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OWNER’S MANUAL Safety, Assembly, Operating, and Maintenance Instructions Model MT (20.0 / 25.0 HP) (Covers Serial Numbers 95-21329 and on) ™ Please Read and Save These Instructions For Safety, Read All Safety and Operation Instructions Prior to Operating Machine Effective Date: 08-14-98 P/N 8000-1 Price $5.00 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 us at (970) 221-5614. 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 call our service department, at (970) 221-5614, for clarification before operating or servicing this mower. This manual covers Model MT with the Kohler Command CH20 (20.0 HP) gasoline engine, or optional Kohler Command CH25 (25.0 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. 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_____________ HIGHLIGHTED INFORMATION _____________ GLOSSARY ____________________________ IDENTIFYING NUMBER LOCATIONS ________ ENGINE SERIAL NUMBER LOCATION ______ SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS__________ 1 1 1 2 CONTROL IDENTIFICATION, LOCATION, AND FUNCTION _____________ Operating Controls ___________________ Engine Choke _______________________ Engine Throttle ______________________ Forward Speed Control (FSC) __________ Steering Levers _____________________ Blade Clutch (PTO) __________________ Parking Brake _______________________ Front Body Latch Release _____________ Transmission Lockout Levers ___________ Cold Start Lever (Jackshaft Drive Belt Release)_ Instrument Panel _____________________ Hourmeter _________________________ Voltmeter __________________________ Oil Pressure Warning Light ____________ Over Temperature Warning Light ________ Ignition Switch ______________________ Light Switch (For Optional Lights) _______ Warning Horn _______________________ STARTING THE ENGINE_________________ ADJUSTING GROUND SPEED AND STEERING _________________ ENGAGING THE MOWER ________________ STOPPING THE MACHINE _______________ ADJUSTING CUTTING HEIGHT ___________ TRANSMISSION LOCKOUT ______________ 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 _________________ Power Dump Option __________________ Specifications 2 _______________________ 3 ENGINE________________________________ ELECTRICAL SYSTEM ___________________ TRANSMISSION _________________________ BLADE DRIVE __________________________ TIRE SIZE ______________________________ TIRE PRESSURE ________________________ DIMENSIONS (Tractor and Mower) _________ MOWER DECK __________________________ CURB WEIGHT__________________________ DRIVE BELTS ___________________________ GHS SYSTEM (Optional) __________________ SEAT __________________________________ FRAME/BODY CONSTRUCTION ___________ 3 3 3 4 4 5 5 5 5 6 6 6 6 Component Identification ___________ 7 Safety Instructions _________________ 10 BEFORE OPERATING ___________________ OPERATING ___________________________ MAINTENANCE ________________________ SAFETY, CONTROL, AND INSTRUCTION DECALS _____________ 10 11 12 Assembly Instructions 14 _____________ 16 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 Shield Installation _______ PTO Shaft Guard Installation ___________ Mower Deck Installation on Tractor ______ Deck Installation _____________________ Deck Leveling _______________________ PREOPERATING CHECKLIST ____________ 16 16 16 16 16 17 17 17 17 18 18 18 18 18 20 21 24 24 24 24 25 25 25 25 25 26 26 26 28 29 29 29 29 29 29 29 30 31 32 33 34 34 35 36 37 38 39 40 40 40 40 40 41 41 41 42 Table of Contents Maintenance Instructions __________ 44 MAINTENANCE SCHEDULE CHART _______ IMPORTANT TIPS FOR CARE OF THE KOHLER 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/Oil Filter _ Grease Fitting and Oil Point Lubrication __ Mower Deck Gearbox Lubrication _______ DSD52 or DSD62 Mower Deck Lubrication Tractor PTO Gearbox Lubrication _______ Checking Gearbox Oil Level ____________ Changing Gearbox Oil ________________ Gear Axle Lubrication _________________ Hydrostatic Transmission Fluid _________ Checking Hydrostatic Transmission Fluid Level ______________ Changing Hydrostatic Transmission Fluid __ CLEANING ____________________________ Engine Air Cleaner System _____________ Turbine Precleaner ___________________ Donaldson Radialseal™ Air Cleaner (Primary) _________________ Kohler Air Cleaner (Secondary) _________ Foam Precleaner __________________ Paper Element ____________________ Engine Cooling System ________________ Air Intake System ____________________ Cylinder Head Cooling Fins ____________ Grass Buildup in Mower Housing________ Non-Tilting Decks ____________________ Tilt-Up Decks _______________________ GHS Blower _________________________ GHS Exhaust Screen __________________ Hydrostatic Transmission Cooling Fins __ CHECKING/SERVICING _________________ Security of Air Filtration Components ____ Battery______________________________ Electrolyte Level _____________________ Cleaning the Terminals ________________ Charging the Battery __________________ Tire Pressure ________________________ Sharpen Mower Blades ________________ Drive Belts __________________________ Mower Deck Gearbox Oil Seals _________ Spark Plugs _________________________ 44 45 45 45 45 45 45 46 46 46 46 46 47 50 50 51 51 51 51 52 52 52 53 53 54 54 56 56 56 57 57 57 58 58 58 59 59 60 60 60 60 60 61 61 61 61 62 63 63 Fuel Lines and Clamps ________________ Engine Starter _______________________ Blade Brake Action ___________________ REPLACING/REPAIRING ________________ Drive Belts __________________________ Engine PTO Drive Belt ________________ Jackshaft Drive Belt __________________ GHS Blower Drive Belt ________________ Hydrostatic Ground Drive Belt __________ Fuel Filter ___________________________ Blade Overload Shear Bolts ____________ Mower Blades _______________________ Mower Deck Gearbox Replacement______ GHS Blower Assembly ________________ GHS Blower Assembly Removal ________ Blower Wheel Removal _______________ Blower Wheel Installation ______________ GHS Blower Assembly Installation _______ ADJUSTMENTS ________________________ Safety Switches ______________________ Seat Switch ________________________ FSC Neutral-Park Switch ______________ PTO Switch_________________________ Tail Wheel Bearing Preload_____________ Blade Clutch (PTO) ___________________ Clutch Engagement/Belt Tension ________ Clutch Disengagement/Brake Action _____ Stop Block Eccentric Adjustment ________ Clutch Idler Pulley Travel Adjustment _____ Blade Brake Band Adjustment __________ Transmission Control _________________ Set Forward Travel Limit (Stop) _________ Steering Lever End Play Adjustment _____ Neutral Function Adjustment ___________ Straight Ground Travel Adjustment ______ Forward Speed Control Friction Lock ____ Tilt-Up Deck Adjustable Stop ___________ Carburetor __________________________ Engine Idle Adjustment _______________ GHS “Full” Signal Horn with Grass-Pak® Switch _______________ Troubleshooting (When Horn Fails to Operate) __________ Adjustment (When Horn Sounds at the Wrong Time) __ ELECTRICAL SYSTEM __________________ Circuit Breakers______________________ Wiring Diagram ______________________ 63 63 63 63 63 65 66 67 68 69 69 70 70 71 71 72 72 72 73 73 73 73 73 73 74 74 75 76 76 76 77 77 78 78 79 79 80 80 80 Operator’s Notes ___________________ 84 Warranty ___________________________ 87 81 81 82 82 82 83 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, blade drive gearboxes, 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. • • • • 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) mows but does not collect the mowed material. STEERING LEVERS steer the tractor by controlling the dual hydrostatic transmissions. TRACTOR is the prime mover, including the engine, drive train, operator seat, and controls to operate the mower. TRANSMISSION LOCKOUT releases the hydrostatic transmissions 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 RH side of the RH 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. GROUND DRIVE refers to the dual hydrostatic transmissions which drive the main wheels. HYDROSTATIC TRANSMISSION transmits and controls power from the ground drive belt to the main drive wheel. LEFT HAND (LH) refers to the left-hand side of the tractor when the operator is seated facing forward in the tractor seat. _______________________ Engine Model No. _______________________ Engine Serial No. _______________________ Date of Purchase _______________________ Fill In By Purchaser 1 General Information SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS Serial Number Tractor Serial Number Location Serial Number The detailed servicing and repair of the engine, hydrostatic transmission, 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 Service manuals are available for each of these components from their respective manufacturers as follows: Mower Deck Serial Number Location Kohler Engines Kohler Company Kohler, WI 53044 Hydrostatic Transmissions Eaton Corporation 15151 Highway 5 Eden Prairie, MN 55344 Gearboxes (Deck) Tecumseh Products Co. 900 North Street Grafton, Wl 53024 ENGINE SERIAL NUMBER LOCATION Refer to the engine manual that accompanies this manual for the location of the engine serial number. For the mower model covered by this manual, an engine manual is available covering the Kohler CH20 and CH25 gasoline engines. Serial Number Engine Serial Number Location 2 Specifications MT 20.0 HP MT 25.0 HP Manufacturer/Model Kohler CH20, 2 Cyl., Gasoline (Air Cooled) Kohler CH25, 2 Cyl., Gasoline (Air Cooled) Displacement 38.1 cu. in. (624 cc) 44.0 cu. in. (725 cc) HP (@ 3600 RPM) 20.0 25.0 Max. RPM (No Load) 3750 3750 Governed RPM 3600 3600 Max. Torque [ft-lb (N⋅ m) @ RPM] 32 (43.4) @ 2500 39.5 (53.6) @ 2400 Idle RPM 1200 ± 75 1200 ± 75 MODEL ENGINE Champion RC12YC Spark Plug Type Champion Spark Plug Gap .030 in. (.76 mm) .030 in. (.76 mm) Crankcase Capacity 2.1 qts (2.0 liters) 2.1 qts (2.0 liters) Crankcase Lubricant API SF, SG, or SH Grade Oil Only with 10W-30 Viscosity above 0° F (-18° C), or 5W-20 or 5W-30 Viscosity below 32° F (0° C) API SF, SG, or SH Grade Oil Only with 10W-30 Viscosity above 0° F (-18° C), or 5W-20 or 5W-30 Viscosity below 32° F (0° C) Fuel Tank Capacity 4.3 Gallons (16.3 liters) 4.3 Gallons (16.3 liters) Fuel Regular Grade Unleaded Gasoline (87 Octane) Regular Grade Unleaded Gasoline (87 Octane) Cooling System Capacity Air Cooled Air Cooled Battery 12 Volt, 35AH, 295 CCA 12 Volt, 35AH, 295 CCA Charging System Flywheel Alternator Flywheel Alternator Charging Output 15 Amp DC (Regulated) 15 Amp DC (Regulated) System Polarity Negative Ground Negative Ground Ignition Electronic Capacitive Discharge Electronic Capacitive Discharge Starter 12 Volt Electric Ring-Gear Type, Solenoid Shift 12 Volt Electric Ring-Gear Type, Solenoid Shift Interlock Switch Ignition Lockout by Seat Switch, Transmission Neutral and Blade Clutch Ignition Lockout by Seat Switch, Transmission Neutral and Blade Clutch Circuit Breaker Manual Reset (30A) Manual Reset (30A) Manufacturer/Model Dual Hydrostatic, Eaton Model 7, Each Wheel Independently Driven Dual Hydrostatic, Eaton Model 7, Each Wheel Independently Driven Steering Hand Lever Control / Individual Wheel Hand Lever Control / Individual Wheel Forward Speed Control Precision Friction Lock Lever, Cruise Control, with Neutral-Park Position Precision Friction Lock Lever, Cruise Control, with Neutral-Park Position RC12YC ELECTRICAL SYSTEM TRANSMISSION 3 Specifications MT 20.0 HP MT 25.0 HP Service Brake Dynamic Braking through Hydrostatic Transmission Dynamic Braking through Hydrostatic Transmission Parking Brake Mechanical Pin Lock in Transmission Gear Mechanical Pin Lock in Transmission Gear Neutral Transmission Release by Manual Dump Valve Transmission Release by Manual Dump Valve Final Drive Gear Drive Axle Gear Drive Axle Factory Service SAE 30W Straight Viscosity Motor Oil (Mobil DTE 18M Hydraulic Oil Installed at Factory) SAE 30W Straight Viscosity Motor Oil (Mobil DTE 18M Hydraulic Oil Installed at Factory) Alternate Transmission Fluid Mobil 1 Synthetic Motor Oil (5W30) Mobil 1 Synthetic Motor Oil (5W30) Transmission Fluid Capacity 1 qt (1 liter) 1 qt (1 liter) Transmission Cooling Cooling Fan Mounted on Drive Pulley Cooling Fan Mounted on Drive Pulley 0-5 (0-8) Infinitely Variable 0-5 (0-8) Infinitely Variable 0-5 (0-8) Infinitely Variable 0-5 (0-8) Infinitely Variable PTO Shaft Quick Disconnect Rectangular Shaft with Two High-Speed U-Joints Quick Disconnect Rectangular Shaft with Two High-Speed U-Joints Blade Spindle Each Blade (2) Mounts Direct on Peerless Right Angle Gearbox with Tee Gearbox in Center Connected to PTO Shaft (Complete Geared Drive, Peerless Model 1000 Gearboxes) Each Blade (2) Mounts Direct on Peerless Right Angle Gearbox with Tee Gearbox in Center Connected to PTO Shaft (Complete Geared Drive, Peerless Model 1000 Gearboxes) Blade Drive Clutch and Brake Manual Belt Tightener Clutch and Band Brake (Stops Blades within Five (5) Seconds of Disengagement) Manual Belt Tightener Clutch and Band Brake (Stops Blades within Five (5) Seconds of Disengagement) Max. Blade Speed [25 in. (64 cm) Blade] @ 3600 RPM Engine 2400 RPM [15700 FPM (4785 m/min)] 2400 RPM [15700 FPM (4785 m/min)] Deck Caster Wheel 2.80/2.50-4 Pneumatic (4-Ply) 2.80/2.50-4 Pneumatic (4-Ply) Deck Caster Wheel (Optional) 8.25 x 2.75 Semi-Pneumatic 8.25 x 2.75 Semi-Pneumatic Drive 18 x 9.50-8 (4-Ply) 18 x 9.50-8 (4-Ply) Rear (Dual) 13 x 5.00-6 (4-Ply) 13 x 5.00-6 (4-Ply) MODEL TRANSMISSION (continued) Transmission Fluid Ground Travel Speed Forward m.p.h. (km/h) Reverse m.p.h. (km/h) BLADE DRIVE TIRE SIZE 4 Specifications MT 20.0 HP MT 25.0 HP Deck Caster Wheel 20 PSI (137 kPa) 20 PSI (137 kPa) Drive 15 PSI (103 kPa) 15 PSI (103 kPa) Rear 20 PSI (137 kPa) 20 PSI (137 kPa) 91 in. (231 cm) 91 in. (231 cm) MODEL TIRE PRESSURE DIMENSIONS (Tractor and Mower)* Length Width 49 in. (124 cm) 49 in. (124 cm) Height 44 in. (112 cm) 44 in. (112 cm) Wheel Base (Tractor) 42-1/4 in. (107 cm) 42-1/4 in. (107 cm) Tread Width (Tractor) 29-3/4 in. (76 cm) 29-3/4 in. (76 cm) Width of Cut SD/GHS 42 or 48 in. (107 or 122 cm) 42 or 48 in. (107 or 122 cm) Cutting Height 1 to 4 in. (3 to 10 cm) 1 to 4 in. (3 to 10 cm) Height Adjustment 7 Positions - 1/2 in. (1 cm) Increment Hitch Pins Installed in Multi-Position Deck Support 7 Positions - 1/2 in. (1 cm) Increment Hitch Pins Installed in Multi-Position Deck Support 42 in. (107 cm) SD 22 in. (56 cm) 2 in. (5 cm) Center Overlap (Two Blades, CW Rotation) 22 in. (56 cm) 2 in. (5 cm) Center Overlap (Two Blades, CW Rotation) 48 in. (122 cm) GHS 25 in. (64 cm) 2 in. (5 cm) Center Overlap (Two Blades, Counter Rotate) 25 in. (64 cm) 2 in. (5 cm) Center Overlap (Two Blades, Counter Rotate) Deck Suspension Torsion-Flex Frame with Caster Wheels and Counterweight Springs Torsion-Flex Frame with Caster Wheels and Counterweight Springs SD Tractor Only 660 lb (299 kg) 665 lb (302 kg) GHS Tractor Only 760 lb (345 kg) 765 lb (347 kg) Tractor and Mower* 965 lb (438 kg) 970 lb (440 kg) MOWER DECK Blade Size (Typical) CURB WEIGHT (Approximate) *Dimensions and weight shown are for 48 in. (122 cm) GHS Model (typical). Dimensions for Tractor and Mower with 42 in. (107 cm) deck are: Length = 88 in. (224 cm) Width = 43 in. (110 cm) For SD Models, subtract 7 in. (18 cm) from the height. Deck weight for 48 in. (122 cm) Tilt-Up deck = 205 lb (93 kg). Deck sizes range from 42 to 62 in. (107 to 157 cm), with corresponding deck weights ranging from 170 to 300 lb (77 to 136 kg). Optional (9.5 Bushel) Grass Catcher adds approx. 5 lb (2 kg) and 5 in. (13 cm) in Height 5 Specifications MT 20.0 HP MT 25.0 HP Engine PTO Walker P/N 8230 Walker P/N 8230 Jackshaft Drive Gates 3VX355 (or Walker P/N 6231) Gates 3VX355 (or Walker P/N 6231) Ground Drive, Micro-V Walker P/N 7248 Walker P/N 7248 Blower (GHS Model) Gates 3VX280 (or Walker P/N 7234) Gates 3VX280 (or Walker P/N 7234) Blower 4 x 10 x 1/4 in. (10 x 25 x 1 cm) Three-Blade Paddle Wheel (Driven by Mower Engine) 4 x 10 x 1/4 in. (10 x 25 x 1 cm) Three-Blade Paddle Wheel (Driven by Mower Engine) Blower Brake Band Brake (Works in Combination with PTO Clutch, Stops Blower within Five (5) Seconds of PTO Disengagement) Band Brake (Works in Combination with PTO Clutch, Stops Blower within Five (5) Seconds of PTO Disengagement) Max. Blower Speed 3600 RPM 3600 RPM Grass Catcher Capacity 65 Gallons (246 liters)/ 7.0 Bushels 65 Gallons (246 liters)/ 7.0 Bushels Optional Grass Catcher Capacity 76 Gallons (335 liters)/ 9.5 Bushels 76 Gallons (335 liters)/ 9.5 Bushels Full Signal Oscillating Vane Switch Mounted on Grass Delivery Spout Triggers Horn 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 @ 25 Cycles/Minute Oscillating Delivery Spout Driven by 12 Volt Electric Gearmotor Spreads Material throughout Interior of Catcher @ 25 Cycles/Minute SEAT Contour-Molded, with Nylon Backed Vinyl Cover and Integral Foam Cushion Contour-Molded, with Nylon Backed Vinyl Cover and Integral Foam Cushion All Welded Unitized Steel Chassis All Welded Unitized Steel Chassis MODEL DRIVE BELTS GHS SYSTEM (Optional) FRAME/BODY CONSTRUCTION Frame Body 14 Gauge Steel 14 Gauge Steel Deck 11 Gauge Steel 11 Gauge Steel GHS Catcher and Chutes Molded Cross-Linked Polyethylene (UV Stabilized) 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. 6 Component Identification NOTE: Control Identification shown in Operating Instructions section. Catcher Door Safety Latch Turbine Precleaner Grass Handling System 7.0 Bushel Catcher Tilt-Up Latch Spring Clip Transmission Control Rod Adjustment Nut (LH) Anti-Scuff Roller Deck Support Pins and Height Adjustment Hitch Pins Catcher Lift / Dump Handle Fuel Tank and Cap Counterweight Spring and Protective Cover Transmission Control Rod Adjustment Nut (RH) Deck Support Arms Footrests Deck Lift Handle (Cutting Height Adjustment) Tilt-Up Hook Tilt-Up Deck Handle Deck Caster Wheels Front View and Right Side View 7 Component Identification Catcher Door Gas Spring Instrument Panel Guard Removable Grass Catcher Screen (Not Visible) Catcher Exhaust Deflector Catcher Lift / Dump Handle Instrument Panel Box (Shock Mounted) Catcher Door Dump Plate Catcher Door Handle Deck Lift Rod Muffler Left Hand Drive Wheel Oil Filter Tailpipe Anti-Scuff Roller Oil Drain Plug Tailwheel Fork and Wheels Rear View and Left Side View 8 Component Identification Donaldson Air Cleaner (Primary Air Cleaner) Air Cleaner Cover Air Cleaner Base Plate Fuel Filter Fuel Pump Engine Air Cleaner (Secondary) Air Restriction Indicator (Not Visible) Muffler Grass Shield Air Intake Hose (Primary to Secondary) Throttle and Choke Linkage Muffler Heat Shield Fuel Tank Oil Dipstick/Oil Fill Rubber Bumper (Catcher Support) Precleaner Tube Muffler Jackshaft 20 Amp Fuse (Starter Solenoid) PTO Gearbox Dipstick GHS Blower Turbine Precleaner RH Transmission Lockout Lever RH Hydrostatic Transmission 30 Amp Circuit Breaker LH Hydrostatic Transmission PTO Clutch Lever Positive (+) Battery Cable Negative (-) Battery Cable Battery Neutral Safety Switch LH Transmission Lockout Lever Top View (Engine Compartment) 9 Safety Instructions Pay particular attention to any information labeled DANGER, WARNING, CAUTION, IMPORTANT, and NOTE in this manual. When you see the Safety Alert Symbol ( ), read, 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 1. A POTENTIAL hazard that COULD result in severe personal injury or DEATH, if warning is ignored and proper safety precautions are not taken. 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 Read and understand the contents of this Owner’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 Owner’s Manuals are available by sending the Model and Serial Number to: 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 6. 7. 8. 9. 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. 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. 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. 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 the PTO clutch in the ENGAGED position. 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. 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. 3. For a beginning operator, learn to steer (maneuver) the tractor with a slow engine speed before attempting any mowing operation. Be aware that, with the front mounted mower configuration, the back of the tractor swings to the outside during turns. 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. 5. 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). 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). 6. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and can be deadly. c. Keep matches, cigarettes, cigars, pipes, open flames, or sparks away from the fuel tank and fuel container. 7. Do not carry passengers - maximum seating capacity is one (1) person. 8. 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. 9. 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. 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 10. Disengage the blade drive when transporting the machine across drives, sidewalks, etc. Never raise the mower deck while blades are rotating. 17. In case of a clogged or plugged mower deck or GHS catching system: 11. The maximum recommended side slope operating angle is 20 degrees or 33% 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. 12. 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. 13. For side discharge mower decks, do not operate with the grass deflector chute removed. Keep the deflector in the lowest possible position. 14. For tractors equipped with tilt-up deck, observe the following recommendations: 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 wires. d. Never place hands under the deck or in the GHS blower - use a stick or similar tool to remove clogged material. 18. 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 wires. 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 ft-lb (81.3 N⋅ m). 19. Do not touch the engine or muffler while the engine is running or immediately after stopping the engine. These areas may be hot enough to cause serious burns. a. Do not move tractor with deck in tilt-up position. 20. When leaving the machine unattended, disengage the blade clutch (PTO), stop the engine, and remove the key. b. Never tilt body forward with deck in tilt-up position. MAINTENANCE 15. For GHS equipped models, 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. 16. For GHS equipped models, 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. 12 a. 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 wires. 2. To reduce fire hazards, keep the engine free of grass, leaves, excessive grease, and dirt. 3. Keep all nuts, bolts, and screws tight to ensure the machine is in a safe, working condition. Check the blade mounting nuts frequently, making sure they are tight. Safety Instructions 4. Perform only maintenance instructions described in this manual. Unauthorized maintenance operations or machine modifications may result in unsafe operating conditions. 5. If the engine must be running to perform a maintenance adjustment, keep hands, feet, and clothing away from moving parts. Do not wear jewelry or loose clothing. 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, performance, 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. d. Disconnect both battery cables before unplugging any wiring connectors or making repairs on the electrical system. IMPORTANT: Keep all applicable manuals immediately accessible to anyone who may operate or service this machine. 10. Use genuine factory replacement parts. Substitute parts may result in product malfunction and possible injury to the operator and/or others. 11. Use care when charging the battery or performing maintenance on the battery and electrical system: a. Make sure the battery charger is unplugged before connecting or disconnecting cables to the battery. 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. c. Keep sparks, flames, and smoking materials away from the battery at all times. To avoid sparks, use care when removing battery cables from posts. 13 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. Each End of Mower Deck (5808) SD Deck Discharge Shield (5848) Adjacent to Blower Discharge Chute through Body (5804) Front Body Adjacent to RH Steering Lever (7818) Hydrostat Oil Reservoir (5810) Engine Shroud (5855) On Body Adjacent to Clutch Control Lever (5806) Right Side of Front Body, Below Front Body Latch Release (7820) 14 Rear of Grass Catcher Exhaust Screen (5869) Rear Cross Member of Front Body (8825) 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. Jackshaft Support Adjacent to Dipstick (7827) Deck Gearbox Cover (5807-1) Deck Carrier Frame (8647) Gear Axle (5810-1) Deck Carrier Frame (5865) Deck Carrier Frame (8653) On Engine (6810) Catcher Safety Latch, RH Side (5874) Right Side, Below Operator Seat (7809) Top of Blower Housing (5819) Left Side of Operator Seat (8819) Catcher Door Hinge Bar, LH and RH Sides (5868) Left Side of Operator Seat (7819) Instrument Panel (8823) Fender, RH Side (7802) 15 Assembly Instructions SETUP INSTRUCTIONS Dry Battery Service Walker Mowers are shipped partially assembled. After uncrating the tractor and mower deck, initial setup is required. 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. NOTE: During the process of unpacking, any damaged or missing parts should be noted and reported to the delivering carrier immediately (put in writing within 15 days). The carrier will provide directions for proceeding with a claim to receive compensation for damage. Tire Installation (Tractor) • Install the drive tires using the eight (8) lug bolts that are supplied with the owner’s packet of materials. Drive tires are 18 x 9.50-8, 4-ply; rear tires are 13 x 5.00-6, 4-ply. DANGER • Check and adjust the inflation of the tires. The tire inflation recommendations are: Battery electrolyte is a poisonous and corrosive sulfuric acid solution. Drive = 15 PSI (103 kPa) Rear = 20 PSI (137 kPa) • Avoid spillage and contact with skin, eyes, and clothing - causes severe burns. Battery Service Raise front mower body up for battery access (refer to Front Body Latch Release in Operating Instructions). 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. • 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): Wet Battery Service 1. 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 drinking water to the bottom of the vent wells. 2. Charge battery. Refer to Battery Charging in this section. 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. 16 Remove the battery hold down bar, disconnect the battery cables and lift the battery out of the tray. Remove the filler caps and carefully fill each cell until the electrolyte is just above the plates. Assembly Instructions 3. After the battery is filled with electrolyte, replace the filler caps and charge the battery. Refer to Battery Charging . WARNING Make sure the battery cap vents are open. Improper venting of the battery COULD cause a battery explosion. Battery Charging DANGER BATTERIES PRODUCE EXPLOSIVE GASES Battery Clamp Secured by Wing Nut(s) • 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 (+) Battery Cable Connection open after the battery is filled with acid (check manifold vent on each cap). • Make sure the battery charger is unplugged before connecting or disconnecting cables to the battery. 1. 2. 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. Mower Deck Assembly Deck Caster Wheels Installation 1. Install battery. 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. 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. Battery Installation Install the battery in the mower as shown in Battery Installation photo. Connect the positive and negative cables 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. Remove the bolt, nut, axle spacer tube, and spacer washers from each deck caster wheel fork. NOTE: Spacer washers are used only when the optional semi-pneumatic deck wheels (8.25 x 2.75) are installed. 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. Battery Installation 17 Assembly Instructions Deck Discharge Shield Installation (Side Discharge Models Only) Grease Fitting Locations Attach the deck side discharge shield by positioning the shield hinge lug in front of the deck mount and fastening with two 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. Spacer Washer WARNING Axle Spacer Tube DO NOT operate the machine without the grass deflector chute attached and in the lowest possible position. Deck Caster Wheel Installation 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. Attach Shield 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 the 1/4-20 x 1/2 in. socket button head bolt and 1/4-20 ESNA nut. Position the bolt with the head inside of the chute and the nut on the outside. PTO Shaft Guard Installation Position the shaft guard as shown and mount with two 1/4-20 x 1/2 in. bolts. Carrier Frame Tube Sockets Attach Chute Attach Guard Nut on Top Discharge Chute and PTO Shaft Guard Installation on Rear Discharge Deck 18 Discharge Shield Installation on Side Discharge Deck Mower Deck lnstallation on Tractor Deck Installation 1. Lightly grease each deck support arm (2) on the tractor. Refer to Mower Deck Installation photo on next page for location of deck support arm. 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: all the way if SD equipped model, approximately 3 in. (76 mm) if GHS equipped model. Assembly Instructions NOTE: When installing the DSD52 or DSD62 Mower deck, make sure to retract the dolly wheel after mounting the deck on the tractor. 3. 4. 5. Spring-Loaded Coupler Ring In Fully Forward Position If the deck is rear discharge (GHS equipped model), the rear discharge chute will need to be aligned and connected to the blower inlet during the last 2 in. (51 mm) of slide action on the support arms. NOTE: Raising the mower body may be helpful in fitting and guiding the deck chute into the blower. 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. Connect the mower deck PTO drive shaft assembly to the tractor with the splined quick disconnect coupler. This coupler simplifies shaft alignment and installation. a. Use the arrows on the shaft and tube to align and slide the PTO quick coupler onto the deck rectangular shaft. b. Reaching under the tractor, pull the ring back on the coupler, slide onto the spline shaft on the tractor, and release the ring. Coupler Ring “Locked” Position 6. Raise the front mower body (instead of lifting the front of deck) and clip the counterweight springs to the receptacle on front of body. Lower the front body to tension the springs. (Refer to Deck Counterweight Spring Installation Photo.) Grease Deck Support Arms IMPORTANT: To prevent damage to the mower, make sure the PTO shaft assembly is securely locked on the tractor, with the locking balls fully seated in the groove and the ring in the full forward position (refer to the Coupler Ring “Locked” Position photo). After installation, pull on the shaft to check for security. PTO Connection Pull Back Spring-Loaded Coupler Ring Arrows on Shaft and Tube (used to align when sliding together) Mower Deck Installation (PTO Shaft Connection) 7. Installing PTO Quick Coupler With the counterweight springs connected, the weight on the deck caster wheels should be 15 to 25 Ib (6.8 to 11.3 kg). Check this weight by lifting on the front of the deck carrier frame. If required, the spring tension can be adjusted by tightening or loosening the elastic stop nuts located underneath the lower spring hook. Refer to Deck Counterweight Spring Installation photo. 19 Assembly 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 Spring Tension Adjustment Nut Located Under Lower Spring Hook (Not Visible) The machine must be shut off during this procedure. Counterweight Springs Clip Onto Body With Forward Body Tilted Up 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 1/8 in. (3 mm) difference. Hitch Pins Lock Deck On Support Arms Deck Counterweight Spring Installation 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. Should be 1/8 in. (3 mm) to 1/4 in. (6 mm) higher at the rear of the blade 4 in. (102 mm) Wood Block Should not vary more than 1/8 in. (3 mm) side-to-side Deck Leveling 20 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 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 fuels and lubricants refer to Specifications. FILL FUEL TANK Fill the fuel tank using clean, fresh automotive grade unleaded gasoline (87 octane rating minimum). DANGER 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. IMPORTANT: DO NOT mix oil with gasoline. Always use fresh, automotive grade gasoline. DO NOT use premium, white, or high-test gasoline. 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. CHECK AND SERVICE ENGINE AIR CLEANER SYSTEM • Check air restriction gauge to make sure there is no red indication showing. • Check condition, cleanliness, and security of the complete air cleaner system (clean primary air filter every 100 hours). For detailed procedures, refer to CLEANING the Engine Air Cleaner System in Maintenance Instructions. ADJUST CARBURETOR (Initial Start-up Only) Refer to ADJUSTMENTS of Carburetor in Maintenance Instructions. CHECK ENGINE COOLING SYSTEM 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 two (2) cylinder head access panels to inspect and clean]. Check performance of the cooling system by starting the engine, holding a hand adjacent to the cylinder heads, and feeling the cooling airflow. DANGER 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. Make sure to keep hands clear of exhaust pipe, muffler, and moving parts when checking airflow. 21 Assembly Instructions CHECK GEAR AXLE OIL LEVEL Counterweight Spring Clip Refer to Gear Axle Lubrication in Maintenance Instructions. Deck Lift Rod INSPECT FOUR (4) DRIVE BELTS Engine PTO Drive, Jackshaft Drive, Hydrostatic Ground Drive, and GHS Blower Drive (if equipped). CHECK HYDROSTATIC TRANSMISSION OIL LEVEL Body Bracket Refer to LUBRICATION for Checking Hydrostatic Transmission Fluid Level in Maintenance Instructions. CHECK BATTERY ELECTROLYTE LEVEL Deck Secured in UP Position (Non-Tilting) Refer to CHECKING/SERVICING the Battery in Maintenance Instructions. CHECK FUNCTIONS OF INSTRUMENT PANEL AND WARNING HORN Turn the ignition key to the RUN position. Voltmeter, Oil Pressure Light, and Warning Horn should all operate, indicating normal function. CHECK TIRE PRESSURE Deck Caster Wheel = 20 PSI (137 kPa) Drive = 15 PSI (103 kPa) Rear = 20 PSI (137 kPa) DANGER Never operate cutter blades with deck in raised position because it is hazardous. If equipped, 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 Latch CHECK AND CLEAN GRASS BUILDUP UNDERNEATH MOWER DECK (and inside GHS blower, if equipped) Refer to CLEANING the GHS Blower in Maintenance Instructions for blower cleaning information. NOTE: Mower deck is secured in raised position for cleaning and changing blades by hooking the deck lift rod into the body bracket below the counterweight spring clip. The rod is hinged and is stowed along the footrest of the deck carrier frame. A hitch pin on the end of the rod is used to secure it in place with the deck raised. Tilt-Up Latch Tilt-Up Hook on Deck Deck Lock Lever Deck Secured in TILT-UP Position 22 Assembly Instructions 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, AND SECURITY OF MOUNTING The blade mounting nut should be tightened to 60 ft-lb (81.3 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. PERFORM ANY ADDITIONAL PROCEDURES called for on the MAINTENANCE SCHEDULE CHART in Maintenance Instructions. 23 Operating Instructions CONTROL IDENTIFICATION, LOCATION, AND FUNCTION Operating Controls 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. Forward Speed Control (FSC) 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. Steering Levers Parking Brake Blade Clutch (PTO) Front Body Latch Release Operating Controls 24 Operating Instructions Steering Levers Choke Throttle Choke and Throttle Location Engine Throttle 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. 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 5 mph (0 to 8 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. 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. 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) The blade clutch lever has two positions. Pulling the lever UP engages the PTO that drives the mower blades. Pushing the lever DOWN 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. Parking Brake The parking brake functions by locking a pin into the hydrostatic transmission pinion gear teeth. Moving the lever FORWARD engages the parking brake; moving the lever BACKWARD releases the brake. 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 axle drive. NOTE: If pressure on the parking brake pin (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 release the pin. 25 Operating Instructions 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 forward. NOTE: The transmission plunger on the side of the transmission case (activated by the LOCKOUT LEVER) must be completely released during operation of the mower, otherwise operation of the transmission will be erratic. Optional Cold Start Lever (Jackshaft Drive Belt Release) The cold start lever is used for starting the machine in cold weather [below 40° F (4° C)]. Pulling the lever UP disengages the jackshaft drive belt. When the jackshaft drive belt is released, the hydrostatic transmissions are removed from the engine starter cranking load. Front Body Latch Release Cold Start Lever Disengaged Front Body Latch Release Transmission Lockout Levers The transmission lockout levers disengage the hydrostatic transmissons. By lifting the lever on top of the transmission and locking it into place with the lockout cam, the hydrostatic transmissions are released to permit freewheeling. By releasing the cam and lowering the lever, the transmissions are engaged for normal operation. The transmission lever in the LOCKOUT position is used to enable moving the machine without the engine running (e.g., for service). Refer to TRANSMISSION LOCKOUT in this section for operating instructions. Optional Cold Start Lever Normal Operating Position Cold Start Lever Engaged Lockout Levers Transmission Plunger Lockout Lever Location 26 Optional Cold Start Lever Cold Start Position Operating Instructions The Forward Speed Control also Establishes the Neutral-Park Position of the Steering Levers LEFT WHEEL STEERING LEVER RIGHT WHEEL STEERING LEVER FORWARD SPEED CONTROL LEVER (FSC) Forward Position (No Control Change) Full Forward Ground Speed Position Intermediate Ground Speed Position Neutral-Park Position Neutral-Park Position Disengaged Position Reverse Drive Wheel Motion Position Engaged Position BLADE CLUTCH (PTO) Pull Up to Engage Fast Throttle Position ON Position Engaged Position Disengaged Position Idle Position OFF Position THROTTLE CHOKE PARKING BRAKE Operating Controls (Top View from Drivers Point of View) 27 Operating Instructions Instrument Panel This illustration shows the configuration of the switches and indicators located on the instrument panel. Hourmeter Voltmeter Oil Pressure Warning Light Over Temperature Warning Light Light Switch (Optional) Warning Horn Instrument Panel 28 Ignition Switch Operating Instructions Hourmeter Ignition Switch The hourmeter displays operating time accumulated while the ignition switch is in the ON position. The ignition switch is used to start and stop the engine. The switch has three positions: “O” is the OFF position, 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 “RUN” position. To stop the engine, rotate the key counterclockwise to the “O” position. Voltmeter The voltmeter displays battery and charging system voltage. An indication of low or high voltage (below 11.5 volts or above 15.5 volts) indicates an electrical system failure. The cause of the failure should be determined and corrected. Oil Pressure Warning Light The oil pressure warning light indicates that engine oil pressure is below the safe operating range [below 3 to 5 PSI (21 to 34 kPa)]. This light (and warning horn) will come on when the ignition is turned ON, but should go off after the engine is started. If the light fails to come on when the ignition switch is turned ON, it could indicate a burned out bulb. If the light comes on during engine operation, stop the engine immediately and correct the source of the problem before further engine operation. OFF ON IMPORTANT: Continued operation of the engine with an illuminated oil pressure warning light MAY cause severe engine damage (if a low oil pressure condition exists). START Over Temperature Warning Light The over temperature warning light indicates that engine oil temperature and/or cylinder head temperature are above the safe operating limit and the engine is overheating [above 305° F (152° C) oil or 450° F (232° C) cylinder head]. If this light comes on, there may be a problem with: • Engine cooling system (material packed into cylinder head cooling fins, clogged air intake screen) • Low oil level in crankcase Stop the engine and correct the source of the problem before further operation. Ignition Switch Light Switch (For Optional Lights) Operates headlights (when installed). Warning Horn The warning horn sounds to alert the operator that an unsafe engine condition is being indicated when engine temperature is too high or engine oil pressure is too low. If the horn sounds, check the indicator lights and correct the problem before further operation. IMPORTANT: Continued operation of the engine with an illuminated over temperature warning light MAY cause severe engine damage (if a high oil temperature or head temperature condition exists). 29 Operating Instructions STARTING THE ENGINE Cold Start Lever Engaged CAUTION Before operating the mower, read and understand all Safety Instructions and Operating 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. Optional Cold Start Lever 2. NOTE: The choke may not be required if the engine is warm. NOTE: Release parking brake to prevent extra load on the starter if the transmission neutral is slightly out of adjustment. IMPORTANT: If the engine fails to start after approximately 10 seconds of cranking, the engine should be checked before further cranking. 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. CAUTION A safety interlock switch system PREVENTS CRANKING the engine with either the Forward Speed Control or the blade clutch (PTO) out of neutral. If the engine cranks otherwise, the safety system is not working and should be repaired or adjusted before operating the mower. DO NOT disconnect safety switches; they are for the operator’s protection. NOTE: For starting in cold weather [below 40° F (4° C)], use the optional cold start lever to release the jackshaft drive belt and remove the hydrostatic transmission from the starter cranking load. After the engine has been started and warmed up, lower the lever to re-engage the jackshaft drive belt. 30 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 RUN position as soon as the engine starts. 3. After the engine starts, make sure the oil pressure light goes off. If not, stop the engine immediately and find the cause of the problem. Make sure the oil pressure light is off prior to engaging the mower blades and beginning operation. 4. 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. Operating Instructions 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 IMPORTANT: If the DSD52 or DSD62 Mower deck is installed on the tractor, make sure the dolly wheel is retracted BEFORE moving. 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 HYDROSTATIC TRANSMISSIONS, steering 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 all times when the machine is moving. 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). NOTE: If the FSC lever will not stay in the selected position, the friction lock needs to be adjusted. Refer to ADJUSTMENTS of Forward Speed Control Friction Lock in Maintenance Instructions. 2. Beginning Recommendations are: ♦ Learn operation of the mower in an open area away from buildings, fences, and obstructions. 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 operating 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 lever 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 NEUTRAL-PARK position. 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 ENGAGING THE MOWER 1. Set the engine throttle at about 1/3 speed. Do not attempt to engage the blade clutch at high engine speeds. This will drastically shorten drive belt life. Use only moderate engine speed when engaging the blade clutch. 2. Pull the blade clutch lever SLOWLY up to engage the mower blades. Pull Steering Levers With Left Hand CAUTION Forward Speed Control (FSC) Keep Feet On Footrest When Moving Correct Operator Hand Position on the Controls 3. Reverse direction of the mower by pulling both levers backward. NOTE: Smooth action on the steering levers will produce smooth mower operation. Remember to keep the engine and ground speed slow until learning the control response. 4. 5. 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. Stop ground travel by pulling both steering levers backward to the NEUTRAL position (tractor not moving) and then moving the FSC lever to the NEUTRAL-PARK position. NOTE: If the tractor creeps forward or backward with the FSC lever in the NEUTRAL-PARK position, the transmission control needs to be adjusted. Refer to ADJUSTMENTS of Transmission Control in Maintenance Instructions. 32 A safety interlock 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, sidewalks, loose materials, etc. DO NOT engage the blade clutch with the PTO shaft disconnected (the mower deck removed from tractor). CAUTION If the cutting blades strike a stationary object while mowing, stop the mower immediately, disconnect the spark plug wires, 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 Maintenance Instructions if blades are out of time. Also, make sure the blade retaining nuts are torqued to 60 ft-lb (81.3 N⋅m). Operating Instructions IMPORTANT: DO NOT disengage the blade clutch with high engine speed (above 1/2 throttle) since the brake action on the blade drive will cause premature wear of the brake band. WARNING 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 system malfunctions and the blades do not stop within five (5) seconds, the brake should be adjusted or repaired before operating the mower. Refer to ADJUSTMENTS of Blade Clutch (PTO) in Maintenance Instructions. Engaged Position Blade Clutch Engaged 4. Turn the ignition switch OFF. When stopping the engine, do not reduce the throttle below 1/2 speed. Since the engine is equipped with a shutdown solenoid, stopping at low idle may cause engine run-on or backfiring. WARNING Remove the key from the ignition switch when leaving the mower unattended. This will prevent children and inexperienced operators from starting the engine. Disengaged Position Blade Clutch Disengaged STOPPING THE MACHINE 1. Slow the engine to a fast idle; put the throttle in the 1/2 throttle position. 2. Pull the steering levers to the NEUTRAL position and then move the FSC lever backward to the NEUTRAL-PARK position. 3. Disengage the blade clutch. 5. Engage the parking brake. IMPORTANT: The hydrostatic transmissions lock to prevent the mower from rolling freely with the engine stopped. However, if the mower is parked on a slope, it is necessary to ENGAGE the parking BRAKE to prevent the mower from creeping. This is due to a small amount of slippage in the hydrostatic transmissions, especially when transmission fluid is warm. 33 Operating Instructions ADJUSTING CUTTING HEIGHT 3. WARNING The engine must be stopped before adjusting 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. The mower will “freewheel” with the levers in the LOCKOUT position. The levers must be in the highest position to completely unlock the transmissions. Lockout Lever Cutting height is adjusted by positioning the four 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. Plunger Depressed Cam in LOCKOUT Position Lockout Lever - Freewheel Position 4. Lift Handle Deck Support Pin After moving the mower, release the locking cam, placing the lever DOWN in the normal OPERATING position. Make sure the transmission lockout plunger on the side of the transmission case (activated by the lockout lever) is completely released, otherwise the transmission operation will be erratic. Lockout Lever Hitch Pin Cutting Height Adjustment TRANSMISSION LOCKOUT To move the mower with the engine NOT running (dead battery, maintenance, etc.), the hydrostatic transmissions are unlocked (released). 34 1. Raise the front body. 2. Lift the transmission lockout lever on both the RH and LH transmissions and secure into place with the locking cam. Plunger Released Cam in UNLOCKED Position Lockout Lever - Normal Operating Position Operating Instructions RECOMMENDATIONS FOR MOWING IMPORTANT: Operate the engine at full speed 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 • When using a side discharge mower deck, the side discharge 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 sidewalks or streets to minimize cleanup of clippings. When mowing close to obstacles, orient the side discharge away from obstacles to reduce the chance of damage to property by thrown objects. 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.) • When mowing, operate the engine at or near 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. Side Discharge Shield in Lowest Position • When mowing in adverse conditions (tall and/or • When operating on a slope, reduce speed and 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 use caution to start, stop, and maneuver. Avoid sharp turns or sudden changes in direction. The maximum recommended side slope operating angle is 20 degrees or 33% grade. Maximum Recommended Side Slope - Do Not Operate on Steep Slopes 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 skidding of the drive tires. Use smooth control movements of the steering levers since the hydrostatic transmissions 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). Maximum Recommended Side Slope 35 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. 36 Operating Instructions GRASS HANDLING SYSTEM (GHS) GHS Model Only Catcher Door Safety Latch Powerfil ® Drive Motor Exhaust Screen (Removable) Grass-Pak ® Vane Switch Exhaust Deflector Actuator Rod “Full” Signal Horn Delivery Chute Catcher Door PTO Clutch Catcher Door Spring PTO and Blade Gear Drive Grass Catcher Dump Handle Powerfil ® Delivery Spout Body Chute Assembly Blower Deck Discharge Chute Rear Discharge Mower Deck GHS Flow and Components 37 Operating Instructions General Information The Grass Handling System (GHS) consists of a rear discharge mower deck connected to a 10 in. (25 cm) blower and a rear mounted grass catcher with 7.0 bushel (246 liters) capacity or optional 9.5 bushel (335 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 combination 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. 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. NOTE: When a side discharge or mulching mower deck is installed on the GHS model, a blower intake cover should be installed in the blower intake tube. This cover “unloads” the blower and seals the intake to effectively eliminate power loss and blower noise when the blower is not being used. Blower Intake Cover Blower Intake Cover 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 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. 38 NEVER leave grass clippings in the grass catcher after mowing. Damp clippings generate heat as they decompose. This MAY cause spontaneous combustion. 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 wires, and make sure all movement has stopped before attempting to unclog. • Check the amount of flat section remaining at blade tip. This is the area that is ground away (removed) 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 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 indicate 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. 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 • Check to see if the RH and LH mower blades are 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. installed for the correct rotation - install blades so the cutting edges move toward each other. • Check the interior of the chute connecting the mower deck to the blower for smoothness and freedom from obstruction. Blades Must Operate at Right Angles (90 Degrees) FORWARD • 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 obstruction. Rear Discharge Chute Mounting Nut Torque = 60 ft-lb (81.3 N⋅ m) • 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. Blade Rotation for GHS Mower Deck (view from underneath) 39 Operating Instructions • 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. Remember, anything that restricts airflow or material flow along the entire path from the mower deck to the grass catcher can cause clogging. Using the Tilt-Up Deck Refer to CLEANING of Grass Buildup in Mower Housing for Tilt-Up Decks 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 position and moving the blade clutch to the ENGAGED position. The spout should oscillate approximately 25 cycles per minute. NOTE: If the grass spout fails to oscillate, the clutch switch should be checked for function (the switch closure is adjustable). “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. Oscillating 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, 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 both directions. WARNING DO NOT test the Grass-Pak ® switch with the engine running. Projectiles may be thrown out of the grass delivery spout, and COULD cause serious injury. 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 of GHS “Full” Signal Horn in Maintenance Instructions. 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 (delayed too much) is if grass clippings are falling out of the grass catcher delivery chute when the catcher is dumped. 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 frequently to avoid clogging the mower deck, blower, and chutes due to airflow restriction. Grass Catcher Screen Removal Knobs Grass Catcher Screen Removal for Cleaning 40 Operating Instructions Dumping the Catcher 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. Safety Latch Tailgate Dumping 1. Open the back door by lifting on the door handle. NOTE: To prevent accidental door closure, a safety latch locks the door open in the fully opened position while the catcher is being dumped. Catcher Door Safety Latch Using the Dump Bag (7.0 Bushel Catcher) 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. 4. Close the door by holding the door handle with the left hand and releasing the safety latch on the door hinge mechanism with the right hand. The safety latch is released by pressing in on the top of the latch. Then, smoothly close the door, working against the spring pressure that holds the door closed. DO NOT let the door slam shut by releasing the door before it is closed. 1. Open the back door by lifting on the door handle. NOTE: To prevent accidental door closure, a safety latch locks the door open in the fully opened position while the catcher is being dumped. 2. Orient the dump bag with one of the handle straps on the bag opening facing up. Tailgate Door Handle DANGER PINCH POINT - SPRING LOADED DOOR When lowering the door on the GHS catcher, depress the safety latch on the side of the 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. Hook Bag on Bumper Positioning Dump Bag on Catcher 41 Operating Instructions 3. Hook the bottom of the bag over the rear bumper while lifting on the handle strap. 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 positioning the bag and dumping. Catcher Lift/ Dump Handle DANGER PINCH POINT - SPRING LOADED DOOR When lowering the door on the GHS catcher, depress the safety latch on the side of the 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. Power Dump Option When equipped with the optional power dump system, the operator dumps the catcher while sitting in the seat. A toggle switch operating a power ram is used to raise and lower the catcher. The back door automatically opens and closes during the dump cycle. Hold the toggle switch UP or DOWN to RAISE or LOWER the catcher. When the catcher reaches the full raised or lowered position, the power ram clutch will make a ratcheting sound. Release the toggle switch as soon as this sound is heard. DO NOT operate the ram with the clutch ratcheting for an extended time as this will cause extra wear on the clutch mechanism. Dumping Catcher into Dump Bag 5. 6. 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. Close the door by holding the door handle with the left hand and releasing the safety latch on the door hinge mechanism with the right hand. The safety latch is released by pressing in on the top of the latch. Then, smoothly close the door, working against the spring pressure that holds the door closed. DO NOT let the door slam shut by releasing the door before it is closed. CAUTION The operator should be in the seat and bystanders stay clear when the power dump is operating. The power dump is used ONLY for tailgate dumping. Do not attempt to use the optional dump bag or any other bag with the power dump. NOTE: If grass tends to hang up in the catcher after raising the catcher with the power dump, “jiggle” the steering levers and make the tractor bounce a little to unstick the grass and make it slide out of the catcher. NOTE: With the power dump mechanism in the normal operating position (catcher down), the catcher can be manually raised for access to the engine and the catcher can be manually dumped. 42 Operating Instructions Door Actuator Arm Grass Catcher Catcher Door Gas Spring Cable Guide Lift Channel Power Dump Ram Actuator Fork Catcher Door Cable Rod Guide Cable Assembly Gas Spring Actuator Mount Assembly Dog Leg Assembly Rubber Bumper Power Dump Components 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 MT 25 100 200 Every Service Item Daily Hours Hours Hours Yearly 2 Years Check Engine Crankcase Oil Level x Check/Clean Engine Air Cooling System* x Check Security of Air Filtration Components x Check Air Filter Restriction Gauge x Clean Grass Buildup Under Deck x Clean GHS Exhaust Screen* x Clean GHS Blower* x Service Mower Blades x Check Functions of Instrument Panel and x Warning Horn Lubricate Grease Fittings and Oil Points* x Check PTO Gearbox Oil Level** x Check Battery Electrolyte Level x Check Hydrostatic Transmission Fluid x Check Tire Pressure x Check Drive Belts (Jackshaft, Engine PTO, x GHS Blower, Ground Drive) Check Gearbox Oil Seals x Check Turbine Precleaner* x x Check/Clean Primary Air Filter Element ∆ x Change Engine Crankcase Oil ∆∆ Check/Adjust Blade Clutch (PTO)/ x Brake Action Check Oil Level in Gear Axle x Clean Hydrostatic Transmission Cooling Fins x Clean Engine Cooling Fins x Check/Regap Spark Plugs x Change Engine Oil Filter x Check Fuel Lines and Clamps x Check/Clean Secondary Air x Filter Element and Foam Precleaner ∆ Replace Primary Air Filter Element x and Vacuator™ Valve ∆ Replace Fuel Filter x Service Battery x Check/Adjust FSC Friction Lock x Service Solenoid Shift Starter x x Change Gear Axle Oil ∆∆∆ Change Hydrostatic Transmission Fluid ∆∆∆ x Replace Fuel Lines and Clamps x ∗ ∗∗ ∆ ∆∆ ∆∆∆ 44 More often in extremely dusty or dirty conditions (refer to notes about air cleaner element in IMPORTANT TIPS FOR CARE OF KOHLER ENGINE) Change PTO gearbox oil after first 100 hours of operation (break-in period) Primary air cleaner is remote mounted Donaldson Radialseal™ unit, secondary air cleaner is standard Kohler engine mounted unit, replace primary filter every year or after 6 cleanings Change engine oil and filter after first 5 hours of operation of a new engine (break-in period) Change every 2 years or 1000 hours Ref. Page 46 57 60 54 58 40 59 61 22 47 51 60 52 61 62 63 54 54 46 74 51 60 57 63 46 63 56 54 69 60 79 63 51 52 63 Maintenance Instructions IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE KOHLER TIPS • Operate the engine at full speed when mowing. Fuel System This allows the engine to produce full horsepower and move more cooling air through the engine cooling fins. • Fuel must be clean - free from water, dirt, and or- Air Cleaner System ganic material. • Change fuel filter on a regular basis and when contamination is suspected or found in the fuel. Starting/Stopping • For starting in cold weather [below 40° F (4° C)], • Use only Kohler and Donaldson air cleaner elements. Aftermarket elements may not seal in the air cleaner housing, allowing dirt to enter the engine. Also, aftermarket filters often skimp on the filtration media and require more frequent cleaning and replacement (see following instructions). use the optional cold start lever to release the hydrostatic transmissions from the starter cranking load. • Use the air flow restriction gauge to indicate the • Start engine with the throttle advanced off idle • Do frequently check the Turbine Precleaner for (1/4 to 1/2 throttle). This will aid starting, especially in cold weather. free movement of the internal fan. • Keep the battery fully charged. • Match crankcase oil viscosity to the ambient temperature, allowing the engine to crank faster and start easier. • Use fast idle for stopping engine to avoid run-on or backfiring. Cooling System • 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. need to service the primary air filter. • DO NOT overservice or frequently “disturb” either the primary or the secondary air filter. A dirty air filter actually cleans better than a new one. Changing and cleaning the air filter too often can actually reduce filter efficiency and increase the opportunity for traces of dust to enter the engine. For the primary filter, wait until the element really needs servicing as indicated by the air flow restriction gauge. The secondary air filter should be serviced yearly or if there are indications that the primary filter has failed. • When the primary air filter element is removed or • Check performance of the cooling system by 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. starting the engine, holding a hand adjacent to the cylinder head, and feeling the cooling airflow. • Periodically check the air intake hose for cuts, • Periodically remove two access panels in the engine shroud to inspect and clean cylinder head cooling fins. DANGER Make sure to keep hands clear of exhaust pipe, muffler, and moving parts when checking airflow. nicks, etc., and the hose clamps for tightness. Oil • Use only multi-viscosity oils as specified 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. • Use only Kohler oil filters. Aftermarket filters may not seal properly and/or have the incorrect pressure relief valve for proper lubrication. 45 Maintenance Instructions LUBRICATION LUBRICATION 3. Remove the dipstick, wipe off with a clean rag, then reinsert the dipstick into the tube and press all the way down. 4. Remove the dipstick again and check the oil level on the dipstick. The oil level should be within the “Operating Range” on the dipstick (between the “L” mark and the “F” mark). WARNING DO NOT attempt to lubricate the machine with the engine running. Disengage the PTO clutch, shut off the machine, and remove the ignition key. Proper lubrication is an important maintenance procedure. It reduces wear and makes the machine quieter and easier to operate. Engine Oil 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 5 hours. Thereafter, change oil after every 100 hours of operation. IMPORTANT: DO NOT operate engine without a sufficient oil supply in the crankcase. DO NOT operate with the oil level below the “L” mark or above the “F” mark on the dipstick. 5. If additional oil is needed, refer to Specifications for proper crankcase lubricant. Fill up to, but not above, the “F” mark on the dipstick. IMPORTANT: DO NOT overfill the crankcase (oil above “F” mark) as this CAN result in engine overheating, loss of power, and possible engine damage. Checking Engine Crankcase Oil Level Check the engine crankcase oil level before use and after each 8 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]. Full Mark IMPORTANT: NEVER check or add oil with the engine running. Low Mark 2. Before removing the dipstick, clean the area around the dipstick to keep any dirt or debris out of the engine. Dipstick Operating Range Changing Engine Crankcase Oil/Oil Filter Change the engine crankcase oil after every 100 hours of operation and replace the oil filter every other oil change (every 200 hours of operation). 46 Maintenance Instructions 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. Remove the dipstick and the oil drain plug and drain the oil into a suitable container. Be sure to allow ample time for complete drainage. LUBRICATION 8. Fill the crankcase through the oil filler tube (dipstick opening) with new, clean oil. Use 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 up to, but not above, the “F” mark on the dipstick. Crankcase capacity is 1.85 quarts (1.75 liters) plus 1/2 pint (.24 liters) for the new oil filter. IMPORTANT: Check the dipstick reading before adding the last 1/2 pint of oil and fill only to the “F” mark. DO NOT overfill the crankcase (oil above “F” mark) as this CAN result in engine overheating, loss of power, and possible engine damage. Oil Filter Drain Plug Oil Drain/Oil Filter Location 3. Before removing the oil filter, clean the area around the filter to keep dirt and debris out of the engine. 4. Remove the old oil filter and wipe off the filter mounting surface on the engine. 5. Apply a thin coating of clean oil to the rubber gasket on the replacement oil filter. IMPORTANT: Use ONLY oil filters from the engine manufacturer (Kohler 12-050-01). Aftermarket oil filters may not seal properly and/or may not have the correct pressure relief valve for proper lubrication 6. Install the new oil filter on the engine. Turn the filter clockwise until the rubber gasket contacts the sealing surface, then tighten an additional 1/2 turn. 7. Reinstall the drain plug. Make sure it is tightened to 10 ft-lb (13.6 N·m). 9. Start the engine and check for oil leaks around the oil filter. Stop the engine, recheck the oil level, and add oil if necessary. (When the engine is first operated with a new oil filter, the oil level drops slightly as the filter is filled with oil.) Grease Fitting and Oil Point Lubrication 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 tractor) require routine lubrication after every 8 hours of running time. 47 Maintenance Instructions Ident No. Lubrication Type No. Places 1 2 3 Deck Caster Wheel Fork Pivot Deck Caster Wheel Bearing Tee Gearbox, Deck Grease Grease Oil* 2 2 1 4 5 6 7 8 9 10 11 12 Blade Drive Gearbox PTO Shaft Guard Hinge Universal Joint Shaft Assembly Pivot Assembly, Tilt-Up Deck Deck Support Arm Socket Body Hinge Point FSC Actuator Rod Pivot Pins FSC Lever Pivot FSC Lever Fork (Grease Slide Area) (FSC) Friction Body Pivot Steering Lever Pivot Deck Roller Wheel Deck Support Arm Pivot Deck-to-PTO Coupling (Grease Slide Area) Universal Joint Tube Assembly Universal Joint Quick Connect Spline (Grease Slide Area) Parking Brake Lever Gear Axle Belt Tightener Pivot, Jackshaft Drive Throttle Control Cable Ends Clutch Actuator Push Rod PTO Clutch Lever Pivot Belt Tightener Pivot, PTO Clutch Oil* Oil Grease** Grease Grease Oil Oil Grease Grease 2 1 1 4 2 2 2 1 1 Grease Grease Oil Grease Grease 1 4 2 2 1 Grease** Grease 1 1 Grease Oil*** Grease 1 2 1 Oil Grease Grease Grease 2 2 1 1 13 14 15 16 17 18 19 20 21 22 23 24 25 26 48 Location LUBRICATION Ident No. 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Location Lubrication Type Brake Actuator Rod and Brake Band Pivot Pins (Clevis) Brake Actuator Pivot Anti-Scuff Roller Wheel Catcher Hinge Point Rear Wheel Bearings Engine Oil Choke Control Cable Ends Belt Tightener Pivot, Blower Drive (GHS Model Only) Belt Tightener Pivot, Ground Drive PTO Gearbox Dipstick Hydrostatic Drive Choke Control Pivot Throttle Control Pivot Discharge Chute Hinge * ** *** No. Places Oil 3 Grease Oil Oil Grease Oil*** Oil Grease 1 2 2 2 1 2 1 Grease 1 Oil*** Oil*** Oil Oil Oil 1 2 1 1 1 Gearboxes are permanently lubricated and sealed requiring no scheduled lubrication. Oil level should be checked only when an oil leak is noted. Refer to Mower Deck Gearbox Lubrication in this section. Grease every eight (8) hours. Refer to Gear Axle Lubrication, Engine Oil, Tractor PTO Gearbox Lubrication, and Hydrostatic Transmission Fluid in this section. NOTE: DGHS42 Tilt-Up Deck is shown for reference. For other Deck Lubrication Points, Refer to Deck and Carrier Frame Illustrated Parts Manual. Maintenance Instructions LUBRICATION Chassis and Deck Lubrication Points 49 Maintenance Instructions LUBRICATION 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. Mower Deck Gearbox Lubrication NOTE: These instructions apply to all mower decks with gear-driven blades. Refer to DSD52 or DSD62 Mower Deck Lubrication in this section for the DSD52 or DSD62 deck with belt-driven blades. The mower deck gearboxes (tee gearbox and blade drive gearboxes) are connected as a unitized assembly, and oil flows freely between them. The gearboxes 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 orientation should be the normal operating position. Blade Drive Gearboxes 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 gearboxes. The gearbox assembly is not vented, and overfilling with oil will cause excessive pressure and result in oil leaks. 5. DSD52 or DSD62 Mower Deck Lubrication There are several special lubrication requirements for the DSD52 or DSD62 mower deck in addition to the requirements detailed in the Chassis and Deck Lubrication illustration. Lubricate the locations shown in the Blade Spindle Lubrication and Gearbox, Dolly Wheel, and U-Joint Lubrication photos and check and maintain oil in the belt drive gearbox. 1. Tee Gearbox Check condition of the cover gasket and replace if worn or damaged. Reinstall gearbox cover plates; torque screws to 24 in-lb (2.7 N⋅ m). Lubricate the blade spindles every 25 hours with two (2) shots of SAE general purpose lithium or molybdenum base grease. Blade Spindles Mower Deck Gearboxes (shown with gearbox cover removed for clarity) 50 2. Clean the area around the individual gearbox cover plates to prevent contaminants from entering the gearcase. 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) 90W oil until the oil level is up to (submerges) the horizontal shaft in the gearbox (shaft parallel to cover plate). Blade Spindle Lubrication Maintenance Instructions 2. LUBRICATION Check the oil level in the belt drive gearbox every 100 hours (or sooner if a visible oil leak has developed). With the deck in the normal operating position, remove the level plug in the side of the gearcase. Add SAE E.P. (Extreme Pressure) 90W oil to maintain the oil level to the plug. If the oil level is low, check the gearbox for any indication of an oil leak. If an oil leak is noted, the gearbox will need to be removed and rebuilt. 3. Lubricate the dolly wheel pivot every 25 hours with general purpose grease. 4. Lubricate the U-Joint in the drive shaft every 8 hours with SAE general purpose lithium or molybdenum base grease. Jackshaft Dipstick PTO Gearbox Dipstick Location, Tractor PTO Gearbox Belt Drive Gearbox Changing Gearbox Oil The tractor PTO gearbox is oil filled and vented. No scheduled oil change is required. However, changing the oil after the first 100 hour break-in period will extend gearbox life and is recommended. Dolly Wheel Pivot Level Plug 1. Remove the drain plug in the bottom of the gearcase, drain the oil, and reinstall the plug. 2. Refill the gearbox through the dipstick standpipe using 7 to 8 fl. oz. (21 to 24 cl) of SAE E.P. (Extreme Pressure) 90W gear lube. 3. Check that the oil level is at the FULL mark on the dipstick. DO NOT overfill. U-Joint Gearbox, Dolly Wheel, and U-Joint Lubrication Tractor PTO Gearbox Lubrication Checking Gearbox Oil Level Gear Axle Lubrication Check the gearbox oil level every 25 hours, and if necessary, add oil [SAE E.P. (Extreme Pressure) 90W gear lube] to maintain oil level to the FULL mark on the dipstick. • The gear axle oil lubrication is SAE 80W-90 (API IMPORTANT: DO NOT overfill the PTO gearbox to avoid oil leakage out of the dipstick standpipe. If the oil level is low, check the gearbox for any indication of an oil leak. If an oil leak is noted, the gearbox will need to be removed and rebuilt. GL-5) gear lube. • Check the axle oil level after every 100 hours of operation by removing the oil level plug. If additional oil is needed, remove the breather vent on top of axle and fill until oil is at the level plug. • Change axle oil every 1000 hours or two (2) years. 51 Maintenance Instructions LUBRICATION b. Hydrostatic Transmission Fluid If no fluid leaks from around the air bleed plug: Checking Hydrostatic Transmission Fluid Level * Slowly add fluid into the reservoir until fluid starts to leak from around the plug. (Transmissions are serviced from the factory with Mobil DTE 18M hydraulic oil. When it is necessary to add fluid, refer to Specifications for the proper fluid. Any of the listed fluids may be used.) * As soon as there is fluid leaking from around the air bleed plug, tighten the plug and fill the reservoir to the COLD level mark. Wipe any excess oil off of the transmission housing. Hydrostatic transmission fluid level should be checked every 25 hours of machine operation. It is preferable to check the fluid level when fluid is cold. Check fluid level as follows: 1. Park the mower on a level surface. Stop the engine and wipe dirt and contaminants from around the reservoir cap and air bleed plug. IMPORTANT: Before removing the reservoir cap, clean any dirt from around it. Any dirt or contaminants entering the transmission will accelerate wear and eventually cause loss of power to the drive wheels. 2. Remove the reservoir cap and check the level of the fluid. The reservoir has a fluid level COLD mark and HOT mark. The reservoir oil level should ALWAYS be at or above the COLD mark and NEVER above the HOT mark. Reservoir Cap Hot Level Air Bleed Plug Transmission Reservoir and Air Bleed Plug Location If the fluid is below the COLD mark (or the transmission is not performing properly), loosen the air bleed plug (located on the top of transmission case next to the plastic reservoir). a. 52 IMPORTANT: The transmission reservoir has a fine mesh screen in the bottom to trap dirt and foreign particles from entering the transmission. When filling the reservoir, fluid will flow quite slowly through this screen; so it is essential that there is fluid at the bleed plug before the transmission is considered full. IMPORTANT: Any attempt to remove or in any way alter the filtering screen in the transmission reservoir could cause damage to the transmission and will VOID any transmission warranty. Cold Level 3. IMPORTANT: DO NOT overfill the transmission reservoir. This will result in oil leaking out of the reservoir cap vent when the transmission warms up. It is preferable to add fluid to the transmission when it is cold and make sure the oil is not above or below the COLD level mark. If a small amount of fluid leaks from around the air bleed plug: * The transmission is full of fluid. * Tighten the plug and fill the reservoir to the COLD level mark. Changing Hydrostatic Transmission Fluid The hydrostatic fluid should be changed every 1000 hours or two (2) years. Also, the fluid should be changed if the natural color of the fluid has become black or milky (indicating possible overheating or water contamination of fluid). The transmission may be refilled using any of the fluids listed in Specifications. The fluid is changed as follows: 1. Park the mower on a level surface and stop the engine. 2. Remove the lower drain plug and the air bleed plug. Allow the fluid to drain out. IMPORTANT: Clean any dirt from around the plugs and reservoir cap before removing them. Maintenance Instructions LUBRICATION/CLEANING 3. Reinstall the lower drain plug, making sure the rubber O-ring on the plug is in place and in good condition. 4. Refill the transmission through the air bleed plug hole until it is as full as possible. 7. CLEANING Engine Air Cleaner System There are three main components in the engine air cleaner system: a turbine precleaner, a Donaldson Radialseal™ air cleaner, and the standard Kohler engine air cleaner. Each component is checked, cleaned and maintained on a different schedule based on the filtering action required. Working as the primary air filter, the Donaldson is serviced more frequently than the secondary Kohler engine air filter. Each component is serviced as follows: IMPORTANT: Avoid fluid contamination when filling the reservoir. Use clean container, spout, funnel, etc. when pouring the fluid into the reservoir. 5. Rotate the transmission input shaft about five (5) revolutions to allow any trapped air to escape. 6. Before installing the air bleed plug, fill the reservoir with fluid allowing a small amount to leak out of the air bleed plug hole. Donaldson Air Cleaner (Primary) Turbine Precleaner Install the air bleed plug and fill the reservoir to the COLD level line. Air Cleaner Donaldson Air Cartridge Cleaner Cover Vacuator™ Valve Precleaner Tube Wing Nut Hose Clamp Air Intake Hose Air Restriction Gauge Air Cleaner Cover Air Cleaner Cover Seal Engine Air Cleaner (Secondary) Seal Wing Nut Element Cover Paper Element Foam Precleaner Air Cleaner Base Plate Engine Engine Air Cleaner System Components 53 Maintenance Instructions CLEANING Turbine Precleaner The turbine precleaner is mounted on a remote air intake tube connected to the Donaldson air cleaner. A spinning fan driven by the intake airflow separates dust from the air, giving the initial stage of air cleaning. Dust particles are exhausted through a single small vent in the side of the housing. Since no dust is trapped, the precleaner operates without cleaning. The only maintenance required is to check the operation of the internal fan every 100 hours. Verify operation: 1. Look into the exhaust vent while shining a light into the intake. 2. Start the engine and watch the fan begin to spin as the throttle is advanced. If the fan is not spinning, service or replace the precleaner as required. Donaldson Radialseal™ Air Cleaner (Primary) A remote mounted Donaldson Radialseal™ air cleaner provides the primary air filtering function (ahead of the standard Kohler engine air cleaner). 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 Vacuator™ valve provide dust separation and automatic precleaning action. Daily or frequent servicing of the air cleaner is not required. Use the air restriction gauge on the air cleaner outlet to indicate when the air filter needs servicing -- a red flag will appear when the filter is overly restricting airflow into the engine. IMPORTANT: Use only Donaldson air filter elements for replacement (Donaldson P822686 or Walker 5090-1). Aftermarket filters may not seal properly or filter efficiently. 54 Cover Canister Vacuator™ Valve Radialseal™ Filter Element Cover Latch Air Cleaner Components (shown with cover being removed) IMPORTANT: The Donaldson air cleaner uses a dry paper-type air filter element. NEVER apply oil to the paper element. Push Button to Reset Indicator After Service Air Restriction Gauge Air Restriction Gauge Location Clean and inspect the paper element after every 100 hours of service and replace the element yearly or after six (6) cleanings (or when dirty or damaged). More frequent cleaning may be required when operating in extremely dusty conditions as indicated by the air restriction gauge. Service the air cleaner as follows: Maintenance Instructions 1. 2. 3. Release the top and bottom cover latches and remove the air cleaner cover. Wash the cover and Vacuator™ valve. Check that these components are in good condition. The Vacuator™ 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. CLEANING 8. 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 lubricants on the sealing surfaces of the filter; use talcum powder or dry silicone lubricants if required for filter installation. 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. Clean the filter element using low pressure compressed air [less than 100 PSI (689 kPa)]. Blow out the filter from the interior of the element while turning the element. Canister Outlet Tube Radialseal™ Filter Element NOTE: Washing the element in water or cleaning solution is not recommended. Replace the element if it does not clean up with compressed air. 4. 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 element if necessary. 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. 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. Insert and seat the 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. 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. 10. Check the air intake hose for cuts, nicks, etc., and the hose clamps for tightness. 11. Reset the air restriction indicator (press button on top). IMPORTANT: Any dust left on the inside of the outlet tube will go into the engine and cause wear. 7. Check the outside surface of the outlet tube for smoothness and cleanness (this is the sealing surface). 55 Maintenance Instructions Kohler Air Cleaner (Secondary) NOTE: The Kohler Air Cleaner should only be serviced more often than a yearly interval if there are indications that the Donaldson Radialseal (primary) has failed. • Foam Precleaner An oiled, foam precleaner surrounds the paper element of the Kohler engine air cleaner system. Clean and re-oil the foam precleaner yearly or more often in dusty or dirty conditions. 1. Unscrew the air cleaner cover mounting nut and remove the air cleaner cover. 2. Remove the foam precleaner by sliding it off the paper element. IMPORTANT: Replace the foam precleaner if necessary. Use ONLY Kohler replacement part #24-083-02. 3. Wash the foam precleaner in warm water with detergent. Rinse thoroughly and squeeze out excess water (do not wring). Allow the precleaner to air dry. 4. Saturate the foam with clean engine oil. Squeeze to distribute and remove excess oil. 5. Reinstall the precleaner by sliding it over the paper element. 6. 1. Unscrew the air cleaner cover mounting nut and remove the air cleaner cover and rubber seal on the air cleaner stud. 2. Remove the foam precleaner from the paper element. Replace if necessary. 3. Unscrew the element cover mounting nut and remove the element cover and the paper element. 4. Use a bright light and inspect the inside of the element for dirt or damage. Check very carefully for pin holes or other damage that will allow dirt to leak through the paper. Replace the element if necessary. 5. Check the condition and resilience of the element gaskets. If the gaskets have hardened or cracked or if there is evidence of a gasket not seating evenly, replace the element. 6. Check the air cleaner base plate. Make sure it is secure and not bent or damaged. Check the condition of the rubber seal on the air cleaner stud. Also, check the element cover for damage. Replace any damaged components. 7. Reinstall the paper element, cover, mounting nut, and foam precleaner. Tighten, but do not overtighten, the mounting nut (tighten 1/2 to 1 turn after contacting the cover). NOTE: A light coating of grease on the filter gaskets is recommended to enhance sealing and prevent dust leaks. Reinstall the air cleaner cover and mounting nut. • Paper Element The Kohler engine uses a dry, high density paper air filter element. Check the element (located under the foam precleaner) yearly or more often in dusty or dirty conditions. Replace the element if it is dirty, bent, or damaged. IMPORTANT: Use ONLY Kohler part #47-083-03. Aftermarket filters may not seal properly or filter efficiently. IMPORTANT: Kohler does not recommend cleaning the paper element and reinstalling. DO NOT wash the element or use pressurized air to clean as this will damage the element. NEVER apply oil to the paper element. 56 CLEANING 8. Check the security of the element. Make sure the element is positioned properly and sealed tightly against the air cleaner base plate and element cover. 9. Reinstall the rubber seal on the stud, the air cleaner cover, and mounting nut. Maintenance Instructions Paper Element Gasket Lightly Grease to Improve Sealing Action CLEANING DANGER Make sure to keep hands clear of exhaust pipe, muffler, and moving parts when checking airflow. Every 100 hours, inspect and clean the cooling fins (more often when operating in extremely dusty, dirty conditions). Remove the two (2) cooling fin access panels in the engine shroud and clean the cooling fins and external surfaces using compressed air. Make sure to reinstall the access panels before operating the engine. Rubber Seal NOTE: Some Kohler engines have not been equipped with the cooling fin access panels. Kohler kit #25-755-21 installs the panels if they are missing. Air Cleaner Base Plate (Check Sealing Surface) Engine Cooling Fin Access Panels Air Filter Reinstallation Kohler Engine Shroud Engine Cooling System Air Intake System To prevent engine overheating and possible engine damage, clean grass clippings, chaff, and dirt from the rotating engine 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 the screen several times each day to prevent engine overheating. Engine Air Intake Screen Engine Air Intake Screen and Cooling Fin Access Panels 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. Cylinder Head 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 described below. Check Airflow with Hand Cooling System Airflow 57 Maintenance Instructions CLEANING 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. Grass Buildup in Mower Housing Non-Tilting Decks DANGER Before raising or removing the mower deck for cleaning, stop the engine, remove the ignition key, and disconnect the spark plug wires. 1. Raise the deck and secure it in the UP position by hooking the deck lift rod into the body bracket below the counterweight spring clip. The rod is hinged and is stowed along the footrest of the deck carrier frame. A hitch pin on the end of the rod is used to secure it in place with the deck raised. DANGER Tilt-Up Decks DANGER Before raising or removing the mower deck for cleaning, stop the engine, remove the ignition key, and disconnect the spark plug wires. 1. Raise the deck lock lever handle on each side of the carrier frame and pull out to release carrier 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. NEVER operate cutter blades with the deck in the raised position. Tilt-Up Latch Counterweight Spring Clip Tilt-Up Latch Deck Lift Rod Tilt-Up Hook on Deck Deck Lock Lever Body Bracket Deck Secured in TILT-UP Position Deck Secured in UP Position - 2. DANGER Clean grass buildup underneath the deck using a pressure washer (and scraper if required). Do not operate the mower with deck in tiltup position. Do not move the tractor with the deck in the tilt-up position. 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”. 3. 58 Clean grass buildup underneath the deck using a pressure washer (and scraper if required). Maintenance Instructions CLEANING IMPORTANT: With the belt removed, the blower wheel must spin freely. Any binding or dragging of the wheel is an indication of dirt buildup. This buildup must be cleaned to avoid abrasive wear of the blower blades, excessive power loss and eventual loss of blower performance (clogging). 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. 2. Use a pressure washer or water spray, and direct the spray inside the blower housing against the blower blades. Water pressure will cause the blower wheel to begin to spin and the combination of spinning action and water will effectively wash the inside of the housing. Spray may be directed against the blower blades vertically and horizontally to cause rotation in both directions for thorough washing action. Wash blower until the blower wheel spins freely in both directions. 3. Reinstall the GHS blower drive belt by reversing the removal procedure. CAUTION Do not operate machine with deck tilt-up pivot joint unlocked. GHS Blower Normally, the GHS blower operates with no maintenance or cleaning. However, when mowing grass that is dirty and damp (especially springtime mowing), 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. NOTE: A visual clue of binding of the blower wheel is the blower blade tips are polished from rubbing on dirt. Chassis Belt Tightener Idler Pulley Frame Hook Blower Drive Pulley When a dirt deposit is found, use a high pressure washer or water spray to clean the inside of the housing as follows: DANGER GHS Blower Drive Belt Blower Pulley Before attempting to wash the blower, stop the engine, remove the ignition key, and disconnect the spark plug wires. 1. Remove the GHS blower drive belt by unhooking the belt tension spring from the hook on the chassis frame (located above the blower pulley). Lift the belt tightener idler pulley up and roll the belt off of the blower pulley. The belt should be clear of the blower pulley, allowing free movement of the blower wheel. Belt Tension Spring Collapse Blower Belt Tightener to Remove GHS Blower Drive Belt GHS Exhaust Screen Refer to Cleaning the GHS Exhaust Screen in Operating Instructions. 59 CLEANING/ CHECKING/SERVICING Maintenance Instructions Hydrostatic Transmission Cooling Fins CHECKING/SERVICING Keeping the cooling fins on the hydrostatic transmissions clean and free of obstruction is essential to avoid overheating the transmission fluid and shortening transmission life. The cooling fins should be checked every 100 hours; and cleaned if necessary. To clean the fins, use compressed air and/or a pressure washer. The cooling fins extend all the way around the housing -- the fins underneath need to be clean as well as the more visible fins above. Also, pay close attention to the area under the drive pulley. 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, replace the seal immediately to avoid overheating and damaging the transmission. The input shaft assembly and seal are easily replaced without removing the transmission from the machine. An additional procedure in maintaining transmission cooling is to inspect the cooling fans. Replace the fan(s) if blades are missing or damaged. DANGER 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 wires. Security of Air Filtration Components NOTE: The following inspection is only an external inspection and should be done without “disturbing” the filtration components. On a daily basis, visually inspect the external condition of the complete air cleaner system. The following items should be inspected: 1. Check the security of the engine air cleaner cover and inspect it for damage and make sure it seals properly with the engine baseplate. Improper sealing may be caused by a bent baseplate. 2. 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. 3. Inspect both air intake hoses for cracks, nicks, cuts, etc., and check the hose clamps for tightness. Battery Cooling Fan NOTE: For initial battery service during setup, refer to Battery Service in Assembly Instructions. Electrolyte Level Cooling Fins Hydrostatic Transmission Cooling Fins 60 The battery electrolyte level should be checked after every 25 hours of operation. To check electrolyte level: 1. Remove battery cell filler caps. 2. Check the electrolyte level. If the level is below the bottom of the vent well, fill with drinking water to the bottom of the vent wells [1/4 to 1/2 in. (6 to 13 mm) above the plates]. Maintenance Instructions 3. Replace filler caps. IMPORTANT: DO NOT overfill the battery. Electrolyte will overflow through the vented caps onto parts of the machine and WILL result in severe corrosion. Cleaning the Terminals If battery terminals are corroded, remove battery from the mower. Using a wire brush, remove corrosion 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 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. 2. 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. 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]. CHECKING/SERVICING Tire Pressure Inflate tires to pressures shown below: Deck Caster Wheel = 20 PSI (137 kPa) Drive = 15 PSI (103 kPa) Rear = 20 PSI (137 kPa) Sharpen Mower Blades Check mower blade(s) for straightness, sharpness, 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/REPAIRING 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 disconnect the spark plug wires before raising the mower deck to service blades. 2. Raise the deck and secure it in either the UP position using the deck lift rod (non-tilt deck) or in the TILT-UP position. Refer to CLEANING the Grass Buildup in Mower Housing in this section for deck raising instructions. DANGER DANGER BATTERIES PRODUCE EXPLOSIVE GASES NEVER operate cutter blades with the deck in the raised position. • 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 (check manifold vent on each cap). • Make sure the battery charger is unplugged before connecting or disconnecting cables to the battery. 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 difference in blade tip track is more than 1/8 in. (3 mm), the blade is bent and should be replaced. 61 Maintenance Instructions CHECKING/SERVICING 6. 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. 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. 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. 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 30° Intersection Wear Area Wing Tip Do Not Grind or Sharpen on Underside Mower Blade Profile For Sharpening 62 7. Mount the blade with wing tips pointing up into the housing. Reinstall the blade, washer, lock washer, and nut. Tighten the nut to 60 ft-lb (81.3 N ⋅ m). NOTE: When reinstalling blades on GHS models, remember, the blades turn toward each other (counter-rotate) and the RH and LH blade cannot be switched. Check for proper blade rotation before installing blades on the deck. Refer to Blade Rotation for GHS Mower Deck illustration shown in Clogging Checklist in Operating Instructions for correct blade rotation. Drive Belts Raise the body and inspect the condition of the four (4) belts (3 belts on SD models) every 25 hours of operation - engine PTO drive, jackshaft drive, hydrostatic ground drive, and GHS blower 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/ REPLACING/REPAIRING Maintenance Instructions 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 Mower Deck Gearbox Lubrication in this section. Check the function of the cutter blade brake (and blower brake on GHS models) 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 ADJUSTMENTS of Blade Clutch (PTO) in this section. REPLACING/REPAIRING Spark Plugs DANGER Every 200 hours of operation, remove the spark plugs, inspect, clean, and reset the gap (or replace with new plugs). Before removing the spark plugs, clean the area around the base of the plugs to keep dirt and debris out of the engine. Clean spark plugs with a wire brush. DO NOT use an abrasive grit type cleaner. If the electrodes are burned short or pitted, replace plugs with Champion type RC12YC (or equivalent). Check spark plug gap with a wire-type feeler gauge and set the gap at 0.030 in. (.76 mm). Reinstall and tighten to between 18 and 22 ft-lb (24.4 to 29.8 N⋅ m). IMPORTANT: ALWAYS use genuine factory replacement parts. Substitute parts CAN result in product malfunction and possible injury to the operator and/or others. Fuel Lines and Clamps Drive Belts Every year, inspect the fuel supply line from the tank to engine for deterioration or damage. Also, inspect the fuel line clamps for tightness. Good preventive maintenance calls for complete replace-ment of fuel lines and clamps every two (2) years. There are four (4) individual belts on GHS models or three (3) belts on SD models: 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 wires. • Jackshaft Drive Belt • Engine PTO Drive Belt (3 Groove Power Band) Engine Starter • GHS Blower Drive Belt (GHS Model Only) Yearly or every 500 hours disassemble and clean the solenoid shift starter. Refer to the Kohler Service Manual for this procedure or contact an authorized Kohler engine dealer to perform this service. • Hydrostatic Ground Drive Belt The belts may be removed and replaced using the procedures described on the following pages. Blade Brake Action WARNING It is important to check and maintain blade brake action for safe operation of the machine. 63 Maintenance Instructions REPLACING/REPAIRING Jackshaft Drive Belt Engine PTO Belt GHS Blower Belt (GHS Model Only) Hydrostatic Ground Drive Belt Belt Locations 64 Maintenance Instructions REPLACING/REPAIRING Engine PTO Drive Belt (3 Groove Power Band) 1. c. Raise the clutch lever (engage position) to lift the clutch idler away from the belt. d. Next remove the belt from the engine pulley and then the PTO drive pulley. To remove the engine PTO drive belt: a. Remove the jackshaft drive belt from its idler pulley (by pushing down on idler pulley) and let the belt drop down out of the way. 2. IMPORTANT: Make sure the belt is installed inside the four (4) belt guide pins. NOTE: Step (a) is not essential to removing the PTO belt, but it makes more room to work with the PTO belt. b. Install the PTO drive belt by reversing the removal procedure. Refer to ADJUSTMENTS of Blade Clutch (PTO) in this section to check and make the following adjustments: Push the clutch idler pulley down (until the PTO belt tightener stop block contacts the frame) and then shift the belt off the idler pulley (to the inside). a. Clutch engagement for proper belt tension b. Clutch disengagement and brake action Clutch Linkage Pull UP to Engage PTO Belt Tightener Arm PTO Belt Tightener Stop Block Engine PTO Belt Belt Guide Blade Clutch Lever in the DOWN Position Engine Pulley Belt Guides (Bottom Guide Not Visible) Clutch Idler Pulley Belt Guide PTO Drive Pulley Engine PTO Drive Belt Removal 65 Maintenance Instructions REPLACING/REPAIRING Jackshaft Drive Belt 1. b. Relax the belt by depressing the springloaded idler arm. c. Roll the belt off the jackshaft pulley and remove. To remove the jackshaft drive belt: a. Remove the engine PTO drive belt, as described in previous section. Push Idler Pulley Down to Relax Belt Jackshaft Idler Pulley Jackshaft Drive Belt Engine Pulley Tension Spring Jackshaft Drive Belt (Disengaged) 2. Reverse the removal procedure to replace the jackshaft drive belt. Idler Arm Jackshaft Jackshaft Drive Belt Engine Pulley Tension Spring Jackshaft Drive Belt (Engaged) 66 Maintenance Instructions REPLACING/REPAIRING GHS Blower Drive Belt 1. Remove the GHS blower drive belt by unhooking the belt tension spring from the hook on the chassis frame (located above the blower pulley). Lift the belt tightener idler pulley up and roll belt off the pulleys. Blower Drive Pulley Blower Pulley Chassis Frame Hook GHS Blower Drive Belt Spring Removed Belt Tightener Idler Pulley (Disengaged) GHS Blower Drive Belt Assembly (Disengaged) Blower Drive Belt Spring Removal 2. Reverse the procedure to install the GHS blower drive belt and spring. Spring Attached Idler Pulley (Engaged) GHS Blower Drive Belt Assembly (Engaged) 67 Maintenance Instructions REPLACING/REPAIRING Hydrostatic Ground Drive Belt 1. To remove the hydrostatic ground drive belt: a. b. Slide belt off pulleys, then release the idler. Raise the spring-loaded belt tightener arm and idler pulley to relax belt. Belt Tightener Arm Jackshaft Idler Pulley Transmission Drive Pulley Spring Hydrostatic Ground Drive Belt Hydrostatic Ground Drive Belt Assembly (Disengaged) 2. Reverse the procedure to install the hydrostatic ground drive belt. Belt Tightener Arm Spring Idler Pulley Hydrostatic Ground Drive Belt Hydrostatic Ground Drive Belt Assembly (Engaged) 68 Maintenance Instructions REPLACING/REPAIRING Fuel Filter Model MT is equipped with an in-line fuel filter. Visually inspect the filter periodically, and replace the filter yearly. In-Line Fuel Filter Turn Valve Clockwise to Close Fuel Shut-Off Valve and Filter Blade Overload Shear Bolts NOTE: Shear bolts are not used on the DSD62 mower deck. Fuel Filter Location IMPORTANT: Replace the fuel filter only in a clean area where the fuel line and connections will not be contaminated by any dust and dirt. The cutting blade is keyed to the 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. DANGER Gasoline is extremely flammable and can be highly explosive. To minimize danger: • Use only an approved fuel container for gasoline. Cutting Blade Shear Bolts • DO NOT allow open flames or sparks near the machine while performing maintenance or refueling; DO NOT smoke while working with fuel. • Wipe up spilled gasoline immediately and completely. 1. Close the fuel tank shut-off valve. 2. Expand and slide clamps on either side of the filter away from filter and pull fuel lines off filter. 3. Replace filter. 4. Open fuel tank shut-off valve. Cutting Blade Shear Bolts NOTE: Tightening the 5/8-18 blade mounting nut to 60 ft-lb (81.3 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. 69 Maintenance Instructions REPLACING/REPAIRING After reinstalling the blade, check blade timing by moving blades through one (1) complete revolution. Make sure blade tips pass clear of each other. If timing is incorrect, refer to Mower Deck Gearbox Replacement in this section. 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. Mower Blades Mower blades are removed and remounted as described in Sharpen Mower Blades instructions. 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. Reinstall the blades following procedure from Sharpen Mower Blades instructions. 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. • 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 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. 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. 70 Mower Deck Gearbox Replacement NOTE: Deck gearbox(es) may be changed with the deck mounted on the tractor. However, the deck may be removed from the tractor making the overall job of removing the gearbox assembly easier. Refer to Deck Installation in Assembly Instructions and reverse the procedure to remove the deck. To replace the mower deck gearbox(es), use the following procedure: 1. Remove mower blades. Refer to procedure in Sharpen Mower Blade instructions. 2. Remove gearbox cover (two machine screws) and PTO shaft guard (two 1/4-20 bolts). 3. Remove two (2) 3/8-16 mounting bolts from each blade drive gearbox and lift the entire gearbox assembly from the deck (including PTO drive shaft). 4. Remove the screws securing the cover plates on the gearboxes and remove the covers. Remove all covers to be sure oil is completely drained from all gearboxes. Maintenance Instructions REPLACING/REPAIRING NOTE: With oil flow throughout the unitized gear drive assembly; if one gearbox has internal damage or excessive wear, the remaining gearboxes and connector tubes should be completely disassembled and thoroughly flushed out with solvent before reassembly. 5. Drain and properly dispose of oil. 6. Remove the four (4) bolts mounting the gearbox to the connector tube and slide the gearbox off the splined drive shaft coupling. 7. Install the new gearbox on the spline coupling of the drive shaft. Establish correct timing of the blade drive gearboxes by setting flats on the output shaft at 90 degrees when connecting the gearbox(es) to the spline coupling. Make sure the timing is correct before proceeding with assembly. 8. Reinstall the four (4) bolts mounting the gearbox to the connector tube but do not tighten them at this time; leave connector tube bolts fingertight. 9. Position the gear drive assembly on the deck and install the 3/8-16 bolts mounting the entire assembly. Leave the mount bolts finger-tight. Mower Deck Gearboxes Connector Tubes Mower Deck Gearboxes (Shown with Gearbox Cover Removed for Clarity) GHS Blower Assembly (and/or Blower Wheel) GHS Blower Assembly Removal 1. Remove the mower deck. Refer to Deck Installation in Assembly Instructions and reverse the procedure to remove the deck. Skid Bar Mounting Bolts 10. Torque all the connector tube bolts to 80 in-lb (9 N⋅ m); then tighten the deck mount bolts. NOTE: This fastener tightening sequence aligns the gearbox assembly with the deck housing and eliminates the possibility of mounting the unitized assembly in a bind. 11. Fill gearbox assembly with oil. Refer to Mower Deck Gearbox Lubrication in this section for instructions. 12. Reassemble remaining items onto deck to complete installation. After installing blades, check that the blade timing is correct by moving the blades through one (1) complete revolution. Make sure blade tips pass clear of each other. Blower Assembly Skid Bar Remove Skid Bar for GHS Blower Removal 2. Remove the blower faceplate by removing six (6) 1/4-20 nuts. 3. Remove the GHS blower drive belt. Refer to REPLACING/REPAIRING the Drive Belts in this section for instructions. 71 Maintenance Instructions 4. REPLACING/REPAIRING Remove the blower assembly from the chassis as follows: a. Remove the blower skid bar by removing front and rear mounting bolts from the skid bar (underneath the blower) and removing the bolt connecting the blower housing to the skid bar. b. Remove the blower belt tightener idler arm assembly by removing the pivot bolt. c. Remove two (2) bolts mounting the blower housing to the frame. d. Lower the blower assembly straight down out of the chassis frame and remove. Wheel Puller Hooked to Lugs on Bearing Housing Blower Wheel Removal When required, replace the blower wheel using the following procedure: 1. 2. 3. Loosen blower pulley set screws and remove the pulley using a wheel puller. Remove the locking collar from the back bearing (closest to the pulley) by loosening the set screw and rotating the collar counterclockwise (use punch to drive). Press blower wheel out of the housing using a wheel puller hooked to lugs on the bearing housing. The bearings have been secured in the housing with a retaining compound - Loctite ® RC/680, and considerable force will be required to break this bond. After the bearings have “broken loose” from the housing, only light pressure should be required to remove the wheel assembly out of the housing. NOTE: It may or may not be possible to remove the front bearing from the blower wheel without damaging it. If the bearing is damaged, it will need to be replaced along with the wheel. Pressing Blower Wheel Out of Housing Blower Wheel Installation 1. To install the blower wheel, reverse the removal procedures. The front bearing is mounted on the blower wheel shaft, secured by a locking collar. Drive the locking collar clockwise with a punch, and tighten the set screw. 2. Press blower wheel and front bearing into the blower housing. Use Loctite ® RC/680 retaining compound on the outer bearing race and inside the bearing housing. 3. Press the rear bearing into place, using Loctite® on both the outer bearing race and the housing. 4. Install the locking collar on the rear bearing and install the blower pulley to complete the blower assembly. Torque the blower pulley set screws to 250 in-lb (28.3 N⋅ m). GHS Blower Assembly Installation Reinstall the blower assembly into the mower using the reverse procedures of GHS Blower Assembly Removal. 72 Maintenance Instructions ADJUSTMENTS ADJUSTMENTS DANGER If the engine must be running to perform a maintenance adjustment, keep hands, feet, and clothing from moving parts. DO NOT wear jewelry or loose clothing. Safety Switches There are three (3) safety interlock switches on the tractor. Use the panel nuts on the switch body to position the switch for proper activation of the switch. The adjustment procedure for each switch is: Seat Switch Adjust switch position in body panel to achieve a 1/32 to 1/16 in. (.79 mm to 1.59 mm) air gap between the switch plunger and seat frame with no weight on the seat. Test for proper operation. FSC Neutral-Park Switch 1. Place the FSC in NEUTRAL-PARK position. 2. Adjust switch to the point where the starter engages when the ignition switch is turned to the start position. 3. Adjust switch position forward an additional 1/2 to 1 turn of the panel nuts. NOTE: If the switch cannot be adjusted forward enough to achieve proper function, it may be necessary to bend the switch mounting bracket slightly. PTO Switch With the PTO engaged, adjust switch to achieve a 1/64 to 1/32 in. (.40 mm to .79 mm) gap (plunger extension) between the switch body and the actuator plate. Tail Wheel Bearing Preload Preload the tail wheel bearings by tightening the axle nut until the wheel begins to tighten as it turns (not spin freely), then loosen the nut 1/2 to 1 turn. The wheel should spin freely without excessive end play. Lock the axle nut with the set screw in the nut. 73 Maintenance Instructions ADJUSTMENTS Blade Clutch (PTO) Clutch Engagement/Belt Tension The clutch engagement and PTO belt tension are adjusted using the clutch actuator rod. Initially, after installing a new PTO belt, after 10 hours and every 100 hours thereafter, check and adjust for the two dimensions in the clutch actuator rod as shown in the PTO Clutch Engaged and PTO Clutch Disengaged illustrations. Adjust the bolt head clearance [1/4 in. to 3/8 in. (6.35 mm to 9.53 mm)] first (clutch engaged), then adjust uncompressed spring length (clutch disengaged). The spring must be adjusted to an uncompressed overall length of 2-1/8 in. (54 mm). If adjustments are needed more frequently than every 100 hours to maintain the linkage dimensions, it may suggest problems with pulley wear or belt misalignment. Clutch Actuator Rod 1/4 in. to 3/8 in. (6.35 mm to 9.53 mm) PTO Belt Tightener Arm Locknut Spring Compressed Blade Clutch Lever Engaged PTO Clutch Engaged 74 Maintenance Instructions ADJUSTMENTS Clutch Disengagement/Brake Action WARNING It is important to check and maintain blade brake action for safe operation of the machine. 2-1/8 in. (54 mm) The declutched or disengaged position of the blade clutch idler pulley is adjustable and is set to give belt release without excessive slack and to apply the blade brake. The blade brake is activated by the brake actuator rod linkage to the clutch idler pulley mechanism. The brake is designed to stop the blades within five (5) seconds after disengaging the clutch. Spring Overall Length Knuckle Joint Adjustment Nut Spring Uncompressed Blade Clutch Idler Pulley Blade Clutch Lever Disengaged PTO Clutch Disengaged 75 Maintenance Instructions ADJUSTMENTS Use the following procedures to check and adjust clutch disengagement and brake action: Stop Block Stop Block Eccentric Adjustment - Step 1 Use the stop block attached to PTO belt tightener arm to set the bottom position of the clutch idler pulley in the disengaged position. The stop block should contact the chassis to stop the clutch idler pulley from moving further down in the disengaged position. If the stop block is not contacting the chassis in the disengaged position, it will be necessary to loosen the brake band adjustment nut. The stop block is an “eccentric” block that will allow four adjustment positions from 5/16 in. (8 mm) to 11/16 in. (17 mm). Engage Pulley Travel Disengage Stop Block Contacting Frame 1 in. to 1-1/2 in. (25 mm to 38 mm) Clutch Idler Pulley Travel Adjustment Blade Brake Band Adjustment - Step 3 11/16 in. (17 mm) 9/16 in. (14 mm) After the pulley travel is set, make the following adjustment as needed: 1. 7/16 in. (11 mm) 5/16 in. (8 mm) PTO Belt Tightener Stop Block Adjustments Adjust the blade brake band, using the adjustment nut until there is a gap of approximately 1/8 in. (3 mm) between the PTO belt tightener stop block and chassis. If there are not enough threads on the brake band for adjustment, lengthen the brake actuator rod. Blade Brake Band Adjustment Nut Clutch Idler Pulley Travel Adjustment - Step 2 Adjust the stop block to give 1 in. (25 mm) to 1-1/2 in. (38 mm) pulley travel from “clutch engaged” to “clutch disengaged”. To check and adjust the pulley travel, first engage the clutch, then measure the distance the pulley moves down as the clutch is disengaged and the stop block contacts the frame. Brake Actuator Rod NOTE: The importance of this adjustment is if the pulley travel is excessive and the bolt develops too much slack, the belt will derail when disengaged. Blade Brake Band Adjustment 76 Maintenance Instructions ADJUSTMENTS 2. Blade Clutch Idler Pulley 1/8 in. (3 mm) Stop Block PTO Belt Tightener After adjustments are complete, check blade brake action as described in CHECKING/SERVICING the Blade Brake Action in this section. If blades do not stop within five (5) seconds, check the following: a. Recheck 1/8 in. (3 mm) gap between stop block and chassis. b. Make sure clutch and brake linkage are working freely (no binding). c. Check the brake band lining. d. Check the brake drum on the pulley. If excessive wear is present, it will be necessary to replace worn parts. Chassis Transmission Control Blade Brake Band Adjustment NOTE: The length of the actuator rod is adjusted by disconnecting the bottom clevis and shortening or lengthening accordingly. The standard pre-set length of the actuator rod is set at the factory at 8-1/4 in. (209 mm). IMPORTANT: The proper adjustment of the transmission control stops is essential for efficient operation and life of the transmission. These stops are properly adjusted at the factory and should only require readjustment if the transmission or related control linkage is removed or changed. NOTE: It would not be unusual for a new machine, after initial 5 or 10 hours of operation, to begin to not travel straight (this is due to the break-in of the transmissions). In this case, proceed to Straight Ground Travel Adjustment - Step 4. IMPORTANT: The following adjustment procedures are sequential. Check and adjust each function in the order given. Set Forward Travel Limit (Stop) - Step 1 8-1/4 in. (209 mm) Locknuts Bottom Clevis 1. Move the Forward Speed Control (FSC) lever to the most FORWARD position. 2. Check clearance of the RH and LH steering lever actuator arms with the frame and adjust forward stop bolt so each lever clears the frame by at least 1/16 in. (1.6 mm). Clearance of the arm to the frame should be checked while applying pressure back on the arm to remove any slack in the linkage. Brake Actuator Rod Adjustment 77 Maintenance Instructions 3. ADJUSTMENTS Tighten the jam nut on the forward travel stop adjusting bolt. CAUTION NEVER attempt to disconnect any safety devices or defeat the purpose of these safety devices. Steering Lever Actuator Arms FSC Actuator Clevis Forward Travel Stop Bolt LH Steering Lever (For Orientation) Neutral Safety Switch Steering Adjustment Nut Forward Speed Control Stop and Steering Lever Adjustment Neutral Function Adjustment Steering Lever End Play Adjustment - Step 2 1. Position the FSC lever to the most FORWARD position. 2. Loosen the adjustment nut on each steering lever actuator until end play develops between the lever actuator and the adjustment nut (sliding on transmission control rod). 3. Hold the actuator back as shown (against the spring pressure) and tighten the nut to the point where the end play is removed and then tighten two additional turns. 3. If drive wheels are moving, stop the engine and adjust the FSC neutral stop by adjusting the FSC actuator clevis (see Neutral Function Adjustment photo for clevis location). If the drive wheels are moving backward, remove the cotter pin and clevis pin and screw the clevis forward. If the drive wheels are moving forward, screw the clevis backward. Restart the engine and check for wheel movement (several “trial and error” adjustments may be required). At this point it may not be possible to adjust both wheels stationary since the differential adjustment has not been made. (This is covered by the Straight Ground Travel Adjustment - Step 4.) In this case, the neutral adjustment should be made for one wheel stationary and the other moving forward slightly. 4. Check and adjust the neutral safety switch for closure and function with the FSC in neutral (the engine will not start when the switch is open). Use panel nuts on the switch body to adjust switch position for closure in neutral. Refer to adjustment description for Safety Switches in this section. IMPORTANT: If the adjustment nut is too loose (end play exists) excessive loads are placed on transmission internal control stops. If the adjustment nut is too tight (preferred condition), the maximum forward travel speed is reduced. Neutral Function Adjustment - Step 3 1. Move the FSC lever to the NEUTRAL-PARK position (rear travel limit). 2. Start the engine (operate first at idle and then normal operating speeds) and check for movement of the drive wheels. NOTE: If the engine will not start, check and adjust the neutral safety switch (see item 4 below). 78 Maintenance Instructions ADJUSTMENTS Straight Ground Travel Adjustment - Step 4 Forward Speed Control Friction Lock 1. Sit in the seat, start the engine (operate at normal speed), and with the FSC in the NEUTRALPARK position check for forward movement of either drive wheel (if either wheel moves backward, refer back to Neutral Function Adjustment - Step 3 and readjust). Tighten the steering lever adjustment nut on the side of the mower with the wheel moving forward until wheel movement stops. The FSC friction lock is adjusted to hold the selected forward speed when the steering levers are moved and yet the friction is not too heavy to make moving the control difficult (too much friction). The procedure for checking and adjusting the FSC friction lock is as follows: 2. Check for straight ground track on a level surface (with hands off the steering levers). Set the FSC at several different speeds and observe if the mower moves in a straight line (use cement joint or other line on the ground for reference). FSC Actuator NOTE: The final tracking adjustment is made with the mower moving, since the adjustment is quite sensitive and is more easily “fine tuned” when moving. 3. If travel is not straight, tighten the adjustment nut that is on the same side of the mower as the wheel that is moving too fast, e.g., the mower tracks to the right, indicating the LH wheel is moving too fast, tighten the LH adjustment nut. End Wrench on Adjustment Nut Friction Washer Friction Adjustment Nut Forward Speed Control Friction Lock 1. 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. 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 conditions of both steps 1 and 2 (above) are met. Straight Ground Travel Adjustment 79 Maintenance Instructions 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 existing 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. ADJUSTMENTS The fixed main jet carburetor is designed to deliver the correct fuel-to-air mixture to the engine under all operating conditions. The high idle is set at the factory and cannot be adjusted. The low idle mixture screw is also set at the factory and normally does not need adjustment. The only adjustment normally made to the carburetor is to set the idle speed. However, if the engine exhibits any of the following symptoms, it may be necessary to adjust or service the carburetor: black, sooty exhaust smoke; lack of power; engine miss or backfire; hard to start; rough running; stalls at low idle speed. NOTE: Due to the technical requirements of modern carburetors, refer to the Kohler Service Manual or contact an authorized Kohler engine dealer for carburetor adjustments and service not described in this section. Jam Nut CAUTION Set Screw 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. Tilt-Up Deck Adjustable Stop Carburetor Since the carburetor main jet is non-adjustable, for operation above 5000 ft (1,524 m) above sea level, it may be necessary to change the carburetor main jet for best fuel economy and power. Contact an authorized Kohler dealer to change the carburetor main jet. CAUTION Engine Idle Adjustment DO NOT change the engine governor settings or overspeed the engine. The governor has been factory set for maximum safe engine operating speed. IMPORTANT: Some emission certified engines may not have an adjustable idle mixture needle valve; it is fixed from the factory and the adjustable screw is "capped". In this case, only the idle speed is adjustable and only Step 4 of the instructions below applies. 1. Gently close the idle mixture needle valve by turning it clockwise until it bottoms lightly. IMPORTANT: The needle valve and carburetor seat may be damaged by turning the adjustment screw too tight. 80 Maintenance Instructions 2. Preliminary Setting: Turn the idle mixture needle valve out (counterclockwise) 1-1/2 turns from the closed position. This initial adjustment will allow the engine to be started and warmed up prior to the final adjustment. Low Idle Mixture Needle Valve (May be Non-Adjustable) Idle Speed Screw ADJUSTMENTS GHS “Full” Signal Horn with Grass-Pak® Switch If the GHS “full” signal horn is not sounding or is not adjusted to sound when the catcher is full, the following troubleshooting and adjustment instructions apply: Troubleshooting (When Horn Fails to Operate) 1. Fixed Main Jet Under Shutdown Solenoid Check the horn. a. Disconnect the two wires from the GrassPak® switch electric connector plug and make a jumper wire connection between these wires (bypassing switch). b. Turn the ignition switch ON and move the blade clutch to the ENGAGED position (engine not running) to make the horn sound. c. If the horn does not sound, the horn is bad and needs to be replaced. d. If the horn does sound, proceed to step 2. Carburetor Adjustment DANGER The engine must be running to adjust the carburetor for engine idle. To guard against injury, keep hands, feet, face, and other parts of body away from the muffler/ exhaust pipe, other hot parts of the engine, and moving or rotating parts of the engine. 3. Start the engine and allow it to warm up by running at 1/2 throttle for approximately five (5) minutes. The engine must be warm before making final settings. 4. Move the throttle to the idle position. Adjust idle speed for 1200 rpm (± 75 rpm) by adjusting the idle speed screw. Check the idle speed using a tachometer. 5. With the engine idling, adjust the idle mixture by turning the idle mixture needle valve in (slowly) from the preliminary setting until engine speed decreases and then back out approximately 3/4 to 1 turn to obtain the best low speed performance. 6. Recheck idle speed after the final idle mixture adjustment. 2. Check the Grass-Pak® switch. a. Reconnect the wires to the Grass-Pak® switch electric connector plug. b. Turn the ignition switch ON and move the blade clutch to the ENGAGED position (engine not running). c. Open the catcher back door and trigger the Grass-Pak® vane by hand as it oscillates. WARNING PINCH POINT - SPRING LOADED DOOR When lowering the door on the GHS catcher, depress the safety latch on the side of the catcher 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. d. The horn should sound as the switch is moved in both directions. If the horn does not sound, the switch is bad and needs to be replaced. 81 ADJUSTMENTS/ ELECTRICAL SYSTEM Maintenance Instructions 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. Delay Adjustment Screw Advance Grass-Pak® Switch Vane Adjustment ELECTRICAL SYSTEM Grass-Pak® Vane Switch For troubleshooting, refer to Wiring Diagram. IMPORTANT: Disconnect both battery cables before unplugging any wiring connectors or making repairs on the electrical system. Checking the Grass-Pak® Switch Adjustment (When Horn Sounds at the Wrong Time) Circuit Breakers Very little, if any, adjustment to the Grass-Pak® switch is required. However, to fine tune the timing of the full signal, the vertical position of the switch vane is adjustable approximately 3/4 in. (1.9 mm). A master circuit breaker is mounted on a bracket behind the battery. The circuit breaker may have either the manual or automatic reset function -- both types have been used. See Circuit Breaker Location photo. 1. 2. Loosen the screw mounting the vane on the switch and adjust the position of the vane as follows: a. Move the vane UP to delay the signal. b. Move vane DOWN to advance the signal. 30 Amp Circuit Breaker Retighten the screw. 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). 82 IMPORTANT: Disconnect the battery cables before unplugging and removing the instrument panel. Circuit Breaker Mounting Bracket Circuit Breaker Location Maintenance Instructions ELECTRICAL SYSTEM Wiring Diagram - Model MT 83 Operator’s Notes 84 Operator’s Notes 85 Operator’s Notes 86 LIMITED WARRANTY FOR WALKER COMMERCIAL 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: Kohler Engine Kubota Engine Kawasaki Engine Eaton Hydraulic Transmission Peerless Gearboxes Battery Tires The available warranties covering these items are furnished with each mower. Walker does not assume any warranty obligation, liability or modification for these items, which are covered exclusively by the stated warranty of the respective manufacturers noted above. * An extended three (3) year warranty is offered on the Walker P/N 6200 Gear Axle Assembly. 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 Owner’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 Manufacturing 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. 87 Lwa 104 LpA 96 OPERATOR Sound - Model MT20 Sound - Model MT25 Sound Test Sound Test Sound test conducted was in accordance with 79/113/EEC and was performed on 22 March 96 under the conditions listed: Lwa Sound test conducted was in accordance with 79/113/EEC and was performed on 22 March 96 under the conditions listed: General Condition: LpA General Condition: Clear o 95 o Temperature: 50 (F) 10 (C) Wind Speed: < 5 mph (< 8 kmh) Humidity: 52% 106 OPERATOR Barometric Pressure: 24.9" HG (759 mm Hg) Clear Temperature: 50 (F)o10 (C)o Wind Speed: < 5 mph (< 8 kmh) Humidity: 52% Barometric Pressure: 24.9" HG (759 mm Hg) Vibration - Model MT20 Vibration - Model MT25 Vibration Level Vibration Level 0.8g Vibration levels at the operators handles were measured in the vertical, lateral, and longitudinal directions using calibrated vibration test equipment. 0.7g Tests were performed on 22 March 96 under the conditions listed: General Condition: Clear Clear Vibration levels at the operators handles were measured in the vertical, lateral, and longitudinal directions using calibrated vibration test equipment. Tests were performed on 22 March 96 under the conditions listed: General Condition: Clear Temperature: 50 50 (F) (F) 10 10 (C) (C) Temperature: 50 (F)o10 (C)o Wind Speed: <<55mph mph(< (<88kmh) kmh) Wind Speed: < 5 mph (< 8 kmh) Humidity: 52% 52% Humidity: 52% Barometric Pressure: 24.9" HG (759 mm Hg) oo oo Barometric Pressure: 24.9" 24.9"HG HG(759 (759mm mmHg) Hg) WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, CO 80528 • (970) 221-5614 FORM NO. 101298 PRINTED IN USA ©1998 WALKER MFG. CO
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