il level with oil drain plug. NOTE: Mower deck should remain level to the ground when filling gear box with oil.

Do not fill gearbox with deck raised in the ser vice position.

i) Apply a Teflon pipe sealant to the 3 large oil plugs and re-install into the gear box.

4.2.8 Thread locking adhesives such as “Loctite 242” or “ Fel- Pr o, Pro-Lock Nut Type” are

used on the following fasteners:

a) Cast er wheel spacer nuts.

FIGURE 9

GEARBOX OIL DRAIN LOCATIONS

4.3 ADJUSTMENTS

IMPORTANT: Disengage PTO, shut off engine, wait f or al l moving parts to stop, and

remove key before servicing, cleaning, or making any adjustments to the unit.

4.3.1 Cutting Heig ht Adjustment a) Stop engine, wait for all moving part s t o st op, and remove key. b) Move cotter pins on four deck support pins to proper hole for height of cut

desired.

4.3.2 Deck Leveling: a) Position mower on a flat surface. b) Stop engine, wait for all moving parts to stop, and r em ove k ey. c) Inflate drive tires t o 15 psi ( 103 kPa). d) Verify all hairpins are in the 3” deck height holes with the spacers under the hair

pins. See Figure 10. e) Shorten/lengthen each deck support pin to obtain blade tip height of 3.0” at the

front of the deck and 3.25” at the rear of the deck.

FIGURE 10

DECK SUPPORT PIN ASSEMBLY

4.3.3 Caster pivot bearings pr e-load adjustment

a) Remove dust cap f r om caster and tighten nyloc

nut until washers are flat. Back the nyloc off 1/4

of a turn to properly set the pr e- load on t he

bearings. Note: If disassembled, make sure the spring

washers are reinstalled as shown in Figure 11.

4.3.4 Deck Locking pin stop adjustment:

CASTER ADJUSTMENT

FIGURE 11

a) Slide deck locking pins in on both sides and

rotate to lock the deck in t he “ operation” position. b) Loosen the jam nut and turn the stop screw clockwise until the locking pins is

tight and cannot be rotated by hand. See Figur e 12. c) Loosen the stop screw counter clockwise 1/2 turn and tighten the jam nut. d) Test the locking pin t o m ake sure it slides freely. Readjust if necessary.

FIGURE 12

DECK LOCKING PIN ADJUSTMENT

5. PARTS LIST

5.1 DECK GROUP

Item Part No.

1 1-403005 Danger, Decal........................................2

2 1-413425 Spacer, Deck Support............................4

3 1-513690 Clip, Deck Holdup Rod.... .......... .............1

4 1-523420 Bumper..................................................2

5 1-613204 Balljoint..................................................2

6 1-803075 Screw, Truss Head #10-24 x 3/4.......... ..14

7 1-806003 Hairpin, Cotter........................................2

8 30-8770 Washer..................................................2

9 67-7490 K ey, Machine 1/4 x 1/4 x 1 1/2............ ...1

10 68-8340 Decal, Blade B ol t Torque............. ..........2

11 92-5816 Bolt, Bl ade 1/2-20 x 2 1/4.. .......... .......... .2

12 98-5954 Decal, Danger........................................2

13 99-0283 Bolt, Shear 1/4-20 x 7/8 ................. ........4

14 1-808280 Pin, Clevis 5/16 x 1 ........ .......... ..............2

15 103-9487 Asm, Discharge Tube .......... .......... ........1

16 109-0321 Asm, Front Deck Height Adj.... .......... .....2

17 103-3698-03 Guard, Plenum.......................................1

18 103-3700 Roller, Deck...........................................2

19 109-0322 Asm, Rear Deck Hei ght Adj. (42”)..........2

109-0323 Asm, Rear Deck Height Adj . (48”)..........2

20 103-9485 Asm, Drive Shaft W/Decal ............ .........1

103-9327 Asm, Cross "U" Joi nt ....................... ......2

103-9328 Yoke, Keyed ..........................................1

103-9329 Yok e, Quick Disconnect............ .......... ...1

21 103-4230 Spacer, Roller........................................2

22 103-4974 Hinge.....................................................1

23 103-5868-01 Wld, Spring Mount .................................1

24 103-5979 Guard, PTO ...........................................1

25 103-6183-03 Bracket, PTO Guard ............................. .1

26 103-6230 Decal, Cutting Height Adjustment ..........2

27 103-6290-03 Plate, Drive Line Cover ...... ................... .1

28 103-7353 Hairpin, Cut Height.................................4

29 103-7705 Driver, Blade..........................................2

30 103-7994 Balljoint..................................................1

31 103-8307 Latch, Deck............................................1

32Q 103-8363 Asm, Deck Latch....................................1

33 103-8425 Decal, Driveline......................................1

34 103-8496 Nut, Jam 7/8-9 .......................... .......... ...2

35 103-8610 Stand-Off, 1/2 Hex .................. .......... . ....2

36 103-8841 Spring....................................................1

37 321-2 Screw, HH 1/4-20 x 1/2... . ................... ...2

38 322-3 Screw, HH 5/16-18 x 3/4........... .............7

Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).

V Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on setscrew, item #45. O Deck assembly includes anti skid pad, item #66. P Gearbox cover assembly includes anti skid pad, item #62. Q Deck latch assembly includes nyloc nut, item #52.  Rear deck height adj. assembly includes (1) whizlock nut. Item #48.

Description

Qty.

Item Part No.

39 322-5 Screw, HH 5/16-18 x 1...........................3

40 323-11 Screw, HH 3/8-16 x 2 1/4 (42”)..............2

323-8 Screw, HH 3/8-16 x 1 1/2 (48”) ..............2

41 323-7 Screw, HH 3/8-16 x 1 1/4.......................4

42 323-9 Screw, HH 3/8-16 x 1 3/4.......................1

43 325-14 Screw, HH 1/2-13 x 3 1/2.......................2

44 3219-3 Nut, Hex 3/8-24......................................3

45V 3247-2 Setscrew, 3/8-16 x 3/8...........................1

46 3256-14 Washer, #10 Std....................................9

47 3290-134 Screw, HH Machine 10-24 x 5/8.............1

48 3290-357 Nut, Whizlock 3/8-16 .............................6

49 3296-2 Nut, Nyloc #10-24..................................15

50 3296-29 Nut, Nyloc 5/16-18................................. 3

51 3296-39 Nut, Nyloc 3/8-16...................................1

52 3296-6 Nut, Nyloc 3/8-24 ...................................1

53 32128-20 Nut, Whizlock 5/16-18 ...........................4

54 32128-49 Nut, Whizlock 1/2-13 .............................2

55 114439 Rivet......................................................5

56 103-9024 Decal, Commercial (42")........................ 1

1-403131 Decal, Commercial (48")........................ 1

57 106-5620 Spacer (42") ..........................................2

106-5597 Spacer (48") ..........................................2

58 103-3460 Gearbox,(42") Std.................................. 1

103-3387 Gearbox,48 Std......................................1

59O 103-9479 Asm, Deck W/ Decals (42") ....................1

103-9478 Asm, Deck W/Decals (48") 1

60 103-4209 Blade, LH (42") Black ............................1

103-4207 Blade, LH (48") Black ............................1

61 103-4210 Blade, RH (42") Red.............................. 1

103-4208 Blade, RH (48") Red ..............................1

62P 103-9497 As m, Gearbox Cover W/Decal (42") ...... 1

103-9496 Asm, Gearbox Cover W/Decal (48" ) ...... 1

63 103-8556-01 Wld, Baffle Discharge LH (42")..............1

103-8590-01 Wld, Baffle Discharge LH (48"). ............. 1

64 103-8557-01 Wld, Baffle Discharge RH (42") ............. 1

103-8591-01 Wld, Baffle Discharge RH (48") ............. 1

65 103-8626 Pad, Anti Skid (42")...............................1

103-8629 Pad, Anti Skid (48") ............................... 1

66 103-8667 Pad, Anti Skid (42")...............................1

103-8630 Pad, Anti Skid (48") ............................... 1

67 3296-42 Nut, Nyloc 1/4-20...................................4

68 3256-23 Washer, 5/16 SAE................................. 3

Description

Qty.

5.1 DECK GROUP

5.2 FRONT FRAME GROUP

Item Part No.

1 1-303334 Was her, Spring Disk 5/16 ................ ......2

2 1-513810 Bushing, Flanged...................................4

3 1-543508 Cup, Bearing Tapered Roller ......... ........4

4 1-543509 Cone, Bearing Tapered Roller................4

5 1-543511 Seal, Grease..........................................2

6 1-633508 Washer, Spring Disk..............................6

7 1-811010 Plug .......................................................2

8Q 103-3729-01 Wld, Deck P i vot (RH)....... ......................1

9Q 103-3732-01 Wld, Deck Pivot (LH) .................... .........1

10 103-3772 Plug, Spring Adjuster.............................2

11 103-3773 Shaft, Spring Adjustment .......................2

12 103-4017 Spacer, Front Caster. .......... .......... .........2

13 103-4118 Wld, Deck Loc k (LH) ................... ...........1

14 103-4119 Wld, Deck Loc k (RH).............................1

15 103-9482 Asm, Deck Lift Handl e W/Decal............ .1

16 103-4284 Wld, Spring Tensioner ...........................2

17 103-4285 Mount, Deck Lift Spring....... .......... .........2

18 103-4588 Bearing, Roller Straight..........................2

19 103-4882 Cap, Grease ..........................................2

20 103-7353 Pin, Cut Height.......................................2

21 103-7436 Bushing, Deck Support ... .......... .......... ...2

22 103-7448 E-Ring....................................................2

23 103-7865 Wld, Spring Tube...................................2

24 103-7971 Cover, Deck Spring..... .......... .................2

25 103-8504 Decal, Navigator Model..........................1

26 103-8667 Pad, Anti Skid (42”)................ .......... ......1

103-8630 Pad, Anti Skid (48”)........ .......... .......... ....1

Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).

V Includes frame weldment plus items #7, #13, #14, #19, #21, #25, #37, #38, and Decals. Q Include zerk, item #30. O Includes (2) nyloc nuts, item #38.

Description

Qty.

Item Part No.

27 103-8797 Decal, Folding Deck...............................2

28 103-8798 Decal, Danger........................................1

29 103-8799 Decal, Spring.........................................2

30 302-19 Zerk, 1/4-28 Str......................................4

31 302-61 Zerk, 45° 1/4-28..................................... 4

32 322-4 Screw, HH 5/16-18 x 7/8........................2

33 325-38 Screw, HH 1/2-13 x 4 3/4.......................2

34 3218-3 Nut, Jam 3/8-16.....................................2

35 3243-5 Setscrew, SQH 3/8-16 x 1 .....................2

36 3256-28 Washer, 3/4 SAE................................... 2

37 3296-29 Nut, Nyloc 5/16-18................................. 2

38 3296-39 Nut, Nyloc 3/8-16...................................4

39 3296-45 Nut, Nyloc 1/2-13...................................2

40 3296-51 Nut, Nyloc 3/4-10...................................2

41 32120-33 Ring, Retaining......................................2

42 32121-3 Rollpin 3/16 x 3/4...................................2

43 614672 Screw, Shoulder 3/8-16 x 1.295.............2

44 103-3655-01 Wld, Fork & Spindle...............................2

45 103-4324 Asm, Wheel & Tire 8x3.00-4 Sp.............2

46V 103-9481 Asm , Front Frame W/Decals (42"). ........ 1

103-9480 Asm, Front Frame W/Decals (48").........1

47 103-4281 Spring, Extension...................................2

48 103-9495 Asm, Caster Wheel W/Axle................... 1

49O 103-4280 Asm, Spring Lift Assist...........................2

Description

Qty.

5.2 FRONT FRAME GROUP

5.3 GEARBOX COMPONENTS FOR 103-3460 & 103-3387

Item Part No.

1 109-0188 Asm, I nput Pinion 42”................ .......... ...1

109-0189 As m, Input Pinion 48”............ .......... .......1

2V 109-0190 Center Housing W/Plugs... .......... ...........1

3V 109-0191 End Housing W/Plugs & Race ... . ...........2

4O 109-0192 Output S haft, Gear & Brgs (42” LH) ..... .1

109-0193 Output Shaft, Gear & Brgs (48” LH) ... . ..1

5O 109-0194 Output S haft, Gear & Brgs (42” RH)......1

109-0195 Output Shaft, Gear & Brgs (48” RH)......1

6R 109-0196 Output Cap W/Race...............................2

7VR 109-0197 Asm, Connector Tube 42” S hort......... ....1

Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).

V Includes o-rings, item #11 O Includes (1) output seal assembly, item #9  Apply bead of Mobil HTS grease (P/N 103-5217 1.5 oz packet) between seal, item #10 and v-ring, item #13. S Does not include screw, item #14.

Description

Qty.

Item Part No.

109-0198 Asm, Connector Tube 48” Short............1

8VR 109-0199 Asm, Connector Tube 42” Long............. 1

109-0200 Asm, Connector Tube 48” Long.............1

9 109-0201 Kit, Output Seal ..................................... 2

10 109-0202 Seal, Input.............................................1

11 109-0203 O-ring....................................................7

12 109-0204 Washer, Cupped....................................1

13 109-0205 V-ring.....................................................1

14 93-3987 Screw, HH 3/8-24 x 1 1/4 Gr8................28

Description

Qty.

6. 2-Year Limited Warranty

Exmark Turf Equipment

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 manufactured by Exmark 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 turf equipment purchased on or after October 1, 2004 sold in the US 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.

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

*Please refer to the engine manufacturer’s warranty statement that is included in the literature packet. We are not authorized to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized

• Any damage or deterioration due to normal use, wear

• Cost of regular maintenance service or parts, such as

• Any product or part which has been altered or misused

• Any repairs necessary due to use of parts, accessories

All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts.

1. 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. Customers may also call 402-223-6375.

2. Bring the product and your proof of purchase (sales receipt) to the Exmark Service Dealer.

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 service@exmark.com

Warranty Period

Items and Conditions Not Covered

Exmark Service Dealer. and tear, or exposure. filters, fuel, lubricants, tune-up parts, and adjustments. or required replacement or repair due to normal wear,

accidents, or lack of proper maintenance. 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.

Instructions for Obtaining Warranty Service

(For units purchased on or after October 1, 2004)

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 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.

As a condition to this warranty, customer shall have read the operator's manual and shall have completed and submitted to Exmark Warranty Company, within the prescribed time, the Exmark warranty registration.

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein. Neither Exmark nor Exmark Warranty

Company shall have any liability for any other cost, loss or damage, including but not limited to, any incidental or consequential loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other

extraordinary repair charges or charge 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.

There are no understandings, agreements, representations, or warranties, express or implied, including but not limited to any regarding the merchantability (that product is fit for ordinary use) or fitness for use (that product is fit for a particular purpose), not specified herein, respecting the equipment which is the subject of this 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.

- 18 -

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

E-Z RIDER

Check us out on the Web:

www.exmark.com

FG. CO. INC.

Exmark CD42CD, Cd48cd User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual