Exmark VIKING HYDRO Manual

VIKINGHYDRO™
SetupInstructions
ForSerialNos.314,000,000&Higher
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
TheengineexhaustfromthisproductcontainschemicalsknowntotheStateofCalifornia
tocausecancer,birthdefects,orotherreproductiveharm.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer
extranet.
DealerPack
Part#DescriptionQty.Use
323-4Screw,HH3/8-16x3/4inch8
3290-357Nut,Whizlock3/8-16inch8Installingthefrontcasterwheels.
107-4543Clamp,Tank2
322-10Screw,HH5/16-18x22
3256-3Washer,5/16Std2
104-8300Nut,Nyloc5/16-18Flg2
Installingthefueltank.
323-6Screw,HH3/8-16x1inch4
3290-357Nut,Whizlock3/8-16inch4
98–5975Washer,SpringDisc4
Installingthehandleassembly.
1-806003Hairpin,Cotter1InstallthePTOengagementlinkage.
1-806003Hairpin,Cotter1
1-808280Pin,Clevis1
3272-5Pin,Cotter3/32x1/2inch1
Installingthespeedcontrolrod.
322-9Screw,HH5/16-18x13/4inch2
3296-29Nut,Nyloc5/16-18inch2
3220-16Nut,Jam3/8-24inchLH2
Installingthewheeldrivelinkages.
1-303287Tie,Cable6Connectingthewireharness.
103-2106Key,ExmarkLogo1
1-603511Key,Standard1
Fillouttheonlinewarrantyregistration
formandplacekeysintoliterature
pack.
©2013—ExmarkMfg.Co.,Inc.
P .O.Box808
Beatrice,NE68310
PartNo.4501-701Rev.A
PrintedintheUSA
AllRightsReserved*4501-701*A

LiteraturePack
Manual,Operator's
Manual,EngineOperator's
UncratingtheUnit
1.Leavingtheunitonthepallet,placetheupperhandle
assemblyandthefueltankattherearofthemachine.
Placethecastersatthefrontoftheunit.
2.Placealengthof4inchx4inch(10cmx10cm)
blockbetweenthefrontofthemowerdeckandthe
pallet.
3.Removetheboltbagfromunderthemowerdeck
beltshield.
4.Refertothepartsmanualtohelpyouidentifyand
locatethepartsandtheirproperposition.
InstallingtheFrontCasterWheels
Installthecasterstothefrontofthedeckusingeight
3/8-16x3/4inchboltsandeight3/8inchwhizlock
nuts.Tightenthelowerfourboltsrst,thenthetopfour.
InstallingtheFuelTank
1.Installthefueltankontopofthefueltanksupport.
Secureeachsideofthetankwithaclamp,5/16-18x
2inchscrew ,washer,and5/16inchnylocnut.
2.Attachthefuelsupplyhosetothebottomtanktting
andsecurewiththeclampprovided.
3.Attachthepurgehosefromtheteeontheengine
(canisteronCAunits)tothetopttingofthefuel
tankasshowninFigure1.Pressthehoseintothe
slotonthetanktoretainit.
Figure1
1.Attachpurgehosetotoptting
InstallingtheHandleAssembly
1.Positionthelowerendofthehandleassemblyon
theoutsideoftheupperrearsectionofthefueltank
andhandlesupport.
2.Installfour3/8-16x1inchbolts,fourspringdisk
washersfromtheoutsidein.Secureusingfour
3/8-16whizlocknutsontheinsideofeachhandle
supportandtightenuntilthespringdiskwashersare
at(Figure2).
Note:Besuretheconeofthespringdiskwasheris
againsttheheadofthebolt.
Figure2
1.Frontoftheunit3.Upperhandle
2.Upperhandlemounting
tab
AttachingtheThrottleCable
1.Routethethrottlecablealongtherightsideofthe
upperhandle,underthefueltanksupport,and
positionthecableontheleftsideoftheengine.
2.Positionthethrottlecontrollever(locatedonthe
console)inthefullthrottleposition.Youwillfeela
detentwhenthethrottleleverispushedtowardsthe
upperendoftheslot.
3.Attachtheinnerwireofthethrottlecabletothetop
holeinthethrottlecontrolleverasshowninFigure3.
4.Loosentheclamp,installthethrottlecableonthe
bottomsideoftheclamp,andpullonthecableto
movethethrottlelinkagetothefullthrottleposition.
Tightenthecableclampscrew .
2

Figure3
1.Throttlecontrollever3.Clamp
2.Throttlecable—Located
onbottomsideofclamp.
4.Chokecable
InstallthePTOEngagement
Linkage
1.Installthebladeengagementlinkagetothebellcrank
ontheLeftHandsideoftheenginedeck.
2.Inserttherodthroughtheholefromtheoutsideand
fastenwithcotterhairpin(Figure4).
Figure4
1.Speedcontrolrod
assembly
3.Bellcrank
2.PTOengagementlinkage
InstallingtheSpeedControlRod
1.Locatethespeedcontrolrodassemblywithayoke
atoneend.
2.Inserttheendofthelinkageoppositetheyokeinto
theendofthespeedcontrolleverlocatedunderneath
thehandleconsolefromtherighthandsideand
fastenwithahairpinfromtheboltbag(Figure4).
3.Connectthelowerendofthespeedcontrollinkage
tothespeedcontrolcranklocatedatthetoprearof
thefueltanksupport.Securewithaclevispinand
3/32x1/2inchcotterpin.
InstallingtheWheelDrive
Linkages
1.Positionthespeedcontrolleverinneutral.
2.Positionthedriveleversinneutralandengagethe
neutrallocklatches(Figure5).
3.Threada3/8-24inchLHjamnut,fromtheboltbag,
ontothelowerendofeachdriveleverlinkage.
4.Identifythelowerballjointsinstalledonthehydro
controlarmweldments.Threadthelowerendof
eachdriveleverlinkageintothelowerballjointuntil
theholeinupperballjointalignswithholeindrive
lever.
5.Installa5/16-18x13/4inchhexcapscrewand
a5/8-18inchnylocnutoneachsideandtighten.
Thiswillgiveanapproximatesettingfordrivelever
linkages.
3

Figure5
RightHandSideofUnitShown
1.Hydrocontrollinkage7.Driveleversinneutral
2.Squareswivel8.5/16-18x13/4inchhex
capscrew
3.Shortcrankarm9.3/8-24inchLHjamnut
4.Driveleverlinkage10.Hydrocontrolarm
weldment
5.5/16-18inchnylocnut11.Lowerballjoint
6.Speedcontrolleverin
neutral
AdjustingtheDriveLeverLinkages
1.Raisetherearofmachineoffoftheground.
CAUTION
Raisingtherearoftheunitforassemblyrelying
solelyonmechanicalorhydraulicjackscouldbe
dangerous.Themechanicalorhydraulicjacks
maynotbeenoughsupportormaymalfunction
allowingtheunittofall,whichcouldcause
injury.
DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstandsor
equivalentsupport.
2.Withtherearofmachineonjackstandsandengine
runningatfullthrottle,disengagetheparkbrake
andmovethespeedcontrollevertothemidway
position.Movetherespectivedriveleverupward
untilitreachestheneutralpositionandengagethe
neutrallocklatches(Figure6).Ifthetirerotatesin
eitherdirection,thelengthofthedriveleverlinkwill
needtobeadjusted.
3.Adjustthelinkagelengthbylooseningthejamnuts
atbothendsofthelinkageandrotatingthelinkage
intheballjoints.Lengthenthelinkageifthetireis
turninginreverseandshortenthelinkageifthetire
iscreepingforward.Tightenthejamnutsatboth
ends.Releaseandre-engagetheneutrallocklatch
checkingthatthetirestops.Continuethisprocess
untilthetirenolongerrotates.
Figure6
4.Makethisadjustmentforbothsides.
InstallingtheParkBrakeLever
1.Installtheparkbrakelevertotheinsideofthepark
brakebracketwiththeleverfacingoutwardusingthe
hardwareinstalledintheparkbrakebracketpivot
(Figure7).
2.Installtheboltfromtheoutsidewiththewasher
undertheheadofthebolt.Installthenylocnutand
tighten.
3.Insertthelinkageintotheholeintheparkbrake
leverformtheoutsideandinstallthehairpin.
4

Figure7
RightHandSideofUnitShown
1.Parkbrakebracket3.Parkbrakelinkage
2.Parkbrakelever
ConnectingWireHarness
1.Routethelong,unattachedwiringharnessleadup
thelefthandsideofthehandle.
2.Connecttheconnectorontheendoftheshorter
leadtothekeyswitch.
3.ConnectthetwoagterminalstotheOPCswitch
inanyorder.
4.Continueroutingthisleaddowntherightsideofthe
handleandconnecttheconnectorontheendtothe
parkbrakeswitch.
5.Fastentheharnesstotheleftsideofhandlewithtwo
smallplasticties.Locateonetieattheupperendof
thehandlenexttotheconsoleandlocateonetieat
thelowerendofthehandleclosetothefueltank
support.
6.Repeatfortherightside.
7.Withtheremainingtwoplasticties,fastenthe
harnesstothetwosmallholesinthechannelunder
theconsole.
CheckingTirePressure
1.Checkthetirepressureinthedrivetires.Proper
inationfordrivetiresis12-14psi(83-97kPa).
2.Adjustifnecessary.
GreasingtheUnit
Note:Theunitisnotgreasedatthefactory.
LubricatettingswithNGLIgrade#2multi-purpose
gungrease.RefertothefollowingchartandFigure8for
ttinglocationsandinitialpumps.
LubricationChart
Fitting
Locations
Initial
Pumps
Numberof
Places
Service
Interval
1.FrontCaster
WheelBearings
122Daily
2.FrontCaster
Pivots
22Daily
3.PTO
Engagement
Bellcrank
11Monthly
4.PumpDrive
IdlerPivot
2140hours
5.PumpControl
Bearings
2240hours
6.MowerDeck
IdlerPivots
2140hours
Number4(PumpDriveIdlerPivot)Locatedunderthe
enginedeck.
Number4and6(IdlerArmPivots)Disassembleand
greaseonceamonthundera“NoLoad”condition.
Figure8
5

ServicingtheEngine
Theengineisshippedwithoil;checkoillevelandif
necessarylltotheappropriatelevel.Exmark4-Cycle
PremiumEngineOilisrecommended.Refertothe
EngineOwner’sManualforanacceptablealternative.
ServicingtheHydraulicOil
Themachineisshippedwithhydraulicoilinthe
reservoir.
1.Runthemachineforapproximately15minutesto
allowanyextraairtopurgeoutofthehydraulic
system.
2.Checkhydraulicreservoirandifnecessaryllthe
reservoirtotheappropriatelevelwithExmark
PremiumHydrooil.
3.Replacehydraulicreservoircapandtightenuntil
snug.DoNotovertighten.
Note:Thebafeislabeled“HOT”and“COLD”.
Theoillevelvarieswiththetemperatureoftheoil.
The“HOT”levelshowsthelevelofoilwhenitisat
225°F(107°C).The“COLD”levelshowsthelevelof
theoilwhenitisat75°F(24°C).Filltotheappropriate
leveldependinguponthetemperatureoftheoil.For
example:Iftheoilisabout150°F(65°C).Filltohalfway
betweenthe“HOT”and“COLD”levels.Iftheoilisat
roomtemperature(about75°F(24°C)),llonlytothe
“COLD”level.
FillingOuttheProduct
Registration
Fillouttheonlinewarrantyregistrationformandplace
keysintoliteraturepack.
6