Exmark Vikingtm Hydro 4500-355 User Manual

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Page 1

VIKING™HYDRO

ForSerialNos. 790,000&Higher

PartNo.4500-355Rev.A

Page 2

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct containschemicalsknowntotheStateof Californiatocausecancer,birthdefects,or otherreproductiveharm.

Important:Whenthemowerisusedoroperated onanyCaliforniaforest,brushorgrasscovered land,aworkingsparkarrestermustbeattached tothemufer.Ifnot,theoperatorisviolating statelaw,Section4442PublicResourceCode.To acquireasparkarresterforyourunit,seeyour EngineServiceDealer.

ThissparkignitionsystemcomplieswithCanadian ICES-002Cesystèmed’allumageparètincellede vèhiculeestconformeàlanormeNMB-002du Canada

TheenclosedEngineOwner’sManualis suppliedforinformationregardingTheU.S. EnvironmentalProtectionAgency(EPA)and theCaliforniaEmissionControlRegulationof emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit. ShouldthisengineOwner’sManualbecome damagedorillegible,replaceimmediately. Replacementsmaybeorderedthroughthe enginemanufacturer.

Exmarkreservestherighttomakechangesor addimprovementstoitsproductsatanytime withoutincurringanyobligationtomakesuch changestoproductsmanufacturedpreviously. Exmark,oritsdistributorsanddealers,accept noresponsibilityforvariationswhichmaybe evidentintheactualspecicationsofitsproducts andthestatementsanddescriptionscontained inthispublication.

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Page 3

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety instructions,youwillprolongthelifeofyourmower, maintainitsmaximumefciency,andpromotesafe operation.

Ifadditionalinformationisneeded,orshouldyou requiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor.

AllExmarkequipmentdealersanddistributorsare keptinformedofthelatestmethodsofservicing andareequippedtoprovidepromptandefcient serviceintheeldorattheirservicestations.They carryamplestockofservicepartsorcansecurethem promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Page 4

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.....................10

Specications.......................................................13

ModelNumbers............................................13

Systems.........................................................13

Dimensions...................................................14

TorqueRequirements....................................14

ProductOverview................................................15

Operation.............................................................15

Controls........................................................15

Pre-Start........................................................17

OperatingInstructions..................................17

Transporting.................................................19

Maintenance.........................................................20

RecommendedMaintenanceSchedule(s)...........20

PeriodicMaintenance.......................................21

CheckEngineOilLevel.................................21

CheckMowerBlades.....................................21

CheckSafetyInterlockSystem.......................22

CheckforLooseHardware............................22

ServicePre-CleanerElementandAir

Cleaner......................................................23

ChangeEngineOil........................................23

CheckHydraulicOilLevel.............................23

CheckTirePressures.....................................23

CheckConditionOfBelts..............................23

LubricateGreaseFittings...............................24

CheckSparkPlugs.........................................24

ChangeHydraulicSystemFilter.....................24

WheelHub-SlottedNutTorque

Specication..............................................26

ThreadLockingAdhesives.............................26

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................26

Copper-BasedAnti-seize..............................26

DielectricGrease...........................................26

Adjustments.....................................................27

AdjustingtheCuttingHeight.........................27

AdjustingtheAxlePosition............................28

AdjustingtheNumberofSpacersbelow

CasterSupportHub...................................29

AdjustingtheCuttingHeightwithBlade

Spacers......................................................29

PTOEngagementLinkage

Adjustment...............................................30

PTOSafetySwitchAdjustment......................30

EnginetoMowerDeckBelt

Adjustment...............................................31

BladeBrakeAdjustment................................32

BeltGuideAdjustment..................................32

PumpDriveBeltTensionAdjustment............32

HydroDriveLinkageAdjustment..................33

HydroPumpSpringTensionSetting..............35

ParkBrakeAdjustment..................................35

Cleaning...........................................................36

CleanEngineAirCoolingSystem...................36

RemoveEngineShroudsandCleanCooling

Fins...........................................................36

CleanGrassBuild-UpUnderDeck................36

WasteDisposal..............................................36

Troubleshooting...................................................37

Schematics...........................................................39

Page 5

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER, WARNING,orCAUTION.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses, substantialfootwear,longtrousers,andhearing protection.DoNotoperatewhenbarefootor whenwearingopensandals.Longhair,loose clothingorjewelrymaygettangledinmoving parts.

CAUTION

DANGER:Whitelettering/Redbackground. Indicatesanimminentlyhazardoussituationwhich,if notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Y ellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)can notreadEnglishitistheowner’sresponsibilityto explainthismaterialtothem.

Thismachineproducessoundlevelsin excessof85dBAattheoperator’searand cancausehearinglossthroughextended periodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

•Inspecttheareawheretheequipmentistobe usedandremoveallrocks,toys,sticks,wires, bones,andotherforeignobjectswhichcanbe thrownbythemachineandmaycausepersonal injurytotheoperatororbystanders.

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

Page 6

Safety

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen area,whentheengineiscold.Wipeup anygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletely full.Addgasolinetothefueltankuntil thelevelis1/4to1/2inch(6–13mm) belowthebottomofthellerneck.This emptyspaceinthetankallowsgasoline toexpand.

•Neversmokewhenhandlinggasoline, andstayawayfromanopenameor wheregasolinefumesmaybeignitedby spark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine. Neverremovethecapofthefueltankor addfuelwhenengineisrunningorwhen theengineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitegasolinevapors.Areor explosionfromgasolinecanburnyouand othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperator’spresencecontrols, safetyswitches,andshieldsareattachedand functioningproperly .DoNotoperateunlessthey arefunctioningproperly.

Page 7

Safety

Operation

WARNING

Operatingengineparts,especiallythe mufer,becomeextremelyhot.Severeburns canoccuroncontactanddebris,suchas leaves,grass,brush,etc.cancatchre.

•Allowengineparts,especiallythemufer, tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer andenginearea.

•Installandmaintaininworkingordera sparkarresterbeforeusingequipment onforest-covered,grass-covered,or brush-coveredunimprovedland.

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcan killyou.

DoNotrunengineindoorsorinasmall connedareawheredangerouscarbon monoxidefumescancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.

•Neverraisedeckwithbladesrunning.

•Neveroperatethemowerwithdamagedguards, shields,orcovers.Alwayshavesafetyshields, guards,switchesandotherdevicesinplaceandin properworkingcondition.

•Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly .

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Stopengine,waitforallmovingpartstostop, removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor damageandmakerepairsbeforerestarting

andoperatingthemower). –Beforeclearingblockages. –Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling. –Beforedumpingthegrasscatcher. –Beforemakingheightadjustments.

WARNING

Hands,feet,hair,clothing,oraccessoriescan becomeentangledinrotatingparts.Contact withtherotatingpartscancausetraumatic amputationorseverelacerations.

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.

•Keephands,feet,hair,jewelry,orclothing awayfromrotatingparts.

•DONOToperatethemowerwhenpeople, especiallychildren,orpetsareinthearea.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning onslopesaslossoftractionand/ortip-overcould occur.Theoperatorisresponsibleforsafeoperation onslopes.

Page 8

Safety

DANGER

Operatingonwetgrassorsteepslopescan causeslidingandlossofcontrol.Lossof controland/orlossofoperator’sfooting couldresultinafallwithanarmorleg gettingunderthemowerorenginedeck whichmayresultinseriousinjury,deathor drowning.

•Mowacrossslopes,neverupanddown.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan20 degrees.

•Reducespeedanduseextremecaution onslopes.

•Avoidsuddenturnsorrapidspeed changes.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

•Removeormarkobstaclessuchasrocks,tree limbs,etc.fromthemowingarea.Tallgrasscan hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat changetheoperatingangle,asroughterraincould overturnthemachine.

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.

•Keepengineandengineareafreefrom accumulationofgrass,leaves,excessivegrease oroil,andotherdebriswhichcanaccumulate intheseareas.Thesematerialscanbecome combustibleandmayresultinare.

•Letenginecoolbeforestoringanddonotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

•Usecarewhencheckingblades.Wraptheblade(s) orweargloves,andusecautionwhenservicing them.Onlyreplacedamagedblades.Never straightenorweldthem.

•Keephandsandfeetawayfrommovingparts. Ifpossible,donotmakeadjustmentswiththe enginerunning.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas orequivalenttothepartssuppliedasoriginal equipment.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect

Page 9

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbya doctorfamiliarwiththisformofinjuryor gangrenemayresult.

•Makesureallhydraulicuidhoses andlinesareingoodconditionand allhydraulicconnectionsandttings aretightbeforeapplyingpressureto hydraulicsystem.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands, tondhydraulicleaks.

Safety

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrol leversinneutralandshuttingoffthe enginebeforeperforminganyworkon thehydraulicsystem.

Page 10

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

1-303508

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe backingtoexposetheadhesivesurface.Apply onlytoaclean,drysurface.Smoothtoremove anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

1-403005

1-303517

1-323427

36inchDeckUnitsOnly

1-403143

1-413214

98-5954

Page 11

Safety

103-1798

103-2076

103-2103

103-2196

103-2242

Page 12

Safety

116-0404

103-2243

103-4935

103-5626

48inchDeckUnitsOnly

Page 13

Specications

ModelNumbers

SerialNos:790,000andHigher

VH15KA362;VH15KA483;VH17KA362CA;VH17KA483CA

Specications

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•RPM:FullSpeed:3600RPM(NoLoad)

FuelSystem

•Capacity:5.0gal.(18.9L)

•TypeofFuel:Regularunleadedgasoline,87 octaneorhigher.

•FuelFilter:ReplaceableIn-line

•FuelShut-OffValve:1/4turnincrements

SafetyInterlockSystem

Operatormusthavethespeedcontrolleverinneutral andPTOdisengagedtostartengine.Releaseof OperatorPresenceControl(OPC)leverswillcause enginetostopifspeedcontrolleverisnotinneutral and/orPTOisengaged.

Transmission

•TwoHydroGearvariabledisplacementpiston pumpsindependentlycoupledtotwohigh efciencyParkerwheeldrivemotors.

•HydraulicOil:UseExmarkPremiumHydroOil.

•HydraulicOilCapacity:2.4qt.(2.2L)

•HydraulicFilterisreplaceablecartridgetype.

P/N109–4180:25microns,10psibypass (Summeruseabove32°F(0°C))

P/N1–523541:40microns,18psibypass(Winter usebelow32°F(0°C))

•Speeds:

–0-6.2mph(10.0km/hr)forward.

–0-2.2mph(3.5km/hr)reverse.

WheelDriveSystem

DrivewheelsaredirectcoupledtoParker/Rosswheel drivemotorswith1.0inch(25.4mm)taperedshaft.

Tires&Wheels

Steering/BrakeControls

Fingertipdrivecontrolleversprovideindependent speedcontrol,brakingandneutraltoeachdrive wheelformovingforwardorreverse,stoppingand powerturning.

DriveFrontCaster

Pneumatic

(Air-Filled)

Quantity

Tread

Size16x6.50–89x3.50-4

PlyRating

Pressure

TurfMasterSmooth

14psi (97kPa)

SemiPneumatic

Page 14

Specications

CuttingDeck

•CuttingWidth:

–36inchDeck:35.38inches(89.9cm)

–48inchDeck:47.25inches(120.0cm)

•Discharge:Side

•BladeSize:

–36inchDeck:18.00inches(45.7cm)—

Quantity:2

–48inchDeck:16.25inches(41.3cm)—

Quantity:3

•DeckDrive:Manualengagementofbeltwith over-centerlock.Bladebelttensionisadjustable viaturnbuckle.

•BladeBrake:WhenthePTOengagementcontrol ismovedtothedisengagedpositionafriction brakepadstopstherotationoftheblades.

•DeckMounting:Bolteddirectlytoenginedeck.

•DeckDepth:

–36inchDeck:5.0inches(12.7cm)

–48inchDeck:5.0inches(12.7cm)

•CuttingHeightAdjustment:

Adjustsfrom1inch(2.5cm)to41/4inches(10.8 cm)in1/4inch(6.4mm)incrementsbyvarious adjustmentsofcasterspacers,bladespacers,and axleheight.

TreadWidth:(OutsidetoOutsideof Tires,Widthwise)

36inchDeck48inchDeck

35.6inches (90.4cm)

40.4inches (102.6cm)

CurbWeight:

36inchDeck48inchDeck

498lb(226kg)551lb(250kg)

TorqueRequirements

BoltLocation

Blade/CutterHousing SpindleBolt

CasterBracketMounts

MowerDeck/Engine DeckMount

EngineMountingBolts

WheelLugNuts

WheelHubSlottedNutminimum100ft-lbs

WheelMotorMounting Bolts

Torque

75-80ft-lb(102-109N-m)

30-35ft-lb(41-48N-m)

15-20ft-lb(20-27N-m)

90-95ft-lb(122-129N-m)

(136N-m)

30-35ft-lb(41-48N-m)

Dimensions

OverallWidth:

36inchDeck48inchDeck

DeectorUp36.4inches

(92.5cm)

DeectorDown47.0inches

(119.4cm)

OverallLength:

36inchDeck48inchDeck

77.3inches(196.3cm)72.3inches(183.6cm)

OverallHeight:

36inchDeck48inchDeck

43.2inches(109.7cm)43.2inches(109.7cm)

48.1inches (122.2cm)

57.9inches (147.1cm)

Page 15

Operation

ProductOverview

Figure3

1.ECSHandles3.FuelCap

2.Controls4.BladeSpacers

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

OperatorPresenceControl(OPC) Levers

Locatedontheupperhandleassemblydirectlyabove thehandlegrips.

Whentheseleversaredepressed,theOPCsystem sensesthattheoperatorisinthenormaloperator’s position.Whentheleversarereleased,theOPC systemsensesthattheoperatorhasmovedfromthe normaloperatingpositionandwillkilltheengineif eitherthespeedcontrolleverisnotintheneutral positionorthePTOisengaged(seeFigure4).

Figure4

1.OPCLever

2.Rotateneutrallocklatch downwardforneutral lockposition

3.NeutralLockLatch

4.DriveLeverinneutral position

DriveLevers

Locatedoneachsideoftheupperhandleassembly aheadofandbelowthehandlegrips.

Theseleversindividuallycontrolthespeedand directionofeachdrivewheel.Whenthespeedcontrol leverismovedoutoftheneutralpositionandthe neutrallocklatchesaremovedintothedriveposition,

Page 16

Operation

asshowninFigure4,andthedriveleversarereleased, thedrivewheelsareengagedintheforwarddirection.

Squeezingthelefthandand/orrighthandlever causesthelefthandand/orrighthanddrivewheel respectivelytoslowdown,stop,orreverse,depending onhowfareachdriveleveris“squeezed”.Squeezing thedriveleversbeyondtheneutralpositioncauses thedrivewheelstoengageinthereversedirection regardlessofthepositionoftheneutrallocklatches andthespeedcontrollever.

NeutralLockLatch

Locatedattheendofthehandles.

Thepurposeoftheselatchesistoallowtheoperator tolockthedriveleversina"neutral"positionwhere neitherofthedrivewheelsareengagedineithera forwardorreversedirection(seeFigure4).

ParkBrakeLever

Locatedontherightsideoftheunitabovethe hydraulictank.

Thebrakeleverengagestheparkbrakeonthedrive wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe brake.

Whenparkingonasteepslope,thewheelsmustbe chockedorblockedinadditiontothebrakebeing engaged.Theunitmustbetieddownandbrake engagedwhentransporting.

speedandmovingittotherearwilldecreaseengine speed.Movingthethrottleforwardintothedetent isfullposition.

SpeedControlLever

Locatedinmiddleofcontrolconsole.

Thespeedcontrollevercontrolsthemaximum forwardspeedandisinnitelyvariablefromneutral 0–6.2mph(10.0km/hr).

Parkbrakemustbedisengagedtomovespeedcontrol outofneutralorenginewillkill.

“Off-Run”Switch

Locatedonthecontrolconsole.

Turnthekeytothe“Run”positiontoallowthe enginetobestarted.Turnthekeytothe“Off” positiontoshutengineoff.

FuelShut-OffValve

Locatedinthefuellinemidwaybetweenthetank andengine.

Thefuelshut-offvalveisusedtoshutoffthe owoffuelwhenparkinginsideabuilding,during transportationtoandfromthejobsites,andwhen themachinewillnotbeusedforafewdays.

Rotatevalve1/4turnclockwisetoshutfueloff. Rotatevalve1/4turncounterclockwisetoturnfuel on.

Parkbrakemustbedisengagedtomovespeedcontrol outofneutralorenginewillkill.

ChokeControl

Locatedonthefrontleftcornerofthefueltank support.

Chokeisusedtoaidinstartingacoldengine.The chokecontrolispulledouttobeinthe“ON”position andpushedintobeinthe“OFF”position.DoNot runawarmenginewithchokeinthe“ON”position.

ThrottleControl

Locatedontheonthecontrolconsolerightside.

Thethrottleisusedtocontrolenginespeed.Moving thethrottlecontrolforwardwillincreaseengine

DriveWheelReleaseValves

Locatedonthetoprearcornerofthehydrostatic pumps.

Drivewheelreleasevalvesareusedtoreleasethe hydro-staticdrivesystemtoallowthemachinetobe movedbyhandwithouttheenginerunning.

Witha5/8wrench,turnbothvalvesoneturn counterclockwisetoreleasethedrivesystem.

Turnclockwisetoresetthedrivesystem.DoNot

overtighten.

TrackingAdjustmentKnob

Locatedontheright-handsideoftherearofthefuel tanksupport.

Page 17

Operation

Theknobcanbeadjustedsothatmachinewill “track”straightaheadwiththedriveleversreleased.

PTOEngagementControl

Locatedonleftsideofcontrolconsole.

Toengagetheblades,theknobmustbepulled towardtheoperatoruntiltheturnbuckle(attached tothebladeengagementidler)locksover-center.To disengagetheblades,pushtheknobdownuntilthe assistarmcontactsthepinonthedeck.

ParkbrakemustbedisengagedbeforePTOis engagedorenginewillkill.

ColdStartKit

Locatedontherighthandsideofenginedeck,below andslightlyaheadofthehydrocontrolshield.

Thecoldstartkitisusedtoeasethestartingofthe unitincoldweatherorwhentheunithasnotbeen operatedforaperiodoftime.Thecoldstartkit movestheidlerpulleyawayfromthepumpbelt, releasingthetensiononthebeltwhichallowsthe enginetoturnoverwithlessresistance(seeStarting theEnginesectioninOperation).

Pre-Start

Fillfueltank.Forbestresultsuseonlyclean,fresh regulargradeunleadedgasolinewithanoctanerating of87orhigher.Regulargradeleadedgasolinemay alsobeused;however,combustionchamberand cylinderheadwillrequiremorefrequentservice.See EngineOwner’sManual.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

thatthefuellevelrisesabovealevelthatis1/2inch belowthebottomofthellernecktoallowforfuel expansionandpreventfuelspillage.

OperatingInstructions

OpentheFuelShut-OffValve

Rotatethevalve1/4turncounterclockwisetoturn fuelon.

StartingtheEngine

Note:OperatormusthavePTOdisengagedand

speedcontrolleverinneutralpositionwhenstarting theengine.

Lockdriveleversinneutralandengageparkbrake

Note:Acoldweatherstartingkithasbeenaddedfor easeofstartingineithercoldweatherorwhenthe unithasnotbeenrunforaperiodoftime.

•Tousecoldstartkit:

1.Pullsplitringstraightoutthesideoftheunit, andhooktheringoverthelowerfronthydro controlshieldbolt.

2.Startengine.Refertothefollowingguidelines forfurtherstartingsuggestions.

•Toengagepumpdrive(disengagecoldstartkit):

1.Pullchainstraightoutfromthesideofthe unituntilthesplitringcanberemovedfrom thebolt.

2.Slowlyreleasetensiononchain.

1.Pulloutthechokecontrol.Placethethrottle controlmidwaybetweenthe“Slow”and“Fast” positions.Turnthekeyswitchtothe“Run” position.

2.Pullrecoilropetostartengine.Afterengine warmsup,graduallypushinthechokecontrol. DoNotrunwarmenginewiththechokeinthe “ON”position.

Note:Kawasakienginesgenerallyneedtobe “choked”evenwhenwarm.

PTOEngagement

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

DANGER

Therotatingbladesunderthemowerdeck aredangerous.Bladecontactcancause seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower ormowerdeckwhenthebladesareengaged.

Page 18

Operation

DANGER

Anuncovereddischargeopeningwillallow objectstobethrowninanoperator’sor bystander’sdirection.Also,contactwiththe bladecouldoccur.Thrownobjectsorblade contactcancauseseriousinjuryordeath.

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunless thereisagrasscollectionsystemormulch kitinplaceandworkingproperly.

ThePTOswitchengagesthecuttingblades.Besure thatallpersonsareclearofmowerdeckanddischarge areabeforeengagingthePTO .

1.Setthrottleto“MIDW AY”position.

2.PullthePTOengagementknobuptoengage blades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

Note:ParkbrakemustbedisengagedbeforePTOis engagedorenginewillkill.

DisengagingthePTO

transporting,orwhentheunitisparkedinside abuilding.

DrivingtheMachine

DriveLever/NeutralLockLatchOperation

Tolockthedriveleversin“neutrallock”,squeezethe driveleverstothe“neutral”position(DoNotsqueeze thedriveleversallthewaybackasthiswillcausethe drivewheelstogointofullreversedirection).See Figure5position1.Placethumbsontheinnerlobe oftheneutrallocklatchesandrotatethemunder thedriveleversintothe“neutrallock”position.See Figure5position2.Releasethedrivelevers.

CAUTION

Iftheneutrallocklatchesarenotcompletely engagedthedriveleverscouldunexpectedly slipintotheforwarddriveposition.Ifthe driveleversslipintothedrivepositionthe unitcouldlurchforwardandcauseinjuryor propertydamage.

Besurethedriveleversarepasttherollerand securelyseatedatthebottomoftheneutral locklatches.

1.Setthrottleto“MIDW AY”position.

2.PushdownonthePTOengagementknobto disengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Lockdriveleversin“neutral”position.

3.Engagetheparkingbrake.

4.DisengagethePTO.

5.Movespeedcontrollevertoneutral.

6.Placethethrottlemidwaybetweenthe“SLOW” and“FAST”positions.

7.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

8.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

9.Closethefuelshut-offvalvewhenthemachine willnotbeinuseforafewdays,when

Toplacethedriveleversinthe“forward”position, slightlysqueezethedriveleverswhileplacingthumbs ontheouterthumblobeoftheneutrallocklatches (ortheindexngeronthefrontlobe)androtatethem fromunderthedrivelevers.Slowlyandcarefully releasethedrivelevers.SeeFigure5position3.

Toplacethedriveleversinthe“reverse”position, squeezethedriveleverspasttheneutralposition.See Figure5position4.

Page 19

Figure5

1.DriveLeverinneutral position

2.DriveLeverlockedin neutralposition

DrivingForward

1.Releasetheparkingbrake.

3.DriveLeverinforward position

4.DriveLeverinreverse position

Operation

DrivinginReverse

Tomoverearwardinastraightline,squeezedrive leversintothereverseposition.

Toturnleftorright,squeezetherighthanddrivelever toturnleftandthelefthanddrivelevertoturnright.

Tomakea“zeroturn”,squeezeeitherthelefthand ortherighthanddriveleverbackintothereverse positionwhiletheoppositedriveleverisinaforward positionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine,avoid quick,jerkymovementsofthedrivelevers.Movethe driveleverssmoothlyanddeliberately.

Tostop,squeezedriveleversbacktothe“neutral” position.Movetheneutrallocklatchesintothe “neutrallock”positionandreleasedrivelevers.Move thespeedcontrollevertotheneutralposition.

Transporting

2.Withdriveleverslockedin“neutral”,shiftspeed controllevertodesiredforwardspeed.

3.Slowlysqueezeandholdbothdriveleversin theneutralpositionandrotatebothneutrallock latchesfromtheneutrallockpositiontothe forwardposition.

Note:DoNotsqueezebothdriveleversallthe wayback.Thiswillcausethedrivewheelsto engageinthereversedirection.

4.Tomoveforwardinastraightline,smoothly releasebothdriveleverstoengagedrivewheels.

Toturnleftorright,squeezetherighthanddrive levertoturnrightandthelefthanddrivelever toturnleft.

Tomakea“zeroturn”,squeezeeithertheleft handortherighthanddriveleverbackintothe reversepositionwhiletheoppositedriveleverisin aforwardpositionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine, avoidquick,jerkymovementsofthedrivelevers. Movethedriveleverssmoothlyanddeliberately.

Tostop,squeezedriveleversbacktothe“neutral” position.Movetheneutrallocklatchesintothe “neutrallock”positionandreleasedrivelevers. Movethespeedcontrollevertotheneutral position.

TransportingaUnit

WARNING

Loadingthemowerontoatrailerwithout strongenoughorproperlysupportedramps couldbedangerous.Therampscould collapsecausingtheunittofall,whichcould causeinjury.

•Useproperrampsthataresecuredtothe truckortrailer.

•Keepfeetandlegsoutfromunderthe unitwhenloadingandunloading.

•Ifnecessary,useassistancewhenloading .

Besurethefuelshut-offvalveisclosed.

Useaheavydutytrailertotransportthemachine. Engageneutrallocklatchesandparkbrake,then blockwheels.

Securelyfastenthemachinetothetrailerwithstraps, chains,cables,orropes.

DoNotrelysolelyontheparkingbraketoholdthe machineonthetrailer.

Besurethatthetrailerhasallnecessarylightingand markingasrequiredbylawanduseasafetychain.

Page 20

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecould seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch, engageparkingbrake,andpullthewire(s) offthesparkplug(s)beforeyoudoany maintenance.Alsopushthewire(s)aside soitdoesnotaccidentallycontactthespark plug(s).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkwheelhub-slottedtorquespecication.

WARNING

Theenginecanbecomeveryhot.Touching ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheengine area.

Aftertherst250hours

Beforeeachuseordaily

Every25hours

Every40hours

Every80hours

Every100hours

Every160hours

Every500hours

•Changethehydrauliclter.

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Greasethecasterwheelbearings.

•Greasecasterpivots.

•Cleanengineaircoolingsystem(SeeEngineOwner’sManual)

•Cleanthegrassbuild-upfromunderthedeck.

•Servicetheaircleaner.(Mayneedmoreoftenundersevereconditions.SeetheEngine Owner’smanualforadditionalinformation.)

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasethepumpdriveidlerpivot.

•Greasethepumpcontrolbearings.

•Greasethemowerdeckidlerpivot

•Removeengineshroudsandcleancoolingns.

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Checkthesparkplugs.

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Checkwheelhub-slottedtorquespecication.

Monthly

•GreasethePTOengagementbellcrank.

Page 21

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Cleanareaarounddipstick.Removedipstickand wipeoiloff.Reinsertthedipstickandpushitall thewaydownintothetube.DoNotscrewinto place.Removethedipstickandreadtheoillevel.

4.Iftheoillevelislow ,wipeofftheareaaroundthe oilllcap,removecapandlltothe“FULL” markonthedipstick.Useoilasspeciedin EngineOwner’ sManual.DoNotoverll.

Important:DoNotoperatetheenginewiththe oillevelbelowthe“LOW”(or“ADD”)markon thedipstick,oroverthe“FULL”mark.

Maintenance

Figure6

1.Springdiscwasher(conetowardsbolthead)

2.Bladebolttorqueto75-80ft-lb(102-109N-m).

ReplacingtheDischarge

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstated intheCleanGrassBuild-UpUnderDeck procedure.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Re-installtheblades(iftheywereremoved)and torquebladeboltsto75-80ft-lb(102-109N-m). Besurethespringdiscwasherconeisinstalled towardthebolthead(seeFigure6).

Deector

ServiceInterval:Asrequired

DANGER

Anuncovereddischargeopeningcouldallow thelawnmowertothrowobjectsinthe operator’sorbystander’sdirectionandresult inseriousinjury.Also,contactwiththeblade couldoccur.

Neveroperatethelawnmowerunlessyou installamulchplate,dischargedeector,or grasscollectionsystem.

1.Toremoveadamagedorworndischarge deector,liftthelegofthespringwiththeloop outofthenotchinthedischargedeectorand slidetherodoutofthedischargedeector brackets,anddischargedeector.

2.Toinstallnewdischargedeector,orientthe springontherodasshowninFigure7.Slidethe rodthroughthefrontdischargedeectorbracket, dischargedeector,andreardeectorbracket.

Page 22

Maintenance

Figure7

1.Rod4.Mowerdeck

2.Spring5.Dischargedeector

3.Dischargedeector

3.Hookthebentendoftherodaroundthefront dischargedeectorbrackettoretainitfrom slidingout.Placethelegofthespringwiththe loopinthenotchinthedischargedeectorto holdthedischargedeectorinthedownposition (seeFigure7).

Important:Thedischargedeectormustbe springloadedinthedownposition.Liftthe deectoruptotestthatitsnapstothefull downposition.

bracket

6.Assembledview

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

1.Foryoursafety,yourExmarkmowerisequipped withOperatorPresenceControls,referredtoas (OPC).WheneitherthePTOisengaged,or thespeedcontrolleverisnotinneutralandthe operatorremovesbothhandsfromthehandles, themowerenginemuststop.

2.TodetermineiftheOPCisinoperatingcondition, clearareaofbystanders.Runtheengineat one-thirdthrottle,thenwiththedriveleversand neutrallocklatchesinthe“neutrallock”position, movethespeedcontrolleveroutofneutraland releasetheOPClevers–theenginemuststop.

3.Again,runtheengineatone-thirdthrottle,move thespeedcontrollevertoneutral,engagethe PTOandreleasetheOPClevers–theengine muststop.

Note:Parkbrakemustbedisengagedbeforethe speedcontrolleverismovedoutofneutralor PTOisengagedorenginewillkill.

Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

Page 23

Maintenance

ServicePre-CleanerElement andAirCleaner

ServiceInterval:Every25hours—Service

theaircleaner.(May needmoreoftenunder severeconditions.See theEngineOwner’s manualforadditional information.)

1.Stopengine,waitforallmovingpartstostop,and removekeyorsparkplugwire(s).Engageparking brake.

2.SeetheEngineOwner’ sManualforcleaning instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May needmoreoftenunder severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainhoseassemblyislocatedontheleft sideoftheengine.

Placepanundermachinetocatchoil.Removeoil drainplug.Allowoiltodrainandreplaceoildrain plug.Torqueplugto20-24ft-lb(27-33N-m).

4.ReplacetheoillterpertheEngineOwner’s Manual.Cleanaroundoillterandunscrewlter toremove.Beforethenewlterisinstalled, applyathincoatingofoilonthesurfaceofthe rubberseal.Turnlterclockwiseuntilrubberseal contactsthelteradapter,thentightenlteran additional2/3to3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

6.Useoilrecommendedinengineowner’smanual. DoNotoverll.Starttheengineandcheckfor leaks.Stopengineandrecheckoillevel.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanareaaroundhydraulicreservoircapand removecap.Oillevelshouldbetothetopofthe bafeinsidethetank.Ifnot,addoil.UseExmark PremiumHydrooil.Replacehydraulicreservoir capandtightenuntilsnug.DoNotovertighten.

Note:Thebafeislabeled“HOT”and “COLD”.Theoillevelvarieswiththe temperatureoftheoil.The“HOT”levelshows thelevelofoilwhenitisat225°F(107°C).The “COLD”levelshowstheleveloftheoilwhen itisat75°F(24°C).Filltotheappropriatelevel dependinguponthetemperatureoftheoil.For example:Iftheoilisabout150°F(65°C),llto halfwaybetweenthe“HOT”and“COLD”levels. Iftheoilisatroomtemperature(about75°F (24°C)),llonlytothe“COLD”level.

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto12–14psi(83–97kPa).

4.Inatetirestopressuresstatedabove.Measure thecircumferenceofeachdrivetire.Adjusttire pressureswithintheaboverangetotrytomake tirecircumferencesmatchascloselyaspossible.

5.Semi-pneumaticcastertiresDoNotneedtobe inated.

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removethemowerdeckbeltshieldtocheck mowerbladedrivebeltcondition.

3.Lookunderenginedecktocheckthepumpdrive beltcondition.

4.Checkallidlerarmstobesuretheypivotfreely. Disassemble,cleanandgreasepivotbushingsif necessary.

Page 24

Maintenance

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.LubricatettingswithNGLIgrade#2 multi-purposegungrease.

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

1.CasterWheel Bearings

2.CasterPivots

3.PTO Engagement Bellcrank

4.PumpDrive IdlerPivot

5.Pump Control Bearings

6.MowerDeck IdlerPivots

Initial

Pumps

122

Numberof

Places

Service

Interval

Monthly

40hours

SprayLubricantChart(cont'd.)

PivotPoint

1.PTOEngagement UpperBellcrank

NumberofPlaces

ServiceInterval

40hours

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner’s Manual.

Daily

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledinthefuellinebetweenthe fueltankandtheengine.Replacewhennecessary.

ChangeHydraulicSystem Filter

ServiceInterval:Aftertherst250hours

Every500hours/Yearly (whichevercomes rst)thereafter (Every250hours/Yearlyif usingMobil115W50)

Number4IdlerPivot(PumpDrive)Located

underenginedeck

Number4and6(IdlerPivots)Disassembleandgrease

onceamonthundera“NoLoad”condition.

3.Lubricatepivotpointswithaspraypenetrating lubricantasshownintheSprayLubricantChart.

SprayLubricantChart

Note:UseonlyExmarkPartNo.109–4180for

Summeruseabove32°F(0°C)orP/N1-523541for Winterusebelow32°F(0°C)(RefertoTransmission sectioninSpecicationsforlterspecications).

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Carefullycleanareaaroundlter.Itisimportant thatnodirtorcontaminationenterhydraulic system.

3.Unscrewltertoremoveandallowoiltodrain fromreservoir.

Important:Beforereinstallingnewlter,ll itwithExmarkPremiumHydrooilandapply athincoatofoilonthesurfaceoftherubber seal.

Turnlterclockwiseuntilrubbersealcontactsthe lteradapter,thentightenthelteranadditional 2/3to3/4turn.

Page 25

4.FillreservoirasstatedinCheckHydraulicOil Level.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

Maintenance

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

ChangeInterval

500Hours

250Hours

5.Loosenlter1/2turnandallowasmallamount ofoiltoleakfromtheoillter(thisallowsairto bepurgedfromtheoillterandsupplyhosefrom thehydraulicreservoir).Turnlterclockwise untilrubbersealcontactsthelteradapter.Then tightenthelteranadditional2/3to3/4turn.

6.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

7.Ifeitherdrivewheeldoesnotrotate,oneorboth ofthechargepumps(locatedonthetopofthe mainpumpasshowninFigure8)mayhavelost their“prime”.RefertoHydraulicSystemAir Purgesection.

Note:DoNotchangehydraulicsystemoil(except forwhatcanbedrainedwhenchanginglter),unless itisfelttheoilhasbeencontaminatedorbeen extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

Figure8

1.Chargepumpcap2.Loosen11/2turnsonly

1.Stopengineandwaitforallmovingpartstostop. Raisetherearofthemachineupontojackstands highenoughtoraisethedrivewheelsoffthe ground.

2.CheckoillevelasstatedinCheckEngineOil Levelsection.

3.Startengineandmovethrottlecontrolaheadto fullthrottleposition.Movethespeedcontrol levertothemiddlespeedpositionandplacethe driveleversinthe“drive”position.

Ifeitherdrivewheeldoesnotrotate,itispossible toassistthepurgingofthechargepumpby carefullyrotatingthetireintheforwardposition.

HydraulicSystemAirPurge

ServiceInterval:Asrequired

Airmustbepurgedfromthehydraulicsystem whenanyhydrauliccomponents,includingoil lter,areremovedoranyofthehydrauliclinesare disconnected.

Thecriticalareaforpurgingairfromthehydraulic systemisbetweentheoilreservoirandeach chargepumplocatedonthetopofeachvariable displacementpump(Figure8).Airinotherpartsof thehydraulicsystemwillbepurgedthroughnormal operationoncethechargepumpis“primed”.

Note:Itisnecessarytolightlytouchthecharge pumpcapwithyourhandtocheckthepump temperature.Ifthecapistoohottotouch,turn offengine.Thepumpsmaybedamagedifthe pumpbecomestoohot.

Ifeitherdrivewheelstilldoesnotrotatecontinue withstep4.

4.Thoroughlycleantheareaaroundeachofthe chargepumphousings.

5.To“prime”chargepump,loosentwohexsocket headcapscrews(showninFigure8)11/2turns only.Makesureengineisnotrunning.Lift thechargepumphousingupwardandwaitfor asteadyowofoiltoowoutfromunderthe housing.Retightenthecapscrews.Dothisfor bothpumps.

Page 26

Maintenance

Note:Hydraulicreservoircanbepressurizedup

to5psitospeedthisprocess.

6.Ifeitherdrivewheelstilldoesnotrotate,stop andrepeatsteps4and5abovefortherespective pump.Ifwheelsrotateslowly,thesystemmay primeafteradditionalrunning.Checkoillevelas statedinChecktheEngineOilLevelsection.

7.Allowunittorunseveralminutesafterthecharge pumpsare“primed”withdrivesysteminthefull speedposition.CheckoillevelasstatedinCheck theEngineOilLevelsection.

8.Checkhydrodrivelinkageadjustmentasstatedin HydroDriveLinkageAdjustmentsectionin Adjustments.

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningtheslottednutonthewheelmotor taperedshaft:

1.Torquetheslottednutto100ft-lb(136N-m).

•OPCleverhubsandcross-shaft.

Note:Caremustbeusednottobondthe bearing,nexttoeachOPChub,tothecross-shaft whichcouldcausebindingoftheOPCleversand erraticoperation.

•Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing locations:

Betweenthebladedriveandpumpdrivesheavesand enginecrankshaft.

2.Furthertightenthenutuntilthenextsetofslots lineupwiththecrossholeintheshaft.

3.Replacecotterpin.

Note:Donotuseanti-seizecompoundonthewheel hub.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242” or“Fel-Pro,Pro-LockNutType”areusedonthe followingfasteners:

•Pumpsheavesetscrews.

•Squareheadsetscrewsonhydropumpcontrol arms.

•OPCleversetscrews.

•Shoulderboltsinendsofspeedcontrolcrank.

•Sheaveretainingboltinendofenginecrankshaft.

•Fueltankbulkheadttingthreads

Adhesivessuchas“LoctiteRC/609orRC/680”or “Fel-ProPro-LockRetainingIorRetainingII”are usedonthefollowing:

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

Page 27

Maintenance

Adjustments

Note:DisengagePTO,shutoffengine,waitfor allmovingpartstostop,engageparkingbrake,and removekeybeforeservicing,cleaning,ormakingany adjustmentstotheunit.

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted from1inchto41/4inches(2.54cmto11.4cm)in 1/4inch(.64cm)incrementsbyadjustingtheaxle position,numberofspacersbelowthecasterhub, andnumberofspacersbetweenbladeandspindle.

RefertotheCuttingHeightAdjustmenttableand selectacuttingheightrangeinthelefthandcolumn whichcorrespondstotherangeofcuttingheights youwillmostoftenbeusing.Adjustmentswithinthis rangecanthenbemadebyadjustingthenumberof bladespacersbetweenthebladeandthebottomof thespindle(thisisamucheasieradjustmenttomake

thanadjustingaxlepositionandnumberofspacers belowcastersupporthub).

Notethat:

•Forthebestcutanddischarge,placeaminimum oftwospacersbetweenthebladeandthespindle.

•Forhighestqualitycut,placeallfourspacers betweenthebladeandthespindle.

•Ifmulchingkitisinstalled,thehighestqualitycut canbeobtainedwith3spacersbetweentheblade andthespindle(minimumis1foragoodcut).

•Whenmulchingleavesitisbesttohavefewer spacersbetweenbladeandspindle.

Refertothetableandselectdesiredcuttingheight range.RefertoAdjustingtheAxlePosition,

AdjustingtheNumberofSpacersbelowCaster SupportHub,andAdjustingtheCutting HeightwithBladeSpacersandsectionstomake

adjustmentsmakeadjustmenttoobtainspecic cuttingheight.

CuttingHeightAdjustmentT able(1inchto41/4inches(2.5cm-10.8cm))

Cutting

Height

Range

1–2inches

(2.5–5.0cm)A00

11/8–

21/8inches

(2.9–5.4cm)A01

13/8–

23/8inches

(3.5–6.0cm)A10

13/8–

23/8inches

(3.5–6.0cm)B01

15/8–

25/8inches

(4.1–6.7cm)B10

13/4–

23/4inches

(4.4–7.0cm)B11

2–3inches

(5.0–7.6cm)B20

17/8–

27/8inches

(4.8–7.3cm)C11

Axle

Position

(Figure9)

NumberOfSpacers

BelowCaster

SupportHub

1/2 inch

(1.2cm)

3/16

(.48cm)

Numberof1/4inch(.64cm)BladeSpacersBelowSpindle

inch

1inch

(2.5cm)

11/8inch

(2.9cm)

13/8inch

(3.5cm)

13/8inch

(3.5cm)

15/8inch

(4.1cm)

13/4inch

(4.4cm)

2inch

(5.0cm)

17/8inch

(4.8cm)

11/4inch

(3.2cm)

13/8inch

(3.5cm)

15/8inch

(4.1cm)

15/8inch

(4.1cm)

17/8inch

(4.8cm)

2inch

(5.0cm)

21/4inch

(5.7cm)

21/8inch

(5.4cm)

11/2inch

15/8inch

17/8inch

21/8inch

21/4inch

21/2inch

23/8inch

(3.5cm)

(4.1cm)

(4.8cm)

(5.4cm)

(5.7cm)

(6.4cm)

(6.0cm)

13/4inch

(4.4cm)

17/8inch

(4.8cm)

21/8inch

(5.4cm)

21/8inch

(5.4cm)

23/8inch

(6.0cm)

21/2inch

(6.4cm)

23/4inch

(7.0cm)

25/8inch

(6.7cm)

2inch

(5.0cm)

21/8inch

(5.4cm)

23/8inch

(6.0cm)

23/8inch

(6.0cm)

25/8inch

(6.7cm)

23/4inch

(7.0cm)

3inch

(7.6cm)

27/8inch

(7.3cm)

Page 28

Maintenance

CuttingHeightAdjustmentTable(1inchto41/4inches(2.5cm-10.8cm))(cont'd.)

Cutting

Height

Range

21/8–

31/8inches

(5.4–7.9cm)C20

21/4–

31/4inches

(5.7–8.3cm)C21

21/2–

31/2inches

(6.4–8.9cm)C30

23/8–

33/8inches

(6.0–8.6cm)D21

21/2–

31/2inches

(6.4–8.9cm)D30

23/4–

33/4inches

(7.0–9.5cm)D31

3–4inches

(7.6–10.1cm)D40

27/8–

37/8inches

(7.3–9.8cm)E31

31/8– 41/8inches (7.9–10.5cm)E40

31/4– 41/4inches (8.3–10.8cm)E41

Axle

Position

(Figure9)

NumberOfSpacers

BelowCaster

SupportHub

1/2 inch

(1.2cm)

(.48cm)

Numberof1/4inch(.64cm)BladeSpacersBelowSpindle

3/16

inch

21/8inch

(5.4cm)

21/4inch

(5.7cm)

21/2inch

(6.4cm)

23/8inch

(6.0cm)

21/2inch

(6.4cm)

23/4inch

(7.0cm)

3inch

(7.6cm)

27/8inch

(7.3cm)

31/8inch

(7.9cm)

31/4inch

(8.3cm)

23/8inch

(6.0cm)

21/2inch

(6.4cm)

23/4inch

(7.0cm)

25/8inch

(6.7cm)

23/4inch

(7.0cm)

3inch (7.6cm)

31/4inch

(8.3cm)

31/8inch

(7.9cm)

33/8inch

(8.6cm)

31/2inch

(8.9cm)

25/8inch

(6.7cm)

23/4inch

(7.0cm)

3inch

(7.6cm)

27/8inch

(7.3cm)

3inch

(7.6cm)

31/4inch

(8.3cm)

31/2inch

(8.9cm)

33/8inch

(8.6cm)

35/8inch

(9.2cm)

33/4inch

(9.5cm)

27/8inch

(7.3cm)

3inch

(7.6cm)

31/4inch

(8.3cm)

31/8inch

(7.9cm)

31/4inch

(8.3cm)

31/2inch

(8.9cm)

33/4inch

(9.5cm)

35/8inch

(9.2cm)

37/8inch

(9.8cm)

4inch

(10.1cm)

31/8inch

(7.9cm)

31/4inch

(8.3cm)

31/2inch

(8.9cm)

33/8inch

(8.6cm)

31/2inch

(8.9cm)

33/4inch

(9.5cm)

4inch

(10.1cm)

37/8inch

(9.8cm)

41/8inch

(10.5cm)

41/4inch

(10.8cm)

Important:AlwaysadjusttheNumberofSpacersbelowCasterHubtocorrespondtotheAxle Positionasshownintabletoobtainproper“rake”(bladesshouldalwaysbeleveltotheground ortippedslightlydownatthefront).

AdjustingtheAxlePosition

Desiredcuttingheightrangecanbeobtainedby

3.Raisetherearofthemachineupontojackstands andremovethedrivewheels.

adjustingtherearaxleandplacingcasterspacers aboveorbelowthecasterarm(seeFigure9and Figure10alongwiththeCuttingHeightAdjustment Chart).

Toadjustrearaxle:

1.Stopthemachineandmovethedriveleversto theneutrallockposition.

2.DisengagethePTO.

Page 29

Maintenance

CAUTION

Raisingthemowerforserviceormaintenance relyingsolelyonmechanicalorhydraulic jackscouldbedangerous.Themechanicalor hydraulicjacksmaynotbeenoughsupport ormaymalfunctionallowingtheunittofall, whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

4.Loosenbutdonotremovethetoptwobolts oneachhydraulicmotormountingbracket(see Figure9).

5.Removethebottomsetsofhardwareforeach bracket.

6.Repositionthemountingbrackettothedesired heightandreinstallthebottomhardware.

7.Tightenallhardwareandremountdrivewheels.

8.Removejack.

9.Adjustwheeldriveandbrakelinkagesas required(seeBrakeandWheelDriveLinkage Adjustmentsection).

axleholepositionsthebladeswillretainthesame front-to-backtip(rake).

AdjustingtheNumber ofSpacersbelowCaster SupportHub

1.Stopthemachineandmovethedriveleversto theneutrallockposition.

2.DisengagethePTO.

3.Placethedriveleversinthe“parkbrake”position.

4.Pushdownonhandlestoliftfrontcastersoffthe ground.

5.Supportwithjackstands.

6.Remove“quickpin”fromonecasterandremove casterfromhub(seeFigure10).

Figure9

1.PositionA4.PositionD

2.PositionB5.PositionE

3.PositionC

Note:Theaxlepositionsarein1/2inch(1.3cm) incrementsandthelargecasterspacersare1/2 inch(1.3cm)thick.Therefore,byadjustingthe samenumberof1/2inch(1.3cm)casterspacersas

6.AxlePivotBolt-loosen butDoNotremove

Figure10

1.Four1/2inch(127mm) spacers

2.QuickPin4.Castersupport

7.Adjustthenumberof1/2inchspacersbetween bottomofhubandcasteryoketoobtainthe desiredcuttingheightfromtheCuttingHeight AdjustmentTableintheAdjustingtheCutting Heightsection.

8.Installremainingspacersontopofhub.

9.Install“quickpin”.

10.Repeatforothercaster.

3.3/16inch(4.8mm) spacer

AdjustingtheCuttingHeight withBladeSpacers

1.Stopthemachineandmovethedriveleverstothe neutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

Page 30

Maintenance

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Bladesmaybeadjustedforcuttingheightbyusing thefour1/4inch(.64cm)spacersfoundonthe bladespindlebolts(factorysettingistwoabove andtwobelow).Thisallowsa1inch(2.5cm) rangein1/4inch(.64cm)incrementsofcutting heightinanyaxleposition.Thesamenumber ofbladespacersmustbeusedonallbladesto achievealevelcut(twoaboveandtwobelow ,one aboveandthreebelow ,etc.).

6.Raisefrontofdeckandsupportwithjackstands.

7.Holdbladeboltonbottomandloosenspindle nutontop.

8.Adjustnumberofspacersbetweenbottomof spindleandbladeasindicatedintheCutting HeightAdjustmentTableandnotesinthe AdjustingtheCuttingHeightsection.

9.Installunusedspacersbetweentopofspindleand spindlenut.

PTOEngagementLinkage Adjustment

LocatedbetweenthePTOengagementbellcrankand PTOengagementassistarmbeneaththefront,left handcorneroftheenginedeck.

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.WithPTOengaged(leverpulledup,adjustthe linkagelengthtowherethelowerendofthe bellcrankjustclearstheaxlesupportgusset(see Figure12).Makesuretheassistarmisagainstthe rearassistarmstoponthedeck(seeFigure13). Pushtheleverdowntothedisengagedposition. Theassistarmshouldcontactthefrontassistarm stoponthedeck.Ifitdoesnotcontact,readjust sothatthebellcrankisclosertothegusset.

10.T orqueboltto75–80ft-lb(102–109N-m)(see Figure11).

Figure11

1.Springdiscwasher (conetowardsbolthead)

2.Bladebolttorqueto 75–80ft-lb(102–109 N-m)

Figure12

1.ThebellcrankjustclearsthegussetwiththePTO engaged

2.PTOSafetySwitch(locatedbeneaththeenginedeck)

3.Bellcrank

PTOSafetySwitch Adjustment

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.WithPTOdisengagedandassistarmagainstthe frontassistarmstop,adjustthebladesafetyswitch mountingbracket(ifneeded)untilthebellcrank depressestheplungerby1/4inch(.64cm).

Page 31

3.BesurethebellcrankDoesNottouchtheswitch bodyordamagetotheswitchcouldoccur.

4.Retightenswitchmountingbracket.

EnginetoMowerDeckBelt Adjustment

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.EngagePTO.

3.Checkbeltguidesunderrearengineandfront mowerdecktoseethattheyareproperlyset(see BeltGuideAdjustmentsectionforinstructions).

4.Beltmustbetightenoughsoitdoesnot slipduringheavyloadswhilecuttinggrass. Over-tensioningwillreducebeltandspindle bearinglife.Toadjustbelttension,loosenthe 5/16inchwhizlocknutonturnbuckleandrotate theturnbuckle;rotateturnbuckletowardrearof mowertotighten,andtowardfrontofmowerto loosenbelttension(seeFigure13).

Maintenance

Figure13

48inchDeckShownforReferenceOnly

1.PulleylocationforVikingHydro

2.Beltguidemustbemovedtothefrontpositionifthe pulleyismoved(48inchdeckonly)

3.Pulleycanbemovedtothefrontpositiontotightenthe beltwhenthereisnoadjustmentleftintheturnbuckle (48inchdeckonly)

4.Turnbuckle

5.5/16inch(.79cm)minimumengagement

6.5/16inchwhizlocknut

7.RearAssistArmStop

8.AssistArm

9.FrontAssistArmStop

10.Point“A”

For48inchDecks:Ifthereisnoadjustmentleft intheturnbuckleandthebeltisstillloose,therear idlerpulleycanberepositionedinthefronthole (seeFigure13).Thebeltguidelocatednexttothe pulleymustalsoberepositionedinthefronthole whenthepulleyismoved.Theturnbucklewill needtobereadjusted.

Checkbelttensionafterthersthourofoperation andatleasttwiceduringtherst24hoursof operation.Adjustasnecessary.

Note:Afterreadjustingthebelttensioncheck thebeltguideadjustmentasstatedinthe

BeltGuideAdjustmentandBladeBrake Adjustmentsections.

5.Properbelttensionwillrequireabout10lb(4.5 kg)sidepullonbelt,halfwaybetweenpulleys(see Figure13,item10–PointA)todeectbelt1/2 inch(1.3cm).

MowerDeckBeltRoutings:

Figure14

36inchMowerDeck

Page 32

Maintenance

Figure15

48inchMowerDeck

BladeBrakeAdjustment

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.DisengagePTO.

BeltGuideAdjustment

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.EngagethePTO.

3.Checkbeltguideundertheenginedeckforproper adjustment(seeFigure17andFigure18).Adjust asnecessary.

Figure17

36inchBeltGuideLocation

(Viewedfromunderneaththeenginedeck)

3.Makesurethebladebrakepadrestsagainst thesheave.Adjustthespringmountingbolts toproperlyalignthepadonthesheave(see Figure16).

Figure16

ShownwithBladesDisengaged

1.BladeBrakeRod

2.SpringMountingBolts

3.1/8inchto3/16inch (.32–.47cm)

4.Checkthedistancebetweenthespacerandthe nutattheendofthebladebrakerod.The distanceshouldbebetween1/8inch(.32cm)and 3/16inch(.47cm)(seeFigure16).

5.EngagethePTOandchecktomakesurethe bladebrakepadclearsthesheave.

1.11/4inch(3.1cm)3.Endofslot

2.1/4inch(.64cm) clearance

Figure18

48inchBeltGuideLocation

(Viewedfromunderneaththeenginedeck)

1.13/8inch(3.5cm)3.Endofslot

2.1/4inch(.64cm) clearance

PumpDriveBeltTension Adjustment

Self-tensioning-Noadjustmentnecessary.

Page 33

Maintenance

HydroDriveLinkage Adjustment

•AdjustSpeedControlLinkageandNeutralSafety Switch:

1.Stopengineandwaitforallmovingpartsto

stop.Engageparkingbrake.Removekeyor sparkplugwire(s).

2.Movethespeedcontrollever(locatedon

theconsole)tothefullforwardpositionand checktheorientationofthetabsontheends ofthespeedcontrolcrank(seeFigure19). Thesetabsshouldbepointingstraightdown atthe6o’clockpositionorslightlyforward. Adjustthethreadedyokeatthebottomofthe speedcontrollinkage(seeFigure19)untilthe tabsarepositionedcorrectly.

Note:TheOPCleversmustbehelddown andtheparkbrakemustbedisengaged wheneverthespeedcontrolleverismoved outofneutralortheenginewillkill.

3.Squeezetherespectivedriveleveruntilan increasedresistanceisfelt,thisiswhere neutralshouldbe.

Ifthewheelturnswhileholdingthedrive leverinneutral,theneutralcontrollinkages needtobeadjusted.Ifthewheelstopsthen gotostep7.

Figure19

ViewedfromLeftSideofUnit

1.NeutralSafetySwitch3.5/16inch(.76cm)

2.ActuatingT ab

3.Pullthespeedcontrolleverbacktoneutral. Checkthattheneutralsafetyswitchactuating tabhasdepressedtheplungeroftheswitchso thatthereisabout5/16inch(.79cm)between thetabandtheswitch(seeFigure19).If necessary,movetheswitchforeandaft.

•AdjustNeutralControlLinkages:

1.Raisetherearofthemachineupontojack standshighenoughtoraisethedrivewheels offoftheground.

2.Starttheengineandmovethethrottleahead tothefullthrottleposition.Placetheneutral locklatchesinthe“forward”positionas showninFigure4.Releasetheparkbrake andmovethespeedcontrollevertothe “mid-speed”position.

Figure20

ViewedfromLeftSideofUnit

1.NeutralControlLinkage5.SpeedControlLinkage

2.HydroControlLinkage

3.DriveLeverLinkage7.Loosennut

4.SpeedControlCrank

6.Adjusthere-rotateat approximately1/4 turnincrementsand re-check.

8.Yoke

4.Loosenthenutagainsttheneutralcontrol linkageyokeasshowninFigure20.

5.Adjusttheneutralcontrollinkageuntil therespectivedrivewheelstopswhenthe leverispulledagainsttheneutralspring (neutralposition).Turntheadjustingbolt approximately1/4turnclockwiseifthe wheelisturninginreverseorturnthebolt approximately1/4turncounterclockwiseif thewheelisturningforward.Releasethe drivelevertotheforwarddrivepositionand squeezebackintotheneutralposition.Check

Page 34

Maintenance

toseeifthewheelstops.Ifnot,repeatthe aboveadjustmentprocedure.

6.Makethisadjustmentonbothsides.

7.Afteradjustmentsaremadeandthewheels stopwhenthedriveleversareintheneutral position,tightenthenutsagainsttheyokes.

•AdjustHydroControlLinkages:

1.Placethespeedcontrolleverinthe“neutral” position.Thisadjustmentisagainmadewith rearofmachineonjackstandsandengine runningatfullthrottle.OPCleverswillhave tobehelddownandtheparkbrakemustbe disengagedwheneverspeedcontrolleversare movedoutoftheneutralposition.

Note:Theneutrallocklatchesshouldbe “unlocked”andintheforwardposition.

2.Loosenthefrontnutonlefthydrocontrol linkageasshowninFigure20.Turntherear controllinkageadjustingnutcounterclockwise untilwheelrotatesforward.Turntherearnut ofleftcontrollinkageclockwise1/4ofaturn atatime,stoppingtomovethespeedcontrol forwardandbacktoneutral,untilleftwheel stopsrotatingforward.

Turntherearnutanadditional1/2turnand tightenthefrontnutmakingsurenottoput abindonthelinkage.Makesureatpartof linkageisperpendiculartopinpartofswivel (seeFigure21).

Note:Ifinconsistentneutraloccurs, checktobesurebothspringsareproperly tightenedonthespeedcontrolleverunderthe console–especiallytherearpivotspring.

Repeataboveadjustmentsifnecessary.

3.Placethespeedcontrolleverinneutral.Adjust therightsidelinkagebyturningthequicktrack knobcounterclockwiseuntilthetirebeginsto rotateforward.Begintoretightentheknob clockwiseabout1/4turnatatime,stopping tomovethespeedcontrolforwardandback toneutral.Recheckthedrivewheelrotation toseeiffurtheradjustmentisnecessary.

4.Thespringthatkeepstensionontheknob shouldnormallynotneedadjustment. However,ifadjustmentisneeded,adjustto wherelengthofspringisabout1inch(2.5cm) betweenthewashers.Adjustspringlengthby turningnutatfrontofspring.

•DriveLeverLinkageAdjustment:

1.Withrearofmachinestillonjackstandsand enginerunningatfullthrottle,disengage theparkbrakeandmovethespeedcontrol levertothemidwayposition.Movethe respectivedriveleverupwarduntilitreaches theneutralpositionandengageneutrallock latches(Figure22).Ifthetirerotatesineither direction,thelengthofthedriveleverlinkwill needtobeadjusted.

Figure21

1.LeftHydroControlLink (leftsideshown)

2.Frontnut5.Linkageinincorrect

3.Rearnut

4.Linkageisperpendicular topin(correctposition)

position

6.Endviewofswivel

Afteradjustingthelefthydrocontrollinkage, movethespeedcontrollevertothemid-speed positionandthenbacktotheneutralposition. Rechecktheleftdrivewheelrotationtoseeif furtheradjustmentisnecessary-besurethe speedcontrolleverisintheneutralposition.

Figure22

2.Adjustthelinkagelengthbylooseningthejam nutsatbothendsofthelinkageandrotating thelinkageintheballjoints.Lengthenthe linkageifthetireisturninginreverseand

Page 35

shortenthelinkageifthetireiscreeping forward.Tightenthejamnutsatbothends. Releaseandre-engagetheneutrallocklatch checkingthatthetirestops.Continuethis processuntilthetireisatadeadstop.

3.Makethisadjustmentforbothsides.

•TrackingAdjustment:

1.Stopengineandwaitforallmovingpartsto stop.Engageparkingbrake.Raisetherearof themachine,removejackstandsandcarefully lowerthemachinetotheground.(Checkthe drivetirepressureandtirecircumferencesee ChecktheTirePressuressection.)

Maintenance

2.Runtheunitandobservethetrackingona level,smooth,hardsurfacesuchasconcrete orasphalt.

3.Iftheunittrackstoonesideortheother,turn thequicktrackknob.Turntheknobrightto “steer”right;turntheknobleftto“steer”left.

HydroPumpSpringTension Setting

1.Formediumorheavydutydriveconditionssuch asoperationwithasulkyonsteepslopes,ahigher springforcemayberequiredonthehydropump controlarmstopreventthedrivesystemfrom stalling.

2.Foraheavierdrivesetting,relocatethespring anchorlinkstoeitherthe“medium”or“heavy duty”positionsasshowninFigure23.Thespring anchorlinksareattachedtotheupperrearcorner ofthehydrodriveshieldsontheleftandright handsidesofthemachine.

Figure23

1.Heavyduty

2.Mediumduty4.Retainingbolt

3.Standard

ParkBrakeAdjustment

1.Stopengineandwaitforallmovingpartstostop.

2.Disengagetheparkbrake.

3.Removethehairpininthelowerparkbrake linkage.Turnthelinkageintheyokeuntilthereis 3/16inch(.48cm)to1/4inch(.64cm)clearance betweentheparkbraketirebarsandthetireswith theparkbrakedisengaged.Re-installthehairpin.

Note:Inthe“medium”or“heavyduty” positions,thedriveleverforcesattheupper handlewillalsobeincreased.

Page 36

Maintenance

Cleaning

CleanEngineAirCooling System

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.Cleanalldebrisfromengineairintakescreenand fromaroundengineshrouding.

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every80hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.Removekey orsparkplugwire(s).

WasteDisposal

MotorOilDisposal

Engineoilisapollutanttotheenvironment.Dispose ofusedoilatacertiedrecyclingcenteroraccording toyourstateandlocalregulations.

2.Removecoolingshroudsfromengineandclean coolingns.Alsocleandust,dirt,andoilfrom externalsurfacesofenginewhichcancause impropercooling.

3.Makesurecoolingshroudsareproperly reinstalled.Operatingtheenginewithout coolingshroudswillcauseenginedamagedueto overheating.

CleanGrassBuild-UpUnder Deck

ServiceInterval:Beforeeachuseordaily

1.DisengagePTO.

2.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

3.Raisedeckandsupportunitusingjackstandsor equivalentsupport.

4.Cleanoutanygrassbuild-upfromundersideof deckandindischargechute.

Page 37

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Enginewillnotstart,startshard,orfailsto keeprunning.

Enginelosespower.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Thethrottleandchokearenotinthe correctposition.

4.Dirtinfuellter.4.Replacethefuellter.

5.Dirt,water,orstalefuelisinthefuel system.

6.Aircleanerisdirty.

7.Electricalconnectionsarecorroded,loose orfaulty.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

9.Faultysparkplug.

10.Sparkplugwireisnotconnected.

11.PTOisengaged.

12.Speedcontrolleverisnotinneutral position.

13.OPCleversarereleased.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

5.Ventholeinthefuelcapisplugged.

6.Dirtinfuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel system.

2.Openthefuelshutoffvalve.

3.Besurethethrottlecontrolismidway betweenthe“SLOW”and“F AST” positions,andthechokeisinthe“ON” positionforacoldengineorthe“OFF” positionforawarmengine.

5.ContactanAuthorizedServiceDealer.

6.Cleanorreplacetheaircleanerelement.

7.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

9.Clean,adjustorreplacesparkplug.

10.Checkthesparkplugwireconnection.

11.DisengagethePTO.

12.Ensuretheshifterleverisintheneutral position.

13.DepressOPClevers.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.Cleanorreplacethefuelcap.

7.ContactanAuthorizedServiceDealer.

Engineoverheats.

Mowerpullsleftorright(withleversfully forward).

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

1.Trackingneedsadjustment.1.Adjustthetrackingbyturningknobonthe

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

2.Addoiltothecrankcase.

righthydrocontrollinkageinthedirection thatthemowerneedstobeadjustedto. Turntheknobin1/4turnincrements untilthemowertrackscorrectly.

Page 38

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Machinedoesnotdrive.

Unevencuttingheight.

Abnormalvibration.

Bladesdonotrotate.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty .4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

7.Tipsofadjacentbladesareatanuneven cuttingheight.Bladestipsshouldbeeven within3/16inchwhichisapproximately onebladethickness.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

7.Beltisdamaged.7.Installnewbelt.

1.Deckbeltisworn,looseorbroken.1.Installnewdeckbelt.

2.Deckbeltisoffpulley.2.Installdeckpulleyandchecktheidler

2.Changethebelt.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

pulley,idlerarmandspringforcorrect positionandfunction.

Bladesdonotstopwhendisengaged.

1.Bladebrakeisnotadjustedproperly.1.Adjustbladebrake.

2.Beltguideisnotproperlyset2.Adjustbeltguidetoproperposition.

3.PTOengagementisnotproperlyset.3.CheckthePTOengagementposition.

Page 39

Schematics

GREEN

BLACK

RED

BLACK

GREEN

YELLOW

BLUE

ORANGE

BROWN

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

Schematics

WiringDiagram

Page 40

Schematics

Page 41

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 on these products 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.

This warranty applies to Exmark commercial turf equipment sold in the U.S. or Canada. This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer. The warranty period commences upon the date of the original retail purchase.

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine 2 years*

* The Engine warranty is covered by the engine manufacturer. Please refer to the engine manufacturer’s warranty statement that is included in the literature packet.

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized   Exmark Service Dealer.

• Any damage or deterioration due to normal use, wear and   tear, or exposure.

• Cost of regular maintenance service or parts, such as filters,   fuel, lubricants, tune-up parts, and adjustments.

• Any product or part which has been altered or misused or   required replacement or repair due to normal wear,    accidents, or lack of proper maintenance.

• Any repairs necessary due to use of parts, accessories or   supplies, including gasoline, oil or lubricants, incompatible   with the turf equipment or other than as recommended in   the operator's manual or other operational instructions   provided by Exmark.

There are no other express warranties except for engine and special emission system coverage.

All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts.

Instructions for Obtaining Warranty Service

The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service.

Contact any Exmark Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our website at www.exmark.com. U.S. or 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 to an authorized Exmark service dealer within the warranty period. This warranty extends only to turf equipment operated under normal conditions. You must read the operator’s manual. You must also properly service and maintain your Exmark product as described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein. Neither Exmark

nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other    extraordinary repair charges or charges relating to repairs or  replacements outside of normal business hours at the place   of business of the authorized Exmark Service Dealer.

• Rental of like or similar replacement equipment during the   period of any warranty, repair or replacement work.

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that   covered by the terms of this warranty.

• Any claims for lost revenue, lost profit or additional cost as   a result of a claim of breach of warranty.

• Attorney's fees.

No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower.

All implied warranties of merchantability (that the product is fit for ordinary use) and fitness for use (that the product is fit for a particular purpose) are limited to the duration of the express warranty.

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-425

414243

Page 42

Page 43

Page 44

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-F RONT RIDING AC CESSORIES A ND 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

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-355Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark Vikingtm Hydro 4500-355 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual