Exmark Lawn Mower 4500 370 User Guide

CD42CD/CD48CD  
For Serial Nos.  
790,000 & Higher  
Part No. 4500-370 Rev. A  
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Cutting Deck. This product has been  
carefully designed and manufactured to give you  
a maximum amount of dependability and years of  
trouble-free operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
Figure 1  
1. Model and serial number location  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Model No.  
Serial No.  
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 distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Contents  
Introduction ........................................................... 3  
Periodic Maintenance ....................................... 14  
4
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Safety  
• Never let children or untrained people operate  
Safety  
Safety Alert Symbol  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
Preparation  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
• Do Not modify the Navigator cutting deck.  
• Only use on machines approved by Exmark.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals.  
Figure 2  
1. Safety alert symbol  
CAUTION  
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.  
This machine produces sound levels in  
excess of 85 dBA at the operator’s ear and  
can cause hearing loss through extended  
periods of exposure.  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
Wear hearing protection when operating this  
machine.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
Operation  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
• Never raise deck with blades running.  
Safe Operating Practices  
• Stop engine, wait for all moving parts to stop,  
remove key and engage parking brake:  
Training  
– Before checking, cleaning or working on the  
mower.  
• Read the tractor and cutting deck Operator’s  
Manuals and other training material. If the  
operator(s) or mechanic(s) can not read English  
it is the owner’s responsibility to explain this  
material to them.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating the mower).  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
– Before clearing blockages.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
– Whenever you leave the mower.  
5
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Safety  
WARNING  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
Maintenance and Storage  
• Disengage PTO, set parking brake, stop engine  
and remove key or disconnect spark plug wire.  
Wait for all movement to stop before adjusting,  
cleaning or repairing.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Check all bolts frequently to maintain proper  
tightness.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• All replacement parts must be the same as  
or equivalent to the parts supplied as original  
equipment.  
6
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• 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.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
103-8425  
103-8797  
103-8798  
1-403005  
68-8340  
98–5954  
103-8799  
103-6230  
7
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 790,000 and Higher  
CD42CD; CD48CD  
Systems  
– 48 inch Deck: 4 5/8 inches (11.7 cm)  
• Cutting Height Adjustment:  
Tires & Wheels  
Adjusts from 1 inch (2.5 cm) to 4 inches (10.2 cm)  
in 1/4 inch (.64 cm) increments.  
Front Caster  
Semi-Pneumatic  
2
• Mulching Kit: Optional  
Quantity  
Tread  
Smooth  
Dimensions  
Size  
8 x 3.00–4  
Ply Rating  
Pressure  
Overall Width:  
42 inch Deck  
48 inch Deck  
43.2 inches (109.7 cm)  
49.2 inches (125.0 cm)  
Cutting Deck  
• Model Numbers:  
– CD42CD  
Overall Length:  
42 inch Deck  
48 inch Deck  
– CD48CD  
37.2 inches (94.4 cm)  
39.9 inches (101.3 cm)  
• Cutting Width:  
– 42 inch Deck: 42 inch (106.7 cm)  
– 48 inch Deck: 48 inch (121.9 cm)  
• Discharge: Center  
Overall Height:  
42 inch Deck  
48 inch Deck  
13.1 inches (33.3 cm)  
13.1 inches (33.3 cm)  
• Blade Size: (2 ea.)  
– 42 inch Deck: 22.00 inches (55.9 cm)  
– 48 inch Deck: 25.00 inches (63.5 cm)  
• Deck Drive:  
Curb Weight:  
42 inch Deck  
48 inch Deck  
– Clutching belt on horizontal engine shaft.  
Dual A” section hexagon belt with spring  
tensioned idler to jackshaft and blower.  
295 lb (134 kg)  
325 lb (147 kg)  
– Heavy-duty cast iron, spiral bevel gearbox is  
final drive to blades.  
Torque Requirements  
Bolt Location  
Torque  
• Deck:  
Blade Mounting Bolt  
85-110 ft-lb (115-149 N-m)  
Full floating deck is attached to out-front support  
frame. Deck design allows for bagging or  
mulching.  
Gearbox Mounting Bolts 30-35 ft-lb (41-47 N-m)  
Gearbox Assembly Bolts  
Blade Shear Bolts  
50-55 ft-lb (68-75 N-m)  
80-100 in-lb  
(922-1130 N-cm)  
• Deck Depth:  
– 42 inch Deck: 4 5/8 inches (11.7 cm)  
8
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Setup  
Setup  
WARNING  
Operating a Navigator tractor without an  
approved Exmark front mount attachment  
increases the possibility of operator  
entanglement in drive wheels or forward tip  
over. Entanglement or tip-over could cause  
serious injury or death.  
When operating a Navigator tractor  
without an approved Exmark front mount  
attachment, observe the following:  
Figure 3  
2. Drive shaft  
• Keep feet and clothing away from tires.  
1. Jackshaft  
• Limit operation to minimum required to  
install a different front mount attachment.  
4. 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 4).  
• Minimize speed and use extreme caution.  
• Only operate on a flat level surface.  
• Do Not operate up or down a trailer ramp.  
• Avoid sudden acceleration or deceleration.  
Assemble Deck to Navigator  
Important: Do Not transport Navigator tractor  
without and approved Exmark front mount  
attachment.  
1. Stop engine, wait for all moving parts to stop and  
remove key. Engage parking brake.  
2. Roll the mower deck up to the Navigator tractor  
with the discharge tube down, making sure the  
deck springs are located above the drive wheel  
and below the console on each side.  
3. Raise seat and install drive shaft onto jackshaft  
(see Figure 3)  
Figure 4  
1. Slide the push arm into the deck push arm tube  
2. Secure the push pin arm with lynch pin  
5. 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 5).  
9
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Setup  
Deck Removal  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Raise mower deck up and latch with deck locking  
pins per Raising the Mower Deck to the  
Service Position section in Operation.  
3. Remove hairpins and washers at the top of the  
deck lift assist spring on each side of the unit (see  
Figure 6).  
4. Remove the spring from the spring anchor.  
Repeat for other side of unit.  
Figure 5  
1. Secure PTO guard with clevis pin and hairpin  
5. Un-latch deck from raised position and slowly  
lower deck to ground per Lowering the Mower  
Deck to the Operation Position section in  
Operation.  
6. Release the deck locking pins on each side, raise  
mower deck to the service position and secure  
deck latch onto hook. See Raising the Deck to  
the Service Position section in Operation.  
Note: Deck will become heavier once springs are  
removed from the anchors. Lower deck carefully.  
7. Install springs onto the spring anchor pins under  
the left and right consoles and secure with a  
washer and hairpin (see Figure 6).  
6. Remove lynch pins at front of push arms on both  
sides of the unit (see Figure 4).  
7. Remove hairpin and clevis from both sides of the  
PTO guard (see Figure 5).  
8. Raise seat and disconnect drive shaft using quick  
coupler at jackshaft (see Figure 3).  
9. Pull mower deck forward to remove from unit.  
Important: Do Not transport Navigator  
tractor without an approved Exmark front  
mount attachment.  
Figure 6  
1. Spring anchor pin under console  
2. Secure springs with a washer and hairpin  
3. Slide spring onto spring anchor pin  
8. Un-latch deck from raised position, slowly lower  
deck to ground and lock deck locking pins on  
each side Lowering the Deck to the Operation  
Position section in Operation.  
10  
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Operation  
Product Overview  
Operation  
Adjusting the Cutting Height  
The cutting height of the mower deck is adjusted  
from 1 to 4 inches (2.5 cm to 10.2 cm) in 1/4 inch  
(.63 cm) increments.  
1. Stop the machine and move the speed control  
levers to the neutral position.  
2. Disengage the PTO.  
3. Engage the park brake.  
4. Stop the engine, remove the key and wait for all  
moving parts to stop.  
5. Move cotter pins on four deck support pins to  
proper hole for height of cut desired.  
Figure 7  
1. Cut height adjustment  
2. Caster wheel  
3. Deck lift handle  
Deck Raising and Lowering  
Raising the Mower Deck into Service  
Position  
1. Stop engine, wait for all moving parts to stop and  
remove key. Engage parking brake.  
WARNING  
Incorrectly raising or lowering a mower deck  
can be dangerous. A dropped mower deck  
can result in a serious injury or property  
damage.  
• 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.  
2. Release the deck locking pins on each side  
(Figure 8).  
11  
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Operation  
WARNING  
Operating the mower deck in the raised  
service position can be dangerous. Engaging  
the PTO with a deck in the raised position  
can result in a serious injury or property  
damage.  
Always lower and lock mower deck in the  
operation position before engaging the PTO.  
Lowering the Mower Deck to the  
Operating Position  
1. While firmly holding onto deck lift handle,  
unhook deck latch from tractor section and slowly  
lower deck to ground (see Figure 9).  
Figure 8  
1. Deck lift handle  
2. Rotate the deck locking pin toward the rear and pull  
2. Push deck locking pins inward and rotate forward  
to securely lock deck in lowered position (see  
Figure 8).  
outward to unlock.  
3. Push the deck locking pin in and rotate toward the front  
to lock.  
WARNING  
3. Using deck lift handle, lift deck up and latch in  
“up” position (latch is located at front center of  
seat) (see Figure 9).  
Operating mower without locking pins  
securely latched can result in the mower deck  
folding up unexpectedly. The mower deck  
folding up unexpectedly can cause serious  
injury.  
Always operate mower with locking pins  
securely latched.  
Adjusting Fill Reduction  
System (FRS) Baffles  
The Navigator’s exclusive Fill Reduction System has  
been designed to allow you to reduce the amount of  
clippings collected by varying degrees.  
Figure 9  
1. Secure the deck in  
the raised position by  
securing the deck latch  
onto the hook.  
2. Hook  
Advantages include less frequent emptying of the  
hopper and return of nutrients to the soil.  
Possible Configurations:  
1. Baffles open, standard blades – Maximum  
collection  
2. Baffles closed, standard blades – Partial mulching  
3. Baffles closed, mulch blades – Intermediate  
mulching  
4. Mulch plug installed, mulch blades – Complete  
mulching (requires mulch kit)  
12  
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Operation  
To adjust the FRS baffles:  
1. Stop engine, wait for all moving parts to stop and  
remove key. Engage parking brake.  
2. Remove hair pins and clevis pins from both sides  
of the PTO guard (see Figure 5). Fold guard  
forward.  
3. Loosen nyloc nuts on the rear studs of the FRS  
baffles.  
Figure 11  
1. Baffles shown in closed position  
2. Baffles shown in open position  
Figure 10  
3. Bolt  
4. Washer  
5. Baffles  
1. PTO guard removed for 2. Loosen nyloc nuts  
clarity  
4. Raise deck as stated in Raising the Mower Deck  
to the Service Position section.  
6. Lower deck per Lowering the Mower Deck to  
the Operating Position section.  
5. Remove bolt and washer at the front of each  
of the FRS baffles. Rotate baffles into desired  
position and reinstall bolt and washer.  
7. Snug nyloc nuts on the rear studs of the FRS  
baffles. These nuts may be left slightly loose if  
frequent baffle adjustment is anticipated.  
8. Reinstall PTO guard using clevis pins and hair  
pins removed in step 2.  
13  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could  
seriously injure you or other bystanders.  
Remove the key from the ignition switch,  
engage parking brake, 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).  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change oil in all three gearbox housings. Add oil as needed until level with oil drain plug.  
After the first 50 hours  
• Check the mower blades.  
• Check for loose hardware.  
• Grease the front caster wheel hub.  
• Clean the grass and debris build-up from the cutting deck.  
• Clean the grass build-up from under the deck.  
Before each use or daily  
• Check the condition of the belts.  
• Grease the drive shaft.  
Every 40 hours  
Every 100 hours  
Yearly  
• Change oil in all three gearbox housings. Add oil as needed until level with oil drain plug.  
thereafter  
• Grease the deck flip-up.  
• Grease the pivot arm tubes.  
• Grease the front caster pivots.  
• Lubricate the caster wheel hubs.  
Periodic Maintenance  
3. Inspect blades and sharpen or replace as required.  
4. 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 inch blade bolt that secures the  
blade and blade driver.  
Check Mower Blades  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
5. 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 bolts to  
85-110 ft-lb (115-149 N-m).  
2. Lift deck and secure in raised position as stated  
in section Raising the Mower Deck to the  
Service Position.  
14  
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Maintenance  
Note: Blade driver flats must be aligned with the  
flats on the shaft when installing blade on the  
mower deck.  
Check for Loose Hardware  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
6. Lower the mower deck to the operation position  
(see section Lowering the Mower Deck to the  
Operation Position).  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
WARNING  
Operating a mower deck with loose or  
weakened blade bolts can be dangerous. 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.  
Check Tire Pressures  
Service Interval: Every 40 hours  
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.  
• Replace the blade bolt after striking a  
foreign object.  
• Use only genuine Exmark replacement  
parts.  
• Do Not lubricate the threads of the bolt  
or spindle before assembly.  
Change Gearbox Oil  
Service Interval: After the first 50 hours  
Torque the blade bolt to 85-110 ft-lb  
(115-149 N-m).  
Every 100 hours thereafter  
Torque the shear bolts to 80-100 in-lb  
(922-1130 N-cm).  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Place unit on a level surface.  
3. Remove the gearbox and drive shaft assembly  
from the mower deck. Retain hardware for re-use.  
4. Remove the large oil drain plug on the front of  
each of the three gearbox sections and drain oil  
(Figure 13).  
Figure 12  
1. 1/2-20 x 2 1/4 blade bolt— torque to 85-110 ft-lb  
(115-149 N-m).  
2. Washer  
3. Shear bolts—torque to 80–100 in-lb (922-1130 N-cm)  
4. Blade driver  
5. 1/4-20 nyloc nuts  
Figure 13  
1. Small magnetic plugs  
(front and back)  
3. Small magnetic plug  
(front only)  
2. Large oil drain/fill plug  
15  
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Maintenance  
5. Remove small magnetic plugs and wipe away any  
material accumulated on the plugs.  
6. Apply a Teflon pipe sealant to all small magnetic  
plugs and re-install into the gearbox.  
7. Re-install the gearbox and drive shaft assembly  
to the mower deck.  
8. Fill gearbox with Mobil SHC (synthetic) 75W-90  
gear lube oil until level with oil drain/fill plug.  
Each of the gearbox sections must be filled  
separately.  
Note: Mower deck should remain level to the  
ground when filling gearbox with oil. Do Not fill  
gearbox with deck raised in the service position.  
9. Apply a Teflon pipe sealant to the 3 large oil plugs  
and re-install into the gearbox.  
3. 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.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate fittings with NGLI grade #2  
multi-purpose gun grease.  
Lubricate Caster Wheel Hubs  
Service Interval: Yearly  
Refer to the following chart for fitting locations  
and lubrication schedule.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Lubrication Chart  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
1. Drive  
Shaft  
1
1
3
40 Hours  
2. Front  
Caster  
2
8 Hours  
Wheel Hub  
1
1
4
2
2
100 Hours  
100 Hours  
*Yearly  
3. Deck  
Flip-Up  
Figure 14  
4. Push  
Arm Tubes  
1. Seal guard  
2. Spacer nut with wrench  
flats  
5. Front  
Caster  
Pivots  
*0  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the wheel hub.  
* See step 3 for special lubrication instructions on  
the front caster pivots and the Lubricate Caster  
Wheel Hubs section for special lubrication  
instructions on the front casters wheel hubs.  
4. 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  
16  
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Maintenance  
spacer nuts to the axle. Remove the axle (with  
the other spacer nut still assembled to it) from  
the wheel assembly.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
Caster wheel spacer nuts.  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
7. Insert one bearing, one new seal into the wheel.  
Note: Seals (Exmark PN 103-0063) must be  
replaced.  
8. If the axle assembly has had both spacer nuts  
removed (or broken loose), apply a thread locking  
adhesive to one spacer nut and thread onto the  
axle with the wrench flats facing outward. Do  
Not thread spacer nut all of the way onto the end  
of the axle. Leave approximately 1/8 inch (3 mm)  
from the outer surface of the spacer nut to the  
end of the axle inside the nut.  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
10. With the open end of the wheel facing up, fill  
the area inside the wheel around the axle full of  
NGLI grade #1 multi-purpose grease.  
11. Insert the second bearing and new seal into the  
wheel.  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,  
then re-torque to 20-25 in-lb (2-3 N-m). Make  
sure axle does not extend beyond either nut.  
14. Reinstall the seal guards over the wheel hub and  
insert wheel into caster fork. Reinstall 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.  
Reapply thread locking adhesive.  
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Maintenance  
Adjustments  
Note: Disengage PTO, shut off engine, wait for  
all moving parts to stop, engage parking brake, and  
remove key before servicing, cleaning, or making any  
adjustments to the unit.  
Deck Leveling  
1. Position mower on a flat surface.  
2. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Figure 16  
1. Spring disc washers  
3. Inflate drive tires to 15 psi (103 kPa).  
4. Verify all hairpins are in the 3 inch deck height  
holes with the spacers under the hair pins  
(Figure 15).  
Deck Locking Pin Stop  
Adjustment  
1. Slide deck locking pins in on both sides and rotate  
to lock the deck in the “operation” position.  
2. Loosen the jam nut and turn the stop screw  
clockwise until the locking pins is tight and cannot  
be rotated by hand (Figure 17).  
Figure 15  
Right Hand Side Shown  
1. Hairpin  
2. Spacer  
3. Deck support pin  
5. Shorten/lengthen each deck support pin to obtain  
blade tip height of 3 inches at the front of the  
deck and 3 1/4 inches at the rear of the deck.  
Figure 17  
1. Rotate stop screw clockwise until locking pin is tight,  
then back off 1/2 turn.  
2. Loosen jam nut  
Caster Pivot Bearings  
Pre-load Adjustment  
3. Loosen the stop screw counter clockwise 1/2  
turn and tighten the jam nut  
Remove dust cap from caster and tighten nyloc nut  
until washers are flat. Back the nyloc off 1/4 of a  
turn to properly set the pre-load on the bearings.  
4. Test the locking pin to make sure it slides freely.  
Readjust if necessary.  
Note: If disassembled, make sure the spring washers  
are reinstalled as shown in Figure 16.  
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Maintenance  
Cleaning  
Clean Debris From Cutting  
Deck  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Clean off any oil, debris, or grass build-up on the  
cutting deck, especially under deck belt shields.  
Clean Grass Build-Up Under  
Deck  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Raise mower deck and secure in latched position  
(see Raising the Mower Deck to the Service  
Position section in Operation).  
3. Clean out any grass build-up from underside of  
deck and in discharge chute.  
4. Lower deck to cutting position and lock deck  
locking pins (see Lowering the Mower Deck to  
the Operation Position section in Operation.  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused  
by an empty fuel tank.  
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major  
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.  
Problem  
Uneven cutting height.  
Possible Cause  
1. Blade(s) not sharp.  
Corrective Action  
1. Sharpen the blade(s).  
2. Install new cutting blade(s).  
3. Level mower deck from side-to-side and  
front-to-rear.  
2. Cutting blade(s) is/are bent.  
3. Mower deck is not level.  
4. Underside of mower is dirty.  
5. Tire pressure in drive tires not correct.  
6. Spacers are in wrong location.  
4. Clean the underside of the mower.  
5. Adjust tire pressure in the drive tires.  
6. Position spacers under hairpins.  
7. Tips of adjacent blades are at an uneven  
cutting height. Blades tips should be even  
within 3/16 inch which is approximately  
one blade thickness.  
7. Replace blades, spindles and (or) check  
for damage to mower deck.  
Abnormal vibration.  
Blades Do Not rotate.  
1. Install new cutting blade(s).  
1. Cutting blade(s) is/are bent or unbalanced.  
2. Blade mounting bolt is loose.  
3. Engine mounting bolts are loose.  
4. Engine pulley is damaged.  
5. Blade spindle is bent.  
2. Tighten the blade mounting bolt.  
3. Tighten the engine mounting bolts.  
4. Contact an Authorized Service Dealer.  
5. Contact an Authorized Service Dealer.  
1. PTO belt is worn, loose, or broken.  
1. Check belt tension or replace belt  
2. Connect PTO shaft.  
3. Check belt for damage. Install belt and  
check adjusting shafts and belt guides for  
correct position.  
2. PTO shaft is not connected.  
3. PTO belt is off pulley.  
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Exmark Commercial Turf Equipment  
2Year Limited Warranty  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
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.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
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.  
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.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
2 years*  
• Engine  
* 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.  
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.  
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.  
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 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.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
There are no other express warranties except for engine and  
special emission system coverage.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark mower.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
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.  
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.  
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.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G4500-425  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Model No.  
Serial No.  
© 2009 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-370 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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