VIKING™ HYDRO For Serial Nos. 920,000 & Higher Part No. 4500-693 Rev.
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: The engine in this product is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code (CPRC) Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land as defined in CPRC 4126.
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
Contents Engine to Mower Deck Belt Adjustment ............................................... 31 Blade Brake Adjustment ................................ 32 Belt Guide Adjustment .................................. 33 Pump Drive Belt Tension............................... 33 Hydro Drive Linkage Adjustment .................. 33 Tracking Adjustment ..................................... 36 Hydro Pump Spring Tension Setting .............. 36 Park Brake Adjustment.................................. 36 Cleaning ...
Safety Safety Safety Alert Symbol • This lawn mower meets or exceeds the B71.4 specifications of the American National Standards Institute in effect at the time of production. • • Exmark designed and tested this lawn mower to offer reasonably safe service; however, failure to comply with the following instructions may result in personal injury.
Safety DANGER DANGER In certain conditions gasoline is extremely flammable and vapors are explosive. A fire or explosion from gasoline can burn you, others, and cause property damage. In certain conditions 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. • Fill the fuel tank outdoors on level ground, in an open area, when the engine is cold.
Safety Operation damage and make repairs before restarting and operating the mower). WARNING – Before clearing blockages. Operating engine parts, especially the muffler, become extremely hot. Severe burns can occur on contact and debris, such as leaves, grass, brush, etc. can catch fire. • Allow engine parts, especially the muffler, to cool before touching. • Remove accumulated debris from muffler and engine area.
Safety • Keep engine and engine area free from accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas. These materials can become combustible and may result in a fire. DANGER Operating on wet grass or steep slopes can cause sliding and loss of control. Loss of control and/or loss of operator’s footing could result in a fall with an arm or leg getting under the mower or engine deck which may result in serious injury, death or drowning.
Safety WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. • If equipped, make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels. • Replace all worn, damaged, or missing safety signs. • When replacement components are installed, be sure that current safety signs are affixed to the replaced components. • If an attachment or accessory has been installed, make sure current safety signs are visible.
Safety 103-1798 103-2196 103-2076 103–2242 103-2103 11
Safety 116-0404 103–2243 117–2718 103-4935 103-5626 48 inch Deck Units Only 12
Specifications Specifications Model Numbers Serial Nos: 920,000 and Higher VH16KA362; VH16KA483; VH16KA362CA; VH16KA483CA Systems Transmission Engine • Two Hydro Gear variable displacement piston pumps independently coupled to two high efficiency Parker wheel drive motors. • Engine Specifications: See your Engine Owner’s Manual • Hydraulic Oil: Use Exmark Premium Hydro Oil. • Engine Oil Type: Exmark 4–Cycle Premium Engine Oil • Hydraulic Oil Capacity: 2.4 qt. (2.
Specifications Cutting Deck Tread Width: (Outside to Outside of Tires, Widthwise) • Cutting Width: – 36 inch Deck: 35.38 inches (89.9 cm) – 48 inch Deck: 47.25 inches (120.0 cm) • Discharge: Side • Blade Size: – 36 inch Deck: 18.00 inches (45.7 cm)— Quantity: 2 – 48 inch Deck: 16.25 inches (41.3 cm)— Quantity: 3 • Deck Drive: Manual engagement of belt with over-center lock. Blade belt tension is adjustable via turnbuckle.
Operation Product Overview Operation Note: Determine the left and right sides of the machine from the normal operating position. Controls Operator Presence Control (OPC) Levers Located on the upper handle assembly directly above the handle grips. When these levers are depressed, the OPC system senses that the operator is in the normal operator’s position.
Operation speed and moving it to the rear will decrease engine speed. Moving the throttle forward into the detent is full position. as shown in Figure 4, and the drive levers are released, the drive wheels are engaged in the forward direction. Squeezing the left hand and/or right hand lever causes the left hand and/or right hand drive wheel respectively to slow down, stop, or reverse, depending on how far each drive lever is “squeezed”.
Operation Operating Instructions The knob can be adjusted so that machine will “track” straight ahead with the drive levers released. Open the Fuel Shut-Off Valve PTO Engagement Control Rotate the valve 1/4 turn counterclockwise to turn fuel on. Located on left side of control console. To engage the blades, the knob must be pulled toward the operator until the turnbuckle (attached to the blade engagement idler) locks over-center.
Operation transporting, or when the unit is parked inside a building. DANGER An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also, contact with the blade could occur. Thrown objects or blade contact can cause serious injury or death.
Operation Driving in Reverse 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.
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING WARNING While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders. The engine can become very hot. Touching a hot engine can cause severe burns. Allow the engine to cool completely before service or making repairs around the engine area.
Maintenance Periodic Maintenance Check Engine Oil Level Service Interval: Before each use or daily 1. Stop engine and wait for all moving parts to stop. Make sure unit is on a level surface. 2. Check with engine cold. 3. Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick and push it all the way down into the tube. Do Not screw into place. Remove the dipstick and read the oil level. 4.
Maintenance Check Safety Interlock System Service Interval: Before each use or daily 1. For your safety, your Exmark mower is equipped with Operator Presence Controls, referred to as (OPC). When either the PTO is engaged, or the speed control lever is not in neutral and the operator removes both hands from the handles, the mower engine must stop. 2. To determine if the OPC is in operating condition, clear area of bystanders.
Maintenance Service Air Cleaner 5. Clean around oil fill cap and remove cap. Fill to specified capacity and replace cap. Service Interval: Every 25 hours—Service the foam element. (May need more often under severe conditions. See the Engine Owner’s manual for additional information.) 6. Use oil recommended in the Check Engine Oil Level section. Do Not overfill. Start the engine and check for leaks. Stop engine and recheck oil level. Check Hydraulic Oil Level Every 100 hours—Service the paper element.
Maintenance 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Remove the mower deck belt shield to check mower blade drive belt condition. 3. Look under engine deck to check the pump drive belt condition. 4. Check all idler arms to be sure they pivot freely. Disassemble, clean and grease pivot bushings if necessary. Lubricate Grease Fittings Note: See chart for service intervals. Number 4 Idler Pivot (Pump Drive) Located under engine deck 1.
Maintenance Note: Use only Exmark Part No. 109-4180 for Summer use above 32°F (0°C) or P/N 1-523541 for Winter use below 32°F (0°C) (Refer to Transmission section in Specifications for filter specifications). CAUTION Raising the mower for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury. 1.
Maintenance a steady flow of oil to flow out from under the housing. Retighten the capscrews. Do this for both pumps. Note: Hydraulic reservoir can be pressurized up to 5 psi to speed this process. 6. If either drive wheel still does not rotate, stop and repeat steps 4 and 5 above for the respective pump. If wheels rotate slowly, the system may prime after additional running. Check oil level as stated in Check the Hydraulic Oil Level section. 7.
Maintenance • Sheave retaining bolt in end of engine crankshaft. Torque the slotted nut to 140-155 ft-lb (190-210 N-m). • Fuel tank bulkhead fitting threads Note: Do Not use anti-seize on wheel hub. 1. Remove and discard the cotter pin. Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pro Pro-Lock Retaining I or Retaining II” are used on the following: 2. Torque the slotted nut to 100 ft-lb (136 N-m). • OPC lever hubs and cross-shaft.
Maintenance Adjustments than adjusting axle position and number of spacers below caster support hub). Note: Disengage PTO, shut off engine, wait for all moving parts to stop, engage parking brake, and remove key before servicing, cleaning, or making any adjustments to the unit. Note that: • For the best cut and discharge, place a minimum of two spacers between the blade and the spindle. • For highest quality cut, place all four spacers between the blade and the spindle.
Maintenance Cutting Height Adjustment Table (1 inch to 4 1/4 inches (2.5 cm-10.8 cm)) (cont'd.) Cutting Height Range Axle Position (Figure 11) Number Of Spacers Below Caster Support Hub 1/2 inch (1.2 cm) 3/16 inch (.48 cm) Number of 1/4 inch (.64 cm) Blade Spacers Below Spindle 4 3 2 1 0 2 1/8– 3 1/8 inches (5.4–7.9 cm) C 2 0 2 1/8 inch (5.4 cm) 2 3/8 inch (6.0 cm) 2 5/8 inch (6.7 cm) 2 7/8 inch (7.3 cm) 3 1/8 inch (7.9 cm) 2 1/4– 3 1/4 inches (5.7–8.3 cm) C 2 1 2 1/4 inch (5.
Maintenance 8. Remove jack. 9. Adjust wheel drive and brake linkages as required (see Brake and Wheel Drive Linkage Adjustment section). Figure 12 1. Four 1/2 inch (127 mm) spacers 2. Quick Pin 7. Adjust the number of 1/2 inch spacers between bottom of hub and caster yoke to obtain the desired cutting height from the Cutting Height Adjustment Table in the Adjusting the Cutting Height section. Figure 11 1. Position A 2. Position B 3. Position C 3. 3/16 inch (4.8 mm) spacer 4. Caster support 8.
Maintenance Height Adjustment Table and notes in the Adjusting the Cutting Height section. 9. Install unused spacers between top of spindle and spindle nut. 10. Torque bolt to 75–80 ft-lb (102–109 N-m) (see Figure 13). Figure 14 1. The bellcrank just clears the gusset with the PTO engaged 2. PTO Safety Switch (located beneath the engine deck) 3. Bellcrank PTO Safety Switch Adjustment 1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s). 2.
Maintenance mower to tighten, and toward front of mower to loosen belt tension (see Figure 15). For 48 inch Decks: If there is no adjustment left in the turnbuckle and the belt is still loose, the rear idler pulley can be repositioned in the front hole (see Figure 15). 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.
Maintenance Figure 18 Shown with Blades Disengaged 1. Blade Brake Rod Figure 20 48 inch Belt Guide Location (Viewed from underneath the engine deck) 3. 1/8 inch to 3/16 inch (.32–.47 cm) 2. Spring Mounting Bolts 1. 1 3/8 inch (3.5 cm) 2. 1/4 inch (.64 cm) clearance 4. Check the distance between the spacer and the nut at the end of the blade brake rod. The distance should be between 1/8 inch (.32 cm) and 3/16 inch (.47 cm) (see Figure 18). 5.
Maintenance Figure 21 Viewed from Left Side of Unit 1. Neutral Safety Switch 2. Actuating Tab in neutral position 3. 5/16 inch (7.9 mm) Figure 22 Viewed from Left Side of Unit 3. Pull the speed control lever back to neutral. Check that the neutral safety switch actuating tab has depressed the plunger of the switch so that there is about 5/16 inch (7.9 mm) between the tab and the switch (see Figure 21). If necessary, move the switch fore and aft. 1. Neutral Control Linkage 2. Hydro Control Linkage 3.
Maintenance disengaged whenever speed control levers are moved out of the neutral position. to neutral. Recheck the drive wheel rotation to see if further adjustment is necessary. 4. The spring that keeps tension on the knob should normally not need adjustment. However, if adjustment is needed, adjust to where length of spring is about 1 inch (2.5 cm) between the washers. Adjust spring length by turning nut at front of spring.
Maintenance Tracking Adjustment Park Brake Adjustment 1. Stop engine and wait for all moving parts to stop. 1. Stop engine and wait for all moving parts to stop. 2. Check the drive tire pressures and tire circumferences as stated in Check the Tire Pressures section in Maintenance. 2. Disengage the park brake. 3. Remove the hairpin in the lower park brake linkage. Turn the linkage in the yoke until there is 3/16 inch (.48 cm) to 1/4 inch (.
Maintenance Cleaning recycling center or according to your state and local regulations. Clean Engine Air Cooling System Service Interval: Before each use or daily 1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s). 2. Clean all debris from engine air intake screen and from around engine shrouding. Remove Engine Shrouds and Clean Cooling Fins Service Interval: Every 100 hours 1. Stop engine, wait for all moving parts to stop, and remove key.
Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of trouble. Do Not attempt to service or replace major items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.).
Troubleshooting Problem Machine does not drive. Uneven cutting height. Possible Cause 1. Bypass valve is not closed tight. 1. Tighten the bypass valve. 2. Drive or pump belt is worn, loose or broken. 3. Drive or pump belt is off a pulley. 2. Change the belt. 1. Blade(s) not sharp. 1. Sharpen the blade(s). 2. Cutting blade(s) is/are bent. 3. Mower deck is not level. 2. Install new cutting blade(s). 3. Level mower deck from side-to-side and front-to-rear. 4. Clean the underside of the mower. 5.
Schematics Schematics Wiring Diagram PTO SWITCH N.O. NGE ORA OPC SWITCH N.O. E BLU AB C D E F FROM SAFETY INTERLOCK MODULE BROWN TRANSMISSION SWITCH N.O. GREEN YELLOW GREEN RED BLACK KEY SWITCH PARK BRAKE SWITCH N.O. RED BLACK CONNECTORS ARE VIEWED FROM WIRE END N.C. = NORMALLY CLOSED N.O.
Schematics 41
Exmark Commercial Turf Equipment 2 Year Limited Warranty 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 Conditions and Products Covered Exmark Mfg. Co. Inc.
Notes: 43
Notes: 44
Service Record Date: Description of Work Done: 45 Service Done By:
G011841 Figure 26 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 20 degrees. Use the slope indicator to determine the degree of slope of hills before operating. Do Not operate this machine on a slope greater than 20 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3. Example of how to compare slope with folded edge.
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID-MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM (ROPS) DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO-MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM OUT-FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL-TAIL WHEEL SN
