Robin America Engine EX40 Operator`s manual

Operator’s Manual
Safety, Assembly, Operating, and Maintenance Instructions
Please Read and Save These Instructions
For Safety, Read All Safety and Operation
Instructions Prior to Operating Machine
Beginning S/N: 128442
Effective Date: 05.05.14
P/N 5000-28
Foreword
Thank you. . .for purchasing a Walker mower. Every effort has been made to provide you with the
most reliable mower on the market, and we are sure you will be among our many satisfied customers. If for any reason this product does not perform to your expectations, please contact your local
dealer. Every customer is important to us. Your satisfaction is our goal.
Please. . .read this manual thoroughly! This manual is to be used in conjunction with the engine
manufacturer’s manual for the specific engine on the mower model you have purchased. Before
you operate your new mower, please read this entire manual. Some of the information is crucial for
proper operation and maintenance of this mower - it will help protect your investment and ensure
that the mower performs to your satisfaction. Some of the information is important to your safety,
and must be read and understood to help prevent possible injury to the operator or others. If anything in this manual is confusing or hard to understand, please contact your local authorized dealer
or call our service department, at (970) 221-5614, for clarification before operating or servicing this
mower.
This manual covers Model S14 with the Subaru Robin, EX40 (14 HP) gasoline engine.
All shields and guards must be in place for the proper and safe operation of this machine.
Where they are shown removed in this manual, it is for illustration purposes only. Do not operate
this machine unless all shields and guards are in place.
Specifications given are based on the latest information available at the time this manual was produced for a tractor with standard equipment. Optional equipment is available and may affect the
standard specifications listed.
Walker Mfg. Co. is continually striving to improve the design and performance of its products. We
reserve the right to make changes in specifications and design without thereby incurring any obligation relative to previously manufactured products.
Sincerely,
WALKER MANUFACTURING COMPANY
Bob Walker, President
Table of Contents
General Information_________________ 1
Operating Instructions______________ 25
HIGHLIGHTED INFORMATION______________
GLOSSARY_____________________________
IDENTIFYING NUMBER LOCATIONS_________
ENGINE SERIAL NUMBER LOCATION________
SERVICING OF ENGINE AND
DRIVETRAIN COMPONENTS_______________
CONTROL IDENTIFICATION,
LOCATION, AND FUNCTION ______________
Ignition Switch________________________
Engine Choke_________________________
Engine Throttle________________________
Forward Speed Control (FSC)____________
Front Body Latch Release_______________
Steering Levers_______________________
Blade Clutch (PTO)_____________________
Parking Brake_________________________
Transaxle Lockout Arms________________
Hourmeter____________________________
STARTING THE ENGINE__________________
ADJUSTING GROUND
SPEED AND STEERING___________________
ENGAGING THE BLADE DRIVE____________
STOPPING THE MACHINE________________
ADJUSTING CUTTING HEIGHT_____________
TRANSAXLE LOCKOUTS_________________
RECOMMENDATIONS FOR MOWING_______
RECOMMENDATIONS FOR TILT-UP DECK
OPERATION/TRANSPORT________________
GRASS HANDLING SYSTEM (GHS)_________
General Information____________________
Clogging Checklist_____________________
Using the Tilt-Up Deck__________________
Using the GHS Catcher_________________
Powerfil ®___________________________
“Full” Signal Horn_____________________
Cleaning the GHS Exhaust Screen________
Dumping the Catcher___________________
Tailgate Dumping_____________________
Using the Dump Bag___________________
1
1
1
2
2
Specifications_________________________ 3
ENGINE_________________________________
ELECTRICAL SYSTEM____________________
TRANSMISSION__________________________
BLADE DRIVE___________________________
TIRE SIZE_______________________________
TIRE PRESSURE_________________________
DIMENSIONS (Tractor and Mower)__________
GHS SYSTEM____________________________
MOWER DECK___________________________
DRIVE BELTS____________________________
SEAT___________________________________
FRAME/BODY CONSTRUCTION____________
3
3
3
4
4
4
5
5
6
6
6
6
Component Identification____________ 7
Safety Instructions__________________ 10
BEFORE OPERATING____________________
OPERATING____________________________
MAINTENANCE_________________________
SAFETY, CONTROL, AND
INSTRUCTION DECALS__________________
10
12
14
15
Assembly Instructions_______________ 18
SETUP INSTRUCTIONS___________________
Tire Installation (Tractor)________________
Battery Service________________________
Wet Battery Service___________________
Dry Battery Service____________________
Battery Charging______________________
Battery Installation____________________
Mower Deck Assembly__________________
Deck Caster Wheels Installation__________
Deck Discharge Chute Installation________
Deck Discharge Deflector
Shield Installation_____________________
PTO Shaft Guard Installation____________
Tilt-Up Roller Wheel Installation__________
Mower Deck Installation on Tractor________
Deck Installation______________________
Deck Leveling________________________
PREOPERATING CHECKLIST______________
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Table of Contents
Maintenance Instructions___________ 44
MAINTENANCE SCHEDULE CHART________
IMPORTANT TIPS FOR CARE OF THE
SUBARU ENGINE________________________
Fuel System__________________________
Starting/Stopping______________________
Cooling System_______________________
Air Cleaner System_____________________
Oil__________________________________
LUBRICATION__________________________
Engine Oil____________________________
Engine Break-In Oil____________________
Checking Engine Crankcase Oil Level_____
Changing Engine Crankcase Oil__________
Grease Fitting and Oil Point Lubrication ___
Mower Deck Gearbox Lubrication_________
Mower Deck Spindle Lubrication_________
Transaxle Lubrication__________________
Transaxle Oil and Filter Change__________
CLEANING_____________________________
Engine Air Cleaner System______________
Donaldson Radialseal™ Air Cleaner_______
Fuel Filter____________________________
Engine Cooling System_________________
Cooling Air Intake Screen_______________
Cylinder Head Cooling Fins_____________
Grass Buildup in Mower Deck Housing____
GHS Blower___________________________
GHS Exhaust Screen___________________
Transaxle Housing_____________________
CHECKING/SERVICING___________________
Security of Air Filtration Components_____
Battery_______________________________
Electrolyte Level______________________
Cleaning the Terminals_________________
Charging the Battery___________________
Tire Pressure__________________________
Wheel Nut Torque______________________
Sharpen Mower Blades_________________
Drive Belts____________________________
Mower Deck Gearbox Oil Seals___________
Spark Plug____________________________
Ignition______________________________
Fuel Lines and Clamps__________________
Blade Brake Action_____________________
Safety Switch System__________________
Forward Speed Control Friction Lock______
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REPLACING/REPAIRING__________________
Drive Belts____________________________
Engine Belt__________________________
PTO Drive Belt_______________________
Ground Drive Belt_____________________
Blade Overload Shear Bolts_____________
PTO Shear Pin (If Equipped)_____________
Mower Blades_________________________
ADJUSTMENTS_________________________
Transmission Control__________________
Steering Lever Position Adjustment_______
Steering Handles Adjustment____________
Neutral Position Adjustment_____________
Full Forward Speed Adjustment__________
Straight Tracking Adjustment____________
FSC Neutral Switch Adjustment__________
Forward Speed Control
Friction Adjustment____________________
Blade Clutch (PTO)_____________________
Clutch Engagement/Belt Tension_________
Blade Brake Band Adjustment___________
Tilt-Up Deck Adjustable Stop_____________
GHS “Full” Signal Horn Adjustment_______
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Operator’s Notes________________
77
Warranty______________________
79
General Information
HIGHLIGHTED INFORMATION
Walker Manufacturing recommends that any service
requiring special training or tools be performed by
an authorized Walker Mower dealer. There are several general practices to be aware of in the area of
safety. Most accidents associated with the operation or maintenance of a Walker Mower are caused
by disregarding basic safety precautions or specific
warnings. Such accidents, in most cases, can be
prevented by being aware of the dangers present.
Information of special importance has been highlighted in bold type in this manual. Refer to Safety
Instructions for the meanings of DANGER, WARNING, CAUTION, IMPORTANT, and NOTE.
GLOSSARY
There are many terms that are either unique to this
equipment or that are used as acronyms. The following terms and their definitions will help while using this manual:
• DECK is the mowing attachment mounted on
the front of the tractor which includes the carrier
frame, deck housing, belt or gear drive components, and cutter blades.
• FORWARD SPEED CONTROL (FSC) controls
the maximum forward speed of the tractor;
functioning as a cruise control.
• GRASS HANDLING SYSTEM (GHS®) collects
mowed material and deposits it in the catcher.
• GRASS-PAK® SWITCH is mounted on the
grass delivery spout (in the catcher) and activates the “full” signal horn when the grass
catcher is full.
• GROUND DRIVE refers to the dual transaxles
which drive the main wheels.
• LEFT HAND (LH) refers to the left-hand side of
the tractor when the operator is seated facing
forward in the tractor seat.
• POWER TAKE-OFF (PTO) transmits engine
power to run the cutter blades and GHS blower.
• POWERFIL® spreads the mowed material
throughout the interior of the grass catcher by
an oscillating delivery spout.
• RIGHT HAND (RH) refers to the right-hand side
of the tractor when the operator is seated facing
forward in the tractor seat.
• SIDE DISCHARGE (SD) discharges mowed
material from the right side of the mower deck.
• STEERING LEVERS steer the tractor by controlling the two transaxles.
• TRACTOR is the prime mover, including the engine, drivetrain, operator seat, and controls to
operate the mower.
• TRANSAXLE transmits and controls power
from the ground drive belt to the main drive
wheel.
• TRANSAXLE LOCKOUT ARMS release the
transaxles to permit freewheeling the tractor.
IDENTIFYING NUMBER LOCATIONS
The tractor serial number plate is affixed to the tractor body just below the left rear corner of the seat.
The mower deck serial number plate is affixed
alongside the angle iron framing on the LH side of
the LH mower blade drive. Model and serial numbers are helpful when obtaining replacement parts
and maintenance assistance. For ready reference,
please record these numbers in the space provided.
Tractor Model No. _______________________
Tractor Serial No. _______________________
Deck Serial No. _______________________
Engine Model No. _______________________
Engine Serial No. _______________________
Date of Purchase _______________________
Fill In By Purchaser
1
General Information
Serial Number
Tractor Serial Number Location
Serial Number
SERVICING OF ENGINE AND DRIVETRAIN
COMPONENTS
The detailed servicing and repair of the engine,
transaxles and gearboxes are not covered in this
manual. Only routine maintenance and general
service instructions are provided. For the service
of these components during the limited warranty
period, it is important to find a local, authorized
servicing agent of the component manufacturer.
Any unauthorized work done on these components during the warranty period may void the
warranty. If you have any difficulty finding an authorized outlet or obtaining warranty service,
please contact our Service Department for assistance:
Walker Manufacturing Company
5925 E. Harmony Road
Fort Collins, CO 80528
1-970-221-5614
www.walkermowers.com
Service manuals are available for each of these
components from their respective manufacturers as
follows:
Mower Deck Serial Number Location
ENGINE SERIAL NUMBER LOCATION
Refer to the engine manual that accompanies this
manual or the photo below for the location of the
engine serial number.
Serial Number
Engine Serial Number Location
2
Subaru Robin America Inc.
Subaru Engine A division of Fuji
Industries, Ltd. Group
905 Telser Rd.
Lake Zurich, IL 60047
800-277-6246
www.subarupower.com
Transaxle Hydro-Gear
1411 South Hamilton St.
Sullivan, IL 61951
877-728-7410
www.hydro-gear.com
Gearboxes (Deck) Peerless Gear
1555 South Jackson St.
Salem, IN 47167 USA
866-536-8310
www.peerlessgear.com
Specifications
MODEL
S14
ENGINE
Manufacturer/Model
Subaru Robin, EX40, 1 Cyl. (Air-Cooled)
Displacement cu. in. (cc)
24.65 (404)
Max. Power HP (kW)
14.0 (10.4) @ 3600 RPM
Governed RPM
3600
Max. Torque lb·ft (N·m)
19.9 (27.0) @ 2400 RPM
Idle RPM
1300
Spark Plug Type
NGK BPR5ES
Spark Plug Gap in. (mm)
.030 (0.75)
Crankcase Capacity qt (L)
1.35 (1.3)
Crankcase Lubricant
API SC/SD/SE/SF/SG/SH Grade Oil Only with 10W-30/10W-40
Viscosity or 40W Above 68° F (20° C) Only
Fuel Tank Capacity gal (L)
1.9 (7.2)
Fuel
Regular Grade Unleaded Gasoline (87 Octane Minimum,
10% Ethanol Maximum)
Cooling System
Air Cooled
Air Cleaner
Remote mounted Donaldson RadialsealTM
(Walker P/N 5090-1 Primary/5090-3 Safety Filter)
ELECTRICAL SYSTEM
Battery
12 Volt, 300 CCA (Interstate SP-35)
Charging System
Flywheel Alternator
Charging Output
13 Amp DC (Regulated)
System Polarity
Negative Ground
Ignition
Transistorized Electronic Magneto
Starter
12 Volt Electric Key and Solenoid Operated
Interlock Switches
Ignition Lockout by Seat Switch, Transmission Neutral and Blade
Clutch
Circuit Breaker
Replaceable Fuse (20A)
TRANSMISSION
Manufacturer/Model
Dual, Independent Hydro-Gear® ZT3100 Integrated Transaxles
Steering
Hand Lever Control / Individual Wheel
Forward Speed Control
Precision Friction Lock Lever, Cruise Control, with
Neutral-Park Position
Service Brake
Dynamic Braking through Transaxles
Parking Brake
Internal Mechanical Cog Lock for each Transaxle
(Single Lever Control)
Neutral
Transmission Release by Manual Dump Valve
3
Specifications
MODEL
S14
TRANSMISSION (continued)
Final Drive
Transaxle Direct to Drive Wheel
Transmission Fluid
Factory Service
20W-50 Multi-Viscosity Motor Oil (Minimum SL Grade Oil)
Transmission Oil Capacity fl oz (ml)
79 (2336)
Transmission Cooling
Cooling Fan Mounted on Drive Pulley
Oil Filter
Hydro-Gear® P/N 52114 (Walker P/N 2026-6)
Ground Travel Speed
Forward MPH (km/h)
Reverse MPH (km/h)
0-6.5 (0-10.5) Infinitely Variable
0-5 (0-8) Infinitely Variable
BLADE DRIVE
PTO Shaft
Sliding Spline Shaft with Two (2) High-Speed U-Joints
Blade Drive Clutch and Brake
Manual Belt Tightener Clutch and Band Brake
[Stops Blades within Five (5) Seconds of Disengagement]
TIRE SIZE
Deck Caster
8 x 3.00-4 (Pneumatic 4-Ply, Optional Foamed Rubber)
Drive
18 x 7.00-8 (Pneumatic 4-Ply, Standard)
18 x 8.50-10 (Pneumatic 4-Ply, Optional Low-Profile)
Tailwheel
13 x 6.50-6 (Pneumatic 4-Ply)
TIRE PRESSURE PSI (KPA)
4
Deck Caster Wheel
20 (137)
Drive
15 (103)
Tailwheel
20 (137)
Specifications
MODEL
S14
DIMENSIONS (Tractor and Mower)
Length in. (cm)
Tractor Only
63.75 (162)
Tractor Wheel Base
43 (109)
Tractor with Tilted Deck
(Approximate)
77 (196)
Tractor with 36" Collection Deck
(DC36R-1)
87 (221)
Tractor with 42" Collection Deck
(DC42-1)
88.5 (225)
Width in. (cm)
Tractor Only (Outside Tire)
36 (91.5)
Tractor with 36" Collection Deck
(DC36R-1)
37.25 (95)
Tractor with 42" Collection Deck
(DC42-1)
43.25 (110)
Height in. (cm)
Tractor
46.75 (119)
Weight lb (kg)
Tractor Only
595 (270)
Tractor with 36" Collection Deck
(DC36R-1)
766 (347)
Tractor with 42" Collection Deck
(DC42-1)
786 (356)
GHS SYSTEM
Blower
12.5 in. Diameter, Three-Blade Paddle Wheel
Blower Brake
Band Brake [Works in Combination with PTO Clutch, Stops Blower
within Five (5) Seconds of PTO Disengagement]
Max. Blower RPM
2900
Grass Catcher Capacity
gal / bu / L
65 / 7 / 246
Full Signal
Oscillating Vane Switch Mounted on Grass Delivery Spout Triggers
Horn Signal
Powerfil ®
Oscillating Delivery Spout Driven by 12 Volt Electric Gearmotor
Spreads Material throughout Interior of Catcher @ 35 Cycles/Min
5
Specifications
MODEL
S14
MOWER DECK
Recommended Cut Width
36 or 42 in. (91 or 107 cm)
(Collection, SD, Mulch)
Cutting Height
1 to 4 in. (2.5 to 10 cm) in 1/2 in. (1 cm) Increments
Deck Suspension
Independent Torsion-Flex Frame with Caster Wheels and
Counterweight Springs
DRIVE BELTS
Engine
Walker P/N 5234-3
Ground Drive
Walker P/N 5232-1
PTO Drive
Walker P/N 5234-4
SEAT
Contour-Molded, with Nylon Backed Vinyl Cover and Integral
Foam Cushion
FRAME/BODY CONSTRUCTION
Frame
All Welded Unitized Steel Chassis
Body
14 Gauge Steel
Deck
11 Gauge Steel
GHS Catcher and Chutes
Molded Cross-Linked Polyethylene (UV Stabilized)
NOTE: The manufacturer reserves the right to make changes in specifications shown herein at any time
without notice or obligation. The specifications listed are for a standard configuration tractor, and may
change with the addition of optional equipment.
6
Component Identification
NOTE: Control Identification
shown in Operating
Instructions section.
Grass Handling System
7.0 Bushel Catcher
Tilt-Up Latch
Spring Clip
Counterweight Spring
and Protective Cover
Anti-Scuff
Roller
Deck Support Pins
and Height Adjustment
Hitch Pins
Catcher Lift /
Dump Handle
Tilt-Up
Deck Handle
Deck Support Arm
Footrests
Deck Lift Handle
(Cutting Height Adjustment)
Deck Support Arm
Tilt-Up Hook
(Not Visible)
Deck
Caster Wheels
Front View and Right Side View
7
Component Identification
Catcher Door
Gas Spring
(Not Visible)
Removable Grass
Catcher Screen
(Not Visible)
Catcher Door
Catcher Lift /
Dump Handle
Catcher
Air Exhaust
Catcher
Door Handle
Anti-Scuff
Roller
Left Hand
Drive Wheel
Muffler
Tailpipe
Rotating Engine
Screen
Rear View and Left Side View
8
Tailwheel Fork
and Wheel
Component Identification
Negative (-)
Battery Cable
Battery
Positive (+)
Battery Cable
Air Intake Hose
Donaldson
Air Cleaner
Tailpipe
Air Cleaner
Cover
Fuel Tank
Fuel Tank
Cap
Muffler
Heat Shield
Parking Brake
Lever
PTO Clutch
Lever
GHS Blower
RH Transaxle
Lockout Arm
LH Transaxle
Lockout Arm
RH Transaxle
LH Transaxle
Neutral Safety
Switch
Top View (Body Raised)
9
Safety Instructions - Before Operating
Pay particular attention to any information labeled
DANGER, WARNING, CAUTION, IMPORTANT,
and NOTE in this manual.
), read,
When you see the Safety Alert Symbol (
understand, and follow the instructions. Fail­ure to
comply with safety instructions may result in personal injury.
The seriousness or degree of importance of each
type of information is defined as follows:
DANGER
An IMMEDIATE hazard that WILL result in
severe personal injury or DEATH, if warning is ignored and proper safety precautions are not taken.
Walker Manufacturing cannot predict every potentially dangerous situation. Therefore, items labeled
as such in this manual do not cover all conceivable
situations. Any person using procedures, tools, or
control techniques not recommended by Walker
Manufacturing must take full responsibility for safety.
The Walker Rider Lawnmower has been designed
with many safety features to protect the operator from
personal harm or injury. However, it is necessary for
the operator to use safe operating procedures at all
times. Failure to follow safety instructions contained in this manual may result in personal injury or damage to equipment or property.
If you have any questions concerning setup, operation, maintenance, or safety, please contact your
authorized Walker Mower dealer or call Walker
Manufacturing Company at (970) 221-5614.
BEFORE OPERATING
WARNING
A POTENTIAL hazard that COULD result in
severe personal injury or DEATH, if warning is ignored and proper safety precautions are not taken.
1. Read and understand the contents of this
Operator’s Manual before starting and operating the machine. Become thoroughly familiar with all machine controls and how to stop the
machine and disengage the controls quickly.
Replacement Operator’s Manuals are available
by sending the Model and Serial Number to:
Walker Manufacturing Company
5925 East Harmony Road
Fort Collins, CO 80528
CAUTION
Possible hazards or unsafe practices that
MAY result in MODERATE personal injury
or property damage, or machine damage, if
warning is ignored and proper safety precautions are not taken.
IMPORTANT: Identifies mechanical information
demanding special attention, since it deals with the
possibility of damaging a part or parts of the machine.
NOTE: Identifies information worthy of special attention.
10
2. Never allow children to operate rider mower.
Do not allow adults to operate without proper
instruction.
3. Clear the area to be mowed of any foreign
objects which may be picked up and thrown by
cutter blades. Pick up all sticks, stones, wire,
and any other debris.
4. Keep everyone, especially children and pets, a
safe distance away from the area being mowed.
Do not mow with bystanders in the area.
5. Do not operate the machine barefoot or wearing
sandals, sneakers, tennis shoes, or similar
lightweight footwear. Wear substantial protective footwear.
Safety Instructions - Before Operating
6. Do not wear loose fitting clothing that could get
caught in moving parts. Do not operate this machine while wearing shorts; always wear adequate protective clothing, including long
pants. Wearing safety glasses, safety shoes,
and a helmet is advisable and required by some
local ordinances and insurance regulations.
12. The electrical system battery contains sulfuric
acid. Avoid any contact with skin, eyes, and
clothing. Keep the battery and acid out of reach
of children.
7. Prolonged exposure to loud noise can cause
impairment or loss of hearing. Operator hearing protection is recommended; particularly
for continuous operation of the GHS Model due
to blower noise level. Wear a suitable hearing
protective device, such as earmuffs or earplugs.
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects or
other reproductive harm.
WARNING
8. Keep all protective shields and safety devices in place. If a protective shield, safety
device, or decal is damaged, unusable, or missing, repair or replace it before operating the
machine.
9. Be sure interlock switches are functioning
correctly, so the engine cannot be started unless the Forward Speed Control lever is in the
NEUTRAL-PARK position, and the PTO clutch
is in the DISENGAGED position. Also, the engine should stop if the operator lifts off the seat
with either the Forward Speed Control (FSC)
out of the NEUTRAL-PARK position or the PTO
clutch in the ENGAGED position.
10. Handle gasoline with care. Gasoline is highly
flammable and its vapors are explosive:
a. Use an approved fuel container.
b. Never add fuel to a running engine or hot
engine (allow hot engine to cool several minutes).
c. Keep matches, cigarettes, cigars, pipes,
open flames, or sparks away from the fuel
tank and fuel container.
d. Always fill the fuel tank outdoors using care.
Fill to about one inch from the top of the tank.
Use a funnel or spout to prevent spilling.
e. Replace the machine fuel cap and container
cap securely and clean up any spilled fuel
before starting the engine.
11. Never attempt to make any adjustments
while the engine is running, except where
specifically instructed to do so.
11
Safety Instructions - Operating
1. Operate the mower only in daylight or in
good artificial light with good visibility of the area
being mowed.
2. Sit on the seat when starting the engine and
operating the machine. Keep feet on the deck
footrests at all times when the tractor is moving
and/or mower blades are operating. Never operate the tractor without a deck or imple­
ment installed.
3. For a beginning operator, learn to steer (maneuver) the tractor with a slow engine speed
ation.
before attempting any mowing oper­
Be aware that, with the front mounted mower
configuration, the back of the tractor swings to
the outside during turns.
DANGER
8. Do not run the engine in a confined area
without adequate ventilation. Exhaust fumes
are hazardous and can be deadly.
9. Do not carry passengers - maximum seating
capacity is one (1) person.
10. Watch for holes, rocks, and roots in the terrain
and for other hidden hazards. When mowing
tall grass, mow higher than desired to expose
any hidden obstacles. Then, clean the area and
mow to the desired height.
Do not mow around overhanging tree
branches or bushes at the same height as
the operator’s torso and head where inadvertent contact may cause injury.
11. Avoid sudden starts or stops. Before backing the machine up, look to the rear to be sure
no one is behind the machine. Watch carefully
for traffic when crossing or working near roadways.
4. Remember, for an emergency stop, the forward
motion of the tractor can always be stopped by
pulling the Forward Speed Control (FSC) into
the NEUTRAL-PARK position.
12. When moving forward, do not suddenly put the
tractor in reverse by rapidly pulling on the steering levers, especially when going downhill, as
this can lift the tractor tail wheel off the ground
and set up a bucking motion due to operator
overcontrol. If bucking does occur, immediately
stop the bucking action by pulling the Forward
Speed Control (FSC) lever into the NEUTRALPARK position.
5. If either of the transmission drive belts break
during slope operation, the machine will freewheel down the slope. To maintain control,
immediately (1) Release the steering levers and
simultaneously (2) Move the FSC to the NEUTRAL-PARK position. When the machine is
stopped or moving slowly, engage the parking
brake.
NOTE: The emergency stop procedure is exactly the same procedure used to normally stop
and park the machine.
6. Disengage the blade clutch and put the FSC in
the NEUTRAL-PARK position before starting
the engine (an ignition interlock switch normally
prevents starting of the machine if these controls are in the OPERATING position).
12
7. Do not operate machine if the operator presence safety switch system is not working.
Verify proper operation by having the operator
lift off the seat with the engine running and moving two controls, one at a time; (1) Move the
FSC lever out of the NEUTRAL-PARK position,
and (2) Engage the PTO Clutch. Moving either
control should stop the engine immediately.
13. Disengage the blade drive when transporting
the machine across drives, sidewalks, etc. Never raise the mower deck while blades are
rotating.
DANGER
Do not mow or drive the tractor within
5 feet (1.5 meters) of an embankment or retaining wall with drop off.
Safety Instructions - Operating
14. The maximum recommended slope operating angle is 15 degrees or 26% grade. When
operating the machine on a slope, reduce speed
and use caution to start, stop, and maneuver.
To prevent tipping or loss of control of the machine, avoid sharp turns or sudden changes in
direction. Do not operate the machine on a
slope greater than 15 degrees.
15. Never adjust cutting height with the engine
running. Before adjusting cutting height or
servicing, disengage the blade clutch (PTO),
stop the engine, and remove the ignition key.
Wait for all movement to stop before getting off
the seat.
NOTE: A blade/blower brake should normally
stop drive line rotation within five (5) seconds of
disengaging the PTO clutch.
16. For side discharge mower decks, do not operate with the grass deflector shield removed.
Keep the deflector in the lowest possible position.
17. When using the tilt-up deck, observe the following:
a. Do not move tractor with deck in tilt-up
position.
20. In case of a clogged or plugged mower deck
or GHS catching system:
a. Disengage the blade clutch (PTO) and turn
the engine off before leaving the seat.
b. LOOK to make sure blade drive shaft and
blower drive pulley movement has stopped
before trying to unclog the system.
c. Disconnect the spark plug wire.
d. Never place hands under the deck or in the
GHS blower - use a stick or similar tool to
remove clogged material.
21. If the cutting blades strike a solid object or the
machine begins to vibrate abnormally,
immediately disengage the blade clutch
(PTO), stop the engine, and wait for all
moving parts to stop. To prevent accidental
starting, disconnect the spark plug wire.
Thoroughly inspect the mower and repair any
damage before restarting the engine and
operating the mower. Make sure cutter blades
are in good condition and blade nuts are torqued
to 60 lb·ft (81 N·m) for gear driven decks, and
blade bolts torqued to 70 lb·ft (90 N·m) for belt
driven decks.
b. Never tilt body forward with deck in tilt-up
position.
22. Do not touch the engine or muffler while the
engine is running or immediately after stop­
ping the engine. These areas may be hot
enough to cause serious burns.
18. Do not operate the machine with the grass
catcher in the DUMP position or with the
back door OPEN. Dangerous projectiles may
be thrown out of the discharge chute or the back
of the grass catcher.
23. When leaving the machine unattended, disen­
gage the blade clutch (PTO), stop the engine, and remove the key.
19. Use care when closing the grass catcher
door. Keep fingers and hands away from the
hinge and pinch points when the door is being
closed. Also, keep fingers and hands clear of
the door frame. The door is held closed with
springs and the door may slam shut with considerable force.
CAUTION
Use leg muscles and firm footing when lifting the catcher to dump; avoid bending at
the waist and using back muscles in order
to prevent back injury.
13
Safety Instructions - Maintenance
1. To prevent accidental starting of the engine
when servicing or adjusting the machine, remove the key from the ignition switch and disconnect the spark plug wire.
2. To reduce fire hazards, keep the engine free
of grass, leaves, excessive grease, and dirt.
a. Make sure the battery charger is unplugged
before connecting or disconnecting cables
to the battery.
3. Keep all nuts, bolts, and screws tight to ensure
the machine is in a safe, working condition.
Check the blade mounting nuts frequently, mak­
ing sure they are tight.
b. Charge the battery in a well-ventilated
space, so gases produced while charging
can dissipate. Make sure the battery vents
in the caps are open.
4. Perform only maintenance instructions described in this manual. Unauthorized maintenance operations or machine modifications
may result in unsafe operating conditions.
c. Keep sparks, flames, and smoking materi­
als away from the battery at all times. To
avoid sparks, use care when removing bat­
tery cables from posts.
5. If the engine must be running to perform a main­
tenance adjustment, keep hands, feet, and
clothing away from moving parts. Do not wear
jewelry or loose clothing.
d. Disconnect both battery cables before unplugging any wiring connectors or making
repairs on the electrical system.
6. Always use the proper engine service
manual when working on the engine.
Unauthorized maintenance operations or
modifications to the engine may result in unsafe
operating conditions.
7. Altering the equipment or engine in any manner
which adversely affects its operation, perfor­
mance, durability, or use will VOID the warranty and may cause hazardous conditions.
8. Never attempt to disconnect any safety devices
or defeat the purpose of these safety devices.
9. Do not change the engine governor settings or
overspeed the engine. The governor has been
factory-set for maximum-safe engine operating
speed.
10. Use genuine factory replacement parts.
Sub­stitute parts may result in product malfunction and possible injury to the operator and/or
others.
14
11. Use care when charging the battery or per­
forming maintenance on the battery and electrical system:
IMPORTANT: Keep all applicable manuals immediately accessible to anyone who may operate or service this machine.
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
1.
8600-12
Location: Top of Fuel Tank
Part Number: 8600-12
2.
8600-4
Location: Adjacent to Blower Discharge
Chute through Body
Part Number: 8600-4
1. Warning - rotating impeller is a cutting/dismemberment hazard to fingers and hands.
• Never reach down into the blower discharge
chute.
2. Warning - thrown object hazard.
• Never engage the PTO with grass catcher
raised.
1. Warning – carbon monoxide (CO) poisoning
hazard.
• CO emitted by a running engine can be deadly.
• Do not operate indoors or in other enclosed
areas.
60 lb·ft (81 N·m)
1.
8600-9
Location: Gearbox Cover
(Gear Drive Decks Only)
Part Number: 8600-9
1. Tighten blade nuts on gear driven decks to
60 lb·ft (81 N·m).
9804-1
Location: Rear of Grass Catcher Exhaust Screen
Part Number: 5869
1.
1.
Location: Catcher Door Hinge Bar,
LH and RH Sides
Part Number: 8600-10
1. Caution - Pinch point.
• Keep all body parts clear when closing grass
catcher door.
Location: Chassis Member Behind Transaxles
Part Number: 9804-1
1. Neutral Lock
• Lift and move into slot to unlock transmission and allow machine to freewheel.
15
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
2.
8600-28
Location: Each End of Mower Deck
Part Number: 8600-28
Location: Top of Fuel Tank
Part Number: 5082-5
1. Warning – thrown object hazard.
• Keep bystanders away from the machine
when operating.
• Clear lawn of debris before operating.
• Keep any discharge deflector in place and in
the lowest position.
2. Warning – rotating mower blades are a cutting/
dismemberment hazard to hands and feet.
• Keep all body parts away from rotating mower blades.
• Do not step on end of deck.
1.
1.
5848-2
Location: Deck Discharge Shield
(SD Decks Only)
Part Number: 5848-2
1. Warning – thrown object hazard.
• Always keep the discharge shield in the lowest position when operating.
• Do not remove the discharge shield.
8600-14
Location: Deck Carrier Frame
Part Number: 8600-14
1. Warning – do not operate the machine with the
deck tilted up.
1.
Location: Deck Carrier Frame
Part Number: 8600-15
1. Warning – lock deck tilt-up hinge before operating the machine.
16
1.
Location: Deck Gearbox Cover
Part Number: 8600-7
1. Warning - stop engine and remove ignition key
before adjusting deck cutting height.
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
1.
2.
3.
2.
4.
5.
<15°
6.
1.
7.
2.
3.
4.
8.
5.
Location: LH Fender
Part Number: 8600-27
1.Throttle
2. Warning – read Operator’s Manual before operating the machine.
3. Warning – wear eye and ear protection when operating the machine.
4. Warning – roll-over hazard.
• Do not operate on slopes greater than 15
degrees.
5. Warning – thrown object hazard.
• Keep bystanders away from the machine
when operating.
6.Choke
7. Warning – entanglement hazard.
• Keep all guards in place while engine is running.
8. Parking brake
• Move lever forward to engage Parking
Brake; back to disengage.
Location: RH Fender
Part Number: 8600-26
1. Warning – do not operate the machine without a
deck or other implement attached.
2. Forward Speed Control
• Move lever forward to increase speed; back
to stop.
3. Warning – read Operator’s Manual before servicing or performing maintenance.
• Engage parking brake.
• Remove ignition key.
4. Warning – do not engage PTO clutch with PTO
shaft disconnected.
5. PTO Clutch Lever
• Move lever forward to engage PTO clutch;
back to disengage.
17
Assembly Instructions
SETUP INSTRUCTIONS
Walker Mowers are shipped partially assembled to
our distribution network, and are typically assembled by the selling dealer. For any additional assembly besides the following, contact your Walker
dealer.
Tire Installation (Tractor)
• Install the drive tires using the eight (8) lug bolts
that are supplied with the owner’s packet of
materials. Bolts are torqued to 75 to 85 lb·ft
(102 to 115 N·m).
• Check and adjust the inflation of the tires. The
tire inflation recommendations are:
Drive
Tailwheel
=
=
15 PSI (103 kPa)
20 PSI (137 kPa)
Battery Service
Raise front mower body up for battery access (refer
to Front Body Latch Release in Operating Instruc­
tions). Check the battery for electrolyte level and
charge. The electrolyte level should be at the bottom of the vent wells [1/4 to 1/2 in. (6 to 13 mm)
above plates]. If the specific gravity is less than
1.225, the battery needs charging. If the battery has
been shipped dry, or is wet but needs service, refer
to the following instructions.
IMPORTANT: Make sure battery is securely mounted in the frame. A loose battery may cause damage
to the case resulting in acid leakage and severe damage to the machine. A hazard may be created by
damage to critical working parts and safety systems.
Wet Battery Service
If the battery has been shipped wet, but the electrolyte level is low or the battery needs to be charged
then:
1. Fill each battery cell with distilled water to the
bottom of the vent wells.
2. Charge battery. Refer to Battery Charging in
this section.
Dry Battery Service
DANGER
Activating a battery can be dangerous.
The battery should be taken to a reliable
service station, battery store, or power
equipment dealer where a trained technician can activate the battery safely. DO
NOT attempt to activate the battery unless
you are experienced in battery service
work. The following activation and charging instructions are provided for use by a
trained battery technician.
DANGER
Battery electrolyte is a poisonous and corrosive sulfuric acid solution.
•Avoid spillage and contact with skin,
eyes, and clothing - causes severe burns.
• To prevent accidents, wear safety goggles and rubber gloves when working with
electrolyte.
• Neutralize acid spills with baking soda
and water solution.
To fill (activate) battery with electrolyte (if battery has
been shipped dry):
1. Remove the battery protector plate, disconnect
the battery cables and lift the battery out of the
tray.
IMPORTANT: Battery must be removed from
the mower before filling with electrolyte.
IMPORTANT: Obtain and use only battery
grade sulfuric acid electrolyte with a 1.265 specific gravity to activate the battery. DO NOT use
water or any other liquid during initial activation.
2. Remove the filler caps and carefully fill each cell
until the electrolyte is just above the plates.
3. After the battery is filled with electrolyte, replace
the filler caps and charge the battery. Refer to
Battery Charging.
18
Assembly Instructions
Battery Charging
DANGER
BATTERIES PRODUCE EXPLOSIVE GASES
• Charge the battery in a well-ventilated
area, so that gases produced while charging can dissipate.
• Keep sparks, flames, and smoking materials away from the battery at all times.
• Make sure the battery cap vents are open
after the battery is filled with acid (check
manifold vent on each cap).
Install the battery in the mower as shown in Battery
Installation photo. Connect the positive (+) first and
then the negative (-) cable to the proper battery terminal [red cable and boot connects to the Positive (+) terminal]. Slide the rubber boot up and over
the battery post, making sure it covers the post completely to prevent an electrical short.
WARNING
Make sure the battery cap vents are open.
Improper venting of the battery COULD
cause a battery explosion.
•Make sure the battery charger is un-
(+) Battery Cable
Connection
plugged before connecting or disconnecting cables to the battery.
1. Charge the battery at 15 amps for 10 minutes.
DO NOT exceed 20 amps maximum recommended charging rate. Charge until specific
gravity is at least 1.250. Total charging time
should not exceed one (1) hour.
2. After charging the battery, adjust the electrolyte
level to the bottom of the vent wells [1/4 to 1/2 in.
(6 to 13 mm) above the plates].
IMPORTANT: DO NOT overfill the battery.
Electrolyte will overflow through the vented caps
onto parts of the machine and WILL result in severe corrosion.
3. Install battery.
Battery Clamp
Secured by
Wing Nut(s)
Battery Installation
Mower Deck Assembly
Deck Caster Wheels Installation
1. Remove the bolt, nut, axle spacer tube, and
spacer washers from each deck caster wheel
fork.
Battery Installation
IMPORTANT: Make sure battery is securely mounted in the frame. A loose battery may cause damage
to the case resulting in acid leakage and severe
damage to the machine. A hazard may be created
by damage to critical working parts and safety systems.
NOTE: Spacer washers are used only when
the optional semi-pneumatic deck wheels are
installed.
2. Fit the axle spacer tube through the wheel hub,
position the spacer washer on each side of the
hub (if used), and fit the assembly into the wheel
fork.
3. Insert the 3/8-16 x 4-1/2 in. bolt through the
wheel fork with the bolt head to the outside and
install the 3/8-16 in. Keps nut.
19
Assembly Instructions
4. Tighten the bolt and nut until the axle spacer
tube bottoms against the inside of the wheel
fork (will not turn) while the wheel and spacer
washers (if used) spin freely without binding.
Axle Spacer
Tube
Deck Discharge Deflector Shield Installation
(Side Discharge Models Only)
Attach the side discharge deflector shield using two
(2) 3/8-16 x 1-1/4 in. bolts, 3/8-16 ESNA nuts, and
3/8 in. wave spring washers. The wave washers fit
between the two hinging surfaces. Tighten the nuts
until the shield moves freely but is not loose.
WARNING
Spacer Washer
DO NOT operate the machine without the
grass deflector shield attached and in the
lowest possible position.
Axle Bolt
Deck Caster Wheel Installation
Attach Shield
NOTE: If semi-pneumatic wheels are installed,
make sure the spacer washers fit over the spacer tube and are not caught between the fork and
the end of the tube. The washers should move
freely on the axle spacer tube.
5. Grease the caster wheel bearings and caster
pivot bearings - one grease fitting for each
wheel and each pivot.
Deck Discharge Chute Installation
(GHS Rear Discharge Models Only)
Mount the discharge chute hinge on top of the deck
discharge opening using two (2) 1/4-20 x 1/2 in. button head socket cap screws and 1/4-20 ESNA nuts.
Position the screws with the heads inside the chute
and the nuts on the outside. Attach spring for tilt-up
action from chute to bracket on deck.
Discharge Shield Installation
on Side Discharge Deck
PTO Shaft Guard Installation
Position the shaft guard as shown and mount with
two (2) 1/4-20 x 1/2 in. bolts.
Tilt-Up Roller Wheel Installation
Attach Guard
Attach
Chute
Carrier Frame
Tube Sockets
Nut on Top
Discharge Chute and PTO Shaft Guard
Installation on Rear Discharge Deck
20
Mount the two (2) tilt-up roller wheels on the brackets on the rear skirt of the deck housing using the
P/N 8490 axle bolt, 3/8 in. wave spring washer and
3/8-16 in. Whiz locknut. Tighten the axle bolt until
the wheel rolls freely, but is not loose.
Assembly Instructions
PTO
Connection
Attach Spring
Roller Wheels
Tilt-Up Spring and Roller Wheel
Installation on Rear Discharge Deck
Mower Deck Installation on Tractor
Deck Installation
1. Lightly grease each deck support arm (2) on the
tractor. Refer to Mower Deck Installation
photo for location of deck support arm.
Arrows on Shaft and Tube
(Used to Align When Sliding Together)
PTO Shaft Connection
4. Install the hitch pin through the hole on the end
of each support arm to lock the deck in place
(refer to Deck Counterweight Spring Installation photo). Two (2) hitch pins are included in
the Owner’s Packet of materials.
Spring Tension Adjustment Nut
Located Under Lower
Spring Hook (Not Visible)
Counterweight
Springs Clip
Onto Body
With Forward
Body Tilted Up
Deck Support
Arms
Hitch Pins Lock Deck
on Support Arms
Deck Counterweight Spring Installation
Mower Deck Installation
2. Engage the deck carrier frame tube sockets on
the tractor support arms (refer to Discharge
Chute and PTO Shaft Guard Installation photo for socket location). Slide the deck onto the
support arms approximately 3 in. (76 mm).
3. Align and connect the splined PTO shaft and
socket halves, as shown in PTO Shaft Connection photo. The PTO shaft has a pilot end to
ease alignment of shaft; fit shaft end into socket
and rotate shaft until the splines line up as indicated by arrows, then slide together.
5. Raise mower body (instead of lifting the front of
deck) and clip the counterweight springs to the
receptacle on front of body. Lower the body to
tension the springs. (Refer to Deck Counterweight Spring Installation photo.)
6. With the counterweight springs connected, the
weight on the deck caster wheels should be
15 to 25 Ib (6.8 to 11.3 kg); this adjustment is
preset at the factory. If required, the spring tension can be adjusted by tightening or loosening
the elastic stop nuts located underneath the
lower spring hook, or contact your local dealer
if additional help is required. Refer to Deck
Counterweight Spring Installation photo.
21
Assembly Instructions
Deck Leveling
1. Position mower on a smooth, level surface. Set
the cutting height to the highest position - 4 in.
(102 mm) - for easy access under the deck to
measure blade height. Refer to ADJUSTING
CUTTING HEIGHT in Operating Instructions.
NOTE: A block of wood cut 4 in. (102 mm) high
is a convenient gauge to measure blade height
above ground during the leveling process.
WARNING
2. Check the side-to-side level. Rotate each
blade sideways and measure the distance
from blade tip to ground on each side. If measurements vary more than 1/8 in. (3 mm), add a
washer shim under the deck support pins on the
low side to level the deck.
3. Check the front-to-rear level. Rotate the blades
to point forward. Measure the distance from
blade tip to ground on the front and rear. The rear
of the blade should be 1/8 to 1/4 in. (3 to 6 mm)
higher than the front of the blade; shim the rear
(or front) deck support pins equally to achieve at
least 1/16 in. (2 mm) difference.
The machine must be shut off during this
procedure.
NOTE: The mower deck and support frame are
jig welded; within normal tolerances, very little, if
any, shimming should be required to level the
deck. Tire pressure will influence the levelness
of the deck. Check the tire pressure as a possible cause of the deck not being level.
4 in. (102 mm)
Wood Block
Should be 1/8 in. (3 mm)
to 1/4 in. (6 mm) higher
at the rear of the blade
Should not vary more
than 1/8 in. (3 mm)
side-to-side
4 in. (102 mm)
Wood Block
Deck Leveling
22
Assembly Instructions
PREOPERATING CHECKLIST
Before operating the mower for the first time, and as
a routine before daily operations, it is important to
make sure the mower is properly prepared and
ready for operation. The following is a list of items
to be checked. (For a mower with frequent operation, some of these items will not need to be checked
every day, but the operator should be aware of the
condition of each.)
For proper fuel and lubricants refer to Specifications.
FILL FUEL TANK
IMPORTANT: DO NOT mix oil with gasoline. Always use fresh, automotive grade unleaded gasoline. DO NOT use gasoline containing greater than
10% ethanol. DO NOT use additives, such as carburetor cleaners, deicers, or moisture removing
agents. DO NOT use gasoline blended with methyl
alcohol.
CHECK ENGINE CRANKCASE OIL LEVEL
Check the engine crankcase oil level before use and
after each 5 hours of continuous operation. Refer
to LUBRICATION for Checking Engine Crankcase
Oil Level in Maintenance Instructions.
Raise the mower body and locate the fuel tank on
top of the engine.
CHECK AND SERVICE ENGINE AIR CLEANER SYSTEM
Fill the fuel tank using clean, fresh automotive grade
unleaded gasoline (87 octane minimum, 10% ethanol maximum).
• Check condition, cleanliness, and security of the
DANGER
complete air filter system (inspect air filter every
100 hours). For detailed procedures, refer to
CLEANING the Engine Air Cleaner System in
Maintenance Instructions.
CHECK ENGINE COOLING SYSTEM
Handle gasoline with care. Gasoline is
highly flammable and its vapors are explosive. Use safe refueling procedures:
• DO NOT fill fuel tank with the engine running.
• If the engine is hot, allow to cool before
refueling.
• Use an approved fuel container.
• Fuel the mower outdoors.
• DO NOT smoke while refueling.
• Avoid spilling fuel; use a funnel or spout.
• DO NOT overfill the fuel tank; fill up to
about 1 in. (25 mm) below the top of tank.
Check that the engine cooling air intake screen is
free of obstruction by grass clippings or debris and
clean if required. Also, cylinder head cooling fins
should be inspected and cleaned if any build-up of
debris is noted (remove cylinder head shroud to
clean).
Check performance of the cooling system by starting the engine, holding a hand adjacent to the cylinder head, and feeling the cooling airflow.
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
INSPECT THREE (3) DRIVE BELTS
IMPORTANT: DO NOT permit dirt or other foreign
matter to enter the fuel tank. Wipe dirt from around
the filler cap before removing. Use a clean fuel storage container and funnel.
Engine, PTO, and Hydrostatic Ground Drive.
CHECK HYDROSTATIC TRANSAXLE OIL
LEVEL
Refer to LUBRICATION for Transaxle Lubrication
in Maintenance Instructions.
23
Assembly Instructions
CHECK TIRE PRESSURE
Deck Caster Wheel = 20 PSI (137 kPa)
Drive = 15 PSI (103 kPa)
Tailwheel = 20 PSI (137 kPa)
CHECK AND CLEAN GRASS BUILDUP UNDERNEATH MOWER DECK (and inside GHS
blower, if equipped)
Refer to CLEANING the GHS Blower in Mainte­
nance Instructions for blower cleaning information.
DANGER
Never operate cutter blades with deck in
raised position because it is hazardous.
The tilt-up deck can be secured in the raised position by unlocking the deck lock levers on each side
of the carrier frame and inserting the deck hook into
the tilt-up latch on the tractor body. Before operating
the tractor, make sure to re-engage the deck lock
levers after lowering the deck to the normal operating position.
Tilt-Up Hook and
Latch Connected
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
DANGER
Do not operate the mower with deck in tiltup position. Do not move the tractor with
the deck in the tilt-up position.
CHECK MOWER BLADE CONDITION,
SHARPNESS, BALANCE AND SECURITY OF
MOUNTING
The blade mounting nuts on gear driven decks should
be torqued to 60 lb·ft (81 N·m), and the blade mounting bolts on belt driven decks torqued to 70 lb·ft
(95 N·m). If blade sharpening is required, refer to
CHECKING/SERVICING for Sharpen Mower
Blades in Maintenance Instructions.
ADJUST MOWER CUTTING HEIGHT, IF REQUIRED
Position the hitch pins in the four deck support pins.
Refer to the “Cutting Height Adjustment” decal on
the deck gearbox cover.
CHECK DRIVE WHEEL BOLT TORQUE
The lug bolts mounting the drive tires should be
tightened to 75 to 85 lb·ft (102 to 115 N·m).
Tilt-Up
Latch
CHECK FUNCTION OF SAFETY INTERLOCK
SWITCHES
Tilt-Up Hook
Deck Secured in TILT-UP Position
Refer to Operating Instructions to check for proper
operation of safety switches, both during engine
starting and with the operator leaving the seat with
tractor moving forward or with the mower blades engaged.
PERFORM ANY ADDITIONAL PROCEDURES
called for on the MAINTENANCE SCHEDULE
CHART in Maintenance Instructions.
24
Operating Instructions
CONTROL IDENTIFICATION, LOCATION, AND
FUNCTION
CAUTION
Before operating the mower, become familiar with the location and function of all operator controls. Knowing the location,
function, and operation of these controls is
important for safe and efficient operation
of the mower.
Ignition Switch
The ignition switch is located on the right front of the
body and is used to start and stop the engine. The
switch has three positions: “O” is the OFF position,
ON (RUN) is the position the key returns to after
starting, and “S” is the START position. When starting the engine, turn the key clockwise to the “S” position.
Do not hold the key in the “S” position longer than
10 seconds. If the engine does not start, return the
key to the “O” position for at least 60 seconds before
making a restart attempt. Prolonged cranking can
damage the starter motor and shorten battery life.
Release the key when the engine starts, and it will
return to the ON (RUN) position. To stop the engine,
rotate the key counterclockwise to the “O” position.
Engine Choke
The choke control lever (black knob) is located on
the left side of the seat. To start a cold engine, move
the choke control forward to the ON position. After
engine starts, move the choke control toward the
OFF position, keeping enough choke to allow the
engine to run smoothly as it warms up. As soon as
possible, move the choke to the OFF position. A
warm engine requires little or no choke for starting.
IMPORTANT: Make sure the choke is in the OFF
position during normal engine operation; running
with the choke in the ON position CAN damage the
engine.
OFF
ON
Parking
Brake
START
Blade Clutch
(PTO)
Ignition Switch
Key Positions
Front Body
Latch Release
(Not Visible)
Steering
Levers
Forward Speed
Control (FSC)
Ignition Switch
Hourmeter
Operating Controls
25
Operating Instructions
Engine Throttle
Steering Levers
The throttle control lever (red knob) is located on the
left side of the seat and is used to control engine
speed. Moving the lever forward toward the FAST
position increases engine speed; moving it backward toward the IDLE position decreases engine
speed.
Each drive wheel is controlled by its own independent steering lever, for both steering function and
FORWARD/REVERSE motion. The FSC lever sets
the maximum forward speed, and also sets the forward position of the steering levers. The steering
levers operate only with a backward pulling movement of the lever, which causes the drive wheel for
that lever to first slow down, stop, and then reverse
with a full backward lever stroke. The levers are
released to the FORWARD position for “straightahead” ground travel.
Throttle
Choke
NOTE: Pushing forward on the steering levers will
not cause any change in tractor motion - there will
be no steering lever reaction and there will be no
machine damage.
Blade Clutch (PTO)
Choke and Throttle Location
Forward Speed Control (FSC)
Forward Speed Control (FSC) has two functions:
One is to set forward travel speed, and the other is
to establish the NEUTRAL-PARK position. When
the FSC lever is moved into the FORWARD position, a friction lock holds any forward speed setting
from 0 to 6.5 mph (0 to 10.5 km/h). The ground
speed is proportional to the lever position; the further the lever is advanced forward, the faster the
tractor moves. It is not necessary to hold the FSC
in position since the friction lock maintains the selected lever position. Pulling back on the steering
levers overrides the FSC setting and slows or stops
forward travel. Releasing the steering levers allows
the tractor to resume forward travel at the speed set
by the FSC lever. To stop and park the machine, the
FSC lever is moved backward to the NEUTRALPARK position.
Front Body Latch Release
The front portion of the tractor body hinges forward
for maintenance access and is latched down in the
OPERATING position. To raise the body, move the
latch release backward.
26
The blade clutch lever is located on the right side of
the seat behind the right fender and is used to engage and disengage the mower blades. The blade
clutch has two positions. Pushing the lever DOWN
engages the PTO that drives the mower blades.
Pulling the lever UP disengages the PTO and engages the blade brake.
NOTE: On GHS equipped models, the Powerfil®
motor and Grass-Pak® full signal switch are activated by engaging the blade clutch. Refer to Using
the GHS Catcher in this section for a complete description of GHS operation.
Operating Instructions
Parking Brake
Transaxle Lockout Arms
The parking brake functions by locking a detent arm
to a cog inside the transaxle. Moving the lever FORWARD engages the parking brake; moving the lever BACKWARD releases the brake.
The transaxle lockout arms disengage the transaxles. By lifting the arms up and locking them into
place with the shoulder on the arm in the chassis
notch, the transaxles are released to permit freewheeling. By releasing the arms and recessing
them back toward the chassis, the transaxles are
engaged for normal operation. The transaxle arms
in the LOCKOUT position are used to enable moving the machine without the engine running (e.g., for
service). Refer to TRANSAXLE LOCKOUTS in this
section for operating instructions.
IMPORTANT: Stop the tractor completely before
engaging the parking brake. The parking brake
uses a positive mechanical lock similar to the PARK
position on an automotive automatic transmission.
If the tractor is moving when the brake is engaged,
it will result in sudden stoppage and possible internal damage to the transaxle.
NOTE:
If pressure on the parking brake (e.g.,
parked on a hill) makes it impossible to release the
parking brake with the parking brake lever, move the
mower gently forward or backward to allow the
brake detent to release.
NOTE: The transaxle lockout arms ends should be
completely retracted against the chassis, otherwise
operation of the transaxle may be erratic.
Hydro Lockout
Arms
Hydro Lockout Arm Location
Parking Brake Engaged
Parking Brake Disengaged
27
Operating Instructions
Hourmeter
The hourmeter, which is located on the right front of
the body, displays operating time accumulated
while the PTO (blade drive) clutch is engaged.
The hourmeter provides maintenance reminders after certain hours of operation. The hourmeter screen
will start flashing the reminder one hour prior to the
recommended interval and will continue until one
hour after the recommended interval (two hours).
The hourmeter does not have a manual reset
function.
*
Procedure
Interval*
Reminder
Oil Change
(Break-In)**
4-6 Hours
C
H
G
Lubricate
and Check
Levels
24-26 Hours
Oil Change
49-51 Hours***
OIL
LUBE
C
H
G
OIL
These intervals reflect the actual time that the
reminder will flash (one hour prior to and one
hour after the recommended interval).
** This reminder is only used one time.
*** In normal operating conditions, oil changes in
100-hour intervals are acceptable. Walker and
the engine manufacturers recommend engine
oil changes every 50 hours in extremely dirty or
dusty conditions or for units with less than 100
hours annual use.
NOTE: The blinking hour glass on the display
means that the meter is operating properly.
28
Hourmeter
Operating Instructions
The Forward Speed Control also Establishes the Neutral-Park Position of the Steering Levers
LEFT WHEEL
STEERING LEVER
FORWARD SPEED
CONTROL LEVER (FSC)
RIGHT WHEEL
STEERING LEVER
Forward Position
(No Control Change)
Full Forward
Ground Speed
Position
Neutral-Park
Position
Intermediate
Ground Speed
Position
Reverse Drive
Wheel Motion
Position
Neutral-Park
Position
Fast
Throttle
Position
<15°
1.
2.
Idle
Position
Engaged
Position
THROTTLE
Engaged
Position
Disengaged
Position
ON Position
PARKING
BRAKE
OFF Position
BLADE CLUTCH
(PTO)
Disengaged
Position
CHOKE
Operating Controls (Top View from Drivers Point of View)
29
Operating Instructions
STARTING THE ENGINE
CAUTION
Before operating the mower, read and un­
derstand all Safety Instructions and Operat­
ing Instructions.
WARNING
NEVER run the engine in an enclosed or
poorly ventilated area. Engine exhaust
contains carbon monoxide, an odorless
and deadly gas.
1. Before attempting to start the engine, make
sure the operator is in the seat, the Forward
Speed Control is in NEUTRAL-PARK position,
and the blade clutch and parking brake are DISENGAGED.
NOTE: Release parking brake to prevent extra
load on the starter if the transmission neutral is
slightly out of adjustment.
CAUTION
A safety interlock switch system PRE­
VENTS CRANKING the engine with either
the Forward Speed Control out of neutral,
or the blade clutch (PTO) engaged. If the
engine cranks otherwise, the safety system is not working and should be repaired
or ad­
justed before operating the mower.
DO NOT disconnect safety switches; they
are for the operator’s protection.
2. Move the choke lever to the ON position and
move the throttle 1/4 to 1/2 open (toward FAST).
Turn the ignition switch to the START position
to start the engine. Release the key to ON
(RUN) position as soon as the engine starts.
NOTE: The choke may not be required if the
engine is warm.
30
IMPORTANT: DO NOT crank the engine
continuously for more than 10 seconds at a time.
If the engine does not start, turn the key to the
OFF position and allow a 60 second cool-down
period between starting attempts. Failure to
follow these guidelines can damage the starter
motor and shorten battery life. Consult your
Walker dealer or authorized engine dealer for
additional help.
3. After the engine starts, gradually move the
choke to the OFF position, keeping enough
choke on to allow the engine to run smoothly as
it warms up. As soon as possible, move the
choke to the OFF position.
IMPORTANT: Make sure the choke is in the
OFF position during normal engine operation;
running with the choke in the ON position CAN
damage the engine.
ADJUSTING GROUND SPEED AND STEERING
CAUTION
Learn to START, STOP, and MANEUVER the
mower in a large, open area.
If the operator has not operated a ma­chine
with LEVER STEERING OR DUAL TRANSAXLES, steer­
ing and ground operation
should be learned and practiced until the
operator is completely comfortable handling the ma­chine BEFORE ATTEMPTING
TO MOW.
DANGER
Keep feet on footrests at all times when
the machine is moving. Never operate the
tractor without a deck or implement installed.
Operating Instructions
Beginning Recommendations are:
♦ Learn operation of the mower in an open
area away from buildings, fences, and ob­
structions. Learn operation on flat ground
BEFORE operating on slopes.
♦ Start maneuvering the mower with SLOW
engine speed and SLOW Forward Speed
Control setting until familiar with all operat­
ing characteristics.
♦ Remember it is not necessary to hold the
steering levers forward (a unique Walker
feature); always PULL on the levers for
steering or for reverse motion of the mower.
♦ Learn to operate the mower with your left
hand on the steering levers and right hand
on Forward Speed Control. The use of two
hands on the steering levers tends to cause
overcontrol.
♦ Learn to operate the steering levers with
smooth action. Jerky movements are hard
on the transmission and lawn. For sharp
turns, do not allow the inside wheel to stop
and twist on the grass. Pull the steering le­
ver controlling the inside wheel into reverse
for a smooth “rolling” turn (one wheel roll­ing
forward while the other rolls backward).
♦ Practice maneuvering the mower until
you can make it go exactly where you are
aiming.
♦ Remember, for an emergency stop, or in
case of loss of control, machine movement
can always be stopped quickly by pulling the
Forward Speed Control into the NEU­TRALPARK position.
1. Move the FSC out of NEUTRAL-PARK position
to the desired forward speed. DO NOT hold
for­ward on steering levers. It is not necessary
to hold the FSC lever in position since a friction
lock maintains the selected lever position (and
forward travel speed).
WARNING
If either of the transmission drive belts
break during slope operation, the machine
will freewheel down the slope. To maintain
control, immediately (1) Release the
steering levers and simultaneously (2)
Move the FSC to the NEUTRAL-PARK
position. When the machine is stopped or
moving slowly, engage the parking brake.
NOTE: This is exactly the same procedure
used to normally stop and park the machine.
CAUTION
An operator presence switch (seat switch)
will cause the engine to stop if the FSC is
out of the NEUTRAL-PARK position and
the operator is not in the seat. The function
of this switch should be checked by the op­
erator raising off the seat with the tractor
moving forward; the engine should stop. If
the safety sys­tem is not working, it should
be repaired or replaced before operating
the mower. DO NOT disconnect the safety
switches; they are for the operator’s protection.
NOTE: If the FSC lever will not stay in the selected position, the friction lock needs to be adjusted. Refer to ADJUSTMENTS for Step 7 Forward Speed Control Friction Adjustment in
the Maintenance Instructions.
2. Steer by pulling the lever on the side of desired
direction of turn, e.g., pull the LH lever to turn
left. To minimize the possibility of overcontrol,
use only one hand on both steering levers.
31
Operating Instructions
Pull Steering
Levers With
Left Hand
4. The FSC may be adjusted forward for faster
ground speed and backward for slower ground
speed. When mowing, ground speed should be
adjusted to match the load on the cutter blades,
i.e., as the engine pulls down in heavy cutting,
pull back on the FSC lever to reduce ground
speed. Adjusting ground speed helps maintain
a balance between engine power and blade
speed for high-quality cutting action.
5. Stop ground travel by pulling both steering le­
vers backward to the NEUTRAL-PARK position
(trac­tor not moving) and then moving the FSC
lever to the NEUTRAL-PARK position.
NOTE: If the tractor creeps forward or back­
ward with the FSC lever in the NEUTRAL-PARK
position, the transmission control needs to be
adjusted. Refer to ADJUSTMENTS for Step 3 Neutral Position Adjustment in the Maintenance
Instructions.
Forward Speed Control
(FSC)
ENGAGING THE BLADE DRIVE
Keep Feet on Footrest
When Moving
Correct Operator Hand Position
on the Controls
1. Set the engine throttle at about 1/2 speed. DO
NOT attempt to engage the blade clutch at
high engine speeds. This will drastically short­
en drive belt life. Use only moderate engine
speed when engaging the blade clutch.
3. Reverse direction of the mower by pulling both
levers backward.
2. Push the blade clutch lever SLOWLY forward to
en­gage the mower blades.
NOTE: Smooth action on the steering levers
will produce smooth mower operation. Remem­
ber to keep the engine and ground speed slow
until learning the control response.
WARNING
When moving forward, DO NOT suddenly
put the tractor in reverse by rapidly pulling
on the steering levers, especially when going downhill, as this can lift the tractor tail
wheel off the ground and set up a bucking
motion due to operator overcontrol. If
bucking does occur, immediately stop the
bucking action by pulling the Forward
Speed Control (FSC) lever into the NEUTRAL-PARK position.
32
CAUTION
An operator presence switch (seat switch)
will cause the engine to stop if the blade
clutch is engaged and the operator is not in
the seat. The function of this switch should
be checked by the op­erator raising off the
seat and engaging the blade clutch; the engine should stop. If the switch is not working, it should be repaired or replaced before operating the mower.
DO NOT
disconnect the safety switches; they are
for the operator’s protection.
IMPORTANT: DO NOT engage the blade clutch
when transporting the mower across drives, side­
walks, loose materials, etc. DO NOT engage the
blade clutch with the PTO shaft disconnected
(the mower deck removed from tractor).
Operating Instructions
STOPPING THE MACHINE
1. Pull the steering levers to the NEUTRAL-PARK
posi­tion and then move the FSC lever backward
to the NEUTRAL-PARK position.
2. Slow the engine down by moving the throttle to
the IDLE position.
3. Disengage the blade clutch.
Engaged
Position
Blade Clutch Engaged
NOTE: Reducing engine speed prior to disengaging the blade clutch will reduce wear on the
brake band and brake drum, increasing the life
of these components.
WARNING
Disengaged
Position
Blade Clutch Disengaged
CAUTION
If the cutting blades strike a stationary ob­
ject while mowing, stop the mower imme­
diately, disconnect the spark plug wire, lift
the deck, and inspect the deck and blades
thoroughly for damage. Make sure that the
blade timing has not been dis­turbed (the
blades should be at 90 degrees to each
other). Refer to REPLACING/RE­PAIRING
the Blade Overload Shear Bolts in Mainte­
nance Instructions if blades are out of time.
Also, make sure the blade retain­ing nuts
are torqued to 60 lb·ft (81 N·m).
A brake stops the cutter blades (and
blower on GHS equipped models) from
freewheeling within five (5) seconds after
disengaging the clutch. If the brake sys­
tem malfunctions and the blades do not
stop within five (5) seconds, the brake
should be adjusted or repaired before op­
erating the mower. Contact your Walker
dealer.
4.Turn the ignition switch OFF.
WARNING
Remove the key from the ignition switch
when leaving the mower unattended. This
will prevent children and inexperienced
operators from starting the engine.
5. Engage the parking brake by moving the lever
forward.
IMPORTANT: When the machine is in NEUTRAL it may slowly creep, especially if parked
on a slope. Always engage the parking brake to
prevent any machine movement.
33
Operating Instructions
ADJUSTING CUTTING HEIGHT
WARNING
The engine must be stopped before ad­
justing cutting height. Disengage the blade
clutch (PTO), stop the engine, and remove
the ignition key. Wait for all move­ment to
stop before getting off the seat.
Cutting height is adjusted by positioning the four (4)
re­tainer hitch pins in a series of seven vertical holes
on the deck support pins. Lift handles have been
pro­vided on each end of the deck to assist in raising
the deck while positioning the hitch pins. Cutting
heights range from 1 in. (25 mm) [top holes] to
4 in. (102 mm) [bottom holes] in 1/2 in. (13 mm)
incre­ments.
Lift Handle
Deck Support
Pin
3. The mower will “freewheel” with the arms in the
LOCKOUT position. The levers must be in the
highest position to completely unlock the transmissions.
Hydro Lockout Arm
Hydro Lockout Arm - Freewheel Position
4. After moving the mower, release the arms, placing them in the normal OPERATING position.
The transmission arm ends should be completely retracted against the chassis, otherwise
operation of the transmission maybe erratic.
Hydro Lockout Arm
Hitch Pin
Cutting Height Adjustment
TRANSAXLE LOCKOUTS
IMPORTANT: DO NOT TOW this mower faster than
2 mph (3.2 km/h) with the transmission lockout engaged. Towing can produce excessive internal
pressure and damage the transaxle(s).
To move the mower with the engine NOT running
(dead battery, maintenance, etc.), the transaxles
need to be unlocked (released).
1. Raise the body.
2. Pull up on each transaxle lockout arm and move
toward the center of the machine to engage the
step that holds the arm in the UP (unlocked)
position.
34
Hydro Lockout Arm - Normal Operating Position
Operating Instructions
RECOMMENDATIONS FOR MOWING
DANGER
Do not mow around overhanging tree
branches or bushes at the same height as
the operator’s torso and head where inadvertent contact may cause injury.
• When mowing, operate the engine at full throttle
for the best cutting action and performance of the
grass handling system (GHS). Mowing with a lower
engine RPM causes the mowing blade to not cut
clean and tear the grass. The engine is designed
to be operated at full speed.
• When mowing in adverse conditions (tall and/or
wet grass), mow the grass twice. Raise the mower
to the highest setting - 4 in. (102 mm) - for the first
pass and then make a second pass cutting to the
desired height.
• Use a slow setting on the FSC for trimming operations.
• Make sure the mower is leveled properly for a
smooth cut. Refer to Deck Leveling in Assembly
Instructions.
• Use an alternating stripe mowing pattern for
best appearance and vary the direction of the stripe
each time the grass is mowed to avoid wear patterns
in the grass.
• Avoid damage to the grass by slipping and skid­
ding of the drive tires. Use smooth control move­
ments of the steering levers since the transaxles are
“power boosted controls” and jerk­ing the levers can
easily slip the tires. For sharp turns, do not allow the
inside wheel to stop and twist on grass; pull inside
steering lever into reverse for a smooth “rolling” turn
(one wheel rolling forward while the other rolls
backward).
Avoid Low Hanging Branches
IMPORTANT: Operate the engine at full throttle
when mowing, to allow the engine to produce full
horsepower and to increase efficiency of the engine
cooling system.
• Keep the mower deck and discharge chute clean.
• Mow with sharp blades. A dull blade tears the
grass (resulting in poor lawn appearance) and uses
extra power (slowing the mowing speed).
• It is preferable to cut grass when it is dry and not
too tall. Mow frequently and do not cut grass too
short. (For best appearance, cut off 1/3 or less of
existing grass height.)
35
Operating Instructions
• When using a side discharge mower deck, the
side discharge deflector shield must not be removed and must be kept in the lowest possible position to deflect grass clippings and thrown objects
down­ward. Orient the side discharge away from side­
walks or streets to minimize cleanup of clippings.
When mowing close to obstacles, orient the side dis­
charge away from obstacles to reduce the chance of
damage to property by thrown objects.
Maximum Recommended
Slope - Do Not Operate
on Steep Slopes
Discharge
Shield
60 lb·ft
(81 N·m)
8600-14
8600-9
15°
16 in.
52 in.
Maximum Recommended Slope
Side Discharge Deflector Shield in
Lowest Position
DANGER
• When operating on a slope, reduce speed and
use caution to start, stop, and maneuver. Avoid
sharp turns or sudden changes in direction. The
maximum recommended slope operating angle
is 15 degrees or 26% grade.
Do not mow or dump grass within 5 feet
(1.5 meters) of an embankment or retaining
wall with drop off.
5 FT
MINIMUM
No Driving Zone
36
Operating Instructions
RECOMMENDATIONS FOR TILT-UP DECK
OPERATION/TRANSPORT
To avoid potential deck and/or tractor damage while
using the tilt-up deck, the following recommendations are offered:
• Do not move the tractor with the deck in the tiltup position since both the roller wheels (on the back
of the deck) and the GHS discharge chute may be
damaged by moving the tractor. The tilt-up configuration should only be used when the tractor is
parked.
• The tractor body should never be tilted forward with the deck in the tilt-up position. This can
cause the deck to unhook from the tractor and fall
with considerable force, potentially causing deck or
tractor damage and/or bodily injury.
• When transporting a tractor with the deck in the
tilt-up position (on a truck or trailer), the deck should
be secured to the vehicle with a strap or rope (stop
vertical movement). This will prevent the deck from
bouncing on the rear roller wheels (causing breakage). This will also prevent the deck from unhooking
from the tractor and falling, potentially causing deck
or tractor damage. Damage to other items parked
in front of the deck may also occur.
37
Operating Instructions
GRASS HANDLING SYSTEM (GHS)
GHS Model Only
Grass
Catcher
Exhaust Screen
(Removable)
Grass-Pak®
Vane Switch
Catcher
Door Spring
(Not Visible)
Actuator
Rod
Powerfil ®
Drive Motor
Catcher
Air Exhaust
“Full” Signal
Horn
PTO
Clutch
PTO and Blade
Gear Drive
Catcher
Door
Shear Pin
(If Equipped)
Powerfil ®
Delivery Spout
Shear Bolt
(Gear Driven
Decks Only)
Dump
Handle
Catcher
Chute
Body Chute
Assembly
Blower
Deck
Discharge Chute
Rear Discharge
Mower Deck
GHS Flow and Components
38
Operating Instructions
General Information
The Grass Handling System (GHS) consists of a
rear discharge mower deck connected to a 12.5 in.
(32 cm) blower and a rear mounted grass catcher
with 7.0 bushel (246 liters) capacity. The GHS blower operates any time the mower blade clutch is engaged and moves grass through the rear discharge
deck chute into the grass catcher. Blower airflow is
exhausted out the back of the grass catcher, through
a filtering screen. When the grass catcher is full and
needs to be emptied, a “full” signal horn alerts the
operator. When the “full” signal horn sounds, it is
important to stop mowing to prevent overfilling and
clogging of the blower system.
IMPORTANT: Normally, the GHS blower operates
with no maintenance or cleaning required. However,
under certain operating conditions, the inside of the
blower housing may accumulate a deposit of dirt,
causing wear and binding of the blower wheel.
Normally, dirt buildup occurs when mowing a com­
bination of dirty and damp grass, especially in
the springtime. When operating in these condi­tions,
check the blower wheel frequently for binding
and clean the blower housing as required. Refer to
CLEANING the GHS Blower in Mainte­nance
Instructions.
DANGER
ROTATING BLOWER BLADES
NEVER operate the GHS blower with the
blower discharge chute uncovered (grass
catcher in the dump position) since
dangerous projectiles may be thrown.
NEVER put hands into the blower discharge
chute for any reason. Use a stick or similar
instrument to remove any material if
clogging has occurred.
CAUTION
NEVER leave grass clippings in the grass
catcher after mowing. Damp clippings
generate heat as they decompose. This
MAY cause spontaneous combustion.
NOTE: In Autumn, when using the GHS mower to
vacuum leaves, it is recommended to raise the front
of the mower deck 2 to 3 notches [1 to 1-1/2 in.
(25 to 38 mm)] higher than the rear. This will avoid
“bulldozing” leaves, particularly when the leaves
are piled in a thick layer. To make this ad­justment,
the hitch pins in the two (2) front deck support pins
are repositioned 2 to 3 notches higher while leaving
the rear pins in their original position.
DANGER
NEVER operate the GHS catcher with the
back door open. Objects may be thrown
out the back of the catcher with sufficient
force to cause serious injury to bystand­ers
or property damage.
39
Operating Instructions
Clogging Checklist
In case of clogging, there will be a distinct change
in the sound of the blower, i.e., the blower sound
will stop. Also, the mower deck will begin to leave a
trail of grass clippings. When this occurs, stop the
engine, disconnect the spark plug wire, and make
sure all movement has stopped before attempt­
ing to unclog.
Blades Must Operate at
Right Angles (90 Degrees)
FORWARD
DANGER
NEVER place hands under the mower deck
or in the GHS blower discharge chute.
Use a stick or similar tool to remove any
clogged material.
Normally, any clogging will first develop at the back
of the mower deck in the discharge opening into the
blower chute. Clogging at this point does not indi­
cate a particular problem in this part of the system, but is a symptom of something restrict­ing
the flow of material throughout the entire system.
The following list of items should be checked if a
pattern of clogging begins to develop. All of these
items are capable of causing clogging at the back of
the deck.
• Check to see if the mower blades are installed for
the correct rotation. The blade cutting edges
should move towards each other at the front of the
deck on standard rotation decks (e.g., DC42), and
towards each other at the back of the deck on reverse rotation decks (e.g., DC36R).
Blades Must Operate at
Right Angles (90 Degrees)
FORWARD
Rear Discharge
Chute
Mounting Nut
Torque = 60 lb·ft
(81 N·m)
Blade Rotation for Reverse Rotation
GHS Mower Deck (Bottom View)
• Check the amount of flat section remaining at
blade tip. This is the area that is ground away (re­
moved) when the blades are sharpened. If too much
of the flat section is removed, the “air lift” performance or “shovel” effect of the blade deteriorates to
the point that discharge of grass clippings into the
blower chute is marginal. Replace cutter blades if
less than 3/4 in. (19 mm) flat section remains at the
blade tip.
• Check that the interior of the deck housing and
baffling is reasonably clean and free of grass and
dirt buildup. While some degree of material buildup can be tolerated, a point is finally reached where
the flow of air and grass clippings is restricted.
NOTE: One condition that quickly causes a buildup
of material in the deck housing is mowing grass and/
or weeds which are “juicy.” The material collects
under the deck with sticky, green juice. Clo­ver and
weeds are especially a problem. The mower deck
will need to be cleaned frequently when operating in
these conditions.
• Check the deck cutting height setting. When
Rear Discharge
Chute
Mounting Nut
Torque = 60 lb·ft
(81 N·m)
Blade Rotation for Standard Rotation
GHS Mower Deck (Bottom View)
40
working in thick, tall grass, lower deck settings
[1 to 2 in. (25 to 51 mm) cutting heights] tend to
restrict airflow from moving into and under the deck.
Raising the deck cutting height will signifi­cantly
increase airflow and reduce clogging when working
in thick, tall grass.
• Check the interior of the chute connecting the
mower deck to the blower for smoothness and
freedom from obstruction.
Operating Instructions
• Check the blower wheel for bent blades and
excessive clearance between the blade tip and
the blower housing. A clearance greater than
1/8 in. (3 mm) will cause a significant loss of
blower performance.
• Check the blower discharge chute into the grass
catcher for smoothness and freedom from ob­
struction.
• Check the elbow inside the grass catcher for a
buildup of material in the radius of the elbow. In
certain conditions (damp/dirty grass) a considerable
“clump” of material can accumulate at this point,
greatly restricting material and airflow.
• Check that the openings in the removable air
exhaust screen in the grass catcher are not
plugged. If the screen is clogged, refer to Cleaning
the GHS Exhaust Screen in this section.
“Full” Signal Horn
The GHS catcher has a “full” signal horn to alert
the operator to dump the catcher when it is full (to
prevent overfilling and clogging). The “full” signal
horn is activated by a vane switch (Grass-Pak®
switch) mounted on the grass delivery spout. Oscil­
lating action of the spout triggers the vane switch as
grass begins to fill in around the spout when the
catcher is almost full.
The “full” signal function may be checked by turning
the ignition switch ON (RUN), engaging the blade
clutch (engine not running), opening the catcher
back door, and triggering the Grass-Pak® vane by
hand as it oscillates. The horn should sound as the
switch is moved in one direction.
WARNING
NOTE: An optional exhaust screen with larger
holes (3/4”) is available for use when mowing in wet
grass; the screen provides less airflow restriction
and more clog resistance (use standard screen in
dry conditions to avoid excessive material blowing
out of the catcher).
DO NOT test the Powerfil® oscillation or
Grass-Pak® switch with the engine running. Projectiles may be thrown out of the
grass delivery spout, and COULD cause
serious injury.
Remember, anything that restricts airflow or material flow along the entire path from the mower deck
to the grass catcher can cause clogging.
The “full” signal horn is designed to operate (sound)
when the grass catcher is almost full. The timing
of the signal is adjustable by changing the position
of the vane on the Grass-Pak® switch. If the signal
is coming on too soon (catcher not completely full)
or too late (grass clogging in catcher spout and
deliv­ery chute), refer to ADJUSTMENTS for GHS
“Full” Signal Horn Adjustment in Maintenance In­
structions.
Using the Tilt-Up Deck
Refer to CLEANING of Grass Buildup in Mower
Deck Housing in Maintenance Instructions.
Using the GHS Catcher
Powerfil ®
The GHS catcher has an oscillating grass delivery
spout (POWERFIL®) which is designed to spread
grass clippings throughout the interior of the grass
catcher (even when mowing wet, heavy grass). The
oscillating action may be checked by turning the ignition switch to the ON (RUN) position and moving the
blade clutch to the ENGAGED position. The spout
should oscillate approximately 35 cycles per minute.
NOTE: The horn signal should be adjusted to
sound BEFORE the catcher is completely full to
give the operator time to react and stop mowing. An
indication the horn signal is coming on too late (de­
layed too much) is if grass clippings are falling out of
the grass catcher delivery chute when the catcher is
dumped.
NOTE: If the grass spout fails to oscillate, the clutch
switch should be checked for function.
41
Operating Instructions
Cleaning the GHS Exhaust Screen
To remove the grass catcher screen for cleaning,
open the catcher door, push forward and pull down
on the grass catcher screen knobs (on either side of
the screen), and slide the screen out. Use a high
pressure washer or water spray and brush to clean
the screen.
Keeping the catcher exhaust screen clean and open
is essential to good performance of the catching
system. In some mowing conditions, e.g., wet and
dirty, it will be necessary to clean the screen fre­
quently to avoid clogging the mower deck, blower,
and chutes due to airflow restriction.
Grass Catcher
Screen
Use leg muscles and firm footing when
lifting the catcher to dump; avoid bending
at the waist and using back muscles in
order to prevent back injury.
Tailgate Dumping
1. Open the back door by lifting on the door handle.
2. Tilt the catcher back to dump by lifting on the
catcher lift handle on the lower front corner of
the catcher.
3. Lower the catcher smoothly down to the normal
operating position. DO NOT allow the catcher
to drop down - the gas spring, that holds the
catcher in the raised position, is not a shock
absorber for lowering the catcher.
Removal
Knobs
Grass Catcher Screen Removal for Cleaning
Dumping the Catcher
DANGER
Do not mow or dump grass within 5 feet
(1.5 meters) of an embankment or retaining
wall with drop off.
For dumping, the catcher either tailgate dumps into
a disposal area or dumps into the optional dump
bag. The dump bag is a reusable nylon fabric bag
designed to conveniently move grass clippings from
the catcher to a remote disposal area or container.
42
CAUTION
4. Close the door by pulling down on the door
handle. The door should close smoothly with
the assistance of the gas springs. If the
dampening springs are not functioning properly, they should be replaced to prevent the
door from slamming closed and possibly
causing a pinch point.
Operating Instructions
Using the Dump Bag
1. Open the back door by lifting on the door handle.
Catcher
Dump Handle
2. Orient the dump bag with one of the handle
straps on the bag opening facing up.
Tailgate
Door Handle
Hook Bag
on Bumper
Dumping Catcher into Dump Bag
Positioning Dump Bag on Catcher
­3. Hook the bottom of the bag over the rear bumper while lifting on the handle strap.
6. Close the door by pulling down on the door
handle. The door should close smoothly with
the assistance of the gas springs. If the
dampening springs are not functioning properly,
they should be replaced to prevent the door
from slamming closed and possibly causing a
pinch point.
4. Tilt the catcher back to dump into the bag by
lifting on the catcher lift handle on the lower
front corner of the catcher with the one hand
while continuing to hold up on the bag strap
with the other hand. Refer to photos for posi­
tioning the bag and dumping.
5. Lower the catcher smoothly down to the normal
operating position. DO NOT allow the catcher
to drop down - the gas spring, that holds the
catcher in the raised position, is not a shock
absorber for lowering the catcher.
43
Maintenance Instructions
CAUTION
Maintenance procedures requiring special training or
tools should be performed by a trained technician.
MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL S14
Service Item
Daily
25
Hours
50
Hours
100
Hours
400
Hours Yearly
Every
2 Years
Check Engine Crankcase Oil Level
x
46
Check/Clean Engine Air Cooling System*
x
55
Clean Grass Buildup Under Deck
x
56
Clean GHS Exhaust Screen*
x
56
Clean GHS Blower*
x
56
Service Mower Blades
x
58
Check Security of Air Filtration Components
x
57
Lubricate Grease Fittings and Oil Points*
x
47
Check Battery Electrolyte Level
x
57
Check Transaxle Fluid
x
50
Check Tire Pressure
x
58
Check Drive Belts (Engine, PTO, Ground Drive)
x
60
Check PTO and Deck Gearbox Oil Seals
x
60
Check Safety Switch System
x
61
Change Engine Crankcase Oil **
x
47
Clean Fuel Filter
x
54
Check Air Filter Element*
x
53
Cleaning Transaxle Housing
x
57
Check/Regap Spark Plug
x
60
Check Wheel Bolt Torque (75 to 85 lb·ft)
x
58
Check Blade Brake Action
x
Change Transaxle Oil and Filter
x
60
x
51
Clean Engine Cooling Fins
x
55
Check Fuel Lines and Clamps
Replace Air Filter Element
and Dust Ejection Valve ***
Service Battery
Check/Adjust Vertical Position of
Grass-Pak® Switch
Check/Adjust FSC Friction Lock
x
60
x
53
x
57
x
76
x
61
Replace Fuel Lines and Clamps
44
Ref.
Page
x
∗
More often in extremely dusty or dirty conditions
(see notes about air cleaner element under IMPORTANT TIPS FOR CARE OF THE SUBARU ENGINE)
∗∗
Change engine oil after first 8 hours of operation of a new engine (break-in period)
∗∗∗
Air cleaner is remote mounted Donaldson Radialseal unit, replace filters every year and dust ejection valve
every year or when worn or damaged
60
Maintenance Instructions
IMPORTANT TIPS FOR CARE OF THE
SUBARU ENGINE
Fuel System
• Fuel must be clean - free from water, dirt, and or­
ganic material.
• Clean the fuel filter on a regular basis and when
contamination is suspected or found in the fuel.
Starting/Stopping
• Start engine with the throttle advanced off idle
(1/4 to 1/2 throttle). This will aid starting, especially
in cold weather.
• Keep the battery fully charged.
• Match crankcase oil viscosity to the ambient tem­
perature, allowing the engine to crank faster and
start easier.
• Allow engine to run at idle for a few seconds be­
fore stopping engine to avoid run-on or backfiring.
Cooling System
CAUTION
DO NOT use a pressure washer to clean the
cooling system on an air-cooled engine,
mud may form under the cooling shroud
on the cylinder head and cooling fan.
• Keep engine air intake screen and cylinder head
fins free of grass clippings, chaff, and dirt. Inspect
intake screen and cooling fins for cleanliness and no
damage.
•Check performance of the cooling system by
starting the engine, holding a hand adjacent to the
cylinder head, and feeling the cooling airflow.
SUBARU TIPS
• Operate the engine at full speed when mowing.
This allows the engine to produce full horsepower
and move more cooling air through the engine cool­
ing fins.
Air Cleaner System
•Use only Donaldson air cleaner elements. After­
market elements may not seal in the air cleaner
housing, allowing dirt to enter the engine. Also, af­
termarket filters often skimp on the filtration media
and require more frequent replace­ment (see following instructions).
• DO NOT overservice or frequently “disturb” the
air filter. A dirty air filter actually cleans better than
a new one. Changing the air filter too often can
actually reduce filter efficiency and increase the opportunity for traces of dust to enter the engine.
• When the air filter element is removed or re­placed,
make sure all dust is cleaned out of the air cleaner
housing and hose. Use a damp cloth and wipe the
interior of the canister and hose clean (a lit­tle dirt left
here will be sucked into the engine and reduce engine
life). When the filter is reinstalled, make sure the
element is held tight and straight in the canister for
proper seating and sealing.
• Periodically check the air intake hose for cuts,
nicks, etc., and the hose clamps for tightness.
Oil
• DO NOT screw filler cap into crankcase when
checking oil level.
• Single viscosity or multi-viscosity oils may be
used with the viscosity matching ambient temperatures for the engine operating conditions. This will
aid starting in cold weather and assure proper lubrication in hot weather.
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
45
Maintenance Instructions
LUBRICATION
WARNING
DO NOT attempt to lubricate the machine
with the engine running. Disengage the
PTO clutch, shut off the machine, and re­
move the ignition key.
LUBRICATION
IMPORTANT: DO NOT operate engine without
a sufficient oil supply in the crankcase. DO NOT
operate with oil level below the LOW (L) mark or
above the FULL (H) mark on the dipstick.
NOT SCREWED IN
Filler Plug
Proper lubrication is an important maintenance pro­
cedure. It reduces wear and makes the machine
quieter and easier to operate.
FULL (H) Mark
Engine Oil
LOW (L) Mark
Engine Break-In Oil
No special break-in oil is required. The engine is
serviced with 10W-30, Service Class SG oil from the
factory. Change the oil after the initial engine breakin period of 8 hours. Thereafter, change oil after
every 50 hours of operation.
Dipstick Position for
Checking Oil Level
Checking Engine Crankcase Oil Level
Check the engine crankcase oil level before use and
after each 5 hours of continuous operation.
IMPORTANT: The importance of checking and
maintaining the proper crankcase oil level cannot be
overemphasized. Check the oil level BEFORE
EACH USE.
1. Park the mower on a level surface with the
en­gine stopped. Also, make sure the engine
is cool and oil has had time to drain into the
sump (allow at least five (5) minutes after
stopping the engine).
IMPORTANT: NEVER check or add oil with the
engine running.
2. Before removing the dipstick, clean the area
around the dipstick opening in the engine block
to keep any dirt or debris out of the engine.
3. Unscrew and remove the filler plug/dipstick and
wipe off with a clean rag. Insert dipstick into
filler hole but DO NOT screw it in to check the
oil level. Remove the dipstick and check the
level. The oil level should be within the safe
range (between the H and L marks on the dipstick).
46
FULL (H)
Mark
LOW (L)
Mark
Dipstick Operating Range
4. If additional oil is needed, refer to Specifications
for proper crankcase lubricant. Fill to the FULL
(H) mark.
IMPORTANT: DO NOT overfill crankcase [oil
above FULL (H) level] as this CAN result in engine overheating, loss of power, and possible
engine damage.
Maintenance Instructions
Changing Engine Crankcase Oil
Change the engine crankcase oil after every 50
hours of operation as follows:
1. Park the mower on a level surface with the
en­gine stopped. The engine oil should be
warm before draining. If not warm from operation, start the engine and run a few minutes to
warm the oil.
2. Before removing the dipstick, clean the area
around it to keep any dirt or debris out of the
en­gine.
3. Remove the dipstick and oil drain plug, and
drain oil into a suitable container. Be sure to
allow ample time for complete drainage.
LUBRICATION
5. Fill the crankcase (through the dipstick opening) with oil using only crankcase lubricants recommended by the engine manufacturer. Refer
to Specifications in this manual or the engine
owner’s manual. Use the recommended oil viscosity for the expected ambient temperature.
Oil with the correct viscosity will aid starting in
cold weather and assure proper lubrication in
hot weather. Fill to FULL (H) mark on the dipstick; crankcase capacity is 2.7 pints (1.3 liters).
IMPORTANT: Check the dipstick reading be­
fore adding the last 1/2 pint of oil and fill only to
the FULL (H) mark. The oil level should never
be over the FULL (H) mark on the dipstick; overfilling can result in engine overheating and loss
of power.
6. Start and run the engine. Stop the engine, recheck the oil level, and add oil if necessary.
Grease Fitting and Oil Point Lubrication
Oil Drain
Oil Drain Location
(View from Lower Right Side of Tractor)
Lubricate the grease fittings and oil points after ev­ery
25 hours of operation. Lubricate more often when
operating in dusty or dirty conditions. Use SAE
general purpose lithium or molybdenum base grease
for grease fittings and light machine oil (SAE 10) to
lubricate oil points. Lubricate the locations shown
in the Chassis and Deck Lubrication Points
illustration.
NOTE: PTO universal joints (on the deck and trac­
tor) require routine lubrication after every 8 hours
of running time.
NOTE: The flange bearings on the PTO drive shaft
are sealed and do not require periodic maintenance.
Dipstick
(Oil Fill)
Dipstick (Oil Fill) Location
(View from Lower Right Side of Tractor)
4. Reinstall the drain plug. Make sure it is tightened to 16.5 lb·ft (23 N·m).
47
Maintenance Instructions
Ident Lubrication
No.
Location Type
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Deck Caster Wheel Fork Pivot
Deck Caster Wheel Bearing
Blade Spindle
Pivot Assembly, Tilt-Up Deck
Deck Support Arm Socket
Universal Joint Shaft Assembly
Tee Gearbox, Deck
Blade Drive Gearbox
FSC Lever Pivot
Steering Lever Pivot
Deck-to-PTO Coupling
(Grease Spline Slide Area)
Transaxle Oil Reservoir
Universal Joint Tube Assembly
Deck Support Arm Pivot
Hydro Idler Pivot
PTO Clutch Lever Pivot
Body Latch Pivot
Clutch Actuator Spring Assembly
(Grease Slide Area)
LUBRICATION
No.
Places
Ident No.
Oil/20W-50
Grease**
Grease
Grease
Grease
Oil
Grease
PTO Belt Tightener Pivot
Engine Dipstick / Oil Filler
Catcher Hinge Point
Choke Control Cable Ends
Throttle Control Cable Ends
Engine Idler Pivot
Parking Brake Lever
Choke Control Pivot
Throttle Control Pivot
19
20
21
22
23
24
25
26
27
Grease
2
Grease
2
GreaseΔ2
Grease
4
Grease
2
Grease**1
Oil*
1
Oil*
2
Grease
1
Grease
2
Grease
1
Location Lubrication
Type
Grease
1
Oil***1
Oil
2
Oil
2
Oil
2
Grease
1
Grease
1
Oil
1
Oil
1
* Gearboxes are permanently lubricated and sealed requiring
no scheduled lubrication. Oil level should be checked only
when an oil leak is noted.
2
1
2
1
1
1
1
** Grease every eight (8) hours.
*** Refer to Engine Oil located on page 46.
Δ Belt Driven Decks Only
NOTE: DS42 Belt Drive and DC36R Tilt-Up Decks are shown for
reference. For other Deck Lubrication Points, Refer to
Deck and Carrier Frame Illustrated
Parts Manual.
2
1
1
2
3
3
4
5
6
5
4
Lubrication Points for Optional Belt Driven Decks (DS42 Belt Drive Shown)
48
No.
Places
Maintenance Instructions
1
LUBRICATION
1
2
2
7
8
8
6
4
5
4
4
5
4
10
10
11
9
12
13
14
23 & 27
14
12
22 & 26
15
25
16
17
18
24
23
19
20
22
21
21
Chassis and Deck Lubrication Points (DC36R Shown)
49
Maintenance Instructions
Mower Deck Gearbox Lubrication
On gear driven decks, the mower deck gearboxes
(tee gearbox and blade drive gearboxes) are
connected as a unitized as­sembly, and oil flows
freely between them.
The gear­
boxes are
permanently lubricated (oil filled) and sealed
requiring no scheduled lubrication. Howev­er, the
gearbox oil seals should be checked every 25 hours
for indication of an oil leak; particularly the lower
seals on the blade drive gearboxes should be
inspected, since they operate in a dirty en­vironment.
If an oil leak is noted, replace the oil seal and
relubricate the gearbox assembly as follows:
1. Remove gearbox cover (footrest). Deck orien­
tation should be the normal operating position.
Tee
Gearbox
LUBRICATION
NOTE: Since the gearboxes are connected as
a unit by connector tubes, it is necessary to add
oil slowly. Allow a few minutes after adding oil
for the oil to flow throughout the assembly and
the oil level to stabilize before reassembly.
IMPORTANT: DO NOT overfill the deck gear­
boxes. The gearbox assembly is not vented,
and overfilling with oil will cause excessive pres­
sure and result in oil leaks.
5. Check condition of the cover gasket and replace
if worn or damaged. Reinstall gearbox cover
plates; torque screws to 24 lb·in (3 N·m).
Mower Deck Spindle Lubrication
For the DS42 Belt Drive mower deck, lubricate each
deck spindle grease fitting every 25 hours. Use
SAE general purpose lithium or molybdenum base
grease for grease fittings.
Transaxle Lubrication
• The transaxle oil lubrication is SAE 20W-50 (API
Service Class SL or higher) engine oil.
Blade Drive
Gearboxes
Mower Deck Gearboxes
(Shown with Gearbox Cover
Removed for Clarity)
2. Clean the area around the individual gearbox
cover plates to prevent contaminants from en­
tering the gearcase.
• Inspect both transaxle cases and hoses after every 100 hours of operation for visible leaks.
• The fluid level of each transaxle can be checked
visually by looking at the fluid level in the expansion
reservoir. When the transaxles are cold, the fluid
level in the expansion reservoir should be between
1/4 in. and 1/2 in. (0.64 cm and 1.27 cm).
Reservoir Cap
3. Remove the screws securing the cover plates
on the blade drive gearboxes.
4. Check the level of lubricant in the gearboxes. If
the lubricant is low, add SAE E.P. (Extreme
Pressure) 80W-90 (API GL-5) gear lube until
the oil level is up to (submerges) the horizontal
shaft in the gearbox (shaft parallel to cover
plate).
NOTE: In case the gearboxes are completely
drained of oil, approximately 5 fl. oz. (15 cl) of oil
per gearbox is required to refill the gear drive
assembly.
50
Cold Level
Expansion Reservoir Location
Maintenance Instructions
Transaxle Oil and Filter Change
Change the transaxle oil after the initial break-in
period of 75-100 hours. Thereafter, change oil every 400 hours of operation as follows:
1. Thoroughly clean the exterior of the transmission housing before servicing. Remove expansion tank cap to allow venting. Using a 1/4 in.
hex wrench, remove the plug on the lower inside of each transaxle allowing the oil to drain.
2. Remove the oil filter guard, remove and replace
the oil filter using an oil filter wrench. Tighten
filter by turning filter 3/4 to 1 turn after gasket
contacts the filter base surface. Reinstall the oil
filter guard. (Refer to Transaxle Oil Drain
Plug, Filter, and Guard Location illustration.)
LUBRICATION
7. If the transaxles sound noisy or have poor steering response, there may be air trapped in the
transaxles. Follow purge instructions below.
8. If oil needs to be added refer back to steps 4-7.
9. To purge air from transaxle, raise unit and block
with tires off the ground. With engine running,
slowly move Forward Speed Control forward
and backward 5 to 6 times. Turn off engine and
check oil level and add if needed. Repeat procedure until transaxle operates at normal noise
levels and move smoothly in forward and reverse.
Oil Filter
Oil Filter
Guard
Oil Drain
Plug
Transaxle Oil Drain Plug, Filter, and
Guard Location
(Shown with Deck Support Arms
Removed for Clarity)
3. Reinstall drain plugs.
4. Fill the transaxles with 20W-50 (API Service
Class SL or higher) oil through the reservoir. Fill
up to the opening.
5. Fill both reservoirs to a maximum oil level of
1/4 in. (6.35 mm) with 20W-50 (API Service
Class SL or higher) oil.
6. Start and drive the unit for 1 - 2 minutes.
51
Maintenance Instructions
CLEANING
IMPORTANT: Use only Donaldson air filter ele­
ments for replacement (Donaldson P822686 or
Walker 5090-1). Aftermarket filters may not seal
properly or filter efficiently.
CLEANING
CAUTION
If a pressure washer is used on the exposed working parts, avoid water on the
electrical parts and the engine cooling system.
Cover
Cover
Latch
Engine Air Cleaner System
Donaldson Radialseal™ Air Cleaner
A remote mounted Donaldson Radialseal™ air
cleaner provides the air filtering function. The paper
filter element slides over an outlet tube inside the air
cleaner canister with radial sealing action, eliminating the possibility of dust leaks due to improper filter
installation. Intake design, internal baffling, and a
dust ejection valve provide dust separation and automatic precleaning action. Daily or frequent servicing of the air cleaner is not required.
Canister
Primary
Filter Element
Air Cleaner Components
(Shown with Cover Removed)
IMPORTANT: The Donaldson air cleaner uses a dry
paper-type air filter element. NEVER apply oil to the
paper element.
Mounting
Band
Primary Filter
Element
Safety
Element
Canister
Safety
Filter
Hose
Clamp
860
2
0-1
Cover
Air Intake
Hose
Dust Ejection
Valve
Intake Pipe /
Gasket
Intake
Tube
Engine
Engine Air Cleaner System Components
52
Hose
Clamp
Maintenance Instructions
Inspect the paper element after every 100 hours of
service and replace the element and safety filter
yearly (or when dirty or damaged). More frequent
replacement may be required when operating in extremely dusty con­ditions. Ser­vice the air cleaner as
follows:
1. Release the top and bottom cover latches and
remove the air cleaner cover. Wash the cover
and dust ejection valve. Check that these com­
ponents are in good condition. The dust ejection valve is subject to wear and deterioration
and should be replaced yearly or when damaged. The lips of the valve should close and fit
togeth­er; any cracks, deformation, or wear in
the valve is cause for replacement.
2. Remove the filter element by pulling it out of the
canister. There will be some initial resistance
as the filter seal breaks loose and slides off of
the outlet tube. Gently move the end of the
filter up and down and side to side or twist to
loosen the seal. Use gentle action to minimize
the amount of dust dislodged as the filter is removed.
3. Use a bright light inside the element to inspect
for damage. Check the element very carefully
for pin holes or other damage that will allow
dirt to leak through the paper media. Replace
filter element if dirty or damaged.
NOTE: Washing the element in water or clean­
ing solution is not recommended. Do not try to
clean the element with compressed air.
4. Without removing, visually inspect the condition
of the safety filter for damage or holes. The
safety filter should only be removed for yearly
replacement (or when dirty or damaged).
5. Check the condition and resilience of the radial
sealing surface (inside of the open end) of the
filter. Replace the filter if any cracks, tears, or
other damage to the sealing surface are noted.
CLEANING
7. Check the outside surface of the outlet tube for
smoothness and cleanness (this is the sealing
surface).
8. Insert and seat the safety filter and primary filter
element carefully into the canister, applying
pressure at the outer rim of the filter; not at the
flexible center. Make sure the filter element is
completely in place before installing the cover.
IMPORTANT: DO NOT use the cover latches
to force the filter into the canister -- the cover
should fit on with no extra force.
NOTE: DO NOT use petroleum based lubri­
cants on the sealing surfaces of the filter; use
tal­cum powder or dry silicone lubricants if required for filter installation.
Canister
Safety Filter
Outlet
Tube
Primary
Filter Element
Radial Sealing
Surface
Air Filter Element Replacement
9. Install the cover with the word “TOP” properly
oriented to the top of the canister. Give the
cover a slight twist as it reaches the canister to
make sure the tab inside the cover goes into a
slot, otherwise the cover will not fit properly.
Make sure both the top and bottom cover
latches are securing the cover in place.
6. Use a clean, damp cloth and wipe the interior of
the air cleaner canister clean. Use special care
to clean both the inside and outside surfaces
of the outlet tube.
IMPORTANT: Any dust left on the inside of the
outlet tube will go into the engine and cause
wear.
53
Maintenance Instructions
Cover Latch
Dust Ejection
Valve
Orient to Top
of Canister
CLEANING
Fuel Filter
Clean and inspect the fuel filter screen after every
50 hours of service. Replace if damaged. Service
the fuel filter as follows:
Fuel Shut-Off
Valve
Cover Latch
Proper Orientation of Air Cleaner Cover
10 Check the air intake hose for cuts, nicks, cracks,
etc., and the hose clamps for tightness.
Fuel Filter and
Sediment Bowl
Fuel Filter and Fuel Shut-off Valve Location
IMPORTANT: Service the fuel filter screen only in a
clean area where the fuel filter components will not
be contaminated by any dust and dirt.
DANGER
Gasoline is extremely flammable and can
be highly explosive. To minimize danger:
• Use an approved fuel container for gasoline.
• DO NOT allow open flames or sparks
while performing maintenance or refueling; DO NOT smoke while working with
fuel.
• Wipe up spilled gasoline immediately and
completely.
1. Close the fuel shut-off valve.
2. Loosen sediment bowl and remove filter screen
and gasket. Replace filter screen if damaged.
3. Remove any sediment, wipe clean and reinstall
assembly.
4. Open the fuel shut-off valve.
54
Maintenance Instructions
Engine Cooling System
Cooling Air Intake Screen
CLEANING
NOTE: The planned maintenance schedule calls
for cleaning the cylinder head cooling fins yearly or
every 300 hours as a minimum.
To prevent engine overheating and possible engine
damage, clean grass clippings, chaff, and dirt from
the rotating engine cooling air intake screen after
every 8 hours of operation. In certain mowing conditions (dry grass, leaves, tree “cotton”, etc.), it may
be nec­essary to check and clean this area several
times each day to prevent engine overheating.
CAUTION
Operating the engine with a blocked air
intake screen, dirty or plugged cooling
fins, and/or cooling shrouds removed will
cause engine damage from overheating.
Check for Airflow
Cooling System Airflow
1. Inspect accessible cooling fins and clean with
compressed air as needed. If the buildup is excessive, refer to step 2.
2. Remove the cylinder head shroud by removing
the two (2) bolts as shown in the Inspect and
Clean Cylinder Head Cooling Fins photo.
Slide the shroud forward to disengage the tabs
at the back of the shroud, and then drop the
shroud down under the cylinder head and remove. Clean the cooling fins with compressed
air. If the buildup is excessive, use a wire to
probe between fins and dislodge any debris.
Rotating Engine
Cooling Air
Intake Screen
Keep Rotating Engine Cooling
Air Intake Screen Clean
Cylinder Head Cooling Fins
It is essential for performance and longevity of the
air-cooled engine to keep the cylinder head cooling
fins clean and free of obstruction. After every 8
hours of operation, check the performance of the
cooling system by starting the engine, holding a
hand adjacent to the cylinder head, and feeling the
cooling airflow. If there is little or no airflow, clean
the cooling fins as follows:
3. Reinstall the shroud by reversing the preceding
step. Make sure that the tabs at the back of the
shroud are correctly inserted underneath the
cylinder head. Start the engine and confirm
cooling airflow.
Cooling
Fins
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
Cylinder Head Shroud
Bolts (One Not Visible)
Spark Plug
Wire
Inspect and Clean Cylinder Head Cooling Fins
(Viewed from Left Front Side of Tractor)
55
Maintenance Instructions
Grass Buildup in Mower Deck Housing
DANGER
Before raising or removing the mower
deck for cleaning, stop the engine, re­move
the ignition key, and disconnect the spark
plug wire.
1. Raise the deck lock lever handle on each side
of the carrier frame and pull out to release car­
rier frame for tilting action.
2. Using the carrier frame lift handle, raise deck to
the TILT-UP position and insert the deck hook
into the tilt-up latch on the tractor body.
Tilt-Up Hook and
Latch Connected
CLEANING
3. Clean grass buildup underneath the deck using
a pressure washer (and scraper if required).
NOTE: If the buildup is severe, it may be easier
to clean the deck by removing the deck assembly from the tractor and standing the deck assembly on its “nose”.
NOTE: While some degree of material buildup
in the mower deck housing can be tolerated, a
point is finally reached where cutting quality
deteriorates and clogging begins to occur
because of too much buildup on the baffling and
housing.
4. Lower the deck to the normal operating position
and re-engage the deck lock levers.
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
GHS Blower
Normally, the GHS blower operates with no mainte­
nance or cleaning. However, when mowing grass
that is dirty and damp (especially certain springtime mow­ing conditions), a deposit of dirt may accumulate inside the blower housing, causing wear
and binding of the blower wheel. When operating in
these conditions, inspect the blower frequently
for dirt buildup.
Tilt-Up
Latch
Tilt-Up Hook
Deck Secured in TILT-UP Position
DANGER
Do not operate the mower with deck in TILTUP position. Do not move the tractor with
the deck in the tilt-up position.
NOTE: A visual clue of binding of the blower wheel
is the blower blade tips are polished from rubbing
on dirt.
If a dirt deposit is found, the best way to remove it is
by mowing grass with high moisture content (such
as early morning dew or recent irrigation). The wet
grass will break down and remove the deposit.
GHS Exhaust Screen
Refer to Cleaning the GHS Exhaust Screen in Op­
erating Instructions.
56
Maintenance Instructions
Transaxle Housing
CLEANING/
CHECKING/SERVICING
CHECKING/SERVICING
Keeping the housing on the transaxles clean and
free of obstruction is essential to avoid overheating the transmission fluid and shortening transmission life. The housing should be checked every 100
hours; and cleaned if necessary.
To clean the housing, use compressed air and/or a
pressure washer. Pay close attention to any oily dirt
build up on the transaxle housings. This may be the
result of an oil leak. If an oil leak is noticed, contact
your local Walker dealer.
DANGER
To prevent accidental starting of the en­
gine when servicing or adjusting the ma­
chine, remove the key from the ignition
switch and disconnect the spark plug wire.
Security of Air Filtration Components
NOTE: The following inspection is only an exter­nal
inspection and should be done without “dis­
turbing” the filtration components.
Cooling
Fins
On a daily basis, visually inspect the external condi­
tion of the complete air cleaner system. The follow­
ing items should be inspected:
1. Check the Donaldson Radialseal™ air cleaner
canister for damage. Make sure the cover is in
place and the cover latches are secure - do not
run the engine without the air cleaner cover in
place and secure.
Transaxle Housing and Cooling Fins
IMPORTANT: In case an oil leak develops on the
input shaft, the cooling fan blowing dusty air and oil
on the transmission will quickly pack the cooling
fins with oily dirt. If this condition occurs, contact
your dealer immediately to avoid overheating and
dam­aging the transaxle.
An additional procedure in maintaining transaxle
cooling is to inspect the cooling fans. Replace the
fan(s) if blades are missing or damaged.
2. Inspect the air intake hose for cracks, nicks,
cuts, etc., and check the hose clamps for tight­
ness.
Battery
NOTE: For initial battery service during setup, re­fer
to Battery Service in Assembly Instructions.
IMPORTANT: Make sure battery is securely mount­
ed in the frame. A loose battery may cause damage
to the case resulting in acid leakage and severe dam­
age to the machine. A hazard may be created by
damage to critical working parts and safety systems.
Electrolyte Level
The battery electrolyte level should be checked af­
ter every 25 hours of operation. To check electro­
lyte level:
1. Remove battery cell filler caps.
Cooling
Fans
2. Check the electrolyte level. If the level is below
the bottom of the vent well, fill with drinking wa­
ter to the bottom of the vent wells [1/4 to 1/2 in.
(6 to 13 mm) above the plates].
Transaxle Cooling Fans
57
Maintenance Instructions
3. Replace filler caps.
Tire Pressure
IMPORTANT: DO NOT overfill the battery. Electro­
lyte will overflow through the vent tube onto parts of
the machine and WILL result in severe corrosion.
Inflate tires to pressures shown below:
Cleaning the Terminals
If battery terminals are corroded, remove battery
from the mower. Using a wire brush, remove corro­
sion with a solution of one part baking soda and
four parts water. Rinse with clean water. Coat the
terminals with petroleum jelly or terminal protector
spray to retard further corrosion.
Charging the Battery
DANGER
BATTERIES PRODUCE EXPLOSIVE
GASES
• Charge the battery in a well-ventilated
area, so that gases produced while charg­
ing can dissipate.
• Keep sparks, flames, and smoking ma­
terials away from the battery at all times.
• Make sure the battery cap vents are
open (check manifold vent on each cap).
• Make sure the battery charger is un­
plugged before connecting or disconnecting cables to the battery.
Check the battery charge by measuring the specific
gravity of electrolyte; if specific gravity is less than
1.225, the battery will need to be charged as follows:
1. Charge the battery at 15 amps for 10 minutes.
DO NOT exceed 20 amps maximum recom­
mended charging rate. Charge until specific
gravity is at least 1.250. Total charging time
should not exceed one (1) hour.
2. After charging the battery, use drinking water to
adjust the electrolyte level to the bottom of the
vent wells [1/4 to 1/2 in. (6 to 13 mm) above the
plates].
58
CHECKING/SERVICING
Deck Caster Wheel = 20 PSI (137 kPa)
Drive = 15 PSI (103 kPa)
Tailwheel = 20 PSI (137 kPa)
Wheel Nut Torque
Check the eight (8) Drive Tire mounting nuts. Every
100 hours they should each be torqued to
75 to 85 lb·ft (102 to 115 N·m).
Sharpen Mower Blades
Check mower blade(s) for straightness, sharp­
ness, condition of the cutting edge, and balance
every 10 hours of operation (or more often when
mowing abrasive type grass or operating on sandy
soils). Replace blades if worn, bent, cracked, or
otherwise damaged (refer to REPLACING/RE­
PAIRING the Mower Blades in this section). Use
the following procedure to check and sharpen
blades:
NOTE: Keep blades sharp - cutting with dull blades
not only yields a poor mowing job but slows the
cutting speed of the mower and causes extra wear
on the engine and blade drive by pulling hard.
1. Stop the engine, remove ignition key, and dis­
connect the spark plug wire before raising the
mower deck to service blades.
2. Raise the deck and secure it in the TILT-UP
position (refer to Deck Secured in TILT-UP Position photo in CLEANING of Grass Buildup
in Mower Deck Housing in this section).
DANGER
NEVER operate cutter blades with the
deck in the raised position.
NOTE: PTO shaft must be disconnected be­
fore checking blades for straightness.
3. Check the blades for straightness by marking
the blade tip position inside the deck housing,
and then rotating the opposite end of the blade
to the same position and comparing. If the dif­
ference in blade tip track is more than 1/8 in.
(3 mm), the blade is bent and should be re­
placed.
Maintenance Instructions
CHECKING/SERVICING
WARNING
DO NOT try to straighten a blade that is
bent. NEVER weld a broken or cracked
blade. ALWAYS replace with a new blade
to assure safety.
6. Check blade balance by positioning the blade
horizontally on a blade balancer or use a nail
or shaft through the center hole. If either end of
the blade rotates downward, grind (remove)
metal on that end until the blade will balance.
The blade is properly balanced when neither
end drops. Balance of a blade is generally
maintained by removing an equal amount of
material from each end of the blade when
sharpening.
4. If the blade cutting edge is dull or nicked, it
should be sharpened. Remove blades for
sharpening by grasping the end of the blade using a rag or a thick, padded glove, while loosening and removing the nut, lock washer, and flat
washer that mounts the blade.
5. Grind cutting edge at the same bevel as the
original. Sharpen only the top of the cutting
edge to maintain sharpness.
Blade Balancer
NOTE: Blades can be sharpened with an electric blade sharpener, conventional electric grinder, or a hand file.
Blade Balanced on Magnetic
Wall-Mounted Balancer
CAUTION
ALWAYS wear eye protection and gloves
when sharpening a blade.
Sharpen at
Original 30° Angle
Intersection
Wear Area
30°
Wing
Tip
Do Not Grind or
Sharpen on Underside
7. Mount the blade with wing tips pointing up into
the housing. For gear driven decks reinstall
the blade, washer, lock washer, and nut. Tighten the nut to 60 lb·ft (81 N·m). For belt driven
decks reinstall the spacer (if applicable), blade,
washer, and bolt. Tighten the bolt to 70 lb·ft
(90 N·m).
NOTE: When reinstalling blades on GHS models,
remember, the blades counter-rotate and the LH
and RH blades must not be switched. Check for
proper blade rotation before installing blades on the
deck. Refer to Blade Rotation illustrations shown
in Clogging Checklist in Operating Instructions for
correct blade rotation.
Mower Blade Profile for Sharpening
59
Maintenance Instructions
Drive Belts
Raise the body and inspect the condition of the three
(3) drive belts after every 25 hours of operation -engine, PTO drive, and ground drive. If the belts
show signs of cracking or deteriorating, the belts
should be replaced. Refer to REPLACING/REPAIRING the Drive Belts in this section.
CHECKING/SERVICING
Blade Brake Action
WARNING
It is important to check and maintain blade
brake action for safe operation of the machine.
Mower Deck Gearbox Oil Seals
The mower deck gearbox seals should be inspected
every 25 hours for evidence of oil leaking; particularly the lower oil seal on the blade drive gearbox.
This seal is protected by the trash guard on the blade
hub and seal protector plate on the housing, but is
still vulnerable to seal damage due to operating in
an adverse environment. The mower blade must be
removed for inspection of the seal, so it is recommended to inspect the gearbox seals when blades
are removed for sharpening. If an oil leak is noted,
the seal should be replaced and the gearbox assembly relubricated. Refer to LUBRICATION for
Mower Deck Gearbox Lubrication in this section.
Spark Plug
Every 100 hours, remove the spark plug, inspect,
clean, and reset the gap (or replace with a new
plug). Clean spark plug with a wire brush. If the
electrodes are burned short or pitted, replace the
plug (refer to Specifications for the proper type of
replacement plug). Check the spark plug gap with
a wire-type feeler gauge and set the gap between
0.028 and 0.032 in. (0.7 and 0.8 mm). Reinstall and
tighten to 17 lb·ft (23 N·m).
Ignition
The Subaru engine is equipped with an electronic
ignition. No breaker points, maintenance, or adjustments are necessary with this system. Contact an
authorized Subaru engine dealer in case of ignition
failure.
Fuel Lines and Clamps
Every year, inspect the fuel line from the tank to
engine for deterioration or damage. Also, inspect
the fuel line clamps for tightness. Good preventive maintenance calls for complete replacement of
fuel lines and clamps every two (2) years.
60
Check the function of the cutter blade brake and
blower brake by engaging the blade clutch (PTO),
operating the engine at full throttle, then disengaging
the clutch and measuring how quickly the blades
stop. Watch the rotation of the blade drive shaft and
blower pulley as a visual indication that movement
has stopped. If the brake is working properly, all
rotation will stop five (5) seconds after disengagement of the clutch. If the brake system malfunctions - blades do not stop in five (5) seconds adjust or repair the brake before operating the
mower. Refer to Blade Brake Band Adjustment in
ADJUSTMENTS in this section, or contact your authorized Walker dealer for this service.
Maintenance Instructions
Safety Switch System
WARNING
It is important to check and maintain the
safety switch system for safe operation of
the machine.
There are three (3) safety interlock switches on the
tractor; Seat Switch, FSC Neutral - Park Switch, and
PTO Switch.
If any of the following conditions occur during starting or operating, a safety interlock switch may be
malfunctioning. Contact your Walker dealer for troubleshooting and/or replacement.
• With or without an operator in the seat, the engine
starts with the Forward Speed Control (FSC) and/or
the PTO engaged.
• With or without an operator in the seat, with the
Forward Speed Control (FSC) lever in Neutral-Park
and the PTO clutch disengaged, the starter will not
engage.
CHECKING/SERVICING
Forward Speed Control Friction Lock
The FSC friction lock is designed to hold the selected forward travel speed when the steering levers are moved and yet the friction is not too heavy
to make moving the FSC control difficult (too much
friction). The procedure for checking the FSC friction lock is as follows:
1. With the engine off, place the FSC in the full
FORWARD position and pull both steering levers back; the FSC lever should not move. If
the FSC lever moves back when the steering
levers are pulled back, the friction needs to be
increased.
2. With the steering levers held back, move the
FSC lever back from the FORWARD position.
With a proper amount of friction adjusted, the
FSC lever should move back with a slight
amount of resistance (friction). If the FSC lever
movement is “stiff”, the friction needs to be
decreased.
If the FSC friction lock needs to be adjusted. Refer
to ADJUSTMENTS for Step 7 - Forward Speed
Control Friction Adjustment in this section.
• With an operator in the seat, the engine starts but
dies soon after the Forward Speed Control (FSC) or
PTO is engaged.
• Without an operator in the seat, the engine starts
and continues to run with the Forward Speed Control
(FSC) and/or PTO engaged.
61
Maintenance Instructions
REPLACING/REPAIRING
REPLACING/REPAIRING
Drive Belts
There are three (3) individual belts on the machine:
DANGER
To prevent accidental starting of the engine when replacing parts or repairing the
machine, remove the key from the ignition
switch and disconnect the spark plug
wire.
• Engine Belt
• PTO Drive Belt
• Ground Drive Belt
The belts may be removed and replaced using the
procedures described on the following pages.
IMPORTANT: ALWAYS use genuine factory replacement parts. Substitute parts CAN result in
product malfunction and possible injury to the operator and/or others.
Ground Drive Belt
PTO Drive Belt
Engine Belt
Belt Locations
62
Maintenance Instructions
REPLACING/REPAIRING
Engine Belt
1. To remove the engine belt:
b. Roll the belt off the pulleys and remove the
belt, then slowly release the idler.
a. Relax belt by depressing idler arm.
Compound
Pulley
Idler Pulley
Engine Belt
Push Idler Pulley
to Relax Belt
Tension Spring
Belt Tightener
Arm
Engine Pulley
Engine Belt (Disengaged)
2. To replace the engine belt:
a. Reverse the removal procedure to replace
the engine belt.
Compound
Pulley
Engine Belt
Idler Pulley
Tension Spring
Belt Tightener
Arm
Engine Pulley
Engine Belt (Engaged)
63
Maintenance Instructions
REPLACING/REPAIRING
PTO Drive Belt
1. To remove the PTO drive belt:
b. With the PTO clutch disengaged, roll the
belt off the idler pulley and remove the belt.
a. Remove the engine belt, as described in
previous section.
PTO
Drive Belt
Compound
Pulley
Push Actuator Pulley
to Relax Belt
PTO/Clutch/Brake
Actuator Arm
PTO Drive
Pulley
PTO Drive Belt (Disengaged)
2. To replace the PTO belt:
a. Install the PTO drive belt by reversing the
removal procedure. Replace engine belt.
Compound
Pulley
NOTE: If installing a new PTO belt is difficult, the
blade brake band adjustment nut might need to be
loosened. If so, follow the Blade Brake Band Adjustment procedure in this section.
PTO
Drive Belt
PTO/Clutch/Brake
Actuator Arm
PTO Drive
Pulley
PTO Drive Belt (Engaged)
64
Maintenance Instructions
REPLACING/REPAIRING
Ground Drive Belt
1. To remove the ground drive belt:
b. Slide belt off pulleys, then slowly release
the idler.
a. Raise the spring-loaded idler to relax belt.
Raise Idler Pulley to Relax Belt
Transmission
Drive Pulley
Hydrostatic
Drive Pulley
Ground Drive
Belt
Idler Pulley
Hydrostatic
Drive Pulley
Ground Drive Belt Assembly (Disengaged)
2. Reverse the procedure to install the ground
drive belt.
Ground Drive
Belt
Transmission
Drive Pulley
Hydrostatic
Drive Pulley
Idler Pulley
Hydrostatic
Drive Pulley
Ground Drive Belt Assembly (Engaged)
65
Maintenance Instructions
REPLACING/REPAIRING
Blade Overload Shear Bolts
PTO Shear Pin (If Equipped)
NOTE: Blade shear bolts are not used on belt driven decks.
The PTO drive shaft connection to the deck gearbox
has a shear pin to provide shock load protection to
the mower deck drive. This system provides primary shock protection in case of blade impact and
will normally shear before the individual shear bolts
on the blade hub.
On gear driven decks each cutting blade is keyed to
a blade hub by two (2) shear bolts (10-24 x 5/8 in.
stainless steel machine screws). These bolts are
designed to shear and protect the blade drive gearbox from damage if the blade encounters a shock
load.
When the PTO pin has sheared, use the following
procedure to replace it:
1. Loosen the two bolts securing the PTO shaft
guard on the deck; lift the guard off. (Holes in
guard are slotted for easy removal.)
Cutting Blade
Shear Bolts
2. Rotate U-joint on shaft to align the shear pin
hole with the hole (and shear pin fragment) in
the shaft. Use a punch to drive the remaining
portion of the old shear pin out.
3. Install new shear pin and secure with cotter pin.
Set Screw
Shear Pin
Split Spring Pin
Cutting Blade Shear Bolts
U-Joint
Tube Assembly
NOTE: Tightening the 5/8-18 blade mounting nut
to 60 lb·ft (81 N·m) is also important for proper
shock load protection. It is important to not overtighten the mounting nut since this defeats (overrides) the function of the shear bolts.
If these bolts shear, remove the blade and install
new bolts. Refer to CHECKING/SERVICING in
this section for Sharpen Mower Blades which describes the blade removal and installation procedure.
After reinstalling the blade, check blade timing (on
gear driven decks) by moving blades through one
(1) complete revolution. Make sure blade tips
pass clear of each other. If timing is incorrect, contact your Walker dealer.
U-Joint
Shaft Assembly
Cotter Pin
PTO Shear Pin
IMPORTANT: Use only Walker P/N 8067-13
shear pins for replacement to provide proper
shock protection -- these pins are hardened to
shear under a specific amount of load.
4. Reinstall the PTO shaft guard.
Before operating the deck, inspect the blade overload shear bolts and also check blade timing (on
gear driven decks) by moving blades through one
(1) complete revolution. Make sure blade tips
pass clear of each other. If timing is incorrect, contact your Walker dealer.
66
Maintenance Instructions
Mower Blades
REPLACING/REPAIRING
WARNING
Mower blades are removed and remounted as described in Sharpen Mower Blades instructions (refer to CHECKING/SERVICING in this section). During the course of sharpening and inspecting mower
blades, if there are any of the following conditions
of wear or damage, blades should be replaced
for reasons of safety and performance of the machine:
• An excessive amount of the flat section of the
blade has been ground away (removed) when the
blade is sharpened. Replace the blade when less
than a 3/4 in. (19 mm) flat section remains at the
blade tip.
• Examine ends of the blade carefully, especially
the intersection where the flat section of the blade
turns up to form the “wing tip” (refer to CHECKING/
SERVICING for Mower Blade Profile for Sharpening illustration in Sharpen Mower Blades instructions). Since sand and abrasive material can wear
metal away in this area, the blade should be replaced when metal thickness has worn to
1/16 in. (1.6 mm) or less.
DO NOT try to straighten a blade that is
bent. NEVER weld a broken or cracked
blade. ALWAYS replace with a new blade
to assure safety.
Reinstall the blades following procedure from
Sharpen Mower Blades instructions in CHECKING/SERVICING in this section. If blades are replaced, always use Walker original equipment
blades to ensure safety and optimum performance.
The quality and performance of replacement
blades offered by other manufacturers cannot be
guaranteed, they could be dangerous.
CAUTION
ALWAYS use genuine factory replacement parts. Substitute parts CAN result
in product malfunction and possible injury to the operator.
DANGER
When blades are operated over sandy
soil, and if blades are allowed to wear, a
“slot” may be worn into the wing tip of
blade. Eventually a piece of the blade
may break off creating a serious potential
for injury or damage.
• Check the blades for straightness by marking
blade tip position inside the deck housing and then
rotating the opposite end of the blade to the same
position and comparing. If the difference in blade tip
track is more than 1/8 in. (3 mm), the blade is bent
and should be replaced.
• Inspect the blade surface, especially in formed
areas, for cracks. Replace the blade if any cracks
are found.
67
Maintenance Instructions
ADJUSTMENTS
Transmission Control
IMPORTANT:
The proper adjustment of the
transaxle control stops is essential for efficient
operation and life of the transaxle. These stops are
properly adjusted at the factory and should only
require read­
justment if the transaxle or related
control linkage is removed or changed.
ADJUSTMENTS
2. Adjust the position of the RH lever by turning the
stop bolt in the Speed Control Actuator in or out.
Turning the stop bolt in will make the RH lever
move back, and turning it out will make it move
forward. Tighten the locknut.
Stop
Bolt
NOTE: It would not be unusual for a new machine,
after the initial 5 or 10 hours of operation, to begin to
not travel straight (this is due to the break-in of the
transaxles). To fine tune tracking, refer to Step 5 Straight Tracking Adjustment in this section.
Step 1 - Steering Lever Position Adjustment
NOTE: For proper operation, the steering levers
should be adjusted to sit evenly using the following
procedure.
1. Examine the steering levers to make sure they
are parallel front to back in relation to one an­
other. If they are not equal, adjust accordingly.
(The handles may or may not be even at this
point.)
NOTE: The LH steering lever is non-adjust­
able. This procedure will require adjustment of
the RH lever to make it even with the LH lever.
Levers should sit
parallel to each other
Lever Alignment
68
Stop Bolt Location
Maintenance Instructions
ADJUSTMENTS
Step 2 - Steering Handles Adjustment
Step 3 - Neutral Position Adjustment
1. An adjustment range of approximately 3 in.
(76.2 mm) is available on the steering handles the han­
dles can be adjusted forward or aft
depending on the arm length of the operator.
The handles can be adjusted by loosening the
locknut at the pivot point and the locknut holding
the handle in position in the adjustment slide.
Adjust the han­dles into the most comfortable
position and tighten both locknuts.
1. With the Forward Speed Control (FSC) in NEU­
TRAL-PARK, the lever should be straight up.
Adjust by loosening the jam nuts on the FSC
Rod and turn the rod to attain the straight up
position. Tighten the jam nuts.
Adjustment
Slide
Locknut
(Position)
Correct FSC Lever NEUTRAL-PARK Position
Locknut
(Pivot Point)
Steering Handles Adjustment
Adjust Length of
Rod to Position
FSC Lever
FSC Lever Position Adjustment
69
Maintenance Instructions
ADJUSTMENTS
2. Securely block the tractor up so the drive tires
are off the ground.
WARNING
3. Adjust the tracking adjustment nuts at the front
of both control rods so that 2 or 3 threads are
visible, then loosen the jam nuts on the ball joints
at the back of the control rods.
The following adjustments are made with
the engine running. Keep all body parts
and tools away from rotating and hot
components, and secure all loose clothing.
Control Arm
4. With the body lowered and the FSC in NEUTRAL-PARK, start the engine. With the engine
at normal operating speed, check for movement
of the drive wheels.
Control Rods
5. Lift the body to access the steering adjustment
components.
Transmission Control Rod and Arm Location
(Front Body Hidden for Clarity)
Ball Joint
Maximum Speed
Adjustment Set Screw
Jam Nut
Control Rod
Locating Stud
Transmission
Control Arm
Tracking Adjustment Nut
(Adjusts Length of Control Rod)
Tracking Adjustment Components
70
NOTE: It may be necessary to tighten the FSC
friction adjustment if the transmissions are
moved out of neutral when the body is raised.
Refer to Step 7 - Forward Speed Control Friction
Adjustment later in this section for location of the
FSC friction adjustment nut.
6. Using a wrench on one tracking adjustment nut,
rotate the control rod clockwise just until the
wheel on that side begins to move forward.
Then, counting the turns required, rotate the
control rod counterclockwise just until the
wheel stops and then begins to move in reverse. Rotate the control rod back clockwise
half the number of turns required to make the
wheel go from moving forward to reverse. The
transmission is now centered in the neutral window. Tighten the jam nut on the ball joint and
repeat the same procedure on the other transmission.
7. Turn off the engine, and then lower the drive
tires onto the ground.
Maintenance Instructions
ADJUSTMENTS
IMPORTANT: After tracking adjustments are
complete, confirm that there is at least one (1)
thread visible on both control rods past the tracking adjustment nuts.
Step 4 - Full Forward Speed Adjustment
1. Move the FSC to the full FORWARD speed
position.
2. Raise the body. The maximum speed tracking
adjustment set screw in both transmission control arms should not be contacting the limit stud
on the transaxle. If they are, back the set screws
out until they do not touch.
T-Handle
Hex Wrench
4. If the machine is tracking straight throughout
the speed range except at maximum speed,
use the following adjustment procedure:
a. With the engine off, place the FSC in full
FORWARD. On the faster transmission,
loosen the jam nut and turn the maximum
speed tracking adjustment set screw in until it just contacts the limit stud, and then
turn it in an additional 1/8 turn (turning the
set screw in slows the drive wheel).
Maximum
Speed Tracking
Adjustment
b. Recheck maximum speed tracking, and if
necessary continue adjusting the set screw
in small increments until straight travel is
achieved.
Transmission
Control Arm
c. Tighten the jam nut.
Step 6 - FSC Neutral Switch Adjustment
Maximum Speed Tracking Adjustment
(Shown with Parts Removed for Clarity)
Step 5 - Straight Tracking Adjustment
1. Sit in the seat, start the engine, set throttle at full
speed, and with the FSC in the NEUTRALPARK po­sition check for movement of either
drive wheel (if either wheel moves backward or
fer to Step 3 - Neutral Position
forward, re­
Adjustment and readjust).
2. Check for straight ground tracking on a level
surface (with hands off the steering levers). Set
the FSC at several different speeds and observe
if the machine moves in a straight line (use
cement joint or other line on ground for
reference).
3. If tracking is not straight, shorten the control rod
on the faster side by turning the tracking
adjustment nut clockwise. If straight tracking
and neutral are both achieved proceed to the
next step. If straight tracking and neutral cannot
both be achieved, turn the tracking adjustment
nut on the faster side counterclockwise until
neutral is restored. Then, lengthen the control
rod on the slower side by turning the tracking
adjustment nut counterclockwise until straight
tracking and neutral are both achieved.
1. Place the FSC lever in the NEUTRAL-PARK
position. Raise the body and adjust the switch
adjustment bolt up until it just makes contact
with the FSC switch plunger, and then turn the
switch adjustment bolt up an additional two (2)
turns and tighten the jam nut.
NOTE: It may be necessary to tighten the FSC
friction adjustment if the transmissions are
moved out of neutral when the body is raised.
Refer to Step 7 - Forward Speed Control Friction Adjustment later in this section for location
of the FSC friction adjustment nut.
FSC Switch
FSC Neutral Switch Location
71
Maintenance Instructions
ADJUSTMENTS
Step 7 - Forward Speed Control Friction Adjustment
NOTE: Adjust the
bolt downward for
quicker activation.
FSC Switch
Actuator Arm
Switch Closed
in Neutral
Switch Adjustment
Bolt
Jam Nut
Friction Nut
Front of Mower
FSC Neutral Switch Adjustment
(Side View Through Chassis)
CAUTION
Before testing the FSC Neutral Switch,
disconnect the spark plug wire from the
engine and engage the parking brake to
prevent accidental starting and inadvertent machine movement.
2. Check operation of the FSC Neutral Switch by
placing the FSC lever in the full FORWARD position. While holding the ignition switch in the
START position, slowly move the FSC lever toward the NEUTRAL-PARK position and stop
when the starter motor engages. Note the position of the FSC lever where it passes through
the slot in the body. The FSC lever should be
within 1/8 in. (3 mm) of the NEUTRAL-PARK
position. If this distance is greater than 1/8 in.
(3 mm), turn the adjustment bolt down slightly
and recheck switch operation. When finished
adjusting, tighten the jam nut and reconnect the
spark plug wire.
FSC Friction Adjustment Test
1. Place the FSC lever in the full FORWARD
position, and pull both steering levers fully back;
the FSC lever should not move. If the FSC lever
moves back the friction needs to be increased.
2. With the steering levers held back, move the
FSC lever back from the FORWARD position.
With a proper amount of friction adjusted, the
ver should move back with a slight
FSC le­
amount of re­sistance (friction). If the FSC lever
movement is “stiff”, the friction needs to be
decreased.
3. The FSC friction is increased or decreased by
tightening or loosening the friction adjustment nut. Loosen or tighten the nut and check
the control function until the conditions of both
steps 1 and 2 (above) are met.
FSC Friction
Adjustment Nut
FSC Friction Adjustment Nut
72
Maintenance Instructions
ADJUSTMENTS
Blade Clutch (PTO)
With the clutch engaged, adjust the length of the
clutch actuator rod to achieve a clutch spring
assembly bolt head clearance of 1/4 in. to 5/16 in.
(6.5 mm to 8 mm). To adjust the clutch actuator rod
length, loosen both ball joint jam nuts (one ball joint
will have LH threads) and shorten the rod to
increase the clutch spring assembly bolt head
clearance, or lengthen the rod to decrease the bolt
head clearance. If adjustments are needed more
frequently than every 100 hours to maintain
dimensions, it may suggest problems with pulley
wear or belt misalignment.
Clutch Engagement/Belt Tension
The clutch engagement and PTO belt tension are
adjusted using the clutch actuator rod. After installing a new PTO belt, after 10 hours and every 100
hours thereafter, check and adjust for the clutch
spring assembly bolt head clearance dimension as
shown in the PTO Clutch Engaged illustration. If
the clutch actuator rod or clutch spring assembly
have been disassembled, first reset them to their
factory preset lengths (see PTO Clutch Disengaged illustration) and then proceed with adjustment as follows.
Bolt Head Clearance
1/4 in. to 5/16 in.
(6.5 mm to 8 mm)
Blade Clutch
Engaged
Clutch Idler
Arm
Clutch Spring Assembly
(Spring Compressed)
Blade Clutch
Idler Pulley
Clutch
Actuator Arm
Safety
Switch
Clutch
Actuator Rod
Front of Mower
PTO Clutch Engaged
73
Maintenance Instructions
ADJUSTMENTS
11 in.*
(280 mm)
6 in.*
(152.5 mm)
Knuckle
Joint
Clutch Spring Assembly
(Spring Uncompressed)
2-1/8 in.*
(54 mm)
*NOTE: Factory preset dimensions. Reset to these
dimensions prior to adjustment if components have
been disassembled.
PTO Clutch Disengaged
Blade Brake Band Adjustment
The blade brake is designed to stop the blades within five (5) seconds after clutch disengagement. Every 100 hours of operation verify correct performance of the blade brake by following the procedure
in CHECKING/SERVICING the Blade Brake Action in this section.
WARNING
It is important to check and maintain blade
brake action for safe operation of the machine.
74
Adjust the working travel of the clutch idler pulley by
adjusting the brake band nut:
1. With the clutch disengaged, adjust the blade
brake band nut to achieve a 1/4 in. to 3/8 in.
(6.5 mm to 9.5 mm) gap between the PTO pulley and clutch idler pulley as shown in the Blade
Brake Band Adjustment illustration.
NOTE: As the blade brake band/drum wears,
idler pulley travel will increase and it will be necessary to adjust the brake band nut to maintain
the correct 1/4 in. to 3/8 in. (6.5 mm to 9.5 mm)
gap. If the gap is greater than this in the disengaged position, the PTO belt may not declutch
adequately. Every 100 hours of operation
check the pulley gap and adjust if necessary.
Maintenance Instructions
2. After adjustments are complete, verify blade
brake performance by following the procedure
in CHECKING/SERVICING the Blade Brake
Action in this section. If the blades do not stop
within five (5) seconds, check the following:
a. Make sure clutch and brake linkages are
working freely (no binding).
b. Check the brake band and PTO pulley
brake drum for wear. Replace any components that are excessively worn.
c. Verify that the PTO belt is declutching completely from the pulleys.
ADJUSTMENTS
Tilt-Up Deck Adjustable Stop
When the carrier frame hinge joint is properly adjusted, the deck lock levers should move in and out
of the engaged and disengaged positions freely. All
four hitch pins used for height adjustment should sit
flush on the washers above the deck pin bushing.
On a level surface, if any pin is sticking up (likely the
front pins), tighten the opposite side or loosen the
same side to lower the pin. Adjustments are made
by loosening the jam nut and tightening or loosening
the set screws on the Deck Mount Pivot Brackets.
Retighten the jam nut when the adjustment is complete.
Jam Nut
Set Screw
Tilt-Up Deck Adjustable Stop
Clutch Idler
Pulley
Pulley Gap
1/4" to 3/8"
Blade Brake
Band
Chassis Mount
(Ref)
Blade Brake
Band Adjustment Nut
PTO
Pulley
Blade Brake Band Adjustment
(Clutch Disengaged)
75
Maintenance Instructions
ADJUSTMENTS
GHS “Full” Signal Horn Adjustment
DANGER
Exhaust
Screen
4 to 4-1/2 in.
(10.16 to 11.43 cm)
PINCH POINT - SPRING LOADED DOOR
When lowering the door on the GHS
catcher, BE VERY CAREFUL to keep
hands, fingers, etc. out of the hinging
mechanism and away from the door frame
as the door closes. The springs that hold
the door closed during operation are very
powerful, and the door can slam shut with
considerable force.
The vertical position of the Grass-Pak® switch is
critical to make sure the catcher box does not overfill causing the delivery chute to clog. The vertical
position can be adjusted by moving the aluminum
shaft and vane on the Grass-Pak® switch.
1. Position the discharge chute so that it is pointing
straight back.
a. Turn the ignition switch ON (RUN) and
move the blade clutch to the ENGAGED
position (engine not running).
b. Open the catcher back door and monitor
the spout position (as it oscillates) and
move the blade clutch to the DISENGAGED
position and turn the ignition switch to the
OFF position.
WARNING
DO NOT test the Grass-Pak® switch with
the engine running. Projectiles CAN be
thrown out of the grass delivery spout
and CAN cause serious injury to bystanders or property damage.
2. Measure from the exhaust screen (top of catcher) to the top of the Grass-Pak® switch actuator
vane, refer to Adjusting the Grass-Pak®
Switch illustration. The proper measurement
should be between 4 and 4-1/2 in. (10.16 and
11.43 cm).
76
Adjustment Nut
Adjusting the Grass-Pak® Switch
(Side View of Catcher Box)
3. If adjustment is required, loosen front adjustment nut then move aluminum shaft and vane to
the recommended measurement. Adjustments
should be done in very small increments checking the measurement each time until the recommended measurement is achieved.
NOTE: It will not be possible to adjust the switch to
give a signal at the precise instant the catcher is full
for a wide variety of mowing conditions. For example, wet heavy grass will fill the catcher differently
than dry fluffy grass, causing the signal to come on
a little sooner or later than usual. Primarily, the
switch should be adjusted to give the “full” signal
with a little advance warning before overfilling
and clogging of the grass delivery chute begins (regardless of mowing conditions).
Operator’s Notes
77
Operator’s Notes
78
LIMITED WARRANTY
FOR
WALKER MODEL S14
RIDER MOWER
1.
WHAT THIS WARRANTY COVERS, AND FOR HOW LONG:
Walker Manufacturing company will, at its option, repair or replace, without charge, any part covered by this warranty which
is found to be defective in material and/or workmanship within one (1) year* after date of sale to the original retail purchaser
unless the product is used for rental purposes, in which case this warranty is limited to ninety (90) days. At Walker’s request,
customer will make the defective part available for inspection by Walker and/or return the defective part to Walker, transportation charges prepaid. All parts and components of the Walker Mower are covered by this warranty except the following
components which are warranted separately by their respective manufacturers:
Subaru Engine
Battery
The available warranties covering these items are furnished with each mower. Walker does not assume any warranty obli­
gation, liability or modification for these items, which are covered exclusively by the stated warranty of the respective man­
ufacturers noted above.
* A two (2) year or 2000 hour (whichever comes first) warranty is offered for Hydro-Gear ZT3100 hydrostatic transmissions;
covers full cost of replacement up to 1000 hours of use, and after 1000 hours warranty coverage is prorated against 2000
hours.
2.
3.
WHAT THIS WARRANTY DOES NOT COVER:
A.
This warranty does not cover defects caused by depreciation or damage caused by normal wear, accidents, improper
maintenance, improper use or abuse of the product, alterations, or failure to follow the instructions contained in the
Operator’s Manual for operation and maintenance.
B.
The customer shall pay any charges for making service calls and/or for transporting the mower to and from the place
where the inspection and/or warranty work is performed.
HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:
Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Walker Man­
ufacturing Company, 5925 East Harmony Road, Ft. Collins, CO 80528. Proof of the date of purchase may be required to
verify warranty coverage.
4.
WARRANTY LIMITATION:
A.
THERE IS NO OTHER EXPRESS WARRANTY. ANY WARRANTY THAT MAY BE IMPLIED FROM THIS PURCHASE
INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY LIMITED TO THE
DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED
WARRANTIES ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts, so the
above limitations may not apply to you.
B.
WALKER WILL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, OR SPECIAL DAMAGES AND/OR
EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply
to you.
C.
Only the warranty expressed in this limited warranty shall apply and no dealer, distributor, or individual is authorized to
amend, modify, or extend this warranty in any way. Accordingly, additional statements such as dealer advertising or
presentations, whether oral or written, do not constitute warranties by Walker, and should not be relied upon.
D.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
79
WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, CO 80528 • (970) 221-5614
FORM NO. 050514
PRINTED IN USA
www.walkermowers.com
©2014 WALKER MFG. CO