Exmark Vikingtm Hydro, Operator'S Manual

Page 1: ...VIKING HYDRO For Serial Nos 790 000 Higher Part No 4500 355 Rev A ...

Page 2: ...pplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes ...

Page 3: ...tributor 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...

Page 4: ... Plugs 24 Change Hydraulic System Filter 24 Wheel Hub Slotted Nut Torque Specification 26 Thread Locking Adhesives 26 Mobil HTS Grease Or Food Grade Anti seize 26 Copper Based Anti seize 26 Dielectric Grease 26 Adjustments 27 Adjusting the Cutting Height 27 Adjusting the Axle Position 28 Adjusting the Number of Spacers below Caster Support Hub 29 Adjusting the Cutting Height with Blade Spacers 29 ...

Page 5: ... mechanic s can not read English it is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate or service the equipment Local regulations may restrict the age of t...

Page 6: ...during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners m...

Page 7: ...ning or working on the mower After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage parking brake Before refueling Before dumping the grass catcher Before making height adjustments WARNING Hands...

Page 8: ...y Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control Maintenance and Storage Disengage drives lower implement set parking brake stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Keep engine and engine area free from accumulation of grass leaves excess...

Page 9: ...id hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and...

Page 10: ...lled make sure current safety signs are visible New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc 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 Familiarize yourself with the following safety signs and instruction labels They...

Page 11: ...Safety 103 1798 103 2076 103 2103 103 2196 103 2242 11 ...

Page 12: ...Safety 103 2243 103 4935 103 5626 48 inch Deck Units Only 116 0404 12 ...

Page 13: ... levers provide independent speed control braking and neutral to each drive wheel for moving forward or reverse stopping and power turning Transmission Two Hydro Gear variable displacement piston pumps independently coupled to two high efficiency Parker wheel drive motors Hydraulic Oil Use Exmark Premium Hydro Oil Hydraulic Oil Capacity 2 4 qt 2 2 L Hydraulic Filter is replaceable cartridge type P...

Page 14: ...r spacers blade spacers and axle height Dimensions Overall Width 36 inch Deck 48 inch Deck Deflector Up 36 4 inches 92 5 cm 48 1 inches 122 2 cm Deflector Down 47 0 inches 119 4 cm 57 9 inches 147 1 cm Overall Length 36 inch Deck 48 inch Deck 77 3 inches 196 3 cm 72 3 inches 183 6 cm Overall Height 36 inch Deck 48 inch Deck 43 2 inches 109 7 cm 43 2 inches 109 7 cm Tread Width Outside to Outside o...

Page 15: ... system senses that the operator has moved from the normal operating position and will kill the engine if either the speed control lever is not in the neutral position or the PTO is engaged see Figure 4 Figure 4 1 OPC Lever 3 Neutral Lock Latch 2 Rotate neutral lock latch downward for neutral lock position 4 Drive Lever in neutral position Drive Levers Located on each side of the upper handle asse...

Page 16: ... in to be in the OFF position Do Not run a warm engine with choke in the ON position Throttle Control Located on the on the control console right side The throttle is used to control engine speed Moving the throttle control forward will increase engine speed and moving it to the rear will decrease engine speed Moving the throttle forward into the detent is full position Speed Control Lever Located...

Page 17: ...prevent fuel spillage Make sure you understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all the necessary inspection and maintenance steps Operating Instructions Open the Fuel Shut Off Valve Rotate the valve 1 4 turn counterclockwise to turn fuel on Starting the Engine Note Operator must have PTO disengaged and speed co...

Page 18: ...n or other unauthorized persons from starting engine 9 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machine Drive Lever Neutral Lock Latch Operation To lock the drive levers in neutral lock squeeze the drive levers to the neutral position Do Not squeeze the drive levers all the way back a...

Page 19: ...erse To move rearward in a straight line squeeze drive levers into the reverse position To turn left or right squeeze the right hand drive lever to turn left and the left hand drive lever to turn right To make a zero turn squeeze either the left hand or the right hand drive lever back into the reverse position while the opposite drive lever is in a forward position at an equal but opposite speed N...

Page 20: ...ecification After the first 250 hours Change the hydraulic filter Before each use or daily Check the engine oil level Check the mower blades Check the safety interlock system Check for loose hardware Grease the caster wheel bearings Grease caster pivots Clean engine air cooling system See Engine Owner s Manual Clean the grass build up from under the deck Every 25 hours Service the air cleaner May ...

Page 21: ...p Under Deck procedure 3 Inspect blades and sharpen or replace as required 4 Re install the blades if they were removed and torque blade bolts to 75 80 ft lb 102 109 N m Be sure the spring disc washer cone is installed toward the bolt head see Figure 6 Figure 6 1 Spring disc washer cone towards bolt head 2 Blade bolt torque to 75 80 ft lb 102 109 N m Replacing the Discharge Deflector Service Inter...

Page 22: ...OPC is in operating condition clear area of bystanders Run the engine at one third throttle then with the drive levers and neutral lock latches in the neutral lock position move the speed control lever out of neutral and release the OPC levers the engine must stop 3 Again run the engine at one third throttle move the speed control lever to neutral engage the PTO and release the OPC levers the engi...

Page 23: ...op engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean area around hydraulic reservoir cap and remove cap Oil level should be to the top of the baffle inside the tank If not add oil Use Exmark Premium Hydro oil Replace hydraulic reservoir cap and tighten until snug Do Not overtighten Note The baffle is labeled HOT and COLD The oil level varies with the temperature ...

Page 24: ...eck Spark Plugs Service Interval Every 160 hours Remove spark plugs check condition and reset gaps or replace with new plugs See Engine Owner s Manual Change Fuel Filter Service Interval As required A fuel filter is installed in the fuel line between the fuel tank and the engine Replace when necessary Change Hydraulic System Filter Service Interval After the first 250 hours Every 500 hours Yearly ...

Page 25: ...raulic lines are disconnected The critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump Figure 8 Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is primed Figure 8 1 Charge pump cap 2 Loosen 1 1 2 turns only 1 Stop engine and wait for all...

Page 26: ...dhesives Thread locking adhesives such as Loctite 242 or Fel Pro Pro Lock Nut Type are used on the following fasteners Pump sheave setscrews Square head setscrews on hydro pump control arms OPC lever setscrews Shoulder bolts in ends of speed control crank Sheave retaining bolt in end of engine crankshaft Fuel tank bulkhead fitting threads Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro L...

Page 27: ...Refer to the table and select desired cutting height range Refer to Adjusting the Axle Position Adjusting the Number of Spacers below Caster Support Hub and Adjusting the Cutting Height with Blade Spacers and sections to make adjustments make adjustment to obtain specific cutting height Cutting Height Adjustment Table 1 inch to 4 1 4 inches 2 5 cm 10 8 cm Number Of Spacers Below Caster Support Hub...

Page 28: ...m 3 1 2 inch 8 9 cm 3 3 4 inch 9 5 cm 3 4 inches 7 6 10 1 cm D 4 0 3 inch 7 6 cm 3 1 4 inch 8 3 cm 3 1 2 inch 8 9 cm 3 3 4 inch 9 5 cm 4 inch 10 1 cm 2 7 8 3 7 8 inches 7 3 9 8 cm E 3 1 2 7 8 inch 7 3 cm 3 1 8 inch 7 9 cm 3 3 8 inch 8 6 cm 3 5 8 inch 9 2 cm 3 7 8 inch 9 8 cm 3 1 8 4 1 8 inches 7 9 10 5 cm E 4 0 3 1 8 inch 7 9 cm 3 3 8 inch 8 6 cm 3 5 8 inch 9 2 cm 3 7 8 inch 9 8 cm 4 1 8 inch 10 5...

Page 29: ... 3 cm increments and the large caster spacers are 1 2 inch 1 3 cm thick Therefore by adjusting the same number of 1 2 inch 1 3 cm caster spacers as axle hole positions the blades will retain the same front to back tip rake Adjusting the Number of Spacers below Caster Support Hub 1 Stop the machine and move the drive levers to the neutral lock position 2 Disengage the PTO 3 Place the drive levers i...

Page 30: ... 102 109 N m PTO Engagement Linkage Adjustment Located between the PTO engagement bellcrank and PTO engagement assist arm beneath the front left hand corner of the engine deck 1 Stop engine and wait for all moving parts to stop Engage parking brake Remove key or spark plug wire s 2 With PTO engaged lever pulled up adjust the linkage length to where the lower end of the bellcrank just clears the ax...

Page 31: ...d in the front hole see Figure 13 The belt guide located next to the pulley must also be repositioned in the front hole when the pulley is moved The turnbuckle will need to be readjusted Check belt tension after the first hour of operation and at least twice during the first 24 hours of operation Adjust as necessary Note After readjusting the belt tension check the belt guide adjustment as stated ...

Page 32: ...d be between 1 8 inch 32 cm and 3 16 inch 47 cm see Figure 16 5 Engage the PTO and check to make sure the blade brake pad clears the sheave Belt Guide Adjustment 1 Stop engine and wait for all moving parts to stop Engage parking brake Remove key or spark plug wire s 2 Engage the PTO 3 Check belt guide under the engine deck for proper adjustment see Figure 17 and Figure 18 Adjust as necessary Figur...

Page 33: ...ll throttle position Place the neutral lock latches in the forward position as shown in Figure 4 Release the park brake and move the speed control lever to the mid speed position Note The OPC levers must be held down and the park brake must be disengaged whenever the speed control lever is moved out of neutral or the engine will kill 3 Squeeze the respective drive lever until an increased resistan...

Page 34: ...eed control lever to the mid speed position and then back to the neutral position Recheck the left drive wheel rotation to see if further adjustment is necessary be sure the speed control lever is in the neutral position Note If inconsistent neutral occurs check to be sure both springs are properly tightened on the speed control lever under the console especially the rear pivot spring Repeat above...

Page 35: ...ension Setting 1 For medium or heavy duty drive conditions such as operation with a sulky on steep slopes a higher spring force may be required on the hydro pump control arms to prevent the drive system from stalling 2 For a heavier drive setting relocate the spring anchor links to either the medium or heavy duty positions as shown in Figure 23 The spring anchor links are attached to the upper rea...

Page 36: ...ust dirt and oil from external surfaces of engine which can cause improper cooling 3 Make sure cooling shrouds are properly reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Disengage PTO 2 Stop engine and wait for all moving parts to stop Engage parking brake Remove key o...

Page 37: ...with electrical contact cleaner apply dielectric grease and reconnect 8 Relay or switch is defective 8 Contact an Authorized Service Dealer 9 Faulty spark plug 9 Clean adjust or replace spark plug 10 Spark plug wire is not connected 10 Check the spark plug wire connection 11 PTO is engaged 11 Disengage the PTO 12 Speed control lever is not in neutral position 12 Ensure the shifter lever is in the ...

Page 38: ...de thickness 7 Replace blades spindles and or check for damage to mower deck 1 Cutting blade s is are bent or unbalanced 1 Install new cutting blade s 2 Blade mounting bolt is loose 2 Tighten the blade mounting bolt 3 Engine mounting bolts are loose 3 Tighten the engine mounting bolts 4 Loose engine pulley idler pulley or blade pulley 4 Tighten the appropriate pulley 5 Engine pulley is damaged 5 C...

Page 39: ... BLACK GREEN YELLOW BLUE ORANGE BROWN A B C D E F CONNECTORS ARE VIEWED FROM WIRE END N C NORMALLY CLOSED N O NORMALLY OPEN FROM SAFETY INTERLOCK MODULE TRANSMISSION SWITCH N O PTO SWITCH N O OPC SWITCH N O KEY SWITCH ENGINE PARK BRAKE SWITCH N O G006968 39 ...

Page 40: ...Schematics 40 ...

Page 41: ...r Canada customers may also call 402 223 6375 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned t...

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Page 44: ...DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB Place Model No and Serial No Label Here Included in the Literature Pack or Fill i...