MFG. CO. INC. ® Part No. 109-4823 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.
OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment, and safety instructions for your Exmark OCD01. 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.
TABLE OF CONTENTS 1. SAFETY 1.1 1.2 1.3 1.4 1.5 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 machine 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.
1.3.2 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 ♦ The mower that the OCD01 attaches to produces sound levels in excess of 85 dBA at the operator’s ear when in operation. WHAT CAN HAPPEN ♦ Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss. HOW TO AVOID THE HAZARD ♦ Wear hearing protection when operating this machine. 1.3.
1.5.5 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. 1.5.6 Familiarize yourself with the following safety signs and instruction labels. They are critical to the safe operation of your Exmark commercial mower. PART NO. 1-403005 LOCATION: On Top of the Gate Linkage Assembly PART NO. 109-3595 LOCATION: On Top of the Cable Bracket Assembly 2. SPECIFICATIONS 2.1 MODEL NUMBER: OCD01 3 PART NO.
3. ASSEMBLY INSTRUCTIONS IMPORTANT: Disengage blade, shut off engine, wait for all moving parts to stop, engage parking brake, remove key, and disconnect the wire from the spark plug before servicing, cleaning, or making any adjustments to the unit. 3.1 ASSEMBLY DIAGRAM Item Part No. Description Qty. Item 1 2 3 Part No. Description Qty. 109-3880 Asm, Cable Bracket w/Decal ................... 1 12 109-3603 Asm, Gate Linkage w/Decals ................... 1 3296-29 Nut, Nyloc 5/16-18 .................
3.2 INSTALLING OCD01 TO THE MOWER DECK 3.2.1 Remove discharge chute from deck. For UltraCut Decks: Remove and discard discharge chute and hardware. Decks with serial numbers 669,999 and lower require a flexible discharge chute, kit # 109-3860. The kit is not supplied with the OCD01 accessory and needs to be purchased separately. For Triton Decks: Remove and retain the discharge chute and hardware. 3.2.2 Use Figure 2 to locate the correct mounting holes on the pedal pivot bracket. FIGURE 2 3.2.
3.2.5 Install the cable bracket (item 1) by the foot pedal and leave the hardware loose. Use the correct mounting holes as shown in Figure 5A. FIGURE 5A 3.2.6 FIGURE 5B Install cable. Make sure the nuts are centered as shown in Figure 6. FIGURE 6 3.2.7 Remove the belt cover near the discharge opening. 3.2.8 Route the cable over the left side of the cross-shaft. Remove the seal and run the nuts off the cable. Feed the parts loosely through one hole of the cable hanger strap.
FIGURE 7 3.2.9 If there are protruding welds on the discharge opening, grind them flush. NOTE: Any welds left protruding from the face of the discharge opening could interfere with free operation of the discharge gate. For Triton decks only: Install the blocker plate (item 17) as shown in Figure 8. FIGURE 8 3.2.10 For Triton (series 5) decks 46”, 50”, & 56” and UltraCut (series 4) decks 52” & 60”, cut the discharge gate as shown in Figure 9.
3.2.11 Hook the gate assembly (item16) to the gate linkage assembly (item 12). Install the washer (item15) and fasten with the hairpin (item 14) as shown in Figure 10. FIGURE 10 3.2.12 Mount the gate linkage assembly to the deck. NOTE: The gate is easier to retain on the link assembly if rotated to the “open” position when installing on the deck. For UltraCut deck: a) Install three 1/4-20 self-tapping screws (item 11) into the chute pivot bracket (item 19) as shown in Figure 11A.
FIGURE 11B FIGURE 11C For 46”-60” Triton decks: a) Locate the correct mounting hole as shown in Figure 11D. Install two 5/16-18 x 1 bolts (item 13) and fasten to the deck with washer (item 6) and nyloc nut (item 2). Install 5/16-18 x 3/4 bolt (item 18) from the bottom of the deck, and draw up into hole using the whizlock nut (item 7), see Figure 11E for correct mounting hole location.
FIGURE 11E For 66” & 72” Triton decks: a) Install two 5/16-18 x 1 bolts (item 13) and fasten to the deck with washer (item 6) and nyloc nut (item 2) as shown in Figure 11E. Drill Ø.375 hole in the deck to mate up with the gate linkage assembly (item 12) where shown in Figure 11F. The drilled hole location will avoid under deck baffles on the deck. Install 5/1618 x 3/4 bolt (item 18) from the bottom of the deck, and draw up into hole using the whizlock nut (item 7). FIGURE 11F 3.2.
3.2.14 Slide the bracket that is shown in Figure 6, back and forth to adjust the cable tension. Take up the slack in the cable, but it should not be taut. Tighten hardware to retain the bracket. 3.2.15 When pushing on the spring, there should be a 1/16” gap between the spring and the blocker pivot plate assembly. Fine adjustments can be made by adjusting the cable mounting nuts as shown in Figure 13.
3.2.18 Remove the discharge chute bracket from the discharge chute and retain hardware. Use the appropriate template provided as a guide to cut off the lip. Follow steps a) through d). For UltraCut 52”-60” use template 109-4091. For Triton 46”-56” use template 109-4091. For Trition 60”-72” use template 109-3592. a) Place the template onto the chute lip. FIGURE 16A b) Cut ends as shown on template.
c) Remove remaining lip as shown in Figure 16C. G0945 G0938 FIGURE 16C CHUTE WITH LIP FIGURE 16D CHUTE WITH LIP REMOVED d) Using the existing hardware, reinstall the discharge chute bracket into the flexible discharge chute as shown in Figure 17. For UltraCut Only: Install 5/16-18 x 1-1/4 screw (item 20) and 3 or 4 washers (item 6) in the center hole of the bracket as shown in Figure 17, so that the edge of the chute will be parallel with the deck in the down position.
4. OPERATION IMPORTANT: Always mow with the flexible discharge chute installed and in the down position. DANGER POTENTIAL HAZARD ♦ An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also, contact with the blade could occur. WHAT CAN HAPPEN ♦ Thrown objects or blade contact can cause serious injury or death.
4.1 OPENING THE DISCHARGE GATE 4.1.1 Press the pedal into the forward lock position and the discharge gate will be open. FIGURE 18 4.2 CLOSING THE DISCHARGE GATE 4.2.1 Depress the lower tab to unlock the pedal. Then the discharge gate will then close off the discharge opening.
5. ADJUSTMENTS IMPORTANT: Disengage blade, shut off engine, wait for all moving parts to stop, engage parking brake, remove key, and disconnect the wire from the spark plug before servicing, cleaning, or making any adjustments to the unit. 5.1. Refer back to installation instructions. 6. TROUBLESHOOTING 6.1 GATE DOES NOT LOCK WHEN CLOSED If you try to open the gate with your hands, the gate should be locked into place. If the gate opens, the cable is tensioned too tightly.
7. PARTS LIST 7.1 OCD01 ASSEMBLY Item 1 2 3 4 5 6 7 8 9 10 11 12 Part No. Description Qty. 109-3603 109-3605 109-3880 109-3881-01 109-3884 109-4089-01 109-4097-01 109-4101 322-3 3230-1 3230-2 3230-2 3230-9 3230-9 Asm, Gate Linkage W/Decals...............1 Asm, Gate ............................................1 Asm, Cable Bracket W/Decal ...............1 Bracket, Chute Pivot (Ultra Cut) ...........1 Pedal, Foot...........................................1 Plate, Blocker (Triton).........................
7.2 COMPONENTS FOR 109-3603 ASSEMBLY Item 1 2 3 4 5 Part No. Description 1-403005 98-5954 109-3600 109-3604 109-4093-01 Decal, Danger ......................................1 Decal, Danger ......................................1 Link, Gate ............................................1 Spring, Extension .................................1 Bracket, Link Pivot................................1 Qty. Item 6 7 8 9 10 18 Part No. Description 109-4096 3256-23 3272-5 9266714 9266934 Wld, Gate Crank ........
7.3 COMPONENTS FOR 109-3884 ASSEMBLY Item 1 2 3 4 Part No. Description 109-3608-01 109-3609-01 109-3610 109-3877-01 Bracket, Pedal Pivot .............................1 Pedal, Gate ..........................................1 Rod, Pedal Link ...................................1 Channel, Pedal Link .............................1 Qty. Item 5 6 7 8 19 Part No. Description 109-3878 109-3879-01 3256-23 32112-11 Rod, Pedal Pivot .................................. 2 Latch, Gate Pedal ....................
8. 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.
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SERVICE RECORD Date Description of Work Done Service Done By 22
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