For Serial Nos. 510,000 & Higher Part No. 103-8614 Rev.
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 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. 2.
WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system) in place and in proper working condition. ♦ Stop engine and wait for all moving parts to stop. Remove spark plug wire(s) or remove key before adjusting, servicing, or performing maintenance.
CONGRATULATIONS on the purchase of your Exmark Navigator Cutting 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.
TABLE OF CONTENTS 1. SAFETY 1.1 1.2 1.3 1.4 1.5 1.6 PAGE Safety Alert Symbol ....................................................................................... 1 Training ......................................................................................................... 1 Preparation................................................................................................. 1-2 Operation ......................................................................................................
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 lettering / Red background.
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 operator or bystanders. 1.
1.6.5 Safety signs may be affixed by peeling off the backing to 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 instruction 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 Front Frame PART NO. 68-8340 LOCATION: On Top of Deck LH & RH Sides PART NO.
2. SPECIFICATIONS 2.1 MODEL NUMBER: CD42CD; CD48CD 2.2 DIMENSIONS Overall Width Overall Height Overall Length Weight 42” Deck 43.2” (109.7 cm) 13.1” (33.3 cm) 37.2” (94.4 cm) 295 lbs. (134 kg) 48” Deck 49.2” (125.0 cm) 13.1 (33.3 cm) 39.9” (101.3 cm) 325 lbs. (147 kg) 2.3 TORQUE REQUIREMENTS Bolt Location Torque Blade Mounting Bolt..................................................... 85-110 ft-lbs. (115-149 N-m) Gearbox Mounting Bolts ....................................................30-35 ft-lbs.
c) d) e) f) g) Raise seat and install drive shaft onto jackshaft (See Figure 2). FIGURE 2 JACKSHAFT AND DRIVE SHAFT CONNECTION 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 the unit. See Figure 3. FIGURE 3 PUSH ARM INSTALLATION Align upper portion of the PTO rubber guard to the tabs on the front of the console and secure with a clevis pin and hairpin on each side. See Figure 4.
FIGURE 5 DECK SPRING INSTALLATION h) Un-latch deck from raised position, slowly lower deck to ground and lock deck locking pins on each side per section 4.1.2, Lowering the Deck to the Operation Position. 3.4 DECK REMOVAL a) b) c) d) e) f) g) h) i) Stop engine, wait for all moving parts to stop, and remove key. Raise mower deck up and latch with deck locking pins per section 4.1.1, Raising the Mower Deck to the Service Position.
4.1 DECK RAISING AND LOWERING 4.1.1 Raising the Mower Deck into Service Position: a) Stop engine, wait for all moving parts 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.
b) Push deck locking pins inward and rotate forward to securely lock deck in lowered position. See Figure 6. WARNING POTENTIAL HAZARD ♦ Operating mower without locking pins securely latched 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 4.2.
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.
GREASE FITTING LUBRICATION CHART FITTING LOCATIONS 1. Drive Shaft 2. Front Caster Wheel Hub 3. Deck Flip-Up 4. Push Arm Tubes 5. Caster Pivots ∗ NO. of PLACES 3 2 SERVICE INTERVAL 40 hours 8 hours 1 1 *0 4 2 3 100 hours 100 hours *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) 4.2.6 INITIAL PUMPS 1 1 Lubricate caster pivots once a year. Remove hex plug and cap.
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 the 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 thread locking adhesive. c) 4.2.
4.3.2 Deck Leveling: a) Position mower on a flat surface. b) Stop engine, wait for all moving parts to stop, and remove key. c) Inflate drive tires to 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.
5. PARTS LIST 5.1 DECK GROUP Item Part No. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1-403005 1-413425 1-513690 1-523420 1-613204 1-803075 1-806003 30-8770 67-7490 68-8340 92-5816 98-5954 99-0283 1-808280 103-9487 109-0321 103-3698-03 103-3700 109-0322 109-0323 103-9485 103-9327 103-9328 103-9329 103-4230 103-4974 103-5868-01 103-5979 103-6183-03 103-6230 103-6290-03 103-7353 103-7705 103-7994 103-8307 103-8363 103-8425 103-8496 103-8610 103-8841 321-2 322-3 Danger, Decal ..........
5.
5.2 FRONT FRAME GROUP Item Part No. Description Item Part No. Description 1 1-303334 Washer, Spring Disk 5/16 ......................2 Qty. 27 103-8797 Decal, Folding Deck............................... 2 Qty. Decal, Danger........................................ 1 2 1-513810 Bushing, Flanged ...................................4 28 103-8798 3 1-543508 Cup, Bearing Tapered Roller .................4 29 103-8799 Decal, Spring .........................................
5.
5.3 GEARBOX COMPONENTS FOR 103-3460 & 103-3387 Item Part No. Description 1 109-0188 Asm, Input Pinion 42”.............................1 Qty. Item Part No. 109-0189 Asm, 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 Shaft, Gear & Brgs (42” LH) ......1 O 5O 109-0193 Output Shaft, Gear & Brgs (48” LH) ......1 11 109-0203 O-ring .......................
6. 2-Year Limited Warranty Exmark Turf Equipment (For units purchased on or after October 1, 2004) 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.
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 © 2005 EXMARK MFG. CO. INC.
