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.

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 .

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.

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.

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

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.

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