Exmark Lawn Mower CD42CD User Manual

For Serial Nos.  
510,000 & Higher  
Part No. 103-8614 Rev. A  
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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.  
If mower deck becomes clogged, stop engine and wait for all  
moving parts to stop. Remove spark plug wire(s) or remove key  
before cleaning blockage.  
Keep hands, feet, and clothing away from power driven parts.  
Keep off mower unless seat platform is provided.  
Keep others off mower.  
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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.  
By following the operating, maintenance, and safety instructions, you will prolong  
the life of your equipment, maintain its maximum efficiency, and promote 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 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.  
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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  
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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. Indicates an imminently hazardous situation  
which, if not avoided, WILL result in death or serious injury.  
WARNING: Black lettering / Orange background. Indicates a potentially hazardous situation  
which, if not avoided, COULD result in death or serious injury.  
CAUTION: Black lettering / Yellow background. 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 equipment 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 controls and the proper use of the  
equipment. If the operator(s) or mechanic(s) can not read English, it is the owner’s  
responsibility to explain this material to them.  
1.2.3  
1.2.4  
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.  
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 modify the Navigator cutting deck and only use on approved Exmark  
machines.  
1.3.2  
The use of personal protective equipment, such as (but not limited to) protection for  
the eyes, ears, feet, and head is recommended.  
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.  
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1.3.3  
1.3.4  
While mowing, always wear substantial footwear and long trousers. Do not operate  
equipment when barefoot or when wearing open sandals.  
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.  
1.4 OPERATION  
Although hazard control and accident prevention are partially dependent upon the  
design and configuration of the equipment, these factors are also dependent upon the  
awareness, concern, prudence, and proper training of the personnel involved in the  
operation, transport, maintenance, and storage of the equipment. It is essential that all  
Operator Safety Mechanisms be connected and in operating condition prior to use for  
mowing.  
WARNING  
POTENTIAL HAZARD  
Hands, feet, hair, clothing, or accessories can become  
entangled in rotating parts.  
WHAT CAN HAPPEN  
Contact with rotating parts can cause traumatic amputation  
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, jewelry, or clothing away from  
rotating parts.  
1.4.1  
1.4.2  
Give complete, undivided attention to the job at hand.  
Mow only in daylight or good artificial light, keeping away from holes and hidden  
hazards. NEVER carry passengers.  
1.4.3  
1.4.4  
Use EXTREME caution when backing up. LOOK BEHIND YOU!  
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 guards, shields, or covers. Always have  
safety shields, guards, switches, and other devices in place and in proper working  
condition.  
1.5 MAINTENANCE AND STORAGE  
1.5.1  
1.5.2  
1.5.3  
1.5.4  
Check all bolts frequently to maintain proper tightness.  
Keep all guards, shields, and all safety devices in place and in safe working condition.  
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.  
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  
1.6.3  
Safety signs must be replaced if they are missing or illegible.  
When new components are installed, be sure that current safety signs are affixed to  
the replaced components.  
1.6.4  
New safety signs may be obtained from Exmark Mfg. Co. Inc.  
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1.6.5  
1.6.6  
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.  
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. 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. 1-403005  
PART NO. 103-8798  
LOCATION: Front RH Surface of Front Frame  
LOCATION: On Top of Mower Deck  
LH & RH Sides  
PART NO. 103-8425  
LOCATION: -On Driveshaft  
PART NO. 103-6230  
LOCATION: On Top of Deck,  
Centered on Each Side  
PART NO. 103-8799  
LOCATION: On Top of Front Frame, Near Deck  
Springs  
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2. SPECIFICATIONS  
2.1 MODEL NUMBER: CD42CD; CD48CD  
2.2 DIMENSIONS  
42” Deck  
48” Deck  
Overall Width  
Overall Height  
Overall Length  
Weight  
43.2” (109.7 cm)  
13.1” (33.3 cm)  
37.2” (94.4 cm)  
295 lbs. (134 kg)  
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. (41-47 N-m)  
Gearbox Assembly Bolts....................................................50-55 ft-lbs. (68-75 N-m)  
3. ASSEMBLY INSTRUCTIONS  
3.1 UNCRATE DECK  
a)  
Remove flat hairpins from under front frame and discard. See Figure 1.  
3.2 ASSEMBLE DISCHARGE CHUTE  
a)  
b)  
c)  
Locate the 3 holes at the rear of the mower deck shown in Figure 1 and remove the 3  
#10-24 x 3/4 truss head screws and 3 #10-24 nyloc nuts.  
Assemble the discharge tube to the mower deck as shown using the hardware removed in  
3.2.1., with hinge positioned on top of mower deck.  
Locate the discharge tube spring on the mower deck and hook onto the discharge tube  
spring bracket. See Figure 1.  
FIGURE 1  
DISCHARGE TUBE ASSEMBLY  
3.3 ASSEMBLE DECK TO NAVIGATOR  
a)  
b)  
Stop engine, wait for all moving parts to stop and remove key.  
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.  
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c)  
Raise seat and install drive 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 the unit. See Figure 3.  
FIGURE 3  
PUSH ARM INSTALLATION  
e)  
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 4  
PTO GUARD INSTALLATION  
f)  
Release the deck locking pins on each side, raise mower deck to the service position and  
secure deck latch onto hook. See section 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.  
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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)  
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.  
c)  
Remove hairpins and washers at the top of the deck lift assist spring on each side of the  
unit. See Figure 5.  
d)  
e)  
Remove the spring from the spring anchor. Repeat for other side of unit.  
Un-latch deck from raised position and slowly lower deck to ground per section 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 arms on both sides of the unit. See Figure 3.  
Remove hairpin and clevis from both sides of the PTO guard. See Figure 4.  
Raise seat and disconnect drive shaft using quick coupler at jackshaft. See Figure 2.  
Pull mower deck forward to remove from unit.  
g)  
h)  
i)  
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 ignition 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).  
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4.1DECK 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.  
Always make sure the deck is securely latched in the  
“up” or “down” position.  
b)  
Release the 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 raised service  
position can be dangerous.  
WHAT CAN HAPPEN  
Engaging the PTO with a deck in the 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 the Mower Deck to the Operation Position:  
a)  
While firmly holding onto deck lift handle, unhook deck latch from tractor section  
and slowly lower deck to ground.  
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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  
a) Stop engine, wait for all moving parts to stop, and remove key.  
b) Raise mower deck and secure 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 discharge 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 remove key.  
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 driver  
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 bolts 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.  
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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) Stop engine, wait for all moving parts to stop, and remove key.  
b) Visually inspect machine for any loose hardware or any other possible  
4.2.4 Check tire pressures:  
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) Stop engine, wait for all moving parts to stop, and remove key.  
b) Lubricate fittings with one to two pumps of NGLI grade #2 multi-purpose gun  
grease.  
Refer to the following chart for fitting locations and lubrication schedule.  
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GREASE FITTING LUBRICATION CHART  
FITTING  
LOCATIONS  
INITIAL  
PUMPS  
NO. of  
PLACES  
SERVICE  
INTERVAL  
1. Drive Shaft  
1
1
3
2
40 hours  
8 hours  
2. Front Caster Wheel Hub  
3. Deck Flip-Up  
1
1
*0  
4
2
3
100 hours  
100 hours  
*yearly  
4. Push Arm Tubes  
5. Caster Pivots  
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.  
4.2.6  
Lubricate caster wheel hub:  
Service Interval: Once Yearly  
a)  
Stop engine, wait for all moving parts to stop,  
and remove key.  
b)  
c)  
d)  
Remove caster wheel from caster forks.  
Remove seal guards from the wheel hub.  
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) from the wheel  
assembly.  
FIGURE 8  
CASTER WHEEL ASSEMBLY  
Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
e)  
f)  
Pack the bearings with a NGLI grade #1 multi-purpose grease.  
Insert (1) bearing, (1) new seal into the wheel.  
g)  
NOTE: Seals (Exmark PN 103-0063) must be replaced.  
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 thread 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)  
j)  
Insert the assembled nut and axle into the wheel on the side of the wheel with  
the new seal and bearing.  
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.  
k)  
l)  
Insert the second bearing and new seal into the wheel.  
Apply a thread locking adhesive to the 2nd 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.  
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n)  
c)  
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.  
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)  
b)  
c)  
Stop engine, wait for all moving parts to stop, and remove key.  
Place unit on a level surface.  
Remove the gearbox and drive shaft assembly from the mower deck. Retain  
hardware for re-use.  
d)  
e)  
Remove the large oil drain plug on the front of each of the 3 gearboxes and drain  
oil. See Figure 9.  
Remove small magnetic plugs and wipe away any material accumulated on the  
plugs. See Figure 9.  
FIGURE 9  
GEARBOX OIL DRAIN LOCATIONS  
f)  
Apply a Teflon pipe sealant to all small magnetic plugs and re-install into the  
gearbox.  
g)  
h)  
Re-install the gearbox and drive shaft assembly to the mower deck.  
Fill gearbox with Mobil 1 75W-90 gear lube oil until level with oil drain plug.  
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.  
i)  
Apply a Teflon pipe sealant to the 3 large oil plugs and re-install into the gearbox.  
4.2.8 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type” are  
used on the following fasteners:  
a)  
Caster wheel spacer nuts.  
4.3 ADJUSTMENTS  
IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop, and  
remove key before servicing, cleaning, or making any adjustments to the unit.  
4.3.1 Cutting Height Adjustment:  
a)  
b)  
Stop engine, wait for all moving parts to stop, and remove key.  
Move cotter pins on four deck support pins to proper hole for height of cut  
desired.  
11  
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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  
4.3.3 Caster pivot bearings pre-load adjustment:  
a) 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.  
Note: If disassembled, make sure the spring  
washers are reinstalled as shown in Figure 11.  
FIGURE 11  
CASTER ADJUSTMENT  
4.3.4  
Deck Locking pin stop adjustment:  
a) Slide deck locking pins in on both sides and  
rotate to lock the deck in the “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 Figure 12.  
c) Loosen the stop screw counter clockwise 1/2 turn and tighten the jam nut.  
d) Test the locking pin to make sure it slides freely. Readjust if necessary.  
FIGURE 12  
DECK LOCKING PIN ADJUSTMENT  
12  
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5. PARTS LIST  
5.1 DECK GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
8
9
1-403005  
1-413425  
1-513690  
1-523420  
1-613204  
1-803075  
1-806003  
30-8770  
Danger, Decal........................................2  
Spacer, Deck Support............................4  
Clip, Deck Holdup Rod...........................1  
Bumper..................................................2  
Balljoint..................................................2  
Screw, Truss Head #10-24 x 3/4............14  
Hairpin, Cotter........................................2  
Washer..................................................2  
Key, Machine 1/4 x 1/4 x 1 1/2...............1  
Decal, Blade Bolt Torque .......................2  
Bolt, Blade 1/2-20 x 2 1/4.......................2  
Decal, Danger........................................2  
Bolt, Shear 1/4-20 x 7/8 .........................4  
Pin, Clevis 5/16 x 1 ................................2  
Asm, Discharge Tube ............................1  
Asm, Front Deck Height Adj...................2  
39 322-5  
40 323-11  
323-8  
Screw, HH 5/16-18 x 1........................... 3  
Screw, HH 3/8-16 x 2 1/4 (42”) .............. 2  
Screw, HH 3/8-16 x 1 1/2 (48”) .............. 2  
Screw, HH 3/8-16 x 1 1/4....................... 4  
Screw, HH 3/8-16 x 1 3/4....................... 1  
Screw, HH 1/2-13 x 3 1/2....................... 2  
Nut, Hex 3/8-24...................................... 3  
Setscrew, 3/8-16 x 3/8........................... 1  
Washer, #10 Std.................................... 9  
Screw, HH Machine 10-24 x 5/8............. 1  
Nut, Whizlock 3/8-16 ............................. 6  
Nut, Nyloc #10-24.................................. 15  
Nut, Nyloc 5/16-18................................. 3  
Nut, Nyloc 3/8-16................................... 1  
Nut, Nyloc 3/8-24................................... 1  
Nut, Whizlock 5/16-18 ........................... 4  
Nut, Whizlock 1/2-13 ............................. 2  
Rivet ...................................................... 5  
Decal, Commercial (42")........................ 1  
Decal, Commercial (48")........................ 1  
Spacer (42") .......................................... 2  
Spacer (48") .......................................... 2  
Gearbox,(42") Std.................................. 1  
Gearbox,48 Std...................................... 1  
Asm, Deck W/Decals (42") .................... 1  
41 323-7  
42 323-9  
43 325-14  
44 3219-3  
45V 3247-2  
46 3256-14  
47 3290-134  
48 3290-357  
49 3296-2  
50 3296-29  
51 3296-39  
52 3296-6  
53 32128-20  
54 32128-49  
55 114439  
56 103-9024  
1-403131  
67-7490  
10 68-8340  
11 92-5816  
12 98-5954  
13 99-0283  
14 1-808280  
15 103-9487  
16 109-0321  
17 103-3698-03 Guard, Plenum.......................................1  
18 103-3700  
19109-0322  
109-0323  
Roller, Deck ...........................................2  
Asm, Rear Deck Height Adj. (42”)..........2  
Asm, Rear Deck Height Adj. (48”)..........2  
Asm, Drive Shaft W/Decal .....................1  
Asm, Cross "U" Joint .............................2  
Yoke, Keyed ..........................................1  
Yoke, Quick Disconnect.........................1  
Spacer, Roller........................................2  
Hinge .....................................................1  
20 103-9485  
103-9327  
57 106-5620  
106-5597  
103-9328  
58 103-3460  
103-3387  
103-9329  
21 103-4230  
22 103-4974  
59O 103-9479  
103-9478  
Asm, Deck W/Decals (48")  
1
O
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  
60 103-4209  
103-4207  
Blade, LH (42") Black ............................ 1  
Blade, LH (48") Black ............................ 1  
Blade, RH (42") Red .............................. 1  
Blade, RH (48") Red .............................. 1  
Asm, Gearbox Cover W/Decal (42") ...... 1  
Asm, Gearbox Cover W/Decal (48") ...... 1  
61 103-4210  
103-4208  
62P 103-9497  
28 103-7353  
29 103-7705  
30 103-7994  
31 103-8307  
32Q 103-8363  
33 103-8425  
34 103-8496  
35 103-8610  
36 103-8841  
37 321-2  
Hairpin, Cut Height.................................4  
Driver, Blade..........................................2  
Balljoint..................................................1  
Latch, Deck............................................1  
Asm, Deck Latch....................................1  
Decal, Driveline......................................1  
Nut, Jam 7/8-9 .......................................2  
Stand-Off, 1/2 Hex .................................2  
Spring ....................................................1  
Screw, HH 1/4-20 x 1/2..........................2  
Screw, HH 5/16-18 x 3/4........................7  
103-9496  
P
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  
103-8629  
Pad, Anti Skid (42") ............................... 1  
Pad, Anti Skid (48") ............................... 1  
Pad, Anti Skid (42") ............................... 1  
Pad, Anti Skid (48") ............................... 1  
Nut, Nyloc 1/4-20................................... 4  
Washer, 5/16 SAE................................. 3  
66 103-8667  
103-8630  
67 3296-42  
68 3256-23  
38 322-3  
Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).  
V
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Q
Use Pro-Lock, Nut Type (P/N 1-840022, .5ml tube) on setscrew, item #45.  
Deck assembly includes anti skid pad, item #66.  
Gearbox cover assembly includes anti skid pad, item #62.  
Deck latch assembly includes nyloc nut, item #52.  
Rear deck height adj. assembly includes (1) whizlock nut. Item #48.  
13  
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5.1 DECK GROUP  
14  
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5.2 FRONT FRAME GROUP  
Item Part No.  
Description  
Qty.  
Item Part No.  
Description  
Qty.  
1
2
3
4
5
6
7
1-303334  
1-513810  
1-543508  
1-543509  
1-543511  
1-633508  
1-811010  
Washer, Spring Disk 5/16 ......................2  
Bushing, Flanged...................................4  
Cup, Bearing Tapered Roller .................4  
Cone, Bearing Tapered Roller................4  
Seal, Grease..........................................2  
Washer, Spring Disk..............................6  
Plug .......................................................2  
27 103-8797  
28 103-8798  
29 103-8799  
30 302-19  
31 302-61  
32 322-4  
Decal, Folding Deck............................... 2  
Decal, Danger........................................ 1  
Decal, Spring......................................... 2  
Zerk, 1/4-28 Str...................................... 4  
Zerk, 45° 1/4-28..................................... 4  
Screw, HH 5/16-18 x 7/8........................ 2  
Screw, HH 1/2-13 x 4 3/4....................... 2  
Nut, Jam 3/8-16..................................... 2  
Setscrew, SQH 3/8-16 x 1 ..................... 2  
Washer, 3/4 SAE................................... 2  
Nut, Nyloc 5/16-18................................. 2  
Nut, Nyloc 3/8-16................................... 4  
Nut, Nyloc 1/2-13................................... 2  
Nut, Nyloc 3/4-10................................... 2  
Ring, Retaining...................................... 2  
Rollpin 3/16 x 3/4................................... 2  
Screw, Shoulder 3/8-16 x 1.295............. 2  
33 325-38  
34 3218-3  
35 3243-5  
36 3256-28  
37 3296-29  
38 3296-39  
39 3296-45  
40 3296-51  
41 32120-33  
42 32121-3  
43 614672  
8Q 103-3729-01 Wld, Deck Pivot (RH).............................1  
9Q 103-3732-01 Wld, Deck Pivot (LH) .............................1  
10 103-3772  
11 103-3773  
12 103-4017  
13 103-4118  
14 103-4119  
15 103-9482  
16 103-4284  
17 103-4285  
18 103-4588  
19 103-4882  
20 103-7353  
21 103-7436  
22 103-7448  
23 103-7865  
24 103-7971  
25 103-8504  
26 103-8667  
103-8630  
Plug, Spring Adjuster .............................2  
Shaft, Spring Adjustment .......................2  
Spacer, Front Caster..............................2  
Wld, Deck Lock (LH)..............................1  
Wld, Deck Lock (RH) .............................1  
Asm, Deck Lift Handle W/Decal.............1  
Wld, Spring Tensioner ...........................2  
Mount, Deck Lift Spring..........................2  
Bearing, Roller Straight..........................2  
Cap, Grease ..........................................2  
Pin, Cut Height.......................................2  
Bushing, Deck Support ..........................2  
E-Ring....................................................2  
Wld, Spring Tube...................................2  
Cover, Deck Spring................................2  
Decal, Navigator Model..........................1  
Pad, Anti Skid (42”)................................1  
Pad, Anti Skid (48”)................................1  
44 103-3655-01 Wld, Fork & Spindle............................... 2  
45 103-4324  
Asm, Wheel & Tire 8x3.00-4 Sp............. 2  
Asm, Front Frame W/Decals (42")......... 1  
Asm, Front Frame W/Decals (48")......... 1  
Spring, Extension................................... 2  
Asm, Caster Wheel W/Axle ................... 1  
Asm, Spring Lift Assist........................... 2  
46V 103-9481  
103-9480  
V
47 103-4281  
48 103-9495  
49O 103-4280  
Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).  
V
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Includes frame weldment plus items #7, #13, #14, #19, #21, #25, #37, #38, and Decals.  
Include zerk, item #30.  
Includes (2) nyloc nuts, item #38.  
15  
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5.2 FRONT FRAME GROUP  
16  
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5.3 GEARBOX COMPONENTS FOR 103-3460 & 103-3387  
Item Part No.  
Description  
Qty.  
Item Part No.  
109-0198  
8VR 109-0199  
Description  
Qty.  
1
109-0188  
109-0189  
Asm, Input Pinion 42”.............................1  
Asm, Input Pinion 48”.............................1  
Center Housing W/Plugs........................1  
End Housing W/Plugs & Race ...............2  
Output Shaft, Gear & Brgs (42” LH) ......1  
Output Shaft, Gear & Brgs (48” LH) ......1  
Output Shaft, Gear & Brgs (42” RH)......1  
Output Shaft, Gear & Brgs (48” RH)......1  
Output Cap W/Race...............................2  
Asm, Connector Tube 42” Short.............1  
Asm, Connector Tube 48” Short ............ 1  
Asm, Connector Tube 42” Long............. 1  
Asm, Connector Tube 48” Long............. 1  
Kit, Output Seal ..................................... 2  
Seal, Input ............................................. 1  
O-ring .................................................... 7  
Washer, Cupped.................................... 1  
V-ring..................................................... 1  
Screw, HH 3/8-24 x 1 1/4 Gr8................ 28  
V
2V 109-0190  
3V 109-0191  
4O 109-0192  
109-0200  
109-0201  
V
9
10109-0202  
11 109-0203  
12 109-0204  
13109-0205  
14 93-3987  
109-0193  
5O 109-0194  
109-0195  
O
O
6R 109-0196  
7VR 109-0197  
Exmark red touch up paint (spray paint - P/N 1-850337 - .6 oz liquid bottle - P/N 103-9140).  
V
O
S
Includes o-rings, item #11  
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.  
Does not include screw, item #14.  
17  
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6.  
2-Year Limited Warranty  
Exmark Turf Equipment  
(For units purchased on or after October 1, 2004)  
Conditions and Products Covered  
Owner’s Responsibilities  
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.  
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.  
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.  
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  
Products  
Warranty Period  
2 years  
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.  
All Products (except as noted below)  
All Attachments and Accessories  
Metro 21 Series  
1 year  
1 year  
Belts and Tires  
90 days  
Battery  
Engine*  
1 Year Prorated  
In particular, we shall have no liability or responsibility for:  
Warranty is covered by engine manufacturer  
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.  
*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.  
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.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
Pickup and delivery charges to and from any authorized  
Exmark Service Dealer.  
Any damage or deterioration due to normal use, wear  
and tear, or exposure.  
Cost of regular maintenance service or parts, such as  
filters, fuel, lubricants, tune-up parts, and adjustments.  
Any product or part which has been altered or misused  
or required replacement or repair due to normal wear,  
accidents, or lack of proper maintenance.  
Any repairs necessary due to use of parts, accessories  
or supplies, including gasoline, oil or lubricants,  
incompatible with the turf equipment or other than as  
recommended in the operator's manual or other  
operational instructions provided by Exmark.  
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.  
All warranty work must be performed by an authorized Exmark  
Service Dealer using Exmark approved replacement parts.  
Instructions for Obtaining Warranty Service  
1. Contact any Exmark Service Dealer to arrange service at  
their dealership. To locate a dealer convenient to you,  
may also call 402-223-6375.  
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.  
2. Bring the product and your proof of purchase (sales  
receipt) to the Exmark Service Dealer.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
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  
- 18 -  
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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:  
© 2005 EXMARK MFG. CO. INC.  
INDUSTRIAL PARK BOX 808  
BEATRICE, NE 68310  
PART NO. 103-8614 Rev A.  
(402) 223-6300  
FAX (402) 223-5489  
®
ALL RIGHTS RESERVED  
PRINTED IN U.S.A.  
MFG. CO. INC.  
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