SERVICE BULLETIN ATTN: PARTS AND SERVICE MANAGER. Mandatory Rework-Spindle Nut and Washer

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1 SERVICE BULLETIN ATTN: PARTS AND SERVICE MANAGER DATE: October 18, 2013 NUMBER: SUBJECT: Mandatory Rework-Spindle Nut and Washer UNITS AFFECTED: SITUATION: SOLUTION: Commercial 30 Model: ECKA30 Serial Range Exmark has received reports that the nut on the left side spindle is loosening. When this happens the spindle shaft can spin in the bearings and wear the shaft to a smaller diameter. This will allow the shaft to vibrate and may lead to the blade breaking. Units remaining in inventory must be corrected prior to sale. Rework units as described in the attached instructions. A brief summary is provided below. New Unit- Remove the original nut and gold cupped washer from the left spindle and install the new spring washer, black cupped washer and nut. Tighten the nut to 55 ft-lbs. Used Unit-Using a torque wrench, measure the force needed to loosen the spindle nut. If the force is greater than 35 ft-lbs, rework the machine following the same procedure as for new machines. If torque is 35 ft-lbs or less, the spindle shaft must be removed and inspected for damage. If any damage is found then the spindle assembly, brake pulleys, sprockets, and blade must be replaced. Once assembled, tighten the nut to 55 ft-lbs. Discard all replaced components. BAD WASHER-GOLD COLOR GOOD WASHER-BLACK Exmark Mfg. Co., Inc. Beatrice, NE /

2 SERVICE BULLETIN ATTN: PARTS AND SERVICE MANAGER WARRANTY: Use the service bulletin as the failure code for labor reimbursement. There will be a quick file claim available for all units. Since there is more than one quick file to choose from, be sure to select the quick file that applies to the corrective action taken. New Unit Used, Shaft Is Good Used, Shaft Is Damaged Labor Allowance Failed Code PARTS: Part Description Part Number New Unit Used, No Shaft Damaged Used, Shaft is Damaged Nut X X X Cupped Washer X X X (black) Spring Washer X X X Brake Pulley X Sprocket X Spindle X Spindle Shaft X Blade Adapter X Blade X Blade Bolt X EXMARK MFG. CO., INC. Christie Moore Technical Service Representative ROUTING REQUEST Please initial and properly route Service Manager Mechanics Parts Manager Salesperson Warranty Administrator Exmark Mfg. Co., Inc. Beatrice, NE /

3 SAFETY RECALL 2013 Exmark Commercial 30 Mower Model ECKA30 The left hand mower spindle fasteners can lose the required torque and clamping pressure, causing severe vibration that can result in blade fracture. Contact your Authorized Exmark Dealer as soon as possible to have him inspect the spindle assembly and blade, and to have the new washers and nut assembly installed. Stop using your Exmark Commercial 30 mower immediately. Additional Information Call: Exmark Manufacturing Company Beatrice, NE POST UNTIL (6 months from recall)

4 INSTRUCTIONS FOR USED MACHINES Note: These instructions are for the left spindle. The right spindle is not involved in this rework. 4. Remove the original spindle nut and cupped washer (gold colored) (Fig 02). 1. Remove the 4 screws securing the belt cover and remove the belt cover. 2. Place a deep socket (1/4 inch drive, 1/2 inch deep socket works well) in one of the BBC pulley holes, between the belt and belt guide as shown. This will prevent spindle/blade rotation when you loosen the nut (Fig. 01). Fig. 02 PICT-1234 You will need the following parts to complete the repair: Fig. 01 PICT-1369 Part Description Part Number Nut Cupped Washer (black) Spring Washer You will need to determine if 35 ft-lbs. (47 Nm) or more is needed to loosen the spindle nut. Using a torque wrench set to 35 ft-lbs., loosen the spindle nut. 5. Install the spring washer (cupped side down) (Fig 03). If 35 ft-lbs. (47 Nm) or more is needed to loosen the nut, proceed to step 4. If less than 35 ft-lbs. (47 Nm) is needed to loosen the nut, go to step 12. Fig. 03 PICT-1266 Commercial/Heavy Duty Instruction Sheet 1

5 INSTRUCTIONS FOR USED MACHINES 8. Remove the 1/4 inch drive, 1/2 inch deep socket, and move it to the other end of the belt guide. Insert the socket into one of the pulley holes, between the belt and the belt guide as shown (Fig. 06). 6. Install the cupped washer (black) (Fig 04). Fig. 04 PICT Install the nut (Fig 05). Do not tighten the nut at this time. Fig. 06 PICT Tighten nut to 55 ft-lbs. (75 Nm) (Fig 07). Fig. 05 PICT-1272 Fig PICT-1233 Commercial/Heavy Duty Instruction Sheet

6 INSTRUCTIONS FOR USED MACHINES 10. Remove the 1/4 inch drive, 1/2 inch deep socket (Fig. 08). 12. Loosen the cogged belt tensioner so the belt is slack (Fig 09). Fig. 08 PICT-1384 Fig. 09 PICT Install the belt cover. End of repair for machines with 35 ft-lbs. (47 Nm) or more needed to loosen the nut. 13. Remove the original spindle nut and cupped washer (gold colored) (Fig 10). Fig. 10 PICT-1234 Commercial/Heavy Duty Instruction Sheet 3

7 INSTRUCTIONS FOR USED MACHINES 14. Slide the spindle shaft (with blade attached) down and out of the spindle housing (Fig 11). 16. Reinstall the Spindle shaft with the blade attached. Note: Sliding the shaft through the BBC pulley will be easier if you push the pulley towards the back of the machine to align it with the shaft. Another option is to have an assistant pull the BBC Bail towards the handle just enough to remove the brake pressure from the BBC pulley, but not so far as to tighten the belt. You will need the following parts to complete the repair: Fig. 11 PICT-1240a 15. Inspect the spindle shaft for damage. There should be no damage or wear in the areas indicated (Fig 12). Part Description Part Number Nut Cupped Washer (black) Spring Washer Install the spring washer (cupped side down) (Fig 13). If no damage is found, proceed to step 16. If damage is found go to step 24. Fig. 13 PICT-1266 Fig. 12 PICT-1244a 4 Commercial/Heavy Duty Instruction Sheet

8 INSTRUCTIONS FOR USED MACHINES 18. Install the cupped washer (black) (Fig 14). Fig Remove the 1/4 inch drive, 1/2 inch deep socket, and move it to the other end of the belt guide. Insert the socket into one of the pulley holes, between the belt and the belt guide as shown (Fig. 16). PICT Install the nut (Fig 15). Do not tighten the nut at this time. Fig. 16 PICT Tighten nut to 55 ft-lbs. (75 Nm) (Fig 17). Fig. 15 PICT-1272 Fig. 17 Commercial/Heavy Duty Instruction Sheet PICT

9 INSTRUCTIONS FOR USED MACHINES 22. Remove the 1/4 inch drive, 1/2 inch deep socket (Fig. 18). 24. Remove the belt guide, the left side spindle, and all parts attached to the shaft. 25. Install all parts of the spindle assembly listed below (Fig 19). Note: If the shaft is damaged it will vibrate in the spindle housing and damage other parts of the spindle assembly. Even though the parts may appear to be good, they must be replaced if the spindle shaft is damaged. 23. Install the belt cover. Fig. 18 PICT-1384 End of repair for machines with no damage to spindle shaft. Part Description Part Number Nut Cupped Washer (black) Spring Washer Brake Pulley Sprocket Spindle Spindle Shaft Blade Adapter Blade Blade Bolt Fig. 19 PICT-1257a 6 Commercial/Heavy Duty Instruction Sheet

10 INSTRUCTIONS FOR USED MACHINES 26. Install spindle housing (tighten four mounting screws to 160 in-lbs./18 Nm) 33. Install the cupped washer (black) (Fig 21). 27. Install the spindle shaft in the spindle. 28. Install blade adapter and blade. Tighten blade bolt to 60 ft-lbs. (81 Nm). 29. Install sprocket (side with the round center hole goes down). 30. Install brake pulley (have an assistant pull the BBC bail towards the handle just enough to remove the brake pressure from the BBC pulley, but not so far as to tighten the belt). 31. Install the belt guide Fig. 21 PICT Install the spring washer (cupped side down) (Fig 20). 34. Install the nut (Fig 22). Do not tighten the nut at this time. Fig. 20 PICT-1266 Fig. 22 PICT-1272 Commercial/Heavy Duty Instruction Sheet 7

11 INSTRUCTIONS FOR USED MACHINES 35. Tighten nut to 55 ft-lbs. (75 Nm) (Fig 23). 37. Adjust the cogged belt tensioner so the gap at the spring is between and 0.03 inches (0.13 and 0.76 mm) (Fig 25). Note: If there is a visible gap between the gauge and the spring, tighten the adjusting bolt and the nut until the feeler gauge barely slides freely in and out of the gap. Important: Do not over tighten the adjusting bolt. This could damage the blade-drive belt. Fig. 23 PICT Verify the blades are oriented correctly. They should be approximately 90 degrees difference between them (Fig 24). Fig. 25 PICT Install the belt cover. Fig. 24 DSC Commercial/Heavy Duty Instruction Sheet

12 XXXXXXXX XX, 2013 Dear XXXXXX Model: ECKA30 Serial Number XXXXXXXXX Exmark Commercial 30 Walk Behind Mower Potential Broken Blade Hazard In cooperation with the U.S. Consumer Product Safety Commission (CPSC), Exmark is voluntarily recalling model year 2013 Exmark Commercial 30 Walk Behind Mowers. Our records indicate you may have one of the affected mowers. PRODUCT: 2013 Exmark Commercial 30 Walk Behind Mower Model Number Serial Numbers ECKA The model and serial number plate is in one of these 2 locations. PROBLEM: The mower spindle on the left side has a washer that can deform and allow the spindle to loosen. If the spindle loosens, the blade on the left side may fracture due to the excessive vibration. WHAT TO DO: Do not use your machine until an authorized dealer has made the necessary repairs. To locate an authorized Exmark service dealer near you, access our web site at You may also call the number below to contact Exmark Technical Support for assistance Mon - Fri 8:00-5:00 (CST) Note: Some dealers may choose to service only the products they sell. When using the dealer locator, please call the dealer prior to bringing in your machine. We regret any inconvenience this causes. You are a valued customer and we want to ensure you have a product that is safe to use as intended. If you no longer own this product, please call to update our records and avoid further communication directly to you. Thank You, Exmark Technical Service & Support