Walker C19i Operator's Manual

Operator’s Manual
Safety, Assembly, Operating, and Maintenance Instructions
Please Read and Save These Instructions
For Safety, Read All Safety and Operation
Instructions Prior to Operating Machine
Beginning S/N: 134494
P/N 6000-22
Foreword
Thank you. . .for purchasing a Walker mower. Every effort has been made to provide you with the
most reliable mower on the market, and we are sure you will be among our many satisfied customers. If for any reason this product does not perform to your expectations, please contact your local
dealer. Every customer is important to us. Your satisfaction is our goal.
Please. . .read this manual thoroughly! This manual is to be used in conjunction with the engine
manufacturer’s manual for the specific engine on the mower model you have purchased. Before
you operate your new mower, please read this entire manual. Some of the information is crucial for
proper operation and maintenance of this mower - it will help protect your investment and ensure
that the mower performs to your satisfaction. Some of the information is important to your safety
and must be read and understood to help prevent possible injury to the operator or others. If anything in this manual is confusing or hard to understand, please contact your local authorized dealer
or call our service department, at (970) 221-5614, for clarification before operating or servicing this
mower.
This manual covers Model C19i with the Kohler Command Pro ECH630 (19 HP) Electronic Fuel
Injection (EFI) gasoline engine.
All shields and guards must be in place for the proper and safe operation of this machine.
Where they are shown removed in this manual, it is for illustration purposes only. Do not operate
this machine unless all shields and guards are in place.
Specifications given are based on the latest information available at the time this manual was produced for a tractor with standard equipment. Optional equipment is available and may affect the
standard specifications listed.
Walker Mfg. Co. is continually striving to improve the design and performance of its products. We
reserve the right to make changes in specifications and design without thereby incurring any obligation relative to previously manufactured products.
Sincerely,
WALKER MANUFACTURING COMPANY
Bob Walker, President
Table of Contents
General Information_________________ 1
Operating Instructions______________ 27
HIGHLIGHTED INFORMATION______________
GLOSSARY_____________________________
IDENTIFYING NUMBER LOCATIONS_________
ENGINE SERIAL NUMBER LOCATION________
SERVICING OF ENGINE AND
DRIVETRAIN COMPONENTS_______________
CONTROL IDENTIFICATION,
LOCATION, AND FUNCTION ______________
Ignition Switch________________________
Engine Throttle________________________
Forward Speed Control (FSC)____________
Steering Levers_______________________
Blade Clutch (PTO)_____________________
Parking Brake_________________________
Front Body Latch Release_______________
Transmission Lockout Levers____________
Engine Service Light___________________
Hourmeter____________________________
Oil Pressure Warning Horn______________
Circuit Breaker (7 Amp)_________________
Light Switch (For Optional Lights)________
STARTING THE ENGINE__________________
ADJUSTING GROUND
SPEED AND STEERING___________________
ENGAGING THE BLADE DRIVE____________
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___________________
1
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1
2
2
Specifications_________________________ 3
ENGINE_________________________________
ELECTRICAL SYSTEM____________________
TRANSMISSION__________________________
BLADE DRIVE___________________________
TIRE SIZE_______________________________
TIRE PRESSURE_________________________
DRIVE BELTS____________________________
SEAT___________________________________
FRAME/BODY CONSTRUCTION____________
GHS SYSTEM____________________________
MOWER DECK___________________________
DIMENSIONS (Tractor and Mower)__________
3
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4
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Component Identification____________ 6
Safety Instructions___________________ 9
BEFORE OPERATING_____________________ 9
OPERATING____________________________ 11
MAINTENANCE_________________________ 13
SAFETY, CONTROL, AND
INSTRUCTION DECALS__________________ 14
Assembly Instructions_______________ 18
SETUP INSTRUCTIONS___________________
Tire Installation (Tractor)________________
Battery Service________________________
Wet Battery Service___________________
Dry Battery Service____________________
Battery Charging______________________
Battery Installation____________________
Mower Deck Assembly__________________
Deck Caster Wheels Installation__________
Deck Discharge Chute Installation________
Deck Discharge Deflector
Shield Installation_____________________
PTO Shaft Guard Installation____________
Tilt-Up Roller Wheel Installation__________
Mower Deck Installation on Tractor________
Deck Installation______________________
Deck Leveling________________________
PREOPERATING CHECKLIST______________
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Table of Contents
Maintenance Instructions___________ 48
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___
Mower Deck Gearbox Lubrication_________
DS52 or DS62 Mower Deck Lubrication____
Mower Deck Spindle Lubrication_________
Tractor PTO Gearbox Lubrication_________
Checking Gearbox Oil Level_____________
Changing Gearbox Oil_________________
Gear Axle Lubrication__________________
Hydrostatic Transmission Fluid__________
Checking Hydrostatic
Transmission Fluid Level_______________
Grease Fitting and Oil Point Lubrication ___
CLEANING_____________________________
Engine Air Cleaner System______________
Turbine Precleaner____________________
Enginaire™ VLR Air Cleaner____________
Engine Cooling System_________________
Cooling Air Intake Screen_______________
Cylinder Head Cooling Fins_____________
Grass Buildup in Mower Deck Housing____
GHS Blower___________________________
GHS Exhaust Screen___________________
Hydrostatic Transmission Cooling Fins____
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CHECKING/SERVICING___________________
Security of Air Filtration Components_____
Battery_______________________________
Electrolyte Level______________________
Cleaning the Terminals_________________
Charging the Battery___________________
Tire Pressure__________________________
Wheel Bolt Torque_____________________
Sharpen Mower Blades_________________
Drive Belts____________________________
Mower Deck Gearbox Oil Seals___________
Spark Plugs___________________________
Ignition Wires_________________________
Fuel Lines and Clamps__________________
Engine Starter_________________________
Transmission Control Setting____________
Neutral-Park_________________________
Straight Ground Tracking_______________
Blade Brake Action_____________________
PTO U-Joints _________________________
Safety Switch System__________________
Forward Speed Control Friction Lock______
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_________________________
ADJUSTMENTS_________________________
Transmission Control__________________
Set FSC Travel Limits (Stop)_____________
Set Maximum Forward
Travel Speed (Stop)___________________
Neutral Function Adjustment_____________
Straight Ground Travel Adjustment________
Blade Clutch (PTO)_____________________
Clutch Engagement/Belt Tension_________
Clutch Disengagement/Brake Action______
Stop Block Eccentric Adjustment_________
Clutch Idler Pulley Travel Adjustment______
Blade Brake Band Adjustment___________
Forward Speed Control Friction Lock______
Steering Handles______________________
Tilt-Up Deck Adjustable Stop_____________
GHS “Full” Signal Horn Adjustment_______
Operator’s Notes________________
Warranty______________________
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General Information
HIGHLIGHTED INFORMATION
Walker Manufacturing recommends that any service
requiring special training or tools be performed by
an authorized Walker Mower dealer. There are several general practices to be aware of in the area of
safety. Most accidents associated with the operation or maintenance of a Walker Mower are caused
by disregarding basic safety precautions or specific
warnings. Such accidents, in most cases, can be
prevented by being aware of the dangers present.
Information of special importance has been highlighted in bold type in this manual. Refer to Safety
Instructions for the meanings of DANGER, WARNING, CAUTION, IMPORTANT, and NOTE.
GLOSSARY
There are many terms that are either unique to this
equipment or that are used as acronyms. The
following terms and their definitions will help while
using this manual:
●● DECK is the mowing attachment mounted
on the front of the tractor which includes the carrier frame, deck housing, belt or gear drive components, and cutter blades.
●● ELECTRONIC CONTROL UNIT (ECU) controls engine functions such as spark timing,
fuel/air ratio, etc.
●● FORWARD SPEED CONTROL (FSC) controls the maximum forward speed of the tractor;
functioning as a cruise control.
●● GRASS HANDLING SYSTEM (GHS®) collects mowed material and deposits it in the
catcher.
●● GRASS-PAK® SWITCH is mounted on the
grass delivery spout (in the catcher) and activates the “full” signal horn when the grass
catcher is full.
●● GROUND DRIVE refers to the dual 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.
●● 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 righthand side of the tractor when the operator is
seated facing forward in the tractor seat.
●● SIDE DISCHARGE (SD) discharges mowed
material from the right side of the mower deck.
●● STEERING LEVERS steer the tractor by
controlling the dual hydrostatic transmissions.
●● TRACTOR is the prime mover, including
the engine, drivetrain, operator seat, and controls to operate the mower.
●● TRANSMISSION LOCKOUT releases the
hydrostatic transmissions to permit freewheeling the tractor.
●● VERY LOW RESTRICTION (VLR) refers
to engine air cleaner system by EnginaireTM.
IDENTIFYING NUMBER LOCATIONS
The tractor serial number plate is affixed to the tractor body just below the left rear corner of the seat.
The mower deck serial number plate is affixed
alongside the angle iron framing on the LH side of
the LH mower blade drive. Model and serial numbers are helpful when obtaining replacement parts
and maintenance assistance. For ready reference,
please record these numbers in the space provided.
Tractor Model No. _______________________
Tractor Serial No. _______________________
Deck Serial No.
_______________________
Engine Model No. _______________________
Engine Serial No. _______________________
Date of Purchase _______________________
Fill In By Purchaser
1
General Information
Serial Number
Tractor Serial Number Location
Serial Number
SERVICING OF ENGINE AND DRIVETRAIN
COMPONENTS
The detailed servicing and repair of the engine,
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
www.walkermowers.com
Service manuals are available for each of these
components from their respective manufacturers as
follows:
Kohler Engines
Kohler Company
Kohler, WI 53044
800-544-2444
www.kohlerengines.com
Hydrostatic
Transmissions
Eaton Fluid Power Group
Hydraulics Business USA
14615 Lone Oak Road
Eden Prairie, MN 55344 USA
952-937-9800
www.eaton.com/hydraulics
Gearboxes (Deck)
Peerless Gear
1555 South Jackson St.
Salem, IN 47167 USA
866-536-8310
www.peerlessgear.com
Mower Deck Serial Number Location
ENGINE SERIAL NUMBER LOCATION
Refer to the engine manual that accompanies this
manual or the photo below for the location of the
engine serial number.
Serial Number (Not Visible)
Located Under ECU
Engine Serial Number Location
2
Specifications
MODEL
C19i
ENGINE
Manufacturer/Model
Kohler Command Pro ECH630, 2 Cyl., Gasoline (Air-Cooled),
Electronic Fuel Injection (EFI)
Displacement cu. in. (cc)
42.4 (694)
Max. Power HP (kW)
19.0 (14.2) @ 3600 RPM
Governed RPM
3600
Max. Torque lb·ft (N·m)
34.2 (46.4)
Idle RPM
1200
Spark Plug Type
Champion® RC12YC
Spark Plug Gap in. (mm)
.030 (0.76)
Crankcase Capacity qt (L)
2.0 (1.9)
Crankcase Lubricant
API SJ or Higher Grade Oil Only with 10W-30 Viscosity Above
0° F (-18° C), or 5W-20 or 5W-30 Viscosity Below 32° F (0° C)
Oil Filter
Kohler P/N 28-050-01
Fuel Tank Capacity gal (L)
4.0 (15.1)
Fuel
Regular Grade Unleaded Gasoline
(87 Octane Minimum, 10% Ethanol Maximum)
Cooling System
Air-Cooled
Air Cleaner
Remote Mounted EnginaireTM VLR - S/N 133542 And On
(Walker P/N 5090-4 Primary/5090-5 Safety Filter)
ELECTRICAL SYSTEM
Battery
12 Volt, 35 AH, 340 CCA
Charging System
Flywheel Alternator
Charging Output
25 Amp DC (Regulated)
System Polarity
Negative Ground
Ignition
Electronic Capacitive Discharge
Starter
12 Volt Electric Ring-Gear Type, Solenoid Shift
Interlock Switches
Ignition Lockout by Seat Switch, Transmission Neutral and Blade
Clutch
Circuit Breaker
Auto Reset (30A)
Manual Reset (7A) - Front Panel
TRANSMISSION
Manufacturer/Model
Dual Hydrostatic, Eaton Model 7, Each Wheel Independently Driven
Steering
Hand Lever Control / Individual Wheel
Forward Speed Control
Precision Friction Lock Lever, Cruise Control, with Neutral-Park
Position
Service Brake
Dynamic Braking through Hydrostatic Transmission
Parking Brake
Mechanical Pin Lock in Transmission Gear
Neutral
Transmission Release by Manual Dump Valve
3
Specifications
MODEL
C19i
TRANSMISSION (continued)
Final Drive
Gear Drive Axle
Transmission Fluid
Factory Service
Mobil 1 Synthetic Motor Oil (15W-50)
Transmission Oil Capacity fl oz (L)
19 (0.56)
Transmission Cooling
Cooling Fan Mounted on Drive Pulley
Ground Travel Speed
Forward MPH (km/h)
Reverse MPH (km/h)
0-7 (0-11.3) Infinitely Variable
0-5 (0-8) Infinitely Variable
BLADE DRIVE
PTO Shaft
Quick Disconnect Splined Shaft with Two (2) High-Speed U-Joints
Blade Drive Clutch and Brake
Manual Belt Tightener Clutch and Band Brake
[Stops Blades within Five (5) Seconds of Disengagement]
TIRE SIZE
Deck Caster
8 x 3.00-4 Semi-Pneumatic (Standard)
8 x 3.00-4 Pneumatic 4-Ply (Optional)
11 x 4.00-5 Pneumatic 4-Ply (DS52 and DS62 Only)
Drive
18 x 8.50-10 (Pneumatic 4-Ply, Low-Profile)
18 x 7.00-8 (Pneumatic 4-Ply, Optional)
Tailwheel
13 x 6.50-6 (Pneumatic 4-Ply)
TIRE PRESSURE PSI (KPA)
Deck Caster Wheel*
20 (137)
Drive
15 (103)
Tailwheel
20 (137)
* If equipped with optional pneumatic tires
DRIVE BELTS
Engine PTO
Walker P/N 8230
Jackshaft Drive
Walker P/N 6250-1
Ground Drive, Micro-V
Walker P/N 7248
Blower
Walker P/N 7234-2
SEAT
Contour-Molded, with Nylon Backed Vinyl Cover and Integral
Foam Cushion
FRAME/BODY CONSTRUCTION
4
Frame
All Welded Unitized Steel Chassis
Body
14 Gauge Steel
Deck
11 Gauge Steel
GHS Catcher and Chutes
Molded Cross-Linked Polyethylene (UV Stabilized,
High Impact Material)
Specifications
MODEL
C19i
GHS SYSTEM
Blower
10.5 in. Diameter, Three-Blade Paddle Wheel
Blower Brake
Band Brake [Works in Combination with PTO Clutch, Stops
Blower within Five (5) Seconds of PTO Disengagement]
Max. Blower RPM
4000
Grass Catcher Capacity
gal / bu / L
65 / 7 / 246
Full Signal (Grass-Pak® Switch)
Oscillating Vane Switch Mounted on Grass Delivery Spout Triggers
Horn Signal
Powerfil ®
Oscillating Delivery Spout Driven by 12 Volt Electric Gearmotor
Spreads Material throughout Interior of Catcher @ 35 Cycles/Min
MOWER DECK
Recommended Cut Width
Collection
36 to 52 in. (91 to 132 cm)
Side Discharge
36 to 62 in. (91 to 157 cm)
Mulch
36 to 52 in. (91 to 132 cm)
Cutting Height
1.5 to 4 in. (4 to 10 cm) or
1.5 to 4.5 in. (4 to 11.5 cm) (DS52 & DS62 Belt Driven Decks Only)
Deck Suspension
Independent Torsion-Flex Frame with Caster Wheels and
Counterweight Springs
DIMENSIONS (Tractor and Mower)
Length in. (cm)
Tractor Only
64.5 (164)
Tractor Wheel Base
41 (104)
Tractor with Tilted Deck
(Approximate)
77 (196)
Tractor with 42" Collection Deck
(DC42-1)
89.25 (227)
Width in. (cm)
Tractor Only (Outside Tire)
37.75 (96)
Tractor with 42" Collection Deck
(DC42-1)
43.25 (110)
Height in. (cm)
Tractor
47.5 (121)
Weight lb (kg)
Tractor Only
739 (335)
Tractor with 42" Collection Deck
(DC42-1)
930 (422)
NOTE: The manufacturer reserves the right to make changes in specifications shown herein at any time
without notice or obligation. The specifications listed are for a standard configuration tractor, and may
change with the addition of optional equipment.
5
Component Identification
NOTE: Control Identification
shown in Operating
Instructions section.
Grass Handling System
7.0 Bushel Catcher
Tilt-Up Latch
Spring Clip
Counterweight Spring
and Protective Cover
Transmission Control Rod
Adjustment Nut (LH)
Deck Support Pins
and Height Adjustment
Hitch Pins
Anti-Scuff
Roller
Catcher Lift /
Dump Handle
Fuel Tank and Cap
Transmission Control
Rod Adjustment Nut
(RH)
Footrests
Deck Support Arm
Tilt-Up
Hook
(Not Visible)
Deck Lift Handle
(Cutting Height Adjustment)
Front View and Right Side View
6
Tilt-Up
Deck Handle
Deck
Caster Wheels
Component Identification
Removable Grass
Catcher Screen
(Not Visible)
Catcher Door
Catcher Door
Gas Spring
(Not Visible)
Catcher Lift /
Dump Handle
Catcher
Air Exhaust
Footrest
Dump
Flap
Catcher
Door Handle
Anti-Scuff
Roller
Muffler
Left Hand
Drive Wheel
Tailpipe
Oil
Filter
Oil Drain Plug
(Not Visible)
Tailwheel Fork
and Wheel
Rear View and Left Side View
7
Component Identification
Air Cleaner Cover /
Turbine Precleaner
Fuel Filter
(Not Visible)
Air Filter
Restriction
Gauge
Fuel Pump Module
(Not Visible)
Oil Fill
Enginaire™ VLR
Air Cleaner
Oil Cooler
Fuel Pickup
Line
Muffler
Air Intake
Hose
Throttle Linkage
(Not Visible)
EVAP Line
Voltage Regulator /
Rectifier
Rollover Valve
Muffler Heat
Shield
Fuel Gauge
Fuel Tank Cap
Oil
Dipstick
Electronic Control
Unit (ECU)
Rubber Bumper
(Catcher Support)
Jackshaft
GHS Blower
PTO Gearbox
Dipstick
RH Transmission
Lockout Lever
RH Hydrostatic
Transmission
Positive (+)
Battery Cable
LH Steering Lever
Spring / Dampener
PTO
Clutch Lever
30 Amp
Circuit Breaker
(Not Visible)
LH Hydrostatic
Transmission
Negative (-)
Battery Cable
RH Steering Lever
Spring / Dampener
LH Transmission
Lockout Lever
Battery
Neutral
Safety Switch
Top View (Engine Compartment)
8
Safety Instructions - Before Operating
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.
Read and understand the contents of this
Operator’s Manual before starting and operating the machine. Become thoroughly familiar with all machine controls and how to stop the
machine and disengage the controls quickly.
Replacement Operator’s Manuals are available
by sending the Model and Serial Number to:
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.
9
Safety Instructions - Before Operating
6. Do not wear loose fitting clothing that could get
caught in moving parts. Do not operate this machine while wearing shorts; always wear adequate protective clothing, including long
pants. Wearing safety glasses, safety shoes,
and a helmet is advisable and required by some
local ordinances and insurance regulations.
7.
Prolonged exposure to loud noise can cause
impairment or loss of hearing. Operator hearing protection is recommended; particularly
for continuous operation of the GHS Model due
to blower noise level. Wear a suitable hearing
protective device, such as earmuffs or earplugs.
8.
Keep all protective shields and safety devices in place. If a protective shield, safety
device, or decal is damaged, unusable, or missing, repair or replace it before operating the
machine.
9.
Be sure interlock switches are functioning
correctly, so the engine cannot be started unless the Forward Speed Control lever is in the
NEUTRAL-PARK position, and the PTO clutch
is in the DISENGAGED position. Also, the engine should stop if the operator lifts off the seat
with either the Forward Speed Control (FSC)
out of the NEUTRAL-PARK position or the PTO
clutch in the ENGAGED position.
NOTE: There is a 1/2 second time delay function on the seat switch to avoid engine power
interruption when driving over bumps.
10. Handle gasoline with care. Gasoline is highly
flammable and its vapors are explosive:
10
a.
Use an approved fuel container.
b.
Never add fuel to a running engine or hot
engine (allow hot engine to cool several
minutes).
c.
Keep matches, cigarettes, cigars, pipes,
open flames, or sparks away from the fuel
tank and fuel container.
d.
Always fill the fuel tank outdoors using
care. Fill to about one inch from the top of
the tank. Use a funnel or spout to prevent
spilling.
e.
Replace the machine fuel cap and container
cap securely and clean up any spilled fuel
before starting the engine.
11. Never attempt to make any adjustments
while the engine is running, except where
specifically instructed to do so.
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.
WARNING
This product can expose you to
chemicals including Phenylethane which
is known to the State of California to
cause cancer, and N-Methyl-2-Pyrrolidone,
which is known to the State of California
to cause birth defects or other reproductive
harm. For more information go to www.
P65Warnings.ca.gov.
Safety Instructions - Operating
1.
Operate the mower only in daylight or in
good artificial light with good visibility of the area
being mowed.
2.
Sit on the seat when starting the engine and
operating the machine. Keep feet on the deck
footrests at all times when the tractor is moving
and/or mower blades are operating. Never operate the tractor without a deck or imple­
ment installed.
3.
For a beginning operator, learn to steer (maneuver) the tractor with a slow engine speed
before attempting any mowing oper­
ation.
Be aware that, with the front mounted mower
configuration, the back of the tractor swings to
the outside during turns.
DANGER
Do not mow around overhanging tree
branches or bushes at the same height as
the operator’s torso and head where inadvertent contact may cause injury.
4.
5.
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.
In case either of the transmission drive belts
break during operation, and if the machine is on
a slope, the machine will freewheel down the
slope. To maintain control, immediately (1)
Release the steering levers and simultaneously
(2) Move the FSC to the NEUTRAL-PARK position. When the machine is stopped or moving
slowly, engage the parking brake.
NOTE: The emergency stop procedure is exactly the same procedure used to normally stop
and park the machine.
6.
Disengage the blade clutch and put the FSC in
the NEUTRAL-PARK position before starting
the engine (an ignition interlock switch normally
prevents starting of the machine if these controls are in the OPERATING position).
7.
Do not operate machine if the operator presence safety switch system is not working.
Verify proper operation by having the operator
lift off the seat with the engine running and moving two controls, one at a time; (1) Move the
FSC lever out of the NEUTRAL-PARK position,
and (2) Engage the PTO Clutch. Moving either
control should stop the engine after a 1/2 second delay.
8.
Do not run the engine in a confined area
without adequate ventilation. Exhaust fumes
are hazardous and can be deadly.
9.
Do not carry passengers - maximum seating
capacity is one (1) person.
10. Watch for holes, rocks, and roots in the terrain
and for other hidden hazards. When mowing
tall grass, mow higher than desired to expose
any hidden obstacles. Then, clean the area and
mow to the desired height.
11. Avoid sudden starts or stops. Before backing the machine up, look to the rear to be sure
no one is behind the machine. Watch carefully
for traffic when crossing or working near roadways.
12. When moving forward, do not suddenly put the
tractor in reverse by rapidly pulling on the steering levers, especially when going downhill, as
this can lift the tractor tail wheel off the ground
and set up a bucking motion due to operator
overcontrol. If bucking does occur, immediately
stop the bucking action by pulling the Forward
Speed Control (FSC) lever into the NEUTRALPARK position.
13. Disengage the blade drive when transporting
the machine across drives, sidewalks, etc. Never raise the mower deck while blades are
rotating.
DANGER
Do not mow or dump grass within 5 feet
(1.5 meters) of an embankment or retaining
wall with drop off.
11
Safety Instructions - Operating
14. The maximum recommended slope operating angle is 15 degrees or 26% grade. When
operating the machine on a slope, reduce speed
and use caution to start, stop, and maneuver.
To prevent tipping or loss of control of the machine, avoid sharp turns or sudden changes in
direction. Do not operate the machine on a
slope greater than 15 degrees.
15. Never adjust cutting height with the engine
running. Before adjusting cutting height or
servicing, disengage the blade clutch (PTO),
stop the engine, and remove the ignition key.
Wait for all movement to stop before getting off
the seat.
NOTE: A blade/blower brake should normally
stop drive line rotation within five (5) seconds of
disengaging the PTO clutch.
16. For side discharge mower decks, do not operate with the grass deflector shield removed.
Keep the deflector in the lowest possible position.
17. When using the tilt-up deck, observe the following:
a.
Do not move tractor with deck in tilt-up
position.
b.
Never tilt body forward with deck in tilt-up
position.
18. Do not operate the machine with the grass
catcher in the DUMP position or with the
back door OPEN. Dangerous projectiles may
be thrown out of the discharge chute or the back
of the grass catcher.
19. Use care when closing the grass catcher
door. Keep fingers and hands away from the
hinge and pinch points when the door is being
closed. Also, keep fingers and hands clear of
the door frame. The door may slam shut with
considerable force.
12
20. In case of a clogged or plugged mower deck
or GHS catching system:
a.
Disengage the blade clutch (PTO), engage
the parking brake, 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.
21. If the cutting blades strike a solid object or the
machine begins to vibrate abnormally,
immediately disengage the blade clutch
(PTO), stop the engine, and wait for all
moving parts to stop. To prevent accidental
starting, disconnect the spark plug 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 lb·ft (81 N·m) for gear driven decks, and
blade bolts torqued to 70 lb·ft (95 N·m) for belt
driven decks.
22. Do not touch the engine or muffler while the
engine is running or immediately after stop­
ping the engine. These areas may be hot
enough to cause serious burns.
23. When leaving the machine unattended, disen­
gage the blade clutch (PTO), stop the engine, and remove the key.
CAUTION
Use leg muscles and firm footing when lifting the catcher to dump; avoid bending at
the waist and using back muscles in order
to prevent back injury.
Safety Instructions - Maintenance
1.
To prevent accidental starting of the engine
when servicing or adjusting the machine, remove the key from the ignition switch and disconnect the spark plug wires.
2.
To reduce fire hazards, keep the engine free
of grass, leaves, excessive grease, and dirt.
3.
11. Use care when charging the battery or per­
forming maintenance on the battery and electrical system:
a.
Make sure the battery charger is unplugged
before connecting or disconnecting cables
to the battery.
Keep all nuts, bolts, and screws tight to ensure
the machine is in a safe, working condition.
Check the blade mounting nuts frequently, mak­
ing sure they are tight.
b.
Charge the battery in a well-ventilated
space, so gases produced while charging
can dissipate. Make sure the battery vents
in the caps are open.
4.
Perform only maintenance instructions described in this manual. Unauthorized maintenance operations or machine modifications
may result in unsafe operating conditions.
c.
Keep sparks, flames, and smoking materi­
als away from the battery at all times. To
avoid sparks, use care when removing bat­
tery cables from posts.
5.
If the engine must be running to perform a main­
tenance adjustment, keep hands, feet, and
clothing away from moving parts. Do not wear
jewelry or loose clothing.
d.
Disconnect both battery cables before unplugging any wiring connectors or making
repairs on the electrical system.
6.
Always use the proper engine service
manual when working on the engine.
Unauthorized maintenance operations or
modifications to the engine may result in unsafe
operating conditions.
7.
Altering the equipment or engine in any manner
which adversely affects its operation, perfor­
mance, durability, or use will VOID the warranty and may cause hazardous conditions.
8.
Never attempt to disconnect any safety devices
or defeat the purpose of these safety devices.
9.
Do not change the engine governor settings or
overspeed the engine. The governor has been
factory-set for maximum-safe engine operating
speed.
12. Do not attempt to service the engine fuel injection system, which contains high pressure fuel
and may cause injury if mishandled. For service of the pressurized fuel system, including
the fuel pump module, fuel lines, and fuel injectors, contact your Walker dealer or authorized
Kohler service dealer.
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.
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.
1.
1.
8600-12
Location: Front Body, LH Side Above Muffler
Part Number: 8600-12
2.
1.
8600-4
Location: Adjacent to Blower Discharge
Chute through Body
Part Number: 8600-4
Warning - rotating impeller is a cutting/dismemberment hazard to fingers and hands.
●● Never reach down into the blower discharge
chute.
2. Warning - thrown object hazard.
●● Never engage the PTO with grass catcher
raised.
Warning – carbon monoxide (CO) poisoning
hazard.
●● CO emitted by a running engine can be deadly.
●● Do not operate indoors or in other enclosed
areas.
1.
1.
Location: Front Body, RH Side Adjacent to
Operator Seat
Part Number: 8600-30
1.
Parking Brake
●● Move lever forward to engage Parking
Brake; back to disengage.
60 lb·ft (81 N·m)
Location: Engine Shroud
Part Number: 5855
1.
8600-9
8600-16
1.
Location: Rear Cross Member of Front Body
Part Number: 8600-16
1.
Important - Lower front body before lowering
catcher box.
Location: Gearbox Cover
(Gear Drive Decks Only)
Part Number: 8600-9
1.
Tighten blade nuts on gear driven decks to
60 lb·ft (81 N·m).
6807-1
Location: Rear of Grass Catcher Exhaust Screen
Part Number: 5869
14
Location: Front Body, Adjacent to Oil Pressure
Warning Horn
Part Number: 6807-1
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
2.
8600-28
Location: Each End of Mower Deck
Part Number: 8600-28
Location: Front Body, RH Side
Part Number: 5082-5
1.
Warning – thrown object hazard.
●● Keep bystanders away from the machine
when operating.
●● Clear lawn of debris before operating.
●● Keep any discharge deflector in place and in
the lowest position.
2. Warning – rotating mower blades are a cutting/
dismemberment hazard to hands and feet.
●● Keep all body parts away from rotating mower blades.
●● Do not step on end of deck.
1.
Location: Deck Discharge Shield
(SD Decks Only)
Part Number: 5848-3
1.
1.
Warning – thrown object hazard.
●● Always keep the discharge shield in the lowest position when operating.
●● Do not remove the discharge shield.
8600-14
Location: Deck Carrier Frame
Part Number: 8600-14
1.
1.
Location: Deck Carrier Frame
Part Number: 8600-15
1.
1.
Warning – do not operate the machine with the
deck tilted up.
Location: Deck Gearbox Cover
Part Number: 8600-39
1.
Warning - stop engine and remove ignition key
before adjusting deck cutting height.
Warning – lock deck tilt-up hinge before operating the machine.
Location: Gear Axle
Part Number: 5810-1
Location: Jackshaft Support Adjacent
to Dipstick
Part Number: 7827
15
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
1.
2.
1.
2.
2.
8600-23
Location: Right Side, Behind Operator Seat
Part Number: 8600-23
1.
Warning – entanglement hazard.
●● Remove ignition key before raising front
body.
2. Body Tilt Latch
●● Raise lever to release.
●● Lift at back of body to raise.
3.
4.
1.
Location: Catcher Door Hinge Bar,
LH and RH Sides
Part Number: 8600-10
1.
Caution - Pinch point.
●● Keep all body parts clear when closing grass
catcher door.
5.
Location: RH Fender
Part Number: 8600-33
1.
2.
Location: LH Gear Axle
Part Number: 5810-3
3.
4.
5.
16
Warning – read Operator’s Manual before servicing or performing maintenance.
●● Engage parking brake.
●● Remove ignition key.
Forward Speed Control
●● Move lever forward to increase speed; back
to stop.
Warning – do not operate the machine without a
deck or other implement attached.
PTO Clutch Lever
●● Move lever back to engage PTO clutch; forward to disengage.
Warning – do not engage PTO clutch with PTO
shaft disconnected.
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
2.
1.
2.
3.
4.
3.
4.
5.
Warning – read Operator’s Manual before operating the machine.
Warning – wear eye and ear protection when operating the machine.
Throttle
●● Move lever forward to increase engine
speed; back to idle.
Warning – roll-over hazard.
●● Do not operate on slopes greater than 15
degrees.
Warning – thrown object hazard.
●● Keep bystanders away from the machine
when operating.
Warning – entanglement hazard.
●● Keep all guards in place while engine is running.
5.
1.
Location: LH Fender
Part Number: 8600-37
Location: Front Body
Part Number: 5802-5
1.
Engine Service Indicator Light
●● If illuminated during operation contact an
authorized Kohler Service Dealer as soon
as possible.
Location: Hydrostat Oil Reservoir
17
Assembly Instructions
SETUP INSTRUCTIONS
Tire Installation (Tractor)
Raise front mower body up for battery access (refer
to Front Body Latch Release in Operating Instruc­
tions). Check the battery for electrolyte level and
charge. The electrolyte level should be at the bottom of the vent wells [1/4 to 1/2 in. (6 to 13 mm)
above plates]. If the specific gravity is less than
1.225, the battery needs charging. If the battery has
been shipped dry, or is wet but needs service, refer
to the following instructions.
• Install the drive tires using the eight (8) lug bolts
supplied with the Owner’s Packet of materials.
Bolts are torqued to 75 to 85 lb·ft (102 to 115 N·m).
Drive tires are 18 x 8.50-10, 4-ply; rear tires are
13 x 6.50-6, 4-ply.
IMPORTANT: Make sure battery is securely mounted in the frame. A loose battery may cause damage
to the case resulting in acid leakage and severe damage to the machine. A hazard may be created by
damage to critical working parts and safety systems.
• Check and adjust the inflation of the tires. The
tire inflation recommendations are:
Wet Battery Service
Walker Mowers are shipped partially assembled to
our distribution network, and are typically assembled by the selling dealer. For any additional assembly besides the following, contact your Walker
dealer.
Drive
Tailwheel
=
=
15 PSI (103 kPa)
20 PSI (137 kPa)
Battery Service
CAUTION
Important Battery Service, Installation, and
Charging Tips for Electronic Fuel Injection
Engines:
●● Do not allow the battery cables to touch
opposing terminals. When connecting battery cables attach the positive (+) cable to
positive (+) battery terminal first, followed
by negative (-) cable to negative (-) battery
terminal.
●● Never start the engine when the cables
are loose or poorly connected to the battery terminals.
●● Never disconnect battery while engine
is running.
●● Never use a quick battery charger to
start the engine.
●● Never “jump start” the engine using another source. Electricity fluctuations can
damage the ECU (Electronic Control Unit).
●● Always disconnect negative (-) battery
cable lead before charging battery, and
also unplug harness from ECU before performing any welding on equipment.
18
If the battery has been shipped wet, but the electrolyte level is low or the battery needs to be charged
then:
1.
Fill each battery cell with distilled water to the
bottom of the vent wells.
2.
Charge battery. Refer to Battery Charging in
this section.
Dry Battery Service
DANGER
Activating a battery can be dangerous.
The battery should be taken to a reliable
service station, battery store, or power
equipment dealer where a trained technician can activate the battery safely. DO
NOT attempt to activate the battery unless
you are experienced in battery service
work. The following activation and charging instructions are provided for use by a
trained battery technician.
Assembly Instructions
DANGER
Battery Charging
DANGER
Battery electrolyte is a poisonous and corrosive sulfuric acid solution.
BATTERIES PRODUCE EXPLOSIVE GASES
●● Avoid spillage and contact with skin,
eyes, and clothing - causes severe burns.
●● Charge the battery in a well-ventilated
area, so that gases produced while charging can dissipate.
●● To prevent accidents, wear safety goggles and rubber gloves when working with
electrolyte.
●● Keep sparks, flames, and smoking materials away from the battery at all times.
●● Neutralize acid spills with baking soda
and water solution.
●● Make sure the battery cap vents are 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.
To fill (activate) battery with electrolyte (if battery has
been shipped dry):
1.
Remove the battery hold-down bar, disconnect
the battery cables and lift the battery out of the
tray.
IMPORTANT: Battery must be removed from
the mower before filling with electrolyte.
IMPORTANT: Obtain and use only battery
grade sulfuric acid electrolyte with a 1.265 specific gravity to activate the battery. DO NOT use
water or any other liquid during initial activation.
2.
Remove the filler caps and carefully fill each cell
until the electrolyte is just above the plates.
3.
After the battery is filled with electrolyte, replace
the filler caps and charge the battery. Refer to
Battery Charging.
IMPORTANT: Always disconnect the negative (-)
battery terminal before charging. Failure to do so
can result in damage to the ECU.
1.
Charge the battery at 15 amps for 10 minutes.
DO NOT exceed 20 amps maximum recommended charging rate. Charge until specific
gravity is at least 1.250. Total charging time
should not exceed one (1) hour.
2.
After charging the battery, adjust the electrolyte
level to the bottom of the vent wells [1/4 to 1/2 in.
(6 to 13 mm) above the plates].
IMPORTANT: DO NOT overfill the battery.
Electrolyte will overflow through the vented
caps onto parts of the machine and WILL result
in severe corrosion.
3.
Install battery.
19
Assembly Instructions
Battery Installation
Mower Deck Assembly
IMPORTANT: Make sure battery is securely mounted in the frame. A loose battery may cause damage
to the case resulting in acid leakage and severe
damage to the machine. A hazard may be created
by damage to critical working parts and safety systems.
Deck Caster Wheels Installation
Install the battery in the mower as shown in Battery
Installation photo. Connect the positive (+) first and
then the negative (-) cable to the proper battery terminal [red cable and boot connects to the Positive (+) terminal]. Slide the rubber boot up and over
the battery post, making sure it covers the post completely to prevent an electrical short.
1.
Remove the bolt, nut, and axle spacer tube from
each deck caster wheel fork.
2.
Fit the axle spacer tube through the wheel hub
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 inner bearing
race bottoms against the inside of the wheel
fork (will not turn) while the wheel spins freely
without binding.
WARNING
Axle Spacer Tube
Make sure the battery cap vents are open.
Improper venting of the battery COULD
cause a battery explosion.
Battery Clamp
Secured by
Wing Nut(s)
Axle Bolt
Deck Caster Wheel Installation
5.
(+) Battery Cable
Connection
Battery Installation
20
Grease the caster pivot bearings - one grease
fitting for each pivot.
Assembly Instructions
Deck Discharge Chute Installation
(GHS Collection Models Only)
Deck Discharge Deflector Shield Installation
(Side Discharge Models Only)
Mount the discharge chute hinge on top of the deck
discharge opening using two (2) 1/4-20 x 1/2 in. carriage bolts and 1/4-20 ESNA nuts. Position the
screws with the heads inside the chute and the nuts
on the outside. Attach spring for tilt-up action from
chute to bracket on deck.
Attach the side discharge deflector shield using two
(2) 3/8-16 x 1-1/4 in. bolts, 3/8-16 ESNA nuts, and
3/8 in. wave spring washers. The wave washers fit
between the two hinging surfaces. Tighten the nuts
until the shield moves freely but is not loose.
Attach
Guard
Carrier Frame
Tube Sockets
WARNING
DO NOT operate the machine without the
grass deflector shield attached and in the
lowest possible position.
Attach Shield
Nut on Top
Attach Chute
Discharge Chute and PTO Shaft Guard
Installation on Collection Deck
Discharge Shield Installation
on Side Discharge Deck
PTO Shaft Guard Installation
Position the shaft guard as shown and mount with
two (2) 1/4-20 x 1/2 in. bolts.
Attach Guard
PTO Shaft Guard Installation
21
Assembly Instructions
3.
Tilt-Up Roller Wheel Installation
Mount the two (2) tilt-up roller wheels on the brackets on the rear skirt of the deck housing using the
P/N 8490 axle bolt, 3/8 in. wave spring washer and
3/8-16 in. Whiz locknut. Tighten the axle bolt until
the wheel rolls freely, but is not loose.
Retract the spring-loaded quick disconnect ring
on the PTO Coupler and insert the Coupler
Installation Tool (provided in Owner’s Packet)
as shown in the photo below.
NOTE: The Coupler Installation Tool is provided
for convenience, but is not required for installation.
Coupler
Installation Tool
Attach Spring
PTO Coupler
Tube
Roller
Wheels
Tilt-Up Spring and Roller Wheel
Installation on Collection Deck
Mower Deck Installation on Tractor
PTO Coupler Installation Tool
4.
Deck Installation
1.
Retract Spring-Loaded
Quick Disconnect Ring
Lightly grease each deck support arm (2) on the
tractor. Refer to Mower Deck Installation
photo for location of deck support arm.
Reaching under the tractor, slide the PTO coupler tube onto the deck drive shaft (align arrow
decals), then install the coupler quick disconnect onto the tractor PTO drive shaft.
IMPORTANT: When installing the DS52 or
DS62 Mower deck, make sure to retract the dolly wheel after mounting the deck on the tractor.
Arrows on Shaft and Tube
(Used to Align When Sliding Together)
Grease Deck
Support Arm(s)
Deck Support
Arms
PTO
Connection
Mower Deck Installation
2.
22
Engage the deck carrier frame tube sockets on
the tractor support arms (refer to Discharge
Chute and PTO Shaft Guard Installation
photo for socket location), slide the deck onto
the support arms approximately 3 in. (76 mm).
PTO Shaft Connection
5.
Remove Installation Tool from quick disconnect
ring and make sure the ring has “snapped”
securely on the spline shaft.
IMPORTANT: DO NOT operate tractor with
Coupler Installation Tool installed.
Assembly Instructions
IMPORTANT: To prevent damage to the mower, make sure the PTO quick disconnect is securely locked on the tractor, with the locking
balls fully seated in the groove and the ring in the
locked position (refer to the Quick Disconnect
Ring “Locked” Position illustration). After installation, pull on the PTO coupler to check for
security.
Coupler Ring in
Released Position
7.
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.
8.
Raise the mower body (instead of lifting the
front of deck) and clip the counterweight springs
to the receptacle on front of body. Lower the
body to tension the springs. (Refer to Deck
Counterweight Spring Installation photo.)
9.
With the counterweight springs connected, the
weight on the deck caster wheels should be
15 to 25 Ib (6.8 to 11.3 kg); this adjustment is
preset at the factory. If required, the spring tension can be adjusted by tightening or loosening
the elastic stop nuts located underneath the
lower spring hook, or contact your local dealer
if additional help is required. Refer to Deck
Counterweight Spring Installation photo.
PTO Drive
Shaft
PTO Coupler
U-Joint
Counterweight Springs
Clip Onto Body With
Forward Body Tilted Up
Quick Disconnect Ring “Released” Position
Internal Balls
Locked on Shaft
PTO Drive
Shaft
Hitch Pins
Lock Deck on
Support Arms
PTO Coupler
U-Joint
Coupler Ring in
Locked Position
Quick Disconnect Ring “Locked” Position
6.
Slide the deck the rest of the way on the deck
arms. If the deck is collection style (GHS
equipped model), the 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.
Spring Tension Adjustment
Nut Located Under Lower
Spring Hook (Not Visible)
Deck Counterweight Spring Installation
NOTE: Raising the mower body may be helpful
in fitting and guiding the deck chute into the
blower.
23
Assembly Instructions
Deck Leveling
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 of all pneumatic tires as a possible
cause of the deck not being level.
1.
WARNING
The machine must be shut off during this
procedure.
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.
Position mower on a smooth, level surface. Set
the cutting height to the highest position - 4 in.
(102 mm) - for easy access under the deck to
measure blade height. Refer to ADJUSTING
CUTTING HEIGHT in Operating Instructions.
NOTE: A block of wood cut 4 in. (102 mm) high
is a convenient gauge to measure blade height
above ground during the leveling process.
4 in. (102 mm)
Wood Block
Should be 1/8 in. (3 mm)
to 1/4 in. (6 mm) higher
at the rear of the blade
Should not vary more
than 1/8 in. (3 mm)
side-to-side
NOTE:
For decks with three (3) staggered
blades, the front-to-rear level should be set using
the middle blade pointing forward, and either outside blade pointing back.
Deck Leveling
24
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 fuel and lubricants refer to Specifications.
FILL FUEL TANK
Fill the fuel tank using clean, fresh automotive grade
unleaded gasoline (87 octane minimum, 10% ethanol maximum).
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 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.
IMPORTANT: DO NOT mix oil with gasoline. Always use fresh, automotive grade unleaded gasoline. DO NOT use gasoline containing greater than
10% ethanol. DO NOT use additives, such as carburetor cleaners, deicers, or moisture removing
agents. DO NOT use gasoline blended with methyl
alcohol.
CHECK ENGINE CRANKCASE OIL LEVEL
Check the engine crankcase oil level before use and
after each 8 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 filter restriction gauge to make sure the
yellow indicator disk is in the safe operating
(green) range.
●●Check condition, cleanliness, and security of the
complete air cleaner system (inspect air filter paper element every 100 hours). For detailed procedures, refer to CLEANING the Engine Air
Cleaner System 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]. Refer to CLEANING the Cylinder Head Cooling Fins in the Mainte­
nance Instructions for this procedure.
Check performance of the cooling system by starting the engine, holding a hand adjacent to the cylinder heads, and feeling the cooling airflow.
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
CHECK GEAR AXLE OIL LEVEL
Refer to LUBRICATION for Gear Axle Lubrication
in Maintenance Instructions.
INSPECT FOUR (4) DRIVE BELTS
Engine PTO Drive, Jackshaft Drive, Hydrostatic
Ground Drive, and GHS Blower Drive.
25
Assembly Instructions
CHECK HYDROSTATIC TRANSMISSION OIL
LEVEL
Refer to LUBRICATION for Checking Hydrostatic
Transmission Fluid Level in Maintenance Instruc­
tions.
Tilt-Up Handle
Tilt-Up Hook and
Latch Connected
CHECK FUNCTIONS OF INSTRUMENT PANEL AND WARNING HORN
Turn the ignition key to the ON (RUN) position. Voltmeter, Oil Pressure Warning Light, and Warning
Horn should all operate, indicating normal function.
CHECK FUNCTION OF SAFETY INTERLOCK
SWITCHES
Refer to Operating Instructions to check for proper
operation of safety switches, both during engine
starting and with the operator leaving the seat with
tractor moving forward or with the mower blades engaged.
CHECK TIRE PRESSURE
Deck Caster Wheel* = 20 PSI (137 kPa)
Drive = 15 PSI (103 kPa)
Tailwheel
= 20 PSI (137 kPa)
* If equipped with optional pneumatic tires
CHECK AND CLEAN GRASS BUILDUP UNDERNEATH MOWER DECK (and inside GHS
blower, if equipped)
Refer to CLEANING the GHS Blower in Mainte­
nance Instructions for blower cleaning information.
DANGER
Never operate cutter blades with deck in
raised position because it is hazardous.
The tilt-up deck can be secured in the raised position by unlocking the deck lock levers on each side
of the carrier frame and inserting the deck hook into
the tilt-up latch on the tractor body. Before operating
the tractor, make sure to re-engage the deck lock
levers after lowering the deck to the normal operating position.
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
26
Tilt-Up
Latch
Tilt-Up
Hook
Deck Lock
Lever
Deck Secured in TILT-UP Position
DANGER
Do not operate the mower with deck in tiltup position. Do not move the tractor with
the deck in the tilt-up position.
CHECK MOWER BLADE CONDITION,
SHARPNESS, AND SECURITY OF MOUNTING
The blade mounting nuts on gear driven decks should
be torqued to 60 lb·ft (81 N·m), and the blade mounting bolts on belt driven decks torqued to 70 lb·ft
(95 N·m). If blade sharpening is required, refer to
CHECKING/SERVICING for Sharpen Mower
Blades in Maintenance Instructions.
ADJUST MOWER CUTTING HEIGHT, IF REQUIRED
Position the hitch pins in the four deck support pins.
Refer to the “Cutting Height Adjustment” decal on
the deck gearbox cover.
CHECK SECURITY OF DRIVE WHEEL BOLTS
The eight (8) lug bolts mounting the drive tires should
each be torqued to 75 to 85 lb·ft (102 to 115 N·m).
PERFORM ANY ADDITIONAL PROCEDURES
called for on the MAINTENANCE SCHEDULE
CHART in Maintenance Instructions.
Operating Instructions
CONTROL IDENTIFICATION, LOCATION, AND
FUNCTION
CAUTION
Before operating the mower, become familiar with the location and function of all operator controls. Knowing the location,
function, and operation of these controls is
important for safe and efficient operation
of the mower.
Ignition Switch
The ignition switch is located on the left front of the
body and is used to start and stop the engine. The
switch has three positions: “O” is the OFF position,
ON (RUN) is the position the key returns to after
starting, and “S” is the START position. When starting the engine, turn the key clockwise to the “S”
position. Do not hold the key in the “S” position
longer than 10 seconds. If the engine does not start,
return the key to the “O” position for at least 60 seconds before making a restart attempt. Prolonged
cranking can damage the starter motor and shorten
battery life. Release the key when the engine starts,
and it will return to the ON (RUN) position. To stop
the engine, rotate the key counterclockwise to the
“O” position.
OFF
Front Body Latch
Release (Not Visible)
Forward Speed
Control (FSC)
ON
Steering
Levers
START
Throttle
Ignition Switch
Key Positions
Parking
Brake
Ignition Switch
(See Inset)
Blade Clutch
(PTO)
Light Switch
(Optional, Not Shown)
Hourmeter
Engine Service
Light
Oil Pressure
Warning Horn
7 Amp
Circuit Breaker
Operating Controls
27
Operating Instructions
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.
Throttle
Throttle Location
Forward Speed Control (FSC)
Forward Speed Control (FSC) has two functions:
One is to set forward travel speed, and the other is
to establish the NEUTRAL-PARK position. When
the FSC lever is moved into the FORWARD position, a friction lock holds any forward speed setting
from 0 to 7 mph (0 to 11.3 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.
Steering Levers
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.
28
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: The Powerfil® motor and Grass-Pak® full
signal switch are activated by engaging the blade
clutch. Refer to Using the GHS Catcher in this section for a complete description of GHS operation.
Operating Instructions
The Forward Speed Control also Establishes the Neutral-Park Position of the Steering Levers
LEFT WHEEL
STEERING LEVER
FORWARD SPEED
CONTROL LEVER (FSC)
RIGHT WHEEL
STEERING LEVER
Forward Position
(No Control Change)
Full Forward
Ground Speed
Position
Neutral-Park
Position
Intermediate
Ground Speed
Position
Reverse Drive
Wheel Motion
Position
Neutral-Park
Position
PARKING
BRAKE
1.
Engaged
Position
2.
Disengaged
Position Disengaged
Fast
Throttle
Position
Position
Idle
Position
THROTTLE
Engaged
Position
BLADE CLUTCH (PTO)
Pull Up to Engage
Operating Controls (Top View from Drivers Point of View)
29
Operating Instructions
Parking Brake
Front Body Latch Release
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.
The front portion of the tractor body hinges forward
for maintenance access and is latched down in the
OPERATING position. To raise the body, pull the
latch release up and forward.
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.
Front Body
Latch Release
Front Body Latch Release
Transmission Lockout Levers
Parking Brake Engaged
The transmission lockout levers disengage the hydrostatic transmissions. 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.
Lockout
Levers
Parking Brake Disengaged
Transmission
Plunger
Lockout Lever Location
30
Operating Instructions
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.
Engine Service Light
The engine service light indicates that the engine
Electronic Control Unit (ECU) has detected a fault in
the engine performance. When this light illuminates
during operation, contact an authorized Kohler Service dealer to diagnose the fault.
*** In normal operating conditions, oil changes in
100-hour intervals are acceptable. Walker and
the engine manufacturers recommend engine
oil changes every 50 hours in extremely dirty or
dusty conditions or for units with less than 100
hours annual use.
NOTE: The blinking hour glass on the display
means that the meter is operating properly.
IMPORTANT: Continued operation of the engine
with an illuminated engine service light will result in
sub-standard performance and MAY cause engine
damage if not corrected as soon as possible.
Hourmeter
The hourmeter, which is located on the right front of
the body, displays operating time accumulated
while the ignition switch is in the ON (RUN) position.
The hourmeter provides maintenance reminders after certain hours of operation. The hourmeter screen
will start flashing the reminder one hour prior to the
recommended interval and will continue until one
hour after the recommended interval (two hours).
The hourmeter does not have a manual reset
function.
Procedure
Interval*
Reminder
Oil Change
(Break-In)**
4-6 Hours
C
H
G
Lubricate
and Check
Levels
24-26 Hours
Oil Change
*
**
49-51 Hours***
OIL
LUBE
C
H
G
OIL
These intervals reflect the actual time that the
reminder will flash (one hour prior to and one
hour after the recommended interval).
This reminder is only used one time.
Hourmeter
Oil Pressure Warning Horn
The oil pressure warning horn indicates that engine
oil pressure is below the safe operating level [below
3 to 5 PSI (21 to 34 kPa)]. This horn will come on
when the ignition is turned ON, but should go off
after the engine is started. If the horn fails to come
on when the ignition switch is turned ON, it could
indicate a faulty horn. If the horn comes on during
engine operation, stop the engine immediately and
correct the source of the problem before further engine operation.
IMPORTANT: Continued operation of the engine
with oil pressure warning horn sounding MAY cause
severe engine damage (if a low oil pressure condition exists).
Circuit Breaker (7 Amp)
A 7-amp, manual-reset circuit breaker is located below the hourmeter. The button pops up if the circuit
breaker trips. This circuit breaker protects the circuits to the safety switch relays, time delay module,
and GHS. In addition, an auto reset 30 amp master
circuit breaker is located near the battery and a 10
amp fuse protects the ECU.
31
Operating Instructions
Light Switch (For Optional Lights)
IMPORTANT: If the engine fails to start after
approximately 10 seconds of cranking, the
engine should be checked before further crank­
ing. Turn the key to the OFF position and allow
a 60 second cool-down period between starting
attempts. Failure to follow these guidelines can
damage the starter motor and shorten battery
life. Consult your Walker dealer or authorized
Kohler dealer for additional help.
Operates headlights (when installed).
STARTING THE ENGINE
CAUTION
Before operating the mower, read and un­
derstand all Safety Instructions and Operat­
ing Instructions.
WARNING
NEVER run the engine in an enclosed or
poorly ventilated area. Engine exhaust
contains carbon monoxide, an odorless
and deadly gas.
1.
Before attempting to start the engine, make
sure the operator is in the seat, the Forward
Speed Control is in NEUTRAL-PARK position,
and the blade clutch and parking brake are DISENGAGED.
NOTE: Release parking brake to prevent extra
load on the starter if the transmission neutral is
slightly out of adjustment.
CAUTION
A safety interlock switch system PRE­
VENTS CRANKING the engine with either
the Forward Speed Control out of neutral,
or the blade clutch (PTO) engaged. If the
engine cranks otherwise, the safety system is not working and should be repaired
or ad­
justed before operating the mower.
DO NOT disconnect safety switches; they
are for the operator’s protection.
2.
32
Move the throttle 1/4 to 1/2 open (toward FAST).
Turn the ignition switch to the START position
to start the engine. Release the key to ON
(RUN) position as soon as the engine starts.
3.
After the engine starts, make sure the oil pressure horn goes off. If not, stop the engine immediately and find the cause of the problem.
Make sure the oil pressure horn is off prior to
engaging the mower blades and beginning operation.
ADJUSTING GROUND SPEED AND STEERING
IMPORTANT: If the DS52 or DS62 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, steer­
ing and
ground operation should be learned and
practiced until the operator is completely
comfortable handling the ma­
chine BEFORE ATTEMPTING TO MOW.
DANGER
Keep feet on footrests at all times when
the machine is moving. Never operate the
tractor without a deck or implement installed.
Operating Instructions
1.
Move the FSC out of NEUTRAL-PARK position
to the desired forward speed. DO NOT hold
for­ward on steering levers. It is not necessary
to hold the FSC lever in position since a friction
lock maintains the selected lever position (and
forward travel speed).
WARNING
In case either of the transmission drive
belts break during operation, and if the
machine is on a slope, the machine will
freewheel down the slope. To maintain
control, immediately (1) Release the
steering levers and simultaneously (2)
Move the FSC to the NEUTRAL-PARK
position. When the machine is stopped or
moving slowly, engage the parking brake.
NOTE: This is exactly the same procedure
used to normally stop and park the machine.
CAUTION
An operator presence switch (seat switch)
will cause the engine to stop if the FSC is
out of the NEUTRAL-PARK position and
the operator is not in the seat. The function
of this switch should be checked by the op­
erator raising off the seat with the tractor
moving forward (allow 1/2 second “off the
seat” for the time delay function); the engine should stop. If the safety sys­tem is not
working, it should be repaired or replaced
before operating the mower. DO NOT disconnect the safety switches; they are for
the operator’s protection.
Beginning Recommendations are:
♦♦ Learn operation of the mower in an open
area away from buildings, fences, and ob­
structions. Learn operation on flat ground
BEFORE operating on slopes.
♦♦ Start maneuvering the mower with SLOW
engine speed and SLOW Forward Speed
Control setting until familiar with all operat­
ing characteristics.
♦♦ Remember it is not necessary to hold the
steering levers forward (a unique Walker
feature); always PULL on the levers for
steering or for reverse motion of the mower.
♦♦ Learn to operate the mower with your left
hand on the steering levers and right hand
on Forward Speed Control. The use of two
hands on the steering levers tends to cause
overcontrol.
♦♦ Learn to operate the steering levers with
smooth action. Jerky movements are hard
on the transmission and lawn. For sharp
turns, do not allow the inside wheel to stop
and twist on the grass. Pull the steering
le­
ver controlling the inside wheel into
reverse for a smooth “rolling” turn (one
wheel roll­ing forward while the other rolls
backward).
♦♦ Practice maneuvering the mower until
you can make it go exactly where you are
aiming.
♦♦ Remember, for an emergency stop, or in
case of loss of control, machine movement
can always be stopped quickly by pulling
the Forward Speed Control into the NEU­
TRAL-PARK position.
NOTE: If the FSC lever will not stay in the
selected position, the friction lock needs to be
adjusted. Refer to ADJUSTMENTS for FSC
Friction Lock in Mainte­nance Instructions or
contact your Walker dealer.
2.
Steer by pulling the lever on the side of desired
direction of turn, e.g., pull the LH lever to turn
left. To minimize the possibility of overcontrol,
use only one hand on both steering levers.
33
Operating Instructions
5.
Pull Steering
Levers With
Left Hand
Stop ground travel by pulling both steering le­
vers backward to the NEUTRAL position (trac­
tor not moving) and then moving the FSC lever
to the NEUTRAL-PARK position.
NOTE: If the tractor creeps forward or back­
ward with the FSC lever in the NEUTRALPARK position, the transmission control needs
to be adjusted. Refer to ADJUSTMENTS for
Transmission Control and Neutral Function
Adjustment in Mainte­nance Instructions or contact your Walker dealer.
Forward Speed Control
(FSC)
ENGAGING THE BLADE DRIVE
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 short­
en drive belt life. Use only moderate engine
speed when engaging the blade clutch.
2.
Engage the blade clutch by pulling the blade
clutch lever SLOWLY up. For disengagement,
push the blade clutch lever down SLOWLY.
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. Remem­
ber to keep the engine and ground speed slow
until learning the control response.
WARNING
When moving forward, DO NOT suddenly
put the tractor in reverse by rapidly pulling
on the steering levers, especially when going downhill, as this can lift the tractor tail
wheel off the ground and set up a bucking
motion due to operator overcontrol. If
bucking does occur, immediately stop the
bucking action by pulling the Forward
Speed Control (FSC) lever into the NEUTRAL-PARK position.
4.
34
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.
CAUTION
An operator presence switch (seat switch)
will cause the engine to stop if the blade
clutch is engaged and the operator is not in
the seat. The function of this switch should
be checked by the op­erator raising off the
seat and engaging the blade clutch; the engine should stop. If the switch is not working, it should be repaired or replaced before operating the mower.
DO NOT
disconnect the safety switches; they are
for the operator’s protection.
IMPORTANT: DO NOT engage the blade clutch
when transporting the mower across drives, side­
walks, loose materials, etc. DO NOT engage the
blade clutch with the PTO shaft disconnected
(the mower deck removed from tractor).
Operating Instructions
CAUTION
If the cutting blades strike a stationary ob­
ject while mowing, stop the mower imme­
diately, 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 Mainte­
nance Instructions if blades are out of time.
Also, make sure the blade retain­ing nuts
are torqued to 60 lb·ft (81 N·m).
2.
Slow the engine to a fast idle; put the throttle in
the 1/2 throttle position.
3.
Disengage the blade clutch.
IMPORTANT: DO NOT disengage the blade
clutch with high engine speed (above 1/2 throt­
tle) 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
from freewheeling within five (5) seconds
after disengaging the clutch. If the brake
sys­
tem malfunctions and the blades do
not stop within five (5) seconds, the brake
should be adjusted or repaired before op­
erating the mower. Contact your Walker
dealer, or refer to ADJUSTMENTS of
Clutch Disengagement/Brake Action in
Maintenance Instructions.
4.
Engaged
Position
WARNING
Remove the key from the ignition switch
when leaving the mower unattended. This
will prevent children and inexperienced
operators from starting the engine.
Blade Clutch Engaged
5.
Disengaged
Position
Blade Clutch Disengaged
STOPPING THE MACHINE
1.
Slow the engine to idle, put throttle in IDLE position; and turn the ignition switch OFF.
Engage the parking brake. Also, engaging the
parking brake is recommended when stopping
or parking the machine in a confined space with
little tolerance for movement.
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 slip­
page in the hydrostatic transmissions, especially
when transmission fluid is warm.
Pull the steering levers to the NEUTRAL-PARK
posi­tion and then move the FSC lever backward
to the NEUTRAL-PARK position.
35
Operating Instructions
WARNING
In case either of the transmission drive
belts break during operation, and if the
machine is on a slope, the machine will
freewheel down the slope. To maintain
control, immediately (1) Release the
steering levers and simultaneously (2)
Move the FSC to the NEUTRAL-PARK
position. When the machine is stopped or
moving slowly, engage the parking brake.
NOTE: The emergency stop procedure is exactly the same procedure used to normally stop
and park the machine.
TRANSMISSION LOCKOUT
IMPORTANT: DO NOT TOW this mower with the
transmission lockout engaged. Towing can produce
excessive internal pressure and damage the trans­
mission.
To move the mower with the engine NOT running
(dead battery, maintenance, etc.), the hydrostatic
transmissions are unlocked (released).
1.
Raise the body.
2.
Lift the transmission lockout lever on both the
RH and LH transmissions and secure into place
with the locking cam.
3.
The mower will “freewheel” with the levers in the
LOCKOUT position. The levers must be in the
highest position to completely unlock the trans­
missions.
ADJUSTING CUTTING HEIGHT
WARNING
Lockout Lever
The engine must be stopped before ad­
justing cutting height.
Disengage the
blade clutch (PTO), stop the engine, and
remove the ignition key. Wait for all move­
ment to stop before getting off the seat.
Cutting height is adjusted by positioning the four (4)
re­tainer hitch pins in a series of six vertical holes on
the deck support pins. Lift handles have been pro­
vided on each end of the deck to assist in raising the
deck while positioning the hitch pins. Cutting
heights range from 1.5 in. (38 mm) [top holes] to 4
in. (102 mm) [bottom holes] in 1/2 in. (13 mm)
incre­ments.
Lift Handle
Deck Support
Pin
Hitch Pin
Cutting Height Adjustment
36
Plunger
Depressed
Cam in
LOCKOUT
Position
Lockout Lever - Freewheel Position
4.
After moving the mower, release the locking
cam, placing the lever DOWN in the normal OP­
ERATING 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.
Operating Instructions
Lockout Lever
IMPORTANT: Operate the engine at full throttle
when mowing, to allow the engine to produce full
horsepower and to increase efficiency of the engine
cooling system.
●● Keep the mower deck and discharge chute clean.
Plunger
Released
Cam in
UNLOCKED
Position
Lockout Lever - Normal Operating Position
RECOMMENDATIONS FOR MOWING
DANGER
Do not mow around overhanging tree
branches or bushes at the same height as
the operator’s torso and head where inadvertent contact may cause injury.
●● Mow with sharp blades. A dull blade tears the
grass (resulting in poor lawn appearance) and uses
extra power (slowing the mowing speed).
●● It is preferable to cut grass when it is dry and not
too tall. Mow frequently and do not cut grass too
short. (For best appearance, cut off 1/3 or less of
existing grass height.)
●● When mowing, operate the engine at full throttle
for the best cutting action and performance of the
grass handling system (GHS). Mowing with a lower
engine RPM causes the mowing blade to not cut
clean and tear the grass. The engine is designed
to be operated at full speed.
●● When mowing in adverse conditions (tall and/or
wet grass), mow the grass twice. Raise the mower
to the highest setting - 4 in. (102 mm) - for the first
pass and then make a second pass cutting to the
desired height.
●● Use a slow setting on the FSC for trimming operations.
●● Make sure the mower is leveled properly for a
smooth cut. Refer to Deck Leveling in Assembly In­
structions.
●● Use an alternating stripe mowing pattern for
best appearance and vary the direction of the stripe
each time the grass is mowed to avoid wear patterns
in the grass.
●● Avoid damage to the grass by slipping and skid­
ding of the drive tires. Use smooth control move­
ments of the steering levers since the 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).
Avoid Low Hanging Branches
37
Operating Instructions
●● When using a side discharge mower deck, the
side discharge deflector shield must not be removed and must be kept in the lowest possible
position to deflect grass clippings and thrown objects down­ward. Orient the side discharge away
from 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.
Maximum Recommended
Slope - Do Not Operate
on Steep Slopes
Discharge
Shield
6807-1
15°
16 in.
52 in.
Maximum Recommended Slope
Side Discharge Deflector Shield in
Lowest Position
DANGER
●● When operating on a slope, reduce speed and
use caution to start, stop, and maneuver. Avoid
sharp turns or sudden changes in direction. The
maximum recommended slope operating angle
is 15 degrees or 26% grade.
Do not mow or dump grass within 5 feet
(1.5 meters) of an embankment or retaining
wall with drop off.
5 FT
MINIMUM
No Driving Zone
38
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.
39
Operating Instructions
GRASS HANDLING SYSTEM (GHS)
Grass
Catcher
Grass-Pak®
Vane Switch
Exhaust Screen
(Removable)
Catcher
Door Spring
(Not Visible)
“Full” Signal
Horn
Catcher
Air Exhaust
Powerfil ®
Drive Motor
Actuator
Rod
Catcher
Door
PTO Clutch
PTO and Blade
Gear Drive
Powerfil ®
Delivery Spout
Shear
Bolt
Dump
Handle
Catcher Delivery
Chute
Body Chute
Assembly
Blower
Collection
Mower Deck
Deck
Discharge Chute
GHS Flow and Components
40
Operating Instructions
General Information
The Grass Handling System (GHS) consists of a
rear discharge mower deck connected to a 10.5 in.
(27 cm) blower and a rear mounted grass catcher
with 7.0 bushel (246 liters) capacity. The GHS blower oper­ates any time the mower blade clutch is engaged and moves grass through the rear discharge
deck chute into the grass catcher. Blower airflow is
ex­hausted out the back of the grass catcher, through
a filtering screen. When the grass catcher is full and
needs to be emptied, a “full” signal horn alerts the
operator. When the “full” signal horn sounds, it is
important to stop mowing to prevent overfilling and
clogging of the blower system.
IMPORTANT: Normally, the GHS blower operates
with no maintenance or cleaning required. How­ever,
under certain operating conditions, the inside of the
blower housing may accumulate a deposit of dirt,
causing wear and binding of the blower wheel.
Normally, dirt buildup occurs when mowing a com­
bination of dirty and damp grass, especially in
the springtime. When operating in these condi­
tions, check the blower wheel frequently for
binding and clean the blower housing as required.
Refer to CLEANING the GHS Blower in Mainte­
nance 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.
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. NOTE: For noncatching operation, the “No-Catch” Deflector is an available accessory item.
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
NOTE: An alternative to using the blower intake
cover when a side discharge or mulching deck is
installed on a GHS model is the blower lockout kit
(P/N 7541). The blower lockout kit releases ten­sion
on the blower drive belt and does not require the
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 dan­
gerous projectiles may be thrown. NEVER
put hands into the blower discharge chute
for any reason. Use a stick or similar in­
strument to remove any material if clog­ging
has occurred.
CAUTION
NEVER leave grass clippings in the grass
catcher after mowing. Damp clippings
generate heat as they decompose. This
MAY cause spontaneous combustion.
41
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 attempt­
ing to unclog.
Blades Must Operate at
Right Angles (90 Degrees)
FORWARD
DANGER
NEVER place hands under the mower deck
or in the GHS blower discharge chute.
Use a stick or similar tool to remove any
clogged material.
Normally, any clogging will first develop at the back
of the mower deck in the discharge opening into the
blower chute. Clogging at this point does not indi­
cate a particular problem in this part of the system, but is a symptom of something restrict­ing
the flow of material throughout the entire system.
The following list of items should be checked if a
pattern of clogging begins to develop. All of these
items are capable of causing clogging at the back of
the deck.
●● Check to see if the mower blades are installed for
the correct rotation. The blade cutting edges
should move towards each other at the front of the
deck on standard rotation decks (e.g., DC42), and
towards each other at the back of the deck on reverse rotation decks (e.g., DC42R).
Blades Must Operate at
Right Angles (90 Degrees)
Rear Discharge
Chute
FORWARD
Mounting Nut
Torque = 60 lb·ft
(81 N·m)
Blade Rotation for Standard Rotation
GHS Mower Deck (Bottom View)
42
Rear Discharge
Chute
Mounting Nut
Torque = 60 lb·ft
(81 N·m)
Blade Rotation for Reverse Rotation
GHS Mower Deck (Bottom View)
●● Check the amount of flat section remaining at
blade tip. This is the area that is ground away (re­
moved) when the blades are sharpened. If too much
of the flat section is removed, the “air lift” performance or “shovel” effect of the blade deteriorates to
the point that discharge of grass clippings into the
blower chute is marginal. Replace cutter blades if
less than 3/4 in. (19 mm) flat section remains at the
blade tip.
●● Check that the interior of the deck housing and
baffling is reasonably clean and free of grass and
dirt buildup. While some degree of material buildup can be tolerated, a point is finally reached where
the flow of air and grass clippings is restricted.
NOTE: One condition that quickly causes a buildup
of material in the deck housing is mowing grass and/
or weeds which are “juicy.” The material collects
under the deck with sticky, green juice. Clo­ver and
weeds are especially a problem. The mower deck
will need to be cleaned frequently when operating in
these conditions.
●● Check the deck cutting height setting. When
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 signifi­
cantly increase airflow and reduce clogging when
working in thick, tall grass.
●● Check the interior of the chute connecting the
mower deck to the blower for smoothness and
freedom from obstruction.
Operating Instructions
●● Check the blower wheel for bent blades and excessive clearance between the blade tip and the
blower housing.
A clearance greater than
1/8 in. (3 mm) will cause a significant loss of blower
performance.
●● Check the blower discharge chute into the grass
catcher for smoothness and freedom from ob­
struction.
●● Check the elbow inside the grass catcher for a
buildup of material in the radius of the elbow. In
certain conditions (damp/dirty grass) a considerable
“clump” of material can accumulate at this point,
greatly restricting material and airflow.
●● Check that the openings in the removable air
exhaust screen in the grass catcher are not
plugged. If the screen is clogged, refer to Cleaning
the GHS Exhaust Screen in this section.
“Full” Signal Horn
The GHS catcher has a “full” signal horn to alert
the operator to dump the catcher when it is full (to
prevent overfilling and clogging). The “full” signal
horn is activated by a vane switch (Grass-Pak®
switch) mounted on the grass delivery spout. Oscil­
lating action of the spout triggers the vane switch as
grass begins to fill in around the spout when the
catcher is almost full.
The “full” signal function may be checked by turning
the ignition switch ON (RUN), engaging the blade
clutch (engine not running), opening the catcher
back door, and triggering the Grass-Pak® vane by
hand as it oscillates. The horn should sound as the
switch is moved in one direction.
WARNING
NOTE: An optional exhaust screen with larger
holes (3/4") is available for use when mowing in wet
grass; the screen provides less airflow restriction
and more clog resistance (use standard screen in
dry conditions to avoid excessive material blowing
out of the catcher).
DO NOT test the Powerfil® oscillation or
Grass-Pak® switch with the engine running. Projectiles may be thrown out of the
grass delivery spout, and COULD cause
serious injury.
Remember, anything that restricts airflow or material flow along the entire path from the mower deck
to the grass catcher can cause clogging.
The “full” signal horn is designed to operate (sound)
when the grass catcher is almost full. The timing
of the signal is adjustable by changing the position
of the vane on the Grass-Pak® switch. If the signal
is coming on too soon (catcher not completely full)
or too late (grass clogging in catcher spout and
deliv­ery chute), refer to ADJUSTMENTS for GHS
“Full” Signal Horn Adjustment in Maintenance
Instructions.
Using the Tilt-Up Deck
Refer to CLEANING of Grass Buildup in Mower
Deck Housing in Maintenance Instructions.
Using the GHS Catcher
Powerfil ®
The GHS catcher has an oscillating grass delivery
spout (POWERFIL®) which is designed to spread
grass clippings throughout the interior of the grass
catcher (even when mowing wet, heavy grass). The
oscillating action may be checked by turning the ignition switch to the ON (RUN) position and moving
the blade clutch to the ENGAGED position. The
spout should oscillate approximately 35 cycles per
minute.
NOTE: The horn signal should be adjusted to
sound BEFORE the catcher is completely full to
give the operator time to react and stop mowing. An
indication the horn signal is coming on too late (de­
layed too much) is if grass clippings are falling out of
the grass catcher delivery chute when the catcher is
dumped.
NOTE: If the grass spout fails to oscillate, the clutch
switch should be checked for function.
43
Operating Instructions
Cleaning the GHS Exhaust Screen
CAUTION
To remove the grass catcher screen for cleaning,
open the catcher door, push forward and pull down
on the grass catcher screen knobs (on either side of
the screen), and slide the screen out. Use a high
pressure washer or water spray and brush to clean
the screen.
Keeping the catcher exhaust screen clean and open
is essential to good performance of the catching
system. In some mowing conditions, e.g., wet and
dirty, it will be necessary to clean the screen fre­
quently to avoid clogging the mower deck, blower,
and chutes due to airflow restriction.
Grass Catcher
Screen
Removal Knobs
(Not Visible)
Grass Catcher Screen Removal for Cleaning
Dumping the Catcher
DANGER
Do not mow or dump grass within 5 feet
(1.5 meters) of an embankment or retaining
wall with drop off.
For dumping, the catcher either tailgate dumps into
a disposal area or dumps into the optional dump
bag. The dump bag is a reusable nylon fabric bag
designed to conveniently move grass clippings from
the catcher to a remote disposal area or container.
44
Use leg muscles and firm footing when lift­
ing the catcher to dump; avoid bending at
the waist and using back muscles in order
to prevent back injury.
Tailgate Dumping
1.
Open the back door by lifting on the door handle.
2.
Tilt the catcher back to dump by lifting on the
catcher lift/dump 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 pulling down on the door
handle. The door should close smoothly with
the assistance of the gas springs. If the
dampening springs are not functioning properly, they should be replaced to prevent the
door from slamming closed and possibly
causing a pinch point.
Operating Instructions
Using the Dump Bag
1.
Open the back door by lifting on the door handle.
2.
Orient the dump bag with one of the handle
straps on the bag opening facing up.
Catcher Lift /
Dump Handle
Tailgate Door
Handle
Hook Bag
on Bumper
Dumping Catcher into Dump Bag
Positioning Dump Bag on Catcher
­3.
Hook the bottom of the bag over the rear bumper while lifting on the handle strap on bag
opening.
4.
Tilt the catcher back to dump into the bag by
lifting on the catcher lift/dump 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.
5.
Lower the catcher smoothly down to the normal
operating position. DO NOT allow the catcher
to drop down - the gas spring, that holds the
catcher in the raised position, is not a shock
absorber for lowering the catcher.
6.
Close the door by pulling down on the door
handle. The door should close smoothly with
the assistance of the gas springs. If the dampening springs are not functioning properly, they
should be replaced to prevent the door from
slamming closed and possibly causing a pinch
point.
45
Operating Instructions
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.
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.
46
Operating Instructions
Catcher Door
Gas Spring
Door Arm
Actuator
RH Catcher
Door Arm
Catcher
Door
Cable
Guide
Grass Catcher
Lift Channel
Fork
LH Catcher
Door Arm
Dog Leg
Assembly
Cable
Assembly
Gas
Spring
1.
2.
Power Dump
Ram Actuator
Actuator Mount
Assembly
Rubber
Bumper
Power Dump Components
47
CAUTION
Maintenance Instructions
Maintenance procedures requiring special training or
tools should be performed by a trained technician.
MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL C19i
Service Item
Check Engine Crankcase Oil Level
Check/Clean Engine Air Cooling System*
Check Security of Air Filtration Components
Check Air Filter Restriction Gauge
Clean Grass Buildup Under Deck
Clean GHS Exhaust Screen*
Clean GHS Blower*
Service Mower Blades
Check Function of Oil Pressure Warning Horn
Lubricate Grease Fittings and Oil Points*
Check PTO Gearbox Oil Level**
Check Battery Electrolyte Level
Check Hydrostatic Transmission Fluid◊
Check Tire Pressure
Check Drive Belts (Jackshaft, Engine PTO,
GHS Blower, Ground Drive)
Check Deck Gearbox Oil Seals
Check Safety Switch System
Check Turbine Precleaner*
Check Air Filter Element ***
Change Engine Crankcase OilΔ
Check Oil Level in Gear Axle
Clean Hydrostatic Transmission Cooling Fins
Clean Engine Cooling Fins
Check Blade Brake Action
Check Wheel Bolt Torque (75 to 85 lb·ft)
Check/Regap Spark Plugs
Change Engine Oil Filter
Replace Air Filter Element and Safety Filter***
Check Fuel Lines and Clamps
Replace Fuel Filter
Service Battery
Check Transmission Control Setting
Check FSC Friction Lock
Service Solenoid Shift Starter
Check PTO U-Joints for Wear/Looseness
Check Engine Valve Clearance
Remove Engine Shroud and Clean Cylinder
Head Cooling Fins
Change Gear Axle OilΔΔ
Replace Fuel Lines and Clamps
Change Hydrostatic Transmission FluidΔΔ
Replace Ignition Wires
*
**
***
Δ
ΔΔ
ΔΔΔ
◊
48
Daily
x
x
x
x
x
x
x
x
x
25
Hours
100
Hours
200
Hours
400
Every
Hours Yearly 2 Years
Ref.
Page
x
x
x
x
x
50
60
63
58
61
63
62
65
26
55
53
64
54
65
x
66
x
x
67
68
58
59
51
54
63
61
67
65
67
51
59
67
74
64
76
68
67
67
x
x
x
x
x
x
x
x
x
x
x
More often in extremely dusty or dirty conditions
Change PTO gearbox oil after first 100 hours of operation (break-in period)
Air cleaner is remote mounted Enginaire™ unit, replace filter(s) every 400 hours
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
See your Walker dealer for this service or refer to the Walker Service Manual
Hydrostatic transmissions are sealed - DO NOT OPEN RESERVOIR CAPS - refer to
Checking Hydrostatic Transmission Fluid Level in this section
x
x
x
x
x
x
x
x
ΔΔΔ
x
61
x
x
x
x
54
67
ΔΔΔ
67
Maintenance Instructions
KOHLER TIPS
IMPORTANT TIPS FOR CARE OF THE KOHLER
ENGINE
Fuel System
●● Fuel must be clean - free from water, dirt, and or­
ganic material.
●● Change fuel filter on a regular basis and when
contamination is suspected or found in the fuel.
●● The fuel injection system is pressurized. Do not
attempt to service this fuel system. Contact your
Walker dealer or authorized Kohler service dealer
for work on the fuel system.
Starting/Stopping
●● Start engine with the throttle advanced off idle
(1/4 to 1/2 throttle). This will aid starting, especially
in cold weather.
●● Keep the battery fully charged.
●● Match crankcase oil viscosity to the ambient tem­
perature, allowing the engine to crank faster and
start easier.
●● Allow engine to run at idle for a few seconds be­
fore stopping engine to avoid run-on or backfiring.
Cooling System
CAUTION
DO NOT use water or a pressure washer to
clean the cooling system on an air-cooled
engine; mud may form under the cooling
shroud on the cylinder head and cooling
fan resulting in engine overheating.
●● 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.
●● Periodically remove two access panels in the en­
gine shroud to inspect and clean cylinder head cool­
ing fins.
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
●● Operate the engine at full speed when mowing.
This allows the engine to produce full horsepower
and move more cooling air through the engine cool­
ing fins.
Air Cleaner System
●● Use only EnginaireTM air cleaner elements.
After­market elements may not seal in the air cleaner
housing, allowing dirt to enter the engine. Also, af­
termarket filters often skimp on the filtration media
and require more frequent replace­ment (see following instructions).
●● Use the air filter restriction gauge to indicate the
need to service the air filter.
●● Do frequently check the Turbine Precleaner (located in the end cap of the air cleaner assembly) for
free movement of the internal fan. Shine light into
end cap to verify movement of fan with engine running.
●● DO NOT overservice or frequently “disturb” the
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 in­
crease the opportunity for traces of dust to enter the
engine. Wait until the element really needs servicing
as indicated by the air filter restriction gauge.
●● When the air filter element is removed or re­
placed, make sure all dust is cleaned out of the air
cleaner housing and hose. Use a damp cloth and
wipe the interior of the canister and hose clean (a
lit­tle dirt left here will be sucked into the engine and
reduce engine life). When the filter is reinstalled,
make sure the element is held tight and straight
in the canister for proper seating and sealing.
●● Periodically check the air intake hose for cuts,
nicks, etc., and the hose clamps for tightness.
●● Check performance of the cooling system by
starting the engine, holding a hand adjacent to the
cylinder heads, and feeling the cooling airflow.
49
Maintenance Instructions
KOHLER TIPS/LUBRICATION
Oil
2.
●● Use only multi-viscosity oils as specified with the
viscosity matching ambient temperatures for the en­
gine operating conditions. This will aid starting in
cold weather and assure proper lubrication in hot
weather.
Before removing the dipstick, clean the area
around the dipstick to keep any dirt or debris out
of the engine.
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).
●● Use only Kohler oil filters. Aftermarket filters
may not seal properly and/or have the incorrect
pressure relief valve for proper lubrication.
LUBRICATION
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.
WARNING
DO NOT attempt to lubricate the machine
with the engine running. Disengage the
PTO clutch, shut off the machine, and re­
move the ignition key.
Proper lubrication is an important maintenance pro­
cedure. It reduces wear and makes the machine
quieter and easier to operate.
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.
Engine Oil
Engine Break-In Oil
No special break-in oil is required. The engine is
serviced with 10W-30, Service Class SJ 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.
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].
IMPORTANT: NEVER check or add oil with the
engine running.
50
Operating
Range
{
F
L
Dipstick Operating Range
Maintenance Instructions
LUBRICATION
Changing Engine Crankcase Oil/Oil Filter
8.
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).
Reinstall the drain plug. Make sure it is tight­
ened to 10 lb·ft (14 N·m).
9.
Remove the fill cap on the engine valve cover,
and fill the crankcase 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 (0.24 liters) for the new
oil filter.
1.
Park the mower on a level surface with the
en­gine stopped. The engine oil should be
warm before draining. If not warm from operation, start the engine and run a few minutes to
warm the oil.
2.
Before removing the dipstick, clean the area
around it to keep any dirt or debris out of the
en­gine.
3.
Remove the dipstick and oil drain plug, and
drain the oil into a suitable container. Be sure
to allow ample time for complete drainage.
IMPORTANT: Check the dipstick reading be­
fore 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 en­
gine overheating, loss of power, and possible
engine damage.
10. 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.)
Oil Filter
Drain Plug
Oil Drain/Oil Filter Location
4.
Before removing the oil filter, clean the area
around the filter to keep dirt and debris out of
the engine.
5.
Remove the old oil filter and wipe off the filter
mounting surface on the engine.
6.
Apply a thin coating of clean oil to the rubber
gasket on the replacement oil filter.
IMPORTANT: Use ONLY oil filters from the en­
gine manufacturer (Kohler 28-050-01). After­
market oil filters may not seal properly and/or
may not have the correct pressure relief valve
for proper lubrication.
7.
Install the new oil filter on the engine. Turn the
filter clockwise until the rubber gasket contacts
the sealing surface, then tighten an additional
3/4 to 1 turn.
51
Maintenance Instructions
LUBRICATION
Mower Deck Gearbox 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.
NOTE: These instructions apply to all mower decks
with gear-driven blades. Refer to DS52 or DS62
Mower Deck Lubrication in this section for the
DS52 or DS62 deck with belt-driven blades. Refer
to Mower Deck Spindle Lubrication in this section
for the DS42 Belt Drive deck with belt-driven blades.
On gear driven decks, the mower deck gearboxes
(tee gearbox and blade drive gearboxes) are
connected as a unitized as­sembly, and oil flows
freely between them. The gear­boxes are permanently lubricated (oil filled) and sealed requiring no
scheduled lubrication. Howev­
er, the gearbox oil
seals should be checked every 25 hours for indication of an oil leak; particularly the lower seals on the
blade drive gearboxes should be inspected, since
they operate in a dirty environment. If an oil leak is
noted, replace the oil seal and relubricate the
gearbox assembly as follows:
1.
Remove gearbox cover (footrest). Deck orien­
tation should be the normal operating position.
Blade Drive
Gearboxes
Tee
Gearbox
Mower Deck Gearboxes
(Shown with Gearbox Cover
Removed for Clarity)
52
2.
Clean the area around the individual gearbox
cover plates to prevent contaminants from en­
tering 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) 80W-90 (API GL-5) gear lube until
the oil level is up to (submerges) the horizontal
shaft in the gearbox (shaft parallel to cover
plate).
NOTE: Since the gearboxes are connected as
a unit by connector tubes, it is necessary to add
oil slowly. Allow a few minutes after adding oil
for the oil to flow throughout the assembly and
the oil level to stabilize before reassembly.
IMPORTANT: DO NOT overfill the deck gear­
boxes. The gearbox assembly is not vented,
and overfilling with oil will cause excessive pres­
sure and result in oil leaks.
5.
Check condition of the cover gasket and replace
if worn or damaged. Reinstall gearbox cover
plates; torque screws to 24 lb·in. (3 N·m).
Maintenance Instructions
LUBRICATION
DS52 or DS62 Mower Deck Lubrication
Mower Deck Spindle Lubrication
There are several special lubrication requirements
for the DS52 or DS62 mower deck in addition to the
require­
ments detailed in the Chassis and Deck
Lubrica­tion Points illustration. Lubricate the locations shown in the Gearbox, Dol­ly Wheel, and UJoint Lubrication photo and check and maintain oil
in the belt drive gearbox.
For the DS42 Belt Drive mower deck, lubricate each
deck spindle grease fitting every 25 hours. Use
SAE general purpose lithium or molybdenum base
grease for grease fittings.
1.
Check the oil level in the belt drive gearbox ev­
ery 100 hours (or sooner if a visible oil leak has
developed). With the deck in the normal oper­
ating position, remove the level plug in the side
of the gearcase. Add SAE E.P. (Extreme Pres­
sure) 80W-90 (API GL-5) gear lube 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.
2.
Lubricate the dolly wheel pivot every 25 hours
with general purpose grease.
3.
Lubricate both drive shaft u-joints every 25
hours with SAE general purpose lithium or
molybdenum base grease.
Tractor PTO Gearbox Lubrication
Checking Gearbox Oil Level
Check the gearbox oil level every 25 hours, and if
necessary, add oil [SAE E.P. (Extreme Pressure)
80W-90 (API GL-5) gear lube] to maintain oil level to
the FULL mark on the dipstick.
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 indi­
cation of an oil leak. If an oil leak is noted, the gear­
box will need to be removed and rebuilt.
Jackshaft
Dipstick
Belt Drive
Gearbox
PTO
Gearbox
Dolly Wheel
Pivot
Vent Plug
U-Joints
Gearbox, Dolly Wheel, and U-Joint Lubrication
Dipstick Location, Tractor PTO Gearbox
53
Maintenance Instructions
LUBRICATION
Changing Gearbox Oil
Hydrostatic Transmission Fluid
The tractor PTO gearbox is oil filled. 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.
Checking Hydrostatic Transmission Fluid Level
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 stand­
pipe using 7 to 8 fl. oz. (21 to 24 cl) of SAE E.P.
(Extreme Pressure) 80W-90 (API GL-5) gear
lube. Re­move plug in top of gearcase to vent
air when refilling.
3.
Check that the oil level is at the FULL mark on
the dipstick. DO NOT overfill.
The hydrostatic transmissions are sealed units
and do not need to be opened to check the fluid
level. Hydrostatic fluid level should be checked every 25 hours of machine operation. It is preferable
to check the fluid when the fluid is cold. Check
fluid levels as follows:
IMPORTANT: Removing or breaking the seal on
the hydrostatic reservoir cap within the first
1000 hours will VOID THE TRANSMISSION WARRANTY.
1.
Park the mower on a level surface. Stop the
engine and wipe dirt and contaminants from
around the base of the reservoir to better see
the COLD mark.
2.
The level of the oil can be seen through the side
of the opaque reservoir (DO NOT REMOVE
RESERVOIR CAP); using a light next to the
reservoir will help make the level more visible.
Gear Axle Lubrication
●● The gear axle oil lubrication is SAE E.P. 80W-90
(API 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.
Reservoir Cap
●● Change axle oil every 1000 hours or two (2)
years.
Air Bleed Plug
Cold Level
Transmission Reservoir and
Air Bleed Plug Location
54
3.
The reservoir has a fluid level COLD mark. The
reservoir oil level should ALWAYS be at or
slightly above the COLD mark.
4.
If the fluid is below the COLD mark (or the transmission is not performing properly) contact
your local dealer. Attempting to add fluid or
service the transmission may VOID THE
TRANSMISSION WARRANTY.
Maintenance Instructions
NOTE: Loosening the air bleed plug on top of the
transmission can be used to verify a low oil condition
in the transmission. As the plug is loosened (DO
NOT completely remove plug), oil will seep out if the
transmission is full of oil. If no oil appears, the transmission oil level is low and the transmission will
need to be serviced by an authorized Walker dealer.
When a transmission is found to be low on oil, it is
highly probable that has been caused by an oil leak
either on the input drive shaft or the control arm
pivot. Dealer service is required to correct any oil
leak along with refilling the transmission oil to the
proper level.
LUBRICATION
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 trac­
tor) require routine lubrication after every 25 hours
of running time. Remove tractor PTO quick disconnect tube assembly for easy access to grease fittings.
NOTE: The best way to lubricate the PTO tube half
of the universal joint assembly is to remove it from
the tractor. See instructions for removing and install­
ing PTO quick coupler, refer to Deck Installation in
Mower Deck Installation on Tractor in the Assem­
bly Instructions.
55
Maintenance Instructions
LUBRICATION
Ident Lubrication
No.
Location Type
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
No.
Places
Deck Caster Wheel Fork Pivot
Grease
Deck Caster Wheel Bearing
Grease
Blade Spindle
GreaseΔ
Pivot Assembly, Tilt-Up Deck
Grease
Deck Support Arm Socket
Grease
Right Angle Gearbox
Oil*Δ
Universal Joint Shaft Assembly Grease**
Dolly Wheel Retract
OilΔ
Lever and Linkage
Dolly Wheel Pivot
GreaseΔ
Idler Arm Pivot
GreaseΔ
Tee Gearbox, Deck
Oil*
Blade Drive Gearbox
Oil*
Steering Lever Pivot
Grease
Body Hinge Point
Oil
Deck-to-PTO Coupling
Grease
(Grease Spline Slide Area)
(FSC) Friction Body Pivot
Grease
FSC Actuator Rod Pivot Pins
Oil
FSC Lever Pivot
Grease
Deck Support Arm Pivot
Grease
Gear Axle
Oil***
Universal Joint Tube Assembly
Grease**
Parking Brake Lever
Grease
Universal Joint Quick Connect
Grease
Spline (Grease Slide Area)
Belt Tightener Pivot,
Grease
Jackshaft Drive
PTO Clutch Lever Pivot
Grease
Ident
No.
2
2
3
4
2
1
1(2Δ)
1
1
2
1
2
2
1
1
1
1
1
1
3
10
2
3
3
4
5
9
8
No.
Places
Clutch Actuator Push Rod
Grease
2
Belt Tightener Pivot,
Grease
1
PTO Clutch
Brake Actuator Rod and Brake
Oil
3
Band Pivot Pins (Clevis)
Brake Actuator Pivot
Grease
1
Catcher Hinge Point
Oil
2
Engine Oil
Oil***
1
Throttle Control Cable Ends
Oil
2
Belt Tightener Pivot,
Grease
1
Blower Drive
Belt Tightener Pivot,
Grease
1
Ground Drive
PTO Gearbox Dipstick
Oil***
1
Hydrostatic Drive
Oil***
2
Throttle Control Pivot
Oil
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 twenty-five (25) hours.
*** Refer to Gear Axle Lubrication, Engine Oil,
Tractor PTO Gearbox Lubrication, and Hydrostatic Transmission Fluid in this sec­tion.
Δ
Belt Driven Decks Only
NOTE: DC42 and DS62 Tilt-Up Decks are shown for reference.
For other Deck Lubrication Points, refer to Deck and
Carrier Frame Illustrated Parts Manual.
2
7
6
5
4
Lubrication Points for Optional Belt Driven Decks (DS62 Shown)
56
Lubrication
Type
26
27
28
29
30
31
32
33
34
35
36
37
1
1
1
2
4
2
1
1
Location
Maintenance Instructions
1
LUBRICATION
1
11
12
12
7
4
4
5
5
4
15
4
13
14
17
16
14
13
18
32 & 37
19
36
20
19
20
21
22
36
23
35
34
24
25
26
26
29
33
32
28
27
31
30
30
Chassis and Deck Lubrication Points (DC42 Shown)
57
Maintenance Instructions
CLEANING
CLEANING
Every 100 hours check the Turbine Precleaner
(located in the end cap of the air cleaner assembly)
for free movement of the internal fan. Shine light
into end cap to verify movement of fan with engine
running.
CAUTION
If a pressure washer is used on the exposed working parts, avoid water on the
electrical parts and the engine cooling
system.
Enginaire™ VLR Air Cleaner
A remote mounted Enginaire™ air cleaner provides the air filtering function. The paper filter
element slides over an outlet tube inside the air
cleaner canister with radial sealing action, eliminating the possibility of dust leaks due to improper filter installation. Intake design and internal
baffling provide dust separation and automatic
precleaning action. Daily or frequent servicing of
the air cleaner is not required. Use the air filter
restriction gauge on the air cleaner outlet to indicate
when the air filter needs servicing -- a yellow indicator will show when the filter is overly restricting airflow into the engine.
Engine Air Cleaner System
Turbine Precleaner (Enginaire™)
The engine air cleaner system includes a turbine
precleaner; a spinning fan driven by the intake
airflow separates dust from the air, giving the initial
stage of air cleaning.
Air Intake
Hose
Enginaire™
Air Cleaner Cover
Primary Filter
Element
Hose
Clamp
Air Cleaner
Mounting Band
Turbine
Precleaner
Air Filter
Restriction Gauge
Safety
Filter
Enginaire VLR ™
Air Cleaner
Hose
Clamp
Engine
Engine Air Cleaner System Components
58
Maintenance Instructions
IMPORTANT: Use only Enginaire™ air filter elements for replacement (S/N 133542 and on uses
Walker P/N 5090-4 and 5090-5). Aftermarket filters
may not seal properly or filter efficiently.
CLEANING
1.
Unlatch and remove Enginaire™ air cleaner
cover. Wash the cover. Check that the cover is
in good condition.
2.
Remove the filter element by pulling it out of the
canister. There will be some initial resistance
as the filter seal breaks loose and slides off of
the outlet tube. Gently move the end of the
filter up and down and side to side or twist to
loosen the seal. Use gentle action to minimize
the amount of dust dislodged as the filter is removed.
3.
Discard the filter element if excessive air flow
restriction has been indicated by the air filter
restriction gauge and proceed to Step 6. Clean
the filter element by gently tapping on a flat,
hard surface. If excessive restriction still exists
after cleaning the element, it should be replaced.
Canister
Cover
Filter
Element
Air Cleaner Components
(Shown with Cover Being Removed)
NOTE: Use care when cleaning the filter element. The filter element and/or seal surface
may be damaged by tapping too hard or hitting
on an uneven surface or sharp edge. Washing
the element in water or cleaning solution is not
recommended. Do not try to clean the element
with compressed air. Remember, replacing a
filter is less expensive than replacing a dusted
engine.
IMPORTANT: The Enginaire™ 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 Filter Restriction
Gauge
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
filter element if dirty or damaged.
5.
Check the condition and resilience of the radial
sealing surface (inside of the open end) of the
filter. Replace the filter if any cracks, tears, or
other damage to the sealing surface are noted.
6.
Without removing, visually inspect the condition
of the safety filter for damage or holes. The
safety filter should only be removed for replacement every 400 hours (or when dirty or damaged).
Air Filter Restriction Gauge Location
Inspect the paper element after every 100 hours of
service and replace the element and safety filter every 400 hours (or when dirty or damaged). More
frequent replacement may be required when operating in extremely dusty conditions as indicated by the
air filter restriction gauge. Service the air cleaner as
follows:
IMPORTANT: Prior to removing the safety filter,
make sure the inside surface of the air cleaner
canister is clean. This will minimize the risk of
dirt entering the outlet tube which can cause premature engine wear.
59
Maintenance Instructions
7.
CLEANING
After removing the safety filter, 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.
Cover
Latch
IMPORTANT: Any dust left on the inside of the
outlet tube will go into the engine and cause
wear.
8.
Check the outside surface of the outlet tube for
smoothness and cleanness (this is the sealing
surface).
9.
Insert and seat the safety filter and primary filter
el­ement carefully into the canister, applying
pres­sure at the outer rim of the filter; not at the
flexible center. Make sure the filter element is
completely in place before installing the cover.
NOTE: DO NOT use petroleum based lubri­
cants on the sealing surfaces of the filter; use
tal­cum powder or dry silicone lubricants if required for filter installation.
Outlet
Tube
Primary
Filter
Element
Canister
Safety Filter
Radial Sealing
Surface
Air Filter Element Replacement
10. Install the Enginaire™ air cleaner cover. Latch
the two (2) cover latches.
Cover
Latch
Proper Orientation of Air Cleaner Cover
11. Check the air intake hose for cuts, nicks, cracks,
etc., and the hose clamps for tightness.
12. Reset the air filter restriction gauge (press button on the end of the indicator).
Engine Cooling System
Cooling Air Intake Screen
To prevent engine overheating and possible engine
damage, clean grass clippings, chaff, and dirt from
the rotating engine cooling air intake screen after
every 8 hours of operation. In certain mowing conditions (dry grass, leaves, tree “cotton”, etc.), it may
be nec­essary to check and clean the screen several
times each day to prevent engine overheating. Also,
visually check inside cylinder head shroud and between cylinder head fins for material packed in this
area which would prevent cooling airflow; remove
shroud and clean as required.
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.
60
Maintenance Instructions
CLEANING
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 heads, and feeling the
cooling airflow. If there is little or no airflow, clean
the cooling fins as follows:
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 op­
erating the engine.
CAUTION
DO NOT use a pressure washer to clean
the cooling system on an air-cooled engine, mud may form under the cooling
shroud on the cylinder head and cooling
fan.
NOTE: If dirt is packed into the cooling fins it may
be necessary to remove the engine shroud in order
to thoroughly clean the cooling fins.
Engine Cooling
Fin Access Panels
Kohler Engine
Shroud
Engine Cooling Air
Intake Screen
Keep Rotating Cooling Air Intake
Screen and Cooling Fins Clean
IMPORTANT: Yearly, it is good maintenance practice to remove the engine cooling shroud and clean
the cylinder head cooling fins thoroughly to prevent
overheating and extend engine life. Make sure cooling shroud is reinstalled properly. This procedure
will require removing the engine from the chassis.
Cylinder
Head
Check Airflow
with Hand
Check Cooling System Airflow
Grass Buildup in Mower Deck Housing
DANGER
Before raising or removing the mower
deck for cleaning, stop the engine,
re­move the ignition key, and disconnect
the spark plug wires.
61
Maintenance Instructions
1.
Raise the deck lock lever handle on each side
of the carrier frame and pull out to release car­
rier frame for tilting action.
2.
Using the carrier frame lift handle, raise deck to
the TILT-UP position and insert the deck hook
into the tilt-up latch on the tractor body.
Tilt-Up Hook and
Latch Connected
Tilt-Up Handle
Tilt-Up
Latch
Tilt-Up
Hook
Deck Lock
Lever
CLEANING
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
GHS Blower
Normally, the GHS blower operates with no mainte­
nance or cleaning. However, when mowing grass
that is dirty and damp (especially certain springtime mowing conditions), a deposit of dirt may accumulate inside the blower housing, causing wear
and binding of the blower wheel. When operating in
these conditions, inspect the blower frequently
for dirt buildup.
NOTE: A visual clue of binding of the blower wheel
is the blower blade tips are polished from rubbing
on dirt.
When a dirt deposit is found, use a high pressure
washer or water spray to clean the inside of the
housing as follows:
DANGER
Deck Secured in TILT-UP Position
Before attempting to wash the blower,
stop the engine, remove the ignition key,
and disconnect the spark plug wires.
Wear goggles or face shield.
DANGER
Do not operate the mower with deck in
TILT-UP position. Do not move the tractor
with the deck in the tilt-up position.
3.
Clean grass buildup underneath the deck using
a pressure washer (and scraper if required).
NOTE: If the buildup is severe, it may be easier
to clean the deck by removing the deck assembly from the tractor and standing the deck assembly on its “nose”.
NOTE: While some degree of material buildup
in the mower deck housing can be tolerated, a
point is finally reached where cutting quality
deteriorates and clogging begins to occur
because of too much buildup on the baffling and
housing.
4.
62
Lower the deck to the normal operating position
and re-engage the deck lock levers.
1.
Remove the GHS blower drive belt tension by
depressing the idler pulley on the tightener arm.
Roll the belt off the blower pulley. The belt
should be clear of the blower pulley, allowing
free movement of the blower wheel.
IMPORTANT: With the belt removed, the blow­
er wheel must spin freely. Any binding or drag­
ging 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).
Maintenance Instructions
2.
3.
Use a pressure washer or water spray, and di­
rect the spray inside the blower housing against
the blower blades. Water pressure will cause
the blower wheel to begin to spin and the com­
bination of spinning action and water will effec­
tively wash the inside of the housing. Spray
may be directed against the blower blades ver­
tically and horizontally to cause rotation in both
directions for thorough washing action. Wash
blower until the blower wheel spins freely in
both directions.
Reinstall the GHS blower drive belt by reversing
the removal procedure.
Blower
Drive Pulley
Blower
Pulley
GHS Blower
Drive Belt
Depress Idler Pulley
Down to Relax Belt
CLEANING
on the transmission will quickly pack the cooling
fins with oily dirt. If this condition occurs, replace
the seal immediately to avoid overheating and dam­
aging 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.
Cooling Fins
Cooling Fan
Hydrostatic Transmission Cooling Fins
Belt Tightener
Idler Pulley
Collapse Blower Belt Tightener
to Remove GHS Blower Drive Belt
GHS Exhaust Screen
Refer to Cleaning the GHS Exhaust Screen in Op­
erating Instructions.
Hydrostatic Transmission Cooling Fins
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 pres­
sure 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
63
Maintenance Instructions
CHECKING/SERVICING
CHECKING/SERVICING
CAUTION
DANGER
Important Battery Service, Installation, and
Charging Tips for Electronic Fuel Injection
Engines:
To prevent accidental starting of the en­
gine when servicing or adjusting the ma­
chine, remove the key from the ignition
switch and disconnect the spark plug
wires.
Security of Air Filtration Components
●● Do not allow the battery cables to touch
opposing terminals. When connecting battery cables attach the positive (+) cable to
positive (+) battery terminal first, followed
by negative (-) cable to negative (-) battery
terminal.
NOTE: The following inspection is only an exter­nal
inspection and should be done without “dis­
turbing” the filtration components.
●● Never start the engine when the cables
are loose or poorly connected to the battery terminals.
●● Never disconnect battery while engine
is running.
On a daily basis, visually inspect the external condi­
tion of the complete air cleaner system. The follow­
ing items should be inspected:
1.
●● Never use a quick battery charger to
start the engine.
Check the Enginaire™ 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.
2.
Inspect the air intake hose for cracks, nicks,
cuts, etc., and check the hose clamps for tight­
ness.
3.
Check to make sure the air filter restriction
gauge is in place and hose connections are
secure.
Battery
NOTE: For initial battery service during setup, re­fer
to Battery Service in Assembly Instructions.
IMPORTANT: Make sure battery is securely mount­
ed in the frame. A loose battery may cause damage
to the case resulting in acid leakage and severe dam­
age to the machine. A hazard may be created by
damage to critical working parts and safety systems.
●● Never “jump start” the engine using another source. Electricity fluctuations can
damage the ECU (Electronic Control Unit).
●● Always disconnect negative (-) battery
cable lead before charging battery, and
also unplug harness from ECU before performing any welding on equipment.
Electrolyte Level
The battery electrolyte level should be checked af­
ter every 25 hours of operation. To check electro­
lyte level:
1.
Remove battery cell filler caps.
2.
Check the electrolyte level. If the level is below
the bottom of the vent well, fill with distilled wa­
ter to the bottom of the vent wells [1/4 to 1/2 in.
(6 to 13 mm) above the plates].
3.
Replace filler caps.
IMPORTANT: DO NOT overfill the battery. Electro­
lyte 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 corro­
sion with a solution of one part baking soda and
four parts water. Rinse with clean water. Coat the
terminals with petroleum jelly or terminal protector
spray to retard further corrosion.
64
Maintenance Instructions
CHECKING/SERVICING
Sharpen Mower Blades
Charging the Battery
DANGER
BATTERIES PRODUCE EXPLOSIVE GASES
●● Charge the battery in a well-ventilated
area, so that gases produced while charg­
ing can dissipate.
●● Keep sparks, flames, and smoking ma­
terials away from the battery at all times.
●● Make sure the battery cap vents are open
(check manifold vent on each cap).
●● Make sure the battery charger is un­
plugged before connecting or disconnecting cables to the battery.
Check the battery charge by measuring the specific
gravity of electrolyte; if specific gravity is less than
1.225, the battery will need to be charged as follows:
Check mower blade(s) for straightness, sharp­
ness, condition of the cutting edge, and balance
every 10 hours of operation (or more often when
mowing abrasive type grass or operating on sandy
soils). Replace blades if worn, bent, cracked, or
otherwise damaged (refer to REPLACING/RE­
PAIRING the Mower Blades in this section). Use
the following procedure to check and sharpen
blades:
NOTE: Keep blades sharp - cutting with dull blades
not only yields a poor mowing job but slows the
cutting speed of the mower and causes extra wear
on the engine and blade drive by pulling hard.
1.
Stop the engine, remove ignition key, and dis­
connect the spark plug wires before raising the
mower deck to service blades.
2.
Raise the deck and secure it in the TILT-UP
po­sition. Refer to CLEANING the Grass Buildup in Mower Deck Housing in this section for
deck rais­ing instructions.
IMPORTANT: Always disconnect the negative (-)
battery terminal before charging. Failure to do so
can result in damage to the ECU.
1.
Charge the battery at 15 amps for 10 minutes.
DO NOT exceed 20 amps maximum recom­
mended charging rate. Charge until specific
gravity is at least 1.250. Total charging time
should not exceed one (1) hour.
2.
After charging the battery, use distilled 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].
Tire Pressure
Inflate tires to pressures shown below:
Deck Caster Wheel* = 20 PSI (137 kPa)
Drive = 15 PSI (103 kPa)
Tailwheel = 20 PSI (137 kPa)
* If equipped with optional pneumatic tires
Wheel Bolt Torque
Check the eight (8) lug bolts that mount the drive
tires. Every 100 hours they should be torqued to
75 to 85 lb·ft (102 to 115 N·m).
DANGER
NEVER operate cutter blades with the
deck in the raised position.
NOTE: PTO shaft must be disconnected be­
fore checking blades for straightness.
3.
Check the blades for straightness by marking
the blade tip position inside the deck housing,
and then rotating the opposite end of the blade
to the same position and comparing. If the dif­
ference in blade tip track is more than 1/8 in.
(3 mm), the blade is bent and should be
re­placed.
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.
65
Maintenance Instructions
CHECKING/SERVICING
4.
If the blade cutting edge is dull or nicked, it
should be sharpened. Remove blades for
sharpening by grasping the end of the blade using a rag or a thick, padded glove, while loosening and removing the nut, lock washer, and flat
washer that mounts the blade.
5.
Grind cutting edge at the same bevel as the
original. Sharpen only the top of the cutting
edge to maintain sharpness.
Blade Balancer
NOTE: Blades can be sharpened with an
electric blade sharpener, conventional electric
grinder, or a hand file.
Blade Balanced on Magnetic
Wall-Mounted Balancer
CAUTION
ALWAYS wear eye protection and gloves
when sharpening a blade.
Sharpen at
Original 30° Angle
Intersection
Wear Area
30°
Wing
Tip
Do Not Grind or
Sharpen on Underside
Mower Blade Profile for Sharpening
6.
66
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.
7.
Mount the blade with wing tips pointing up into
the housing. For gear driven decks reinstall
the blade, washer, lock washer, and nut. Tighten the nut to 60 lb·ft (81 N·m). For belt driven
decks reinstall the spacer (if applicable), blade,
washer, and bolt. Tighten the bolt to 70 lb·ft
(95 N·m).
NOTE: When reinstalling blades on GHS models, remember, the blades counter-rotate and
the LH and RH blades must not be switched.
Check for proper blade rotation before installing
blades on the deck. Refer to Blade Rotation
illustrations shown in Clogging Checklist in
Operating Instructions for correct blade rotation.
Drive Belts
Raise the body and inspect the condition of the
four (4) belts 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.
Maintenance Instructions
CHECKING/SERVICING
Mower Deck Gearbox Oil Seals
Transmission Control Setting
The mower deck gearbox seals should be inspected
every 25 hours for evidence of oil leaking; particularly the lower oil seal on the blade drive gearbox. This seal is protected by the trash guard on the
blade hub and seal protector plate on the housing,
but is still vulnerable to seal damage due to operating in an adverse environment. The mower blade
must be removed for inspection of the seal, so it is
recommended to inspect the gearbox seals when
blades are removed for sharpening. If an oil leak
is noted, the seal should be replaced and the gearbox assembly relubricated. Refer to LUBRICATION
for Mower Deck Gearbox Lubrication in this section.
On a yearly interval or when an out-of-adjustment
condition is observed, check the transmission control for proper function as follows:
Spark Plugs
Straight Ground Tracking
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. (0.76 mm).
Reinstall and tighten to between 18 and 22 lb·ft
(24 to 30 N·m).
Check for straight ground track by driving on a
smooth, level surface with hands off the steering levers. Set the FSC at different speeds and observe
if the mower moves in a straight line (use a cement
joint or other line on the ground for reference). If the
machine is drifting to the right or left, refer to
ADJUSTMENTS for Straight Ground Travel Adjustment - Step 4 in this section.
Ignition Wires
Good preventive maintenance calls for complete replacement of spark plug wires every two (2) years.
Neutral-Park
With the mower parked on level ground, start and
run the engine, first at idle and then normal operating speeds. With the FSC in the NEUTRAL-PARK
position, there should be no movement of either
drive tire. If the tire(s) are “creeping” forward or reverse, refer to ADJUSTMENTS for the Neutral
Function Adjustment - Step 3 in this section.
Blade Brake Action
WARNING
It is important to check and maintain blade
brake action for safe operation of the machine.
Fuel Lines and Clamps
NOTE: The engine fuel injection system is pressurized and should be serviced by a Walker dealer or
authorized Kohler engine service outlet.
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 replacement of fuel lines and clamps every two (2) years.
Engine Starter
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.
Check the function of the cutter blade brake and
blower brake by engaging the blade clutch (PTO),
operating the engine at full throttle, then disengaging the clutch and measuring how quickly the blades
stop. Watch the rotation of the blade drive shaft and
blower pulley as a visual indication that movement
has stopped. If the brake is working properly, all
rotation will stop five (5) seconds after disengagement of the clutch. If the brake system malfunctions - blades do not stop in five (5) seconds adjust or repair the brake before operating the
mower. Contact your Walker dealer for this service
or refer to ADJUSTMENTS for Clutch Disengagement/Brake Action, Step 3 - Blade Brake Band Adjustment on page 80.
67
Maintenance Instructions
CHECKING/SERVICING
PTO U-Joints
Forward Speed Control Friction Lock
The PTO U-joints should be inspected yearly for
looseness and wear. If either is noticed, the respective shaft or tube should be replaced. A worn U-joint
can cause vibration and extensive damage to the
PTO and the whole machine.
The FSC friction lock is designed to hold the selected forward travel speed when the steering levers are moved and yet the friction is not too heavy
to make moving the FSC control difficult (too much
friction). The procedure for checking the FSC friction lock is as follows:
Safety Switch System
1.
With the engine off, place the FSC in the full
FORWARD position and pull both steering levers back; the FSC lever should not move. If
the FSC lever moves back when the steering
levers are pulled back, the friction needs to be
increased.
2.
With the steering levers held back, move the
FSC lever back from the FORWARD position.
With a proper amount of friction adjusted, the
FSC lever should move back with a slight
amount of resistance (friction). If the FSC lever
movement is “stiff”, the friction needs to be
decreased.
WARNING
It is important to check and maintain the
safety switch system for safe operation of
the machine.
There are three (3) safety interlock switches on the
tractor; Seat Switch, FSC Neutral-Park Switch, and
PTO Switch.
NOTE: There is a 1/2 second time delay function on
the seat switch to avoid engine power interruption
when driving over bumps.
If any of the following conditions occur during starting or operating, a safety interlock switch may be
malfunctioning. Contact your Walker dealer for troubleshooting and/or replacement.
●● With or without an operator in the seat, the engine
starts with the Forward Speed Control (FSC) and/or
the PTO engaged.
●● With an operator in the seat, the engine starts but
dies soon after the Forward Speed Control (FSC) or
PTO is engaged.
●● Without an operator in the seat, the engine starts
and continues to run with the Forward Speed Control
(FSC) and/or PTO engaged.
●● With an operator in the seat, the Forward Speed
Control (FSC) and PTO disengaged and the oil
pressure warning horn sounding, but the starter will
not engage.
68
If the FSC friction lock needs to be adjusted, contact
your Walker dealer or refer to ADJUSTMENTS for
Forward Speed Control Friction Lock in this section.
Maintenance Instructions
REPLACING/REPAIRING
REPLACING/REPAIRING
Drive Belts
There are four (4) individual belts on GHS models:
DANGER
●● Engine PTO Drive Belt (3 Groove Power Band)
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.
IMPORTANT: ALWAYS use genuine factory replacement parts. Substitute parts CAN result in
product malfunction and possible injury to the operator and/or others.
●● Jackshaft Drive Belt
●● GHS Blower Drive Belt
●● Hydrostatic Ground Drive Belt
The belts may be removed and replaced using the
procedures described on the following pages.
Jackshaft
Drive Belt
Engine PTO
Belt
GHS Blower Belt
Hydrostatic Ground
Drive Belt
Belt Locations
69
Maintenance Instructions
REPLACING/REPAIRING
Engine PTO Drive Belt (3 Groove Power Band)
1.
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.
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.
Install the PTO drive belt by reversing the removal procedure.
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.
c.
3.
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).
Refer to ADJUSTMENTS of Blade Clutch
(PTO) in this section to check and make the following adjustments:
a.
Clutch engagement for proper belt tension
b.
Clutch disengagement and brake action
PTO Belt Tightener
Stop Block
Pull UP to Engage
Clutch
Linkage
PTO Belt
Tightener Arm
Belt
Guide
Engine
PTO Belt
Engine
Pulley
Blade Clutch Lever
in the DOWN Position
Belt
Guide
Belt Guides
(Bottom Guide Not Visible)
Clutch Idler
Pulley
PTO Drive
Pulley
Brake Band
Mount Bracket
Engine PTO Drive Belt Removal
70
Micro-V Pulley
(GHS Blower Drive)
Maintenance Instructions
REPLACING/REPAIRING
Jackshaft Drive Belt
1.
To remove the jackshaft drive belt:
a.
Remove the engine PTO drive belt, as
described in previous section.
b.
Relax the belt by depressing the springloaded idler arm.
c.
Roll the belt off the jackshaft pulley and
remove.
Push Idler Pulley Down to Relax Belt
Idler Pulley
Jackshaft
Drive Belt
Engine
Pulley
Tension Spring
Jackshaft
Jackshaft Drive Belt (Disengaged)
2.
Reverse the removal procedure to replace the
jackshaft drive belt.
Idler Arm
Jackshaft
Drive Belt
Engine
Pulley
Tension Spring
Jackshaft
Jackshaft Drive Belt (Engaged)
71
Maintenance Instructions
REPLACING/REPAIRING
GHS Blower Drive Belt
1.
Remove the GHS blower drive belt tension by
depressing the idler pulley on the tightener arm.
Roll the belt off the blower pulley.
Blower Drive
Pulley
GHS Blower
Drive Belt
Blower
Pulley
Depress Idler Pulley
Down to Relax Belt
Belt Tightener
Idler Pulley
(Disengaged)
GHS Blower Drive Belt Assembly (Disengaged)
2.
Reverse the procedure to install the GHS blower
drive belt.
Belt Tightener
Idler Pulley
(Engaged)
GHS Blower Drive Belt Assembly (Engaged)
72
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)
73
Maintenance Instructions
Fuel Filter
REPLACING/REPAIRING
3.
DANGER
Gasoline is extremely flammable and can
be highly explosive. To minimize danger:
●● Before servicing the fuel system:
1) Disconnect the spark plug leads.
2) Disconnect the negative (-) battery cable from battery.
●● Use only an approved fuel container
for gasoline.
●● 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.
Model C19i is equipped with an in-line fuel filter between the fuel tank and the fuel pump (low pressure
fuel pump). Visually inspect the filter periodically,
and replace the filter yearly.
Verify that the fuel lines and clamps are securely attached, and that no fuel leaks are present.
Blade Overload Shear Bolts
NOTE: Blade shear bolts are not used on belt driven decks.
On gear driven decks, each 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.
Cutting Blade
Shear Bolts
Cutting Blade Shear Bolts
NOTE: Tightening the 5/8-18 blade mounting nut
to 60 lb·ft (81 N·m) is also important for proper
shock load protection. It is important to not overtighten the mounting nut since this defeats (overrides) the function of the shear bolts.
In-Line
Fuel Filter
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.
74
1.
Expand and slide clamps on either side of the
filter away from filter and pull fuel lines off filter.
2.
Replace filter, making sure that the arrow on the
filter is aligned with the fuel flow through the
filter.
If these bolts shear, remove the blade and install
new bolts. Refer to CHECKING/SERVICING in
this section for Sharpen Mower Blades which describes the blade removal and installation procedure.
After reinstalling the blade, check blade timing (on
gear driven decks) by moving blades through one
(1) complete revolution. Make sure blade tips
pass clear of each other. If timing is incorrect, contact your Walker dealer.
Maintenance Instructions
Mower Blades
Mower blades are removed and remounted as described in Sharpen Mower Blades instructions (refer to CHECKING/SERVICING in this section). During the course of sharpening and inspecting mower
blades, if there are any of the following conditions
of wear or damage, blades should be replaced
for reasons of safety and performance of the machine:
●● An excessive amount of the flat section of the
blade has been ground away (removed) when the
blade is sharpened. Replace the blade when less
than a 3/4 in. (19 mm) flat section remains at the
blade tip.
●● Examine ends of the blade carefully, especially
the intersection where the flat section of the blade
turns up to form the “wing tip” (refer to CHECKING/
SERVICING for Mower Blade Profile for Sharpening illustration in Sharpen Mower Blades instructions). Since sand and abrasive material can
wear metal away in this area, the blade should be
replaced when metal thickness has worn to
1/16 in. (1.6 mm) or less.
REPLACING/REPAIRING
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.
Reinstall the blades following procedure from
Sharpen Mower Blades instructions in CHECKING/SERVICING in this section. If blades are replaced, always use Walker original equipment
blades to ensure safety and optimum performance.
The quality and performance of replacement
blades offered by other manufacturers cannot be
guaranteed, they could be dangerous.
CAUTION
ALWAYS use genuine factory replacement parts. Substitute parts CAN result
in product malfunction and possible injury to the operator.
DANGER
When blades are operated over sandy
soil, and if blades are allowed to wear, a
“slot” may be worn into the wing tip of
blade. Eventually a piece of the blade
may break off creating a serious potential
for injury or damage.
●● Check the blades for straightness by marking
blade tip position inside the deck housing and then
rotating the opposite end of the blade to the same
position and comparing. If the difference in blade tip
track is more than 1/8 in. (3 mm), the blade is bent
and should be replaced.
●● Inspect the blade surface, especially in formed
areas, for cracks. Replace the blade if any cracks
are found.
75
Maintenance Instructions
ADJUSTMENTS
ADJUSTMENTS
Set FSC Travel Limits (Stop) - Step 1
Transmission Control
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.
The following instructions reflect the most current
transmission linkage configuration with a spring/
dampener connected to the steering lever (starting
S/N 11-109716) and the FSC using direct linkage
instead of a sliding fork disconnect (starting S/N 15134121). Earlier units will need to use the transmission control adjustment instructions from the P/N
9000-30 Service Manual.
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.
Steering Lever
Actuator Arms
Forward Travel
Stop Bolt
IMPORTANT: The following adjustment procedures
are sequential. Check and adjust each function in
the order given.
Forward Speed Control Stop and
Steering Lever Adjustment
3.
76
Steering
Adjustment Nut
Tighten the jam nut on the forward travel stop
adjusting bolt.
Maintenance Instructions
ADJUSTMENTS
Set Maximum Forward Travel Speed (Stop) - Step 2
1.
Position the FSC lever to the most FORWARD
position.
2.
Turn the steering lever adjustment nut(s) until
2 or 3 threads are showing past the end of the
nut.
3.
Loosen the jam nut at the other end of the control rod (where it connects to the transmission
control arm).
4.
For each steering lever, use a wrench on the adjustment nut, turn the control rod counterclockwise (CCW) until the steering lever begins to
move backward, then make two additional
turns. Next, reverse and turn the control rod
clockwise (CW) until the steering lever stops
moving forward and then make one additional turn. Tighten the jam nut.
NOTE: Failure to make at least one extra turn
on the control rod can place excessive loads on
the transmission internal control stops and
cause internal wear and damage to the transmission. Making additional turns beyond one
turn reduces the maximum forward travel speed.
Control
Rod
Adjustment Nut
(2 or 3 Threads
Showing)
Jam Nut
Transmission
Control Arm
Adjustment Components
Neutral Function Adjustment - Step 3
1.
Securely block the tractor up so the drive tires
are off the ground.
2.
Move the FSC lever to the NEUTRAL-PARK
position (rear travel limit).
3.
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 the operation of the neutral safety switch.
CAUTION
NEVER attempt to disconnect any safety
devices or defeat the purpose of these
safety devices.
Transmission
Control Arm
Jam Nut
Adjustment
Nut
Control
Rod
Transmission Control Rod and Arm Location
(Front Body Hidden for Clarity)
77
Maintenance Instructions
ADJUSTMENTS
Straight Ground Travel Adjustment - Step 4
FSC Actuator
Rod
Adjustment
Nut
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.
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).
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.
Neutral Function Adjustment
4.
5.
6.
78
If drive wheels are moving, adjust the FSC
neutral stop by adjusting the FSC actuator rod
(see Neutral Function Adjustment photo). If
the drive wheels are moving backward, loosen
the jam nut and lengthen the FSC actuator rod
by turning the adjustment nut counterclockwise
(CCW). If the drive wheels are moving forward,
use the opposite clockwise (CW) adjustment.
At this point it may not be possible to adjust
both wheels stationary since the differential adjust 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.
Check the neutral safety switch for closure
and function with the FSC in neutral (the engine
will not start when the switch is open).
End Wrench on
Adjustment Nut
Straight Ground Travel Adjustment
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 to 3/8 in.
(6.35 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
PTO Belt
Tightener Arm
Locknut
1/4 to 3/8 in.
(6.35 to 9.53 mm)
Spring
Compressed
Blade Clutch
Lever Engaged
PTO Clutch Engaged
79
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
80
Maintenance Instructions
Use the following procedure to check and adjust
clutch disengagement and brake action:
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 to 11/16 in.
(8 to 17 mm).
11/16 in.
(17 mm)
ADJUSTMENTS
Clutch Idler Pulley Travel Adjustment - Step 2
Adjust the stop block to give 1 to 1-1/2 in. (25 to
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.
NOTE: The importance of this adjustment is if the
pulley travel is excessive and the belt develops too
much slack, the belt will derail when disengaged.
Stop
Block
5/16 in.
(8 mm)
Pulley
Travel
Disengage
9/16 in.
(14 mm)
Stop Block
Contacting Frame
7/16 in.
(11 mm)
Engage
1 to 1-1/2 in.
(25 to 38 mm)
Clutch Idler Pulley Travel Adjustment
PTO Belt Tightener Stop Block Adjustments
81
Maintenance Instructions
ADJUSTMENTS
Blade Brake Band Adjustment - Step 3
After the pulley travel is set, make the following adjustment as needed:
1.
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.
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).
Blade Brake Band
Adjustment Nut
8-1/4 in.
(209 mm)
Locknuts
Brake Actuator
Rod
Bottom
Clevis
Blade Brake Band Adjustment
Brake Actuator Rod Adjustment
Blade Clutch
Idler Pulley
1/8 in.
(3 mm)
Stop Block
PTO Belt Tightener
Chassis
Blade Brake Band Adjustment
82
2.
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.
Maintenance Instructions
Forward Speed Control Friction Lock
The FSC friction lock is adjusted to hold the selected forward speed when the steering levers are
moved. The friction should not be so heavy as to
make moving the FSC difficult (too much friction).
The procedure for checking and adjusting the FSC
friction lock is as follows:
FSC
Actuator
ADJUSTMENTS
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.
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.
Forward Speed Control Position
(Checking Friction Lock)
83
Maintenance Instructions
ADJUSTMENTS
Steering Handles
Tilt-Up Deck Adjustable Stop
An adjustment range of approximately 3 in (76
mm) is available on the steering handles - the handles can be adjusted forward or aft depending on the
arm length of the operator. The handles can be adjusted by loosening the locknut at the pivot point and
the locknut holding the handle in position in the adjustment slide. Adjust handles into the most comfortable position and tighten both locknuts.
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 (4) hitch pins used for height adjustment should
sit flush on the washers above the deck pin bushing.
On a level surface, if any pin is sticking up (likely the
front pins), tighten the opposite side or loosen the
same side to lower the pin. Adjustments are made
by loosening the jam nut and tightening or loosening
the set screws on the Deck Mount Pivot Brackets.
Retighten the jam nut when the adjustment is complete.
Adjustment
Slide
Locknut
(Position)
Jam Nut
Set Screw
Locknut
(Pivot Point)
Tilt-Up Deck Adjustable Stop
Steering Handles Adjustment
84
Maintenance Instructions
ADJUSTMENTS
GHS “Full” Signal Horn Adjustment
Exhaust
Screen
The vertical position of the Grass-Pak® switch is
critical to make sure the catcher box does not overfill causing the delivery chute to clog. The vertical
position can be adjusted by moving the aluminum
shaft and vane on the Grass-Pak® switch.
1.
Position the discharge chute so that it is pointing straight back.
a.
Turn the ignition switch ON (RUN) and
move the blade clutch to the ENGAGED
position (engine not running).
b.
Open the catcher back door and monitor
the spout position (as it oscillates) and
move the blade clutch to the DISENGAGED
position and turn the ignition switch to the
OFF position.
DANGER
PINCH POINT - SPRING LOADED DOOR
When lowering the door on the GHS
catcher, BE VERY CAREFUL to keep
hands, fingers, etc. out of the hinging
mechanism and away from the door frame
as the door closes. The springs that hold
the door closed during operation are very
powerful, and the door can slam shut with
considerable force.
WARNING
DO NOT test the Grass-Pak® switch with
the engine running. Projectiles CAN be
thrown out of the grass delivery spout
and CAN cause serious injury to bystanders or property damage.
2.
4 to 4-1/2 in.
(10 to 11.5 cm)
Adjustment Nut
Adjusting the Grass-Pak® Switch
(Side View of Catcher Box)
3.
If adjustment is required, loosen front adjustment nut then move aluminum shaft and vane
to the recommended measurement. Adjustments should be done in very small increments
checking the measurement each time until the
recommended measurement is achieved.
NOTE: It will not be possible to adjust the switch
to give a signal at the precise instant the catcher
is full for a wide variety of mowing conditions.
For example, wet heavy grass will fill the catcher
differently than dry fluffy grass, causing the signal to come on a little sooner or later than usual.
Primarily, the switch should be adjusted to give
the “full” signal with a little advance warning
before overfilling and clogging of the grass
delivery chute begins (regardless of mowing
conditions).
Measure from the exhaust screen (top of catcher) to the top of the Grass-Pak® switch actuator
vane, refer to Adjusting the Grass-Pak®
Switch illustration. The proper measurement
should be between 4 and 4-1/2 inches (10 and
11.5 cm).
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
Battery
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.
* Extended warranties are offered for the following powertrain components:
• A three (3) year unlimited hour warranty is offered for the Walker P/N 6200-9 Gear Axle Assembly.
• A three (3) year or 3000 hour (whichever comes first) warranty is offered for Eaton Model 7 Hydrostatic transmissions;
covers full cost of replacement up to 1000 hours of use, and after 1000 hours warranty coverage is prorated against
3000 hours.
2.
3.
WHAT THIS WARRANTY DOES NOT COVER:
A.
This warranty does not cover defects caused by depreciation or damage caused by normal wear, accidents, improper
maintenance, improper use or abuse of the product, alterations, or failure to follow the instructions contained in the
Operator’s Manual for operation and maintenance.
B.
The customer shall pay any charges for making service calls and/or for transporting the mower to and from the place
where the inspection and/or warranty work is performed.
HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:
Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Walker 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
WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, CO 80528 • (970) 221-5614
FORM NO. 010518
PRINTED IN USA
www.walkermowers.com
©2017 WALKER MFG. CO