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790,000&HigherPartNo.4500-370Rev.A Exmark reserves the right to make changes oradd improvements to its products at any timewithout incurring any obligation to make suchchanges to products manufactured previously. Exmark, or its distributors and dealers, acceptno responsibility for variations which may beevident in the actual specifications of its productsand the statements and descriptions containedin this publication. © 2009—Exmark Mfg. Co., Inc.Contact us at Industrial Park Box 808 Printed in the USA Beatrice, NE 68310 2 All Rights Reserved 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. By following the operating, maintenance, and safety instructions, you will prolong the life of your mower, 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. 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. Figure1 1. Model and serial number location Model No. Serial No. 3 Contents Introduction ........................................................... 3 Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5 Safe OperatingPractices.................................. 5 Safety and Instructional Decals ....................... 7 Specifications ......................................................... 8 Model Numbers .............................................. 8 Systems ........................................................... 8 Dimensions..................................................... 8 Torque Requirements ...................................... 8 Setup ...................................................................... 9 Assemble Deck to Navigator ........................... 9 Deck Removal............................................... 10 Product Overview ................................................ 11 Operation ............................................................. 11 Adjusting the Cutting Height ......................... 11 Deck Raising and Lowering ........................... 11 Adjusting Fill Reduction System (FRS) Baffles....................................................... 12 Maintenance ......................................................... 14 Recommended Maintenance Schedule(s) ........... 14 Periodic Maintenance ....................................... 14 Check Mower Blades ..................................... 14 Check for Loose Hardware ............................ 15 Check Tire Pressures ..................................... 15 Change Gearbox Oil...................................... 15 LubricateGreaseFittings............................... 16 Lubricate Caster Wheel Hubs ........................ 16 Thread Locking Adhesives............................. 17 Adjustments ..................................................... 18 Deck Leveling ............................................... 18 Caster Pivot Bearings Pre-load Adjustment ............................................... 18 Deck Locking Pin Stop Adjustment ............... 18 Cleaning ........................................................... 19 CleanDebrisFromCuttingDeck................... 19 Clean Grass Build-Up Under Deck ................ 19 Troubleshooting ................................................... 20 Safety 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 This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Figure 2 1. Safety alert symbol 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 letterin...