Walker B19 Operator's Manual

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Walker B19 Operator's Manual | Manualzz
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: 155209
P/N 4000-25
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 custom­
ers. 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 any­
thing 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 B19 with the Kohler Command CH620 (19 HP) gasoline engine.
All shields and guards must be in place for the proper and safe operation of this machine.
Where they are shown removed in this manual, it is for illustration purposes only. Do not operate
this machine unless all shields and guards are in place.
Specifications given are based on the latest information available at the time this manual was pro­
duced 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 obliga­
tion relative to previously manufactured products.
Sincerely,
WALKER MANUFACTURING COMPANY
Bob Walker, President
Table of Contents
General Information_________________ 1
Operating Instructions______________ 25
HIGHLIGHTED INFORMATION______________
GLOSSARY_____________________________
IDENTIFYING NUMBER LOCATIONS_________
ENGINE SERIAL NUMBER LOCATION________
SERVICING OF ENGINE AND
DRIVETRAIN COMPONENTS_______________
CONTROL IDENTIFICATION,
LOCATION, AND FUNCTION ______________
Engine Choke_________________________
Engine Throttle________________________
Forward Speed Control (FSC)____________
Steering Levers_______________________
Blade Clutch (PTO)_____________________
Body Latch___________________________
Parking Brake_________________________
Transaxle Lockout Arms________________
Hourmeter____________________________
Ignition Switch________________________
Circuit Breakers_______________________
STARTING THE ENGINE__________________
ADJUSTING GROUND
SPEED AND STEERING___________________
ENGAGING THE BLADE DRIVE____________
STOPPING THE MACHINE________________
ADJUSTING CUTTING HEIGHT_____________
TRANSAXLE LOCKOUT__________________
RECOMMENDATIONS FOR MOWING_______
RECOMMENDATIONS FOR TILT-UP DECK
OPERATION/TRANSPORT________________
1
1
1
2
2
Specifications_________________________ 3
ENGINE________________________________ 3
ELECTRICAL SYSTEM___________________ 3
TRANSMISSION_________________________ 3
BLADE DRIVE___________________________ 4
TIRE SIZE_______________________________ 4
TIRE PRESSURE ________________________ 4
MOWER DECK __________________________ 4
DIMENSIONS (Tractor and Mower)__________ 5
DRIVE BELTS___________________________ 5
SEAT___________________________________ 5
FRAME/BODY CONSTRUCTION___________ 5
Component Identification____________ 6
Safety Instructions___________________ 9
BEFORE OPERATING_____________________ 9
OPERATING____________________________ 11
MAINTENANCE_________________________ 13
SAFETY, CONTROL,
AND INSTRUCTION DECALS______________ 14
Assembly Instructions_______________ 17
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 Deflector
Shield Installation_____________________
PTO Shaft Guard Installation____________
Tilt-Up Roller Wheel Installation__________
Mower Deck Installation on Tractor________
Deck Installation ______________________
Deck Leveling________________________
PREOPERATING CHECKLIST______________
17
17
17
17
17
18
18
18
18
19
19
19
20
20
22
23
25
25
26
26
26
26
26
28
28
29
29
29
30
30
32
33
34
35
36
37
Maintenance Instructions___________ 38
MAINTENANCE SCHEDULE CHART________
IMPORTANT TIPS FOR CARE
OF THE KOHLER ENGINE_________________
Fuel System__________________________
Starting/Stopping______________________
Cooling System_______________________
Air Cleaner System_____________________
Oil__________________________________
LUBRICATION__________________________
Engine Oil ____________________________
Engine Break-In Oil____________________
Checking Engine Crankcase Oil Level_____
Changing Engine Crankcase Oil/Oil Filter___
Grease Fitting and Oil Point Lubrication ___
Mower Deck Gearbox Lubrication_________
Mower Deck Spindle Lubrication_________
DS52 Mower Deck Lubrication___________
Check Transaxle Fluid Level_____________
Transaxle Oil and Filter Change__________
38
39
39
39
39
39
39
40
40
40
40
41
42
43
43
46
46
46
Table of Contents
CLEANING_____________________________
Engine Air Cooling System______________
Cooling Air Intake Screen_______________
Cylinder Head Cooling Fins_____________
Engine Air Cleaner System______________
Cummins/Fleetguard OptiAir™
Air Cleaner__________________________
Grass Buildup in Mower Deck Housing____
Transaxle Housing_____________________
CHECKING/SERVICING___________________
Security of Air Filtration Components_____
Battery_______________________________
Electrolyte Level______________________
Cleaning the Terminals_________________
Charging the Battery___________________
Tire Pressure__________________________
Wheel Nut Torque______________________
Sharpen Mower Blades_________________
Drive Belts____________________________
Mower Deck Gearbox Oil Seals___________
Spark Plugs___________________________
Ignition Wires_________________________
Fuel Lines and Clamps__________________
Blade Brake Action_____________________
PTO U-Joints _________________________
Engine Starter_________________________
Safety Switch System__________________
Forward Speed Control Friction Lock______
Transmission Control Setting____________
Neutral-Park_________________________
Straight Ground Tracking_______________
47
47
47
48
49
49
51
52
53
53
53
53
53
53
54
54
54
55
55
55
55
55
55
56
56
56
56
56
56
56
REPLACING/REPAIRING__________________
Drive Belts____________________________
Engine/PTO Belt______________________
Ground Drive Belt_____________________
Fuel Filter____________________________
Blade Overload Shear Bolts_____________
Mower Blades_________________________
ADJUSTMENTS_________________________
Transmission Control__________________
Steering Lever Position Adjustment_______
Steering Handles Adjustment____________
Neutral Function Adjustment_____________
Full Forward Speed Adjustment__________
Straight Tracking Adjustment____________
FSC Neutral Switch Adjustment__________
Forward Speed Control
Friction Adjustment____________________
Blade Clutch (PTO)_____________________
Clutch Engagement/Belt Tension_________
Clutch Disengagement/Brake Action______
Idler Pulley Maximum Travel Adjustment___
Blade Brake Band Adjustment___________
Tilt-Up Deck Adjustable Stop_____________
57
57
58
59
60
60
61
62
62
62
63
63
64
65
65
66
67
67
68
68
69
69
MAINTENANCE AND SERVICE
RECORD SHEET________________________ 70
Warranty____________________________ 71
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 sev­
eral general practices to be aware of in the area of
safety. Most accidents associated with the opera­
tion 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 high­
lighted 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 compo­
nents, and cutter blades.
●● TRACTOR is the prime mover, including the
engine, drivetrain, operator seat, and controls
to operate the mower.
●● TRANSAXLE transmits and controls power
from the ground drive belt to the main drive
wheel.
●● TRANSAXLE LOCKOUT ARMS release the
transaxles to permit freewheeling the tractor.
IDENTIFYING NUMBER LOCATIONS
The tractor serial number plate is affixed to the trac­
tor 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 num­
bers 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.
_______________________
●● FORWARD SPEED CONTROL (FSC) controls
the maximum forward speed of the tractor;
functioning as a cruise control.
Engine Model No. _______________________
●● GROUND DRIVE refers to the dual transaxles
which drive the main wheels.
Date of Purchase _______________________
●● 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.
Engine Serial No. _______________________
Fill In By Purchaser
Serial Number
●● RIGHT HAND (RH) refers to the right-hand side
of the tractor when the operator is seated facing
forward in the tractor seat.
●● SIDE DISCHARGE (SD) discharges mowed
material from the right side of the mower deck.
●● STEERING LEVERS steer the tractor by con­
trolling the two transaxles.
Tractor Serial Number Location
1
General Information
SERVICING OF ENGINE AND DRIVETRAIN
COMPONENTS
Serial Number
Mower Deck Serial Number Location
ENGINE SERIAL NUMBER LOCATION
Refer to the engine manual that accompanies this
manual or photo below for the location of the engine
serial number.
The detailed servicing and repair of the engine,
transaxles, and gearboxes are not covered in this
manual. Only routine maintenance and general ser­
vice instructions are provided. For the service of
these components during the limited warranty
period, it is important to find a local, authorized ser­
vicing 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.walker.com
Service manuals are available for each of these
components from their respective manufacturers as
follows:
Serial Number
Engine Serial Number Location
2
Kohler Engines
Kohler Company
Kohler, WI 53044
800-544-2444
www.kohlerengines.com
Transaxles
Hydro-Gear
1411 South Hamilton St.
Sullivan, IL 61951
877-728-7410
www.hydro-gear.com
Gearboxes (Deck)
Peerless Gear
1555 South Jackson St.
Salem, IN 47167 USA
866-536-8310
www.peerlessgear.com
Specifications
MODEL
B19
ENGINE
Manufacturer/Model
Kohler Command CH620, V-Twin, 2 Cyl., Gasoline (Air-Cooled)
Displacement cu. in. (cc)
41.1 (674)
Max. Power HP (kW)
19 (14.2) @ 3600 RPM
Governed RPM
3600
Max. Torque lb·ft (N·m)
35 (47.5)
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 12-050-01
Cooling System
Air-Cooled
Fuel Tank Capacity gal (L)
4.0 (15.1)
Fuel
Automotive Grade Unleaded Gasoline
(87 Octane Minimum, 10% Ethanol Maximum)
Air Cleaner
Remote Mounted Cummins/Fleetguard OptiAirTM
(Walker P/N 2090-1 Primary/2090-3 Safety Filter)
ELECTRICAL SYSTEM
Battery
12 Volt, 300 CCA
Charging System
Flywheel Alternator
Charging Output
15 Amp DC (Regulated)
System Polarity
Negative Ground
Ignition
Electronic Capacitive Discharge
Starter
12 Volt Electric, Key Operated, Solenoid Shift
Interlock Switches
Ignition Lockout by Seat Switch, Transmission Neutral,
Blade Clutch, and Parking Brake
Circuit Breaker(s)
Manual Reset (5A)
Auto Reset (30A)
TRANSMISSION
Manufacturer/Model
Dual, Independent Hydro-Gear® ZT3100 Integrated Transaxles
Steering
Hand Lever Control / Individual Wheel
Forward Speed Control
Precision Friction Lock Lever, Cruise Control, with
Neutral-Park Position
Service Brake
Dynamic Braking through Transaxles
3
Specifications
MODEL
B19
TRANSMISSION (continued)
Parking Brake
Internal Mechanical Cog Lock for each Transaxle
(Single Lever Control)
Neutral
Transmission Release by Manual Dump Valve
Final Drive
Transaxle Direct to Drive Wheel
Transmission Fluid
Factory Service
20W-50 Multi-Viscosity Motor Oil (Minimum SL Grade Oil)
Transmission Oil Capacity fl oz (L)
77 (2.3)
Transmission Cooling
Cooling Fan Mounted on Drive Pulley
Oil Filter
Hydro-Gear® P/N 52114 (Walker P/N 2026-6)
Ground Travel Speed
Forward MPH (km/h)
Reverse MPH (km/h)
0-8 (0-13) 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 Wheel
Drive
Tailwheel
8 x 3.00-4 Semi-Pneumatic (Standard)
8 x 3.00-4 Pneumatic 4-Ply (Optional)
11 x 4.00-5 (Pneumatic 6-Ply, DS52 Only)
18 x 8.50-10 (Pneumatic 4-Ply, Low-Profile)
18 x 7.00-8 (Pneumatic 4-Ply, Optional)
11 x 4.00-5 (Pneumatic 6-Ply)
TIRE PRESSURE PSI (KPA)
Deck Caster Wheel*
20 (137)
Drive
15 (103)
Tailwheel
20 (137)
* If equipped with optional pneumatic tires
MOWER DECK
4
Recommended Cut Width
Side Discharge
36 to 52 in. (91 to 132 cm)
Mulch
36 to 48 in. (91 to 122 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 Belt Driven Deck Only)
Deck Suspension
Independent Torsion-Flex Frame with Caster Wheels and
Counterweight Springs
Specifications
MODEL
B19
DIMENSIONS (Tractor and Mower)
Length in. (cm)
Tractor Only
63 (160)
Tractor Wheel Base
40 (102)
Tractor with Tilted Deck
(Approximate)
72 (183)
Tractor with 48" Mulch Deck
(DM48-2)
90.75 (230)
Width in. (cm)
Tractor Only (Outside Tire)
38.5 (98)
Tractor with 48" Mulch Deck
(DM48-2)
49 (125)
Height in. (cm)
Tractor
39.5 (100)
Weight lb (kg)
Tractor Only
583 (264)
Tractor with 48" Mulch Deck
(DM48-2)
789 (358)
DRIVE BELTS
Engine PTO
Walker P/N 4230-1 (Matched Pair)
Ground Drive
Walker P/N 4230-2
SEAT
Contour-Molded, with Nylon Backed Vinyl Cover and Integral
Foam Cushion
FRAME/BODY CONSTRUCTION
Frame
All Welded Unitized Steel Chassis
Body
14 Gauge Steel
Deck
11 Gauge Steel
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.
Forward Speed
Control (FSC)
Friction
Adjustment
Body Lift
Handle
Tilt-Up Latch
Counterweight Springs and
Protective Covers
Negative (-)
Battery Cable
Deck Support
Arm
Deck Support
Pins and Height
Adjustment
Hitch Pins
Tilt-Up
Deck Handle
Positive (+)
Battery Cable
Body Tilt-Up Latch
(Not Visible)
Deck Support
Arm
Deck Lift Handle
(Cutting Height Adjustment)
Footrests
Footrests
Front View and Right Side View
6
Tilt-Up
Hook
Deck
Caster Wheels
Component Identification
Fuel Pickup
Line
Fuel Gauge
Oil Dipstick /
Oil Fill
Muffler
Tailpipe
Footrests
Left Hand
Drive Wheel
Muffler Heat
Shield
Fuel Tank
and Cap
Cylinder Head
Cooling Fins
Spread Axle
(Tail Wheel)
Tailwheel Fork
and Wheel
Rear View and Left Side View
7
Component Identification
Steering Levers
Spring / Dampener
LH Transmission
Control Rod
RH Transmission
Control Rod
LH Transaxle
RH Transaxle
LH Transaxle
Lockout Arm
RH Transaxle
Lockout Arm
Parking Brake
Linkage
Transaxle Oil
Expansion
Reservoir
Parking Brake
Lever
PTO Clutch
Lever
Fuel Tank Cap
Parking Brake
Linkage
Air Filter
Restriction Gauge
Fuel Gauge
Fuel Pump
Fuel Tank
OptiAirTM
Air Cleaner
Roll Over Valve
EVAP Line
Air Cleaner
Cover Latch
Fuel Pickup Line
Fuel Filter
(Not Visible)
Air Cleaner Cover
30 Amp Circuit
Breaker
(Not Visible)
Throttle and
Choke Linkage
Oil Dipstick /
Oil Fill
Muffler Heat
Shield
Rubber Bumpers
(Body Support)
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.
), read,
When you see the Safety Alert Symbol (
understand, and follow the instructions. Fail­ure to
comply with safety instructions may result in per­
sonal 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 poten­
tially 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 neces­
sary for the operator to use safe operating proce­
dures 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, opera­
tion, 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 ma­
chine.
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 famil­
iar 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 ma­
chine 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. Wear a suit­
able hearing protective device, such as ear­
muffs or earplugs.
8.
Keep all protective shields and safety devices in place. If a protective shield, safety
device, or decal is damaged, unusable, or miss­
ing, repair or replace it before operating the
machine.
9.
Be sure interlock switches are functioning
correctly, so the engine cannot be started un­
less the Forward Speed Control lever is in the
NEUTRAL-PARK position, the PTO clutch is in
the DISENGAGED position, and the Parking
Brake is in the ENGAGED position. Also, the
engine should stop if the operator lifts off the
seat with any one or more of these controls in
the operating position: (1) Forward Speed Con­
trol (FSC) out of NEUTRAL-PARK, (2) PTO
Clutch ENGAGED, or (3) Parking Brake DISENGAGED.
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 contain­
er 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 Di-(2-ethylhexyl) phthalate which
is known to the State of California to cause
cancer, and Di-(2-ethylhexyl) phthalate,
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.
If the transmission drive belt breaks during op­
eration, 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 ex­
actly the same procedure as used to normally
stop and park this machine.
6.
Disengage the blade clutch, put the FSC in the
NEUTRAL-PARK position, and engage the
Parking Brake 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 mov­
ing three controls, one at a time; (1) Move the
FSC lever out of the NEUTRAL-PARK position,
(2) Engage the PTO Clutch, and (3) Disengage
the Parking Brake. Moving any of these
controls should stop the engine immediately.
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 back­
ing 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 road­
ways.
12. When moving forward, do not suddenly put the
tractor in reverse by rapidly pulling on the steer­
ing 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 drive the tractor 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 27% 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 ma­
chine, 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),
engage parking brake, stop the engine, and re­
move the ignition key. Wait for all movement to
stop before getting off the seat.
NOTE: The blade/PTO 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 posi­
tion.
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. In case of a clogged or plugged mower deck:
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
movement has stopped before trying to un­
clog the system.
c.
Disconnect the spark plug wires.
d.
Never place hands under the deck - use a
stick or similar tool to remove clogged ma­
terial.
19. If the cutting blades strike a solid object or the
machine begins to vibrate abnormally, immediately disengage the blade clutch (PTO), engage the parking brake, 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 re­
pair 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.
20. 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.
21. When leaving the machine unattended, disen­
gage the blade clutch (PTO), engage the
parking brake, stop the engine, and remove
the key.
12
Safety Instructions - Maintenance
1.
To prevent accidental starting of the engine
when servicing or adjusting the machine, re­
move the key from the ignition switch and dis­
connect 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 electri­
cal 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 mainte­
nance 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 un­
plugging 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.
IMPORTANT: Keep all applicable manuals im­
mediately accessible to anyone who may oper­
ate or service this machine.
10. Use genuine factory replacement parts.
Sub­stitute parts may result in product malfunc­
tion 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.
2.
8600-28
Location: Each End of Mower Deck
Part Number: 8600-28
8600-2
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 mow­
er blades.
●● Do not step on end of deck.
1.
8600-14
Location: Flex Coupler Guard in Front of Engine
Part Number: 8600-2
1.
1.
Location: Deck Carrier Frame
Part Number: 8600-15
1.
Location: Deck Carrier Frame
Part Number: 8600-14
1.
Warning – entanglement and cutting/dismem­
berment hazards.
●● Keep away from rotating shafts, belts, and
other components.
Warning – lock deck tilt-up hinge before operat­
ing the machine.
Warning – do not operate the machine with the
deck tilted up.
9804-1
1.
1.
Location: Chassis Member Behind Transaxles
Part Number: 9804-1
1.
14
Neutral Lock
●● Lift and move into slot to unlock transmis­
sion and allow machine to freewheel.
Location: Deck Discharge Shield
(SD Decks Only)
Part Number: 5848-3
1.
Warning – thrown object hazard.
●● Always keep the discharge shield in the low­
est position when operating.
●● Do not remove the discharge shield.
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
1.
2.
3.
4.
5.
2.
<15°
6.
1.
5.
8.
Location: LH Fender
Part Number: 8600-46
Location: RH Fender
Part Number: 8600-26
1.
1.
2.
3.
4.
5.
6.
7.
8.
3.
4.
7.
Throttle
●● Move lever forward to increase engine
speed; back to idle.
Warning – read Operator’s Manual before oper­
ating the machine.
Warning – wear eye and ear protection when
operating the machine.
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.
Choke
Warning – entanglement hazard.
●● Keep all guards in place while engine is run­
ning.
Parking Brake
●● Move lever forward to engage Parking
Brake; back to disengage.
2.
2.
3.
4.
5.
Warning – do not operate the machine without a
deck or other implement attached.
Forward Speed Control
●● Move lever forward to increase speed; back
to stop.
Warning – read Operator’s Manual before servic­
ing or performing maintenance.
●● Engage parking brake.
●● Remove ignition key.
Warning – do not engage PTO clutch with PTO
shaft disconnected.
PTO Clutch Lever
●● Move lever forward to engage PTO clutch;
back to disengage.
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.
BELT ROUTING
1.
Location: Deck Gearbox Cover
Part Number: 8600-39
1.
GROUND DRIVE BELT
WALKER P/N 4230-2
Warning - stop engine and remove ignition key
before adjusting deck cutting height.
1.
ENGINE/PTO BELT
WALKER P/N 4230-1
2.
60 lb·ft (81 N·m)
1.
8600-9
Location: Gearbox Cover
(Gear Drive Decks Only)
Part Number: 8600-9
1.
Location: Engine
Part Number: 8600-12
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.
8600-5
Location: Rear Body Near Muffler
Part Number: 8600-5
16
Ground drive belt routing.
Engine/PTO clutch belt routing.
Tighten blade nuts on gear driven decks to
60 lb·ft (81 N·m).
8600-12
1.
Location: Rear Body
Part Number: 4107-12
1.
2.
1.
1.
4107-12
Warning – hot surface, do not touch.
Location: Engine Shroud
Part Number: 5855
Assembly Instructions
SETUP INSTRUCTIONS
Wet Battery Service
Walker Mowers are shipped partially assembled to
our distribution network, and are typically assem­
bled by the selling dealer. For any additional as­
sembly besides the following, contact your Walker
dealer.
If the battery has been shipped wet, but the electro­
lyte level is low or the battery needs to be charged
then:
Tire Installation (Tractor)
●● Install the drive tires using the eight (8) mount­
ing nuts supplied with the Owner’s Packet of
materials. Nuts are torqued to 75 to 85 lb·ft
(102 to 115 N·m).
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
●● Check and adjust the inflation of the tires.
The tire inflation recommendations are:
Drive
Tailwheel
=
=
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 techni­
cian can activate the battery safely. DO
NOT attempt to activate the battery unless
you are experienced in battery service
work. The following activation and charg­
ing instructions are provided for use by a
trained battery technician.
15 PSI (103 kPa)
20 PSI (137 kPa)
Battery Service
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.
DANGER
Battery electrolyte is a poisonous and cor­
rosive sulfuric acid solution.
●● Avoid spillage and contact with skin,
eyes, and clothing - causes severe
burns.
●● To prevent accidents, wear safety gog­
gles and rubber gloves when working
with electrolyte.
Battery Clamp
and Cover
●● Neutralize acid spills with baking soda
and water solution.
Battery Location
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
damage to the machine. A hazard may be created
by damage to critical working parts and safety sys­
tems.
To fill (activate) battery with electrolyte (if battery has
been shipped dry):
1.
Remove the battery cover and hold-down
clamp, disconnect the battery cables and lift the
battery out of the tray.
IMPORTANT: Battery must be removed from
the mower before filling with electrolyte.
17
Assembly Instructions
IMPORTANT: Obtain and use only battery
grade sulfuric acid electrolyte with a 1.265 spe­
cific 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.
Battery Charging
DANGER
Battery Installation
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
damage to the machine. A hazard may be created
by damage to critical working parts and safety sys­
tems.
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 ter­
minal [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 com­
pletely to prevent an electrical short.
WARNING
BATTERIES PRODUCE EXPLOSIVE GASES
●● Charge the battery in a well-ventilated
area, so that gases produced while
charg­ing can dissipate.
Make sure the battery cap vents are open.
Improper venting of the battery COULD
cause a battery explosion.
●● Keep sparks, flames, and smoking mate­
rials away from the battery at all
times.
(+) Battery Cable
Connection
●● 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.
1.
2.
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.
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.
18
Install battery.
Battery Clamp
Secured by
Wing Nut(s)
Battery Installation
Mower Deck Assembly
Deck Caster Wheels Installation
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.
Assembly Instructions
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.
PTO Shaft Guard Installation
Position the shaft guard as shown and mount with
two (2) 1/4-20 x 1/2 in. bolts.
Axle Spacer Tube
Carrier Frame
Tube Sockets
Axle Bolt
Attach
Guard
Deck Caster Wheel Installation
5.
Grease the caster pivot bearings - one grease
fitting for each pivot.
Deck Discharge Deflector Shield Installation
(Side Discharge Models Only)
Attach the side discharge deflector shield using two
(2) 3/8-16 x 1-1/4 in. bolts, 3/8-16 ESNA nuts, and
3/8 in. wave spring washers. The wave washers fit
between the two hinging surfaces. Tighten the nuts
until the shield moves freely but is not loose.
PTO Shaft Guard Installation
Tilt-Up Roller Wheel Installation
Mount the two (2) tilt-up roller wheels on the brack­
ets on the rear skirt of the deck housing using the
P/N F543 axle bolt, 3/8 in. plain washer, 3/8 in.
wave spring washer (between bracket and wheel)
and 3/8-16 Whiz locknut. Tighten the axle bolt until
the wheel rolls freely, but is not loose.
WARNING
DO NOT operate the machine without the
grass deflector shield attached and in the
lowest possible position.
Roller
Wheels
Attach Shield
Roller Wheel Installation
Deck Discharge Shield Installation
19
Assembly Instructions
Mower Deck Installation on Tractor
4.
Deck Installation
1.
Lightly grease each deck support arm (2) on the
tractor. Refer to Mower Deck Installation
photo for location of deck support arm.
Reaching under the tractor, slide the PTO cou­
pler tube onto the deck drive shaft (align arrow
decals), then install the coupler quick discon­
nect onto the tractor PTO drive shaft.
IMPORTANT: When installing the DS52
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)
PTO
Connection
Deck Support
Arms
Grease Deck
Support Arms
Mower Deck Installation
2.
3.
Engage the deck carrier frame tube sockets on
the tractor support arms (refer to PTO Shaft
Guard Installation photo for socket location),
slide the deck onto the support arms approxi­
mately 3 in. (76 mm).
Retract the spring-loaded quick disconnect ring
on the PTO Coupler and insert the Coupler In­
stallation Tool (provided in Owner’s Packet) as
shown in the photo below.
NOTE: The Coupler Installation Tool is provid­
ed for convenience, but is not required for in­
stallation.
Coupler
Installation Tool
PTO Coupler
Tube
Retract Spring-Loaded
Quick Disconnect Ring
PTO Coupler Installation Tool
20
PTO Shaft Connection
5.
Remove Installation Tool from quick disconnect
ring and make sure the ring has “snapped” se­
curely on the spline shaft.
IMPORTANT: DO NOT operate tractor with
Coupler Installation Tool installed.
IMPORTANT: To prevent damage to the mow­
er, make sure the PTO quick disconnect is se­
curely 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 in­
stallation, pull on the PTO coupler to check for
security.
Assembly Instructions
Coupler Ring in
Released Position
PTO Drive
Shaft
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 ten­
sion 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 Coupler
U-Joint
Quick Disconnect Ring “Released” Position
Internal Balls
Locked on Shaft
PTO Coupler
U-Joint
PTO Drive
Shaft
Spring Tension Adjustment Nut
Located Under Lower
Spring Hook (Not Visible)
Coupler Ring in
Locked Position
Counterweight Springs
Clip Onto Body
With Body Tilted Up
Quick Disconnect Ring “Locked” Position
6.
Slide the deck the rest of the way on the deck
arms.
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 to the tilt-up position,
and then raise the front of the 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.)
Hitch Pins
Lock Deck on
Support Arms
Deck Counterweight Spring Installation
21
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 mea­
surements 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 DS52 and DS62 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
22
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 opera­
tion, 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% etha­
nol maximum).
DANGER
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 CLEAN­
ER 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
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 stor­
age container and funnel.
IMPORTANT: DO NOT mix oil with gasoline. Al­
ways use fresh, automotive grade unleaded gaso­
line. DO NOT use gasoline containing greater than
10% ethanol. DO NOT use additives, such as car­
buretor cleaners, deicers, or moisture removing
agents. DO NOT use gasoline blended with methyl
alcohol.
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 ac­
cess 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 start­
ing the engine, holding a hand adjacent to the cylin­
der heads, and feeling the cooling airflow.
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
CHECK HYDROSTATIC TRANSAXLE OIL
LEVEL
Refer to LUBRICATION for Check Transaxle Fluid
Level in Maintenance Instructions.
INSPECT THREE (3) DRIVE BELTS
Engine/PTO (2) and Ground Drive.
23
Assembly Instructions
CHECK FUNCTION OF SAFETY INTERLOCK
SWITCHES
Tilt-Up Handle
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 en­
gaged.
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 SECURITY OF DRIVE TIRE MOUNT­
ING NUTS
The eight (8) Drive Tire mounting nuts should each
be torqued to 75 to 85 lb·ft (102 to 115 N·m).
ADJUST MOWER CUTTING HEIGHT, IF RE­
QUIRED
Position the hitch pins in the four deck support pins.
Refer to the “Cutting Height Adjustment” decal on
the deck gearbox cover.
CHECK AND CLEAN GRASS BUILDUP UN­
DERNEATH MOWER DECK
Refer to CLEANING the Grass Buildup in Mower
Deck Housing in Maintenance Instructions for deck
tilt-up and deck 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 posi­
tion 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 operat­
ing position.
24
Tilt-Up Hook and
Latch Connected
Tilt-Up
Latch
Deck Lock
Lever
Tilt-Up
Hook
Deck Secured in TILT-UP Position
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
DANGER
Do not operate the mower with deck in tiltup position. Do not move the tractor with
the deck in the tilt-up position.
CHECK MOWER BLADE CONDITION,
SHARPNESS, AND SECURITY OF MOUNT­
ING
The blade mounting nuts on gear driven decks should
be torqued to 60 lb·ft (81 N·m), and the blade mount­
ing 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.
PERFORM ANY ADDITIONAL PROCEDURES
called for on the MAINTENANCE SCHEDULE
CHART in Maintenance Instructions.
Operating Instructions
CONTROL IDENTIFICATION, LOCATION, AND
FUNCTION
CAUTION
IMPORTANT: Make sure the choke is in the OFF
position during normal engine operation; running
with the choke in the ON position CAN damage the
engine.
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.
Throttle
Choke
Engine Choke
The choke control lever (black knob) is located on
the left side of the seat. To start a cold engine, move
the choke control forward to the ON position. After
engine starts, move the choke control toward the
OFF position, keeping enough choke to allow the
engine to run smoothly as it warms up. As soon as
possible, move the choke to the OFF position. A
warm engine requires little or no choke for starting.
Choke and Throttle Location
Parking
Brake
Body Lift
Handle
Blade Clutch
(PTO)
Steering
Levers
Forward Speed
Control (FSC)
Choke
Throttle
Body Latch
Ignition
Switch
Circuit
Breaker
Hourmeter
Operating Controls
25
Operating Instructions
Engine Throttle
Blade Clutch (PTO)
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.
The blade clutch lever is located on the right side of
the seat behind the right fender and is used to en­
gage and disengage the mower blades. The blade
clutch lever has two positions. Pushing the lever
DOWN engages the PTO that drives the mower
blades. Pulling the lever UP disengages the PTO
and engages the blade brake.
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 posi­
tion, a friction lock holds any forward speed setting
from 0 to 8 mph (0 to 13 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 posi­
tion since the friction lock maintains the selected
lever position. Pulling back on the steering levers
overrides the FSC setting and slows or stops for­
ward 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.
Body Latch
The tractor body hinges forward for maintenance ac­
cess and is latched down in the OPERATING posi­
tion. To raise the body, pull back on body latch and
lift body using the lift handle on the rear of the body.
Body
Latch
Steering Levers
Each drive wheel is controlled by its own indepen­
dent steering lever, for both steering function and
FORWARD/REVERSE motion. The FSC lever sets
the maximum forward speed, and also sets the for­
ward position of the steering levers. The steering
levers operate only with a backward pulling move­
ment of the lever, which causes the drive wheel for
that lever to first slow down, stop, and then reverse
with a full backward lever stroke. The levers are
released to the FORWARD position for “straightahead” ground travel.
NOTE: Pushing forward on the steering levers will
not cause any change in tractor motion - there will
be no steering lever reaction and there will be no
machine damage.
26
Body Latch
Operating Instructions
The Forward Speed Control also Establishes the Neutral-Park Position of the Steering Levers
LEFT WHEEL
STEERING LEVER
FORWARD SPEED
CONTROL LEVER (FSC)
RIGHT WHEEL
STEERING LEVER
Forward Position
(No Control Change)
Full Forward
Ground Speed
Position
Neutral-Park
Position
Intermediate
Ground Speed
Position
Reverse Drive
Wheel Motion
Position
Neutral-Park
Position
Fast
Throttle
Position
Idle
Position
ON
Position
OFF
Position
<15°
1.
2.
THROTTLE
CHOKE
Engaged
Position
Engaged
Position
Disengaged
Position
PARKING
BRAKE
Disengaged
Position
BLADE CLUTCH
(PTO)
Operating Controls (Top View from Drivers Point of View)
27
Operating Instructions
Parking Brake
Transaxle Lockout Arms
The parking brake functions by locking a detent arm
to a cog in the hydraulic motor rotor. Moving the
lever FORWARD engages the parking brake; mov­
ing the lever BACKWARD releases the brake.
The transaxle lockout arms disengage the transax­
les. By lifting the arms up and locking them into
place with the shoulder on the arm in the chassis
notch, the transaxles are released to permit free­
wheeling. By releasing the arms and recessing
them back toward the chassis, the transaxles are
engaged for normal operation. The transaxle arms
in the LOCKOUT position are used to enable mov­
ing the machine without the engine running (e.g., for
service). Refer to TRANSAXLE LOCKOUT in this
section for operating instructions.
IMPORTANT: Stop the tractor completely before
engaging the parking brake. The parking brake
uses a positive mechanical lock similar to the PARK
position on an automotive automatic transmission.
If the tractor is moving when the brake is engaged,
it will result in sudden stoppage and possible inter­
nal damage to the transaxle.
NOTE: If pressure on the parking brake (e.g.,
parked on a hill) makes it impossible to release the
parking brake with the parking brake lever, move the
mower gently forward or backward to allow the
brake detent to release.
Transaxle Lockout
Arms
Transaxle Lockout Arm Location
Engaged
Position
Parking Brake Engaged
Disengaged
Position
Parking Brake Disengaged
28
NOTE: The transaxle lockout arms ends should be
completely retracted against the chassis, otherwise
operation of the transaxle may be erratic.
Operating Instructions
Hourmeter
Ignition Switch
The hourmeter, which is located on the right front of
the body, displays operating time accumulated
while the PTO (blade drive) clutch is engaged.
The ignition switch is located on the right front of the
body and is used to start and stop the engine. The
switch has three positions: “O” is the OFF position,
ON (RUN) is the position that the key returns to after
starting, and “S” is the START position. When start­
ing 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 sec­
onds 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.
The hourmeter provides maintenance reminders af­
ter 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
ON
OFF
LUBE
C
H
G
OIL
*
These intervals reflect the actual time that the
reminder will flash (one hour prior to and one
hour after the recommended interval).
**
This reminder is only used one time.
*** In normal operating conditions, oil changes in
100-hour intervals are acceptable. Walker and
the engine manufacturers recommend engine
oil changes every 50 hours in extremely dirty or
dusty conditions or for units with less than 100
hours annual use.
NOTE: The blinking hour glass on the display
means that the meter is operating properly.
START
Ignition Switch
Circuit Breakers
A manual reset 5 amp circuit breaker is located on
the right front of the body. The button pops out if the
circuit breaker trips. This circuit breaker protects the
safety circuits and relays. In addition, an auto reset
30 amp master circuit breaker is located in the rear
left of the chassis, and protects the charging system.
Hourmeter
29
Operating Instructions
IMPORTANT: DO NOT crank the engine con­
tinuously for more than 10 seconds at a time. If
the engine does not start, turn the key to the
OFF position and allow a 60 second cool-down
period between starting attempts. Failure to fol­
low these guidelines can damage the starter
motor and shorten battery life. Consult your
Walker dealer or authorized Kohler dealer for
additional help.
STARTING THE ENGINE
CAUTION
Before operating the mower, read and un­
derstand all Safety Instructions and Operat­
ing Instructions.
3.
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,
the parking brake is ENGAGED, and the blade
clutch is DISENGAGED.
CAUTION
A safety interlock switch system PRE­
VENTS CRANKING the engine with any one
of these three controls in the OPERATING
position: (1) Forward Speed Control out of
neutral, (2) blade clutch (PTO) engaged, or
(3) parking brake disengaged. If the engine
cranks otherwise, the safety system is not
working and should be repaired or ad­justed
before operating the mower. DO NOT disconnect safety switches; they are for the
operator’s protection.
2.
Move the choke lever to the ON position and
move the throttle 1/4 to 1/2 open (toward FAST).
Turn the ignition switch to the START position
to start the engine. Release the key to ON
(RUN) position as soon as the engine starts.
NOTE: The choke may not be required if the
engine is warm.
30
After the engine starts, gradually move the
choke to the OFF position, keeping enough
choke on to allow the engine to run smoothly as
it warms up. As soon as possible, move the
choke to the OFF position.
IMPORTANT: Make sure the choke is in the
OFF position during normal engine operation;
running with the choke in the ON position CAN
damage the engine.
ADJUSTING GROUND SPEED AND STEERING
IMPORTANT: If the DS52 mower deck is in­
stalled 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).
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.
Pull Steering
Levers With
Left Hand
WARNING
If the transmission drive belt breaks 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.
Keep Feet On
Footrest When
Moving
Forward Speed Control
(FSC)
Correct Operator Hand Position
on the Controls
CAUTION
An operator presence switch (seat switch)
will cause the engine to stop if the parking
brake is in the DISENGAGED position and/
or the FSC is out of the NEUTRAL-PARK
position (tractor stationary or moving forward) and the operator is not in the seat.
The function of this switch should be
checked by the op­erator raising off the
seat, first with the parking brake DISENGAGED, and then with the tractor moving
forward; the engine should stop. In each
case, if the safety sys­tem is not working, it
should be repaired or replaced before operating the mower. DO NOT disconnect the
safety switches; they are for the operator’s
protection.
NOTE: If the FSC lever will not stay in the
selected position, the friction lock needs to be
adjusted. Refer to ADJUSTMENTS for Step 7 Forward Speed Control Friction Adjustment in
the Maintenance Instructions.
31
Operating Instructions
WARNING
Beginning Recommendations are:
3.
♦♦
Learn operation of the mower in an open
area away from buildings, fences, and
ob­structions. Learn operation on flat
ground BEFORE operating on slopes.
♦♦
Start maneuvering the mower with SLOW
engine speed and SLOW Forward Speed
Control setting until familiar with all
operat­ing characteristics.
♦♦
Remember it is not necessary to hold the
steering levers forward (a unique Walker
feature); always PULL on the levers for
steering or for reverse motion of the
mower.
♦♦
Learn to operate the mower with your left
hand on the steering levers and right
hand on Forward Speed Control. The use
of two hands on the steering levers tends
to cause overcontrol.
♦♦
Learn to operate the steering levers with
smooth action. Jerky movements are
hard on the transmission and lawn. For
sharp turns, do not allow the inside
wheel to stop and twist on the grass. Pull
the steering le­ver controlling the inside
wheel into reverse for a smooth “rolling”
turn (one wheel roll­ing forward while the
other rolls backward).
♦♦
Practice maneuvering the mower until
you can make it go exactly where you are
aiming.
♦♦
Remember, for an emergency stop, or
in case of loss of control, machine
movement can always be stopped
quickly by pulling the Forward Speed
Control into the NEU­
TRAL-PARK
position.
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.
32
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.
The FSC may be adjusted forward for faster
ground speed and backward for slower ground
speed. When mowing, ground speed should be
adjusted to match the load on the cutter blades,
i.e., as the engine pulls down in heavy cutting,
pull back on the FSC lever to reduce ground
speed. Adjusting ground speed helps maintain
a balance between engine power and blade
speed for high-quality cutting action.
5.
Stop ground travel by pulling both steering
le­vers backward to the NEUTRAL position
(trac­tor not moving) and then moving the FSC
lever to the NEUTRAL-PARK position.
NOTE: If the tractor creeps forward or back­ward with the FSC lever in the NEUTRALPARK position, the transmission control needs
to be adjusted. Refer to ADJUSTMENTS for
Transmission Control, Step 3 - Neutral Function Adjustment in the Maintenance Instructions.
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 moving the blade
clutch lever forward SLOWLY. For disengage­
ment, move the blade clutch lever backward
SLOWLY.
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).
Engaged
Position
Blade Clutch Engaged
STOPPING THE MACHINE
Disengaged
Position
1.
Pull the steering levers to the NEUTRAL posi­
tion and then move the FSC lever backward to
the NEUTRAL-PARK position.
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.
Blade Clutch Disengaged
CAUTION
WARNING
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).
A brake stops the cutter blades 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.
Turn the ignition switch OFF. When stopping
the engine, do not reduce the throttle below 1/2
speed. Since the engine is equipped with a fuel
shutoff solenoid, stopping at low idle may cause
engine run-on or backfiring.
33
Operating Instructions
WARNING
Remove the key from the ignition switch
when leaving the mower unattended. This
will prevent children and inexperienced
operators from starting the engine.
5.
Engage the parking brake by moving the lever
forward.
IMPORTANT: The hydrostatic transmissions
lock to prevent the mower from rolling freely
with the engine stopped. However, if the mow­
er is parked on a slope, it is necessary to ENGAGE the parking BRAKE to prevent the
mower from creeping. This is due to a small
amount of slippage in the hydrostatic transmis­
sions, especially when transmission fluid is
warm. Also, engaging the parking brake is rec­
ommended when stopping or parking the ma­
chine in a confined space with little tolerance
for movement.
WARNING
If the transmission drive belt breaks 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.
34
ADJUSTING CUTTING HEIGHT
WARNING
The engine must be stopped before ad­
justing cutting height. Disengage the blade
clutch (PTO), engage the parking brake,
stop the engine, and remove the ignition
key. Wait for all move­ment to stop before
getting off the seat.
Cutting height is adjusted by positioning the four (4)
re­tainer hitch pins in a series of 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
Washer
Hitch Pin
Cutting Height Adjustment
Operating Instructions
TRANSAXLE LOCKOUT
IMPORTANT: DO NOT TOW this mower faster than
2 mph (3.2 km/h) with the transaxle lockout en­
gaged. Towing can produce excessive internal
pressure and damage the transaxle(s).
Transaxle Lockout Arm
To move the mower with the engine NOT running
(dead battery, maintenance, etc.), the transaxles
need to be unlocked (released).
1.
Raise the body.
2.
Pull up on each transaxle lockout arm and move
toward the center of the machine to engage the
step that holds the arm in the UP (unlocked)
position.
3.
Transaxle Lockout Arm - Normal Operating
Position
The mower will “freewheel” with the arms in the
LOCKOUT position. The levers must be in the
highest position to completely unlock the trans­
axles.
Transaxle Lockout Arm
Transaxle Lockout Arm - Freewheel Position
4.
After moving the mower, release the arms, plac­
ing them down in the normal OPERATING posi­
tion. The transaxle lockout arm ends should be
completely retracted against the chassis, other­
wise operation of the transaxle may be erratic.
35
Operating Instructions
RECOMMENDATIONS FOR MOWING
DANGER
Do not mow around overhanging tree
branches or bushes at the same height as
the operator’s torso and head where inadvertent contact may cause injury.
●● When mowing, operate the engine at full throttle for the best cutting action. Mowing with a
lower engine RPM causes the mowing blade to
not cut clean and tear the grass. The engine is
designed to be operated at full speed.
●● When mowing in adverse conditions (tall and/or
wet grass), mow the grass twice. Raise the
mower to the highest setting - 4 in. (102 mm) for the first pass and then make a second pass
cutting to the desired height.
●● Use a slow setting on the FSC for trimming
operations.
●● Make sure the mower is leveled properly for a
smooth cut. Refer to Deck Leveling in Assembly
Instructions.
●● Use an alternating stripe mowing pattern for
best appearance and vary the direction of the
stripe each time the grass is mowed to avoid
wear patterns in the grass.
●● Avoid damage to the grass by slipping and skid­
ding of the drive tires. Use smooth control
move­ments of the steering levers since the
transaxles are “power boosted controls” and
jerk­ing the levers can easily slip the tires. For
sharp turns, do not allow the inside wheel to
stop and twist on grass; pull inside steering lever
into reverse for a smooth “rolling” turn (one
wheel rolling forward while the other rolls back­
ward).
Avoid Low Hanging Branches
IMPORTANT: Operate the engine at full throttle
when mowing, to allow the engine to produce full
horsepower and to increase efficiency of the engine
cooling system.
●● Keep the mower deck and discharge shield
clean.
●● Mow with sharp blades. A dull blade tears the
grass (resulting in poor lawn appearance) and
uses extra power (slowing the mowing speed).
●● 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.
Discharge
Shield
●● 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.)
Side Discharge Deflector
Shield in Lowest Position
36
Operating Instructions
●● 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 27% grade.
Maximum
Recommended
Slope Do Not Operate
on Steep Slopes
To avoid potential deck and/or tractor damage while
using the tilt-up deck, the following recommenda­
tions are offered:
●● Do not move the tractor with the deck in the
tilt-up position since both the roller wheels (on
the back of the deck) may be damaged by mov­
ing 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.
8600-14
60 lb·ft
RECOMMENDATIONS FOR TILT-UP DECK
OPERATION/TRANSPORT
(81 N·m)
8600-9
15°
14 in.
52 in.
Maximum Recommended Slope
DANGER
●● 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 pre­
vent the deck from bouncing on the rear roller
wheels (causing breakage). This will also pre­
vent 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.
Do not mow or drive the tractor within 5 feet
(1.5 meters) of an embankment or retaining
wall with drop off.
5 FT
MINIMUM
No Driving Zone
37
Maintenance Instructions
CAUTION
Maintenance procedures requiring special training or
tools should be performed by a trained technician.
MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL B19
Service Item
Daily
25
Hours
100
Hours
200
Hours
400
Hours
Yearly
Every
2 Years
Ref.
Page
Check Engine Crankcase Oil Level
x
40
Check/Clean Engine Air Cooling System*
x
47
Clean Grass Buildup Under Deck
x
51
Service Mower Blades
x
54
Check Security of Air Filtration Components
x
53
Check Air Filter Restriction Gauge
x
49
Lubricate Grease Fittings and Oil Points*
x
42
Check Battery Electrolyte Level
x
53
Check Transaxle Fluid
x
46
Check Tire Pressure
x
54
Check Drive Belts
(Engine/PTO, Ground Drive)
x
55
Check Deck Gearbox Oil Seals
x
55
Check Safety Switch System
x
56
Check Security of Drive Tire
Mounting Nuts (75 to 85 lb·ft)
x
54
Check Blade Brake Action
x
55
Clean Transaxle Housing
x
52
Clean Engine Cooling Fins
x
47
Check Air Filter Element***
x
49
Change Engine Crankcase Oil**
x
41
Check/Adjust Blade Clutch
x
67
Check/Regap Spark Plugs
x
55
Change Engine Oil Filter
x
41
Replace Fuel Filter
x
Change Transaxle Oil and FilterΔ
60
x
46
Replace Air Filter Element and Safety Filter***
x
50
Check/Adjust FSC Friction Lock
x
56
Check Fuel Lines and Clamps
x
55
Service Solenoid Shift Starter
x
56
Check PTO U-Joints for Wear/Looseness
x
56
Service Battery
x
53
Check Transmission Control Settings
x
56
Replace Fuel Lines and Clamps
x
55
Replace Dust Ejection Valve***
x
50
Replace Ignition Wires
x
55
*
**
***
Δ
38
More often in extremely dusty or dirty conditions
Change engine oil and filter after first 5 hours of operation of a new engine (break-in period)
Air cleaner is remote mounted Cummins/Fleetguard OptiAir™ unit, replace filter(s) every 400 hours and
dust ejection valve every two years or when worn or damaged
Change transaxle oil after the initial break-in period of 75-100 hours operation
Maintenance Instructions
KOHLER TIPS
IMPORTANT TIPS FOR CARE OF THE KOHLER
ENGINE
DANGER
Fuel System
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
●● Fuel must be clean - free from water, dirt, and
or­ganic material.
●● Change fuel filter on a regular basis or when
contamination is suspected or found in the fuel.
Starting/Stopping
●● Start engine with the throttle advanced off idle
(1/4 to 1/2 throttle). This will aid starting, espe­
cially in cold weather.
●● Keep the battery fully charged.
●● Match crankcase oil viscosity to the ambient
tem­perature, allowing the engine to crank faster
and start easier.
●● Allow engine to run at idle for a few seconds
be­fore stopping engine to avoid run-on or back­
firing.
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. In­
spect intake screen and cooling fins for cleanli­
ness and no damage.
●● Periodically remove two access panels in the
engine shroud to inspect and clean cylinder
head cooling fins.
●● Check performance of the cooling system by
starting the engine, holding a hand adjacent to
the cylinder head, and feeling the cooling air­
flow.
●● Operate the engine at full speed when mowing.
This allows the engine to produce full horse­
power and move more cooling air through the
engine cool­ing fins.
Air Cleaner System
●● Use only Cummins/Fleetguard air cleaner ele­
ments. Aftermarket elements may not seal in the
air cleaner housing, allowing dirt to enter the en­
gine. Also, aftermarket filters often skimp on the
filtration media and require more frequent re­
placement (see following instructions).
●● Use the air filter restriction gauge to indicate the
need to service the air filter.
●● 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 efficien­
cy and increase the oppor­tunity for traces of
dust to enter the engine. Wait until the element
really needs servicing as indicated by the air fil­
ter 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.
Oil
●● Use only multi-viscosity oils as specified with the
viscosity matching ambient temperatures for the
en­gine operating conditions. This will aid starting in cold weather and assure proper lubrication
in hot weather.
●● Use only Kohler oil filters. Aftermarket filters
may not seal properly and/or have the incor­
rect pressure relief valve for proper lubrication.
39
Maintenance Instructions
LUBRICATION
LUBRICATION
4.
WARNING
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.
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.
5.
Proper lubrication is an important maintenance pro­
cedure. It reduces wear and makes the machine
quieter and easier to operate.
Engine Oil
Engine Break-In Oil
Remove the dipstick again and check the oil lev­
el on the dipstick. The oil level should be within
the “Operating Range” on the dipstick (between
the “L” mark and the “F” mark).
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 en­
gine overheating, loss of power, and possible
en­gine damage.
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 en­
gine 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.
40
2.
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 hold
all the way down. For correct oil level measure­
ment, do not turn cap on threads.
Full Mark
Operating
Range
Low Mark
Dipstick Operating Range
Maintenance Instructions
LUBRICATION
Changing Engine Crankcase Oil/Oil Filter
Change the engine crankcase oil after every 100
hours of operation and replace the oil filter every
other oil change (every 200 hours of operation).
1.
Park the mower on a level surface with the
en­gine stopped. The engine oil should be
warm before draining. If not warm from opera­
tion, start the engine and run a few minutes to
warm the oil.
2.
Before removing the dipstick, clean the area
around the dipstick to keep any dirt or debris out
of the en­gine.
3.
Remove the dipstick and open oil drain valve
and drain the oil into a suitable container. Be
sure to allow ample time for complete drainage.
Oil Dipstick/
Oil Fill
Oil Filter
Oil Filter Location
(View from the Rear Right Side of Tractor)
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 12-050-01). After­
market oil filters may not seal properly and/or
may not have the correct pressure relief valve
for proper lubrication.
Oil Dipstick/Oil Fill Location
(View from Above Left Side of Tractor)
Oil Drain
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.
8.
Close the oil drain valve and tighten until snug.
Do not overtighten.
9.
Fill the crankcase with new, clean oil. Use only
crankcase lubricants recommended by the en­
gine 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 vis­
cosity 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.
Oil Drain Location
(View from the Rear of Tractor)
41
Maintenance Instructions
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 en­
gine is first operated with a new oil filter, the oil
level will drop slightly as the filter is filled with
oil.)
LUBRICATION
Grease Fitting and Oil Point Lubrication
Lubricate the grease fittings and oil points after ev­
ery 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.
NOTE: The ball bearings on the PTO drive shaft
are sealed and do not require periodic maintenance.
42
Maintenance Instructions
LUBRICATION
NOTE: In case the gearboxes are completely
drained of oil, approximately 5 fl. oz. (15 cl) of oil
per gearbox is required to refill the gear drive
assembly.
Mower Deck Gearbox Lubrication
NOTE: These instructions apply to all mower decks
with gear-driven blades. Refer to DS52 Mower
Deck Lubrication in this section for the DS52
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 con­
nected as a unitized assembly, and oil flows freely
between them. The gearboxes are permanently lu­
bricated (oil filled) and sealed requiring no sched­
uled lubrication. However, the gearbox oil seals
should be checked every 25 hours for indication of
an oil leak; particularly the lower seals on the
blade drive gearboxes should be inspected, since
they operate in a dirty environment. If an oil leak is
noted, replace the oil seal and relubricate the gear­
box assembly as follows:
1.
Remove gearbox cover (footrest). Deck orien­
tation should be the normal operating position.
Blade Drive
Gearboxes
NOTE: Since the gearboxes are connected as
a unit by connector tubes, it is necessary to add
oil slowly. Allow a few minutes after adding oil
for the oil to flow throughout the assembly and
the oil level to stabilize before reassembly.
IMPORTANT: DO NOT overfill the deck gear­
boxes. The gearbox assembly is not vented,
and overfilling with oil will cause excessive pres­
sure and result in oil leaks.
5.
Check condition of the cover gasket and replace if worn or damaged. Reinstall gearbox
cover plates; torque screws to 24 lb·in. (3 N·m).
Mower Deck Spindle Lubrication
For belt driven decks, lubricate each deck spindle
grease fitting every 25 hours. Use SAE general
purpose lithium or molybdenum base grease for
grease fittings.
Tee
Gearbox
Mower Deck Gearboxes
(Shown with Gearbox Cover
Removed for Clarity)
2.
Clean the area around the individual gearbox
cover plates to prevent contaminants from en­
tering the gearcase.
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).
43
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
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
Deck-to-PTO Coupling
Grease
(Grease Spline Slide Area)
Universal Joint Tube Assembly
Grease**
Deck Support Arm Pivot
Grease
Universal Joint Quick Connect
Grease
Spline (Grease Slide Area)
FSC Lever Pivot
Grease
Body Latch Pivot
Oil
Clutch Actuator Push Rod
Grease
Ground Drive Idler Pivot
Grease
PTO Clutch Lever Pivot
Grease
Transaxle Oil Reservoir
Oil/20W-50
Tail Wheel Caster Fork Pivot
Grease
Rear Axle Pivot
Grease
2
No.
Places
Ident
No.
2
2
3
4
2
1
1(2Δ)
1
1
1
1
2
2
1
26
27
28
29
30
31
32
33
34
35
Rear Wheel Bearing
Engine Oil Fill / Dipstick
Throttle Control Cable Ends
Choke Control Cable Ends
Brake Band Pivot Pins
PTO Belt Tightener Pivot
Parking Brake Clevis
Parking Brake Lever
Choke Control Pivot
Throttle Control Pivot
*
Grease
Oil***
Oil
Oil
Oil
Grease
Oil
Grease
Oil
Oil
1
2
1
** Grease every twenty-five (25) hours.
1
1
1
1
1
1
2
1
Δ
5
9
8
2
1
2
2
2
1
2
1
1
1
Belt Driven Decks Only
NOTE: DS42 and DS52 Tilt-Up Decks are shown for reference.
For other Deck Lubrication Points, Refer to Deck and
Carrier Frame Illustrated Parts Manual.
2
1
3
3
4
No.
Places
*** Refer to Engine Oil located on page 40.
3
7
6
5
4
Lubrication Points for Optional Belt Driven Decks (DS52 Shown)
44
Lubrication
Type
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.
.
10
1
Location
Maintenance Instructions
LUBRICATION
1
1
11
12
12
7
4
5
4
5
4
4
13
28 & 35
14
15
16
29 & 34
16
17
32
33
32
31
18
19
20
20
21
22
30
23
29
28
27
24
24
25
26
Chassis and Deck Lubrication Points (DS42 Shown)
45
Maintenance Instructions
LUBRICATION
DS52 Mower Deck Lubrication
Reservoir Cap
There are several special lubrication requirements
for the DS52 mower deck in addition to the require­
ments detailed in the Chassis and Deck Lubrica­
tion Points illustration. Lubricate the locations
shown in the Gearbox, Dol­ly Wheel, and U-Joint
Lubrication photo and check and maintain oil in the
belt drive gearbox.
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.
Belt Drive
Gearbox
Dolly Wheel
Pivot
Hot Level
Cold Level
Hose to
Transaxles
Expansion Reservoir Location
Transaxle Oil and Filter Change
Change the transaxle oil after the initial break-in
period of 75-100 hours. Thereafter, change oil every 400 hours of operation as follows:
1.
Thoroughly clean the exterior of the transaxle
housing before servicing. Remove expansion
reservoir cap to allow venting. Using a 1/4 in.
hex wrench, remove the plug on the lower in­
side of each transaxle allowing the oil to drain.
2.
Remove the oil filter guard, remove and replace
the oil filter using an oil filter wrench. Tighten
filter by turning filter 3/4 to 1 turn after gasket
contacts the filter base surface. Reinstall the oil
filter guard. (Refer to Transaxle Oil Drain
Plug, Filter, and Guard Location illustration.)
Oil Filter
U-Joints
Gearbox, Dolly Wheel, and U-Joint Lubrication
Check Transaxle Fluid Level
●● The transaxle oil lubrication is SAE 20W-50 (API
Service Class SL or higher) engine oil.
●● Inspect both transaxle cases and hoses after
every 25 hours of operation for visible leaks.
●● The fluid level of the transaxles can be checked
visually by looking at the fluid level in the expan­
sion reservoir. When the transaxles are cold, the
fluid level in the expansion reservoir should be
between 1/4 in. and 1/2 in. (0.64 cm and 1.27 cm).
46
Oil Filter
Guard
Oil Drain
Plug
Transaxle Oil Drain Plug, Filter, and
Guard Location
Maintenance Instructions
3. Reinstall drain plugs.
4.
Remove the oil reservoir hose attached to the
elbow on top of the transaxles. Remove the
elbows to access the oil fill opening.
5.
Fill the transaxles with 20W-50 (API Service
Class SL or higher) oil through the opening
(where the elbows were). Fill up to the opening.
6.
Before reinstalling the elbows, screw the lock­
ing nut on the elbows down until they are snug
(the o-ring on the elbow will be to the bottom of
the o-ring groove).
Elbow
Screw Locking
Nut Down
LUBRICATION/CLEANING
CLEANING
CAUTION
If a pressure washer is used on the exposed working parts, avoid water on the
electrical parts and the engine cooling
system.
Engine Air 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 overheat­
ing. 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.
Reinstall Transaxle Elbows
7.
Reinstall the elbows. When the elbow begins to
be snug, position the elbow as it was when re­
moved and tighten the locknut. Reinstall reser­
voir hoses to elbows.
8.
Fill reservoir to 1/4-1/2 in. (6-13 mm) with
20W-50 (API Service Class SL or higher) oil.
9.
Start and drive the unit for 1-2 minutes.
10. If the transaxles sound noisy or have poor steer­
ing response, there may be air trapped in the
transaxles. Follow purge instructions below.
11. If oil needs to be added refer back to steps 5-10.
Rotating Engine Cooling
Air Intake Screen
Keep Rotating Engine Cooling
Air Intake Screen Clean
12. To purge air from transaxle, raise tractor and
block with tires off the ground. With engine run­
ning, slowly move Forward Speed Control for­
ward and backward 5 to 6 times. Turn off en­
gine and check oil level and add if needed.
Repeat procedure until transaxles operate at
normal noise levels and move smoothly in for­
ward and reverse.
47
Maintenance Instructions
CLEANING
CAUTION
Operating the engine with a blocked air
intake screen, dirty or plugged cooling
fins, and/or cooling shrouds removed will
cause engine damage from overheating.
Cylinder Head Cooling Fins
It is essential for performance and longevity of the
air-cooled engine to keep the cylinder head cooling
fins clean and free of obstruction. After every 8
hours of operation, check the performance of the
cooling system by starting the engine, holding a
hand adjacent to the cylinder head, and feeling the
cooling airflow. If there is little or no airflow, clean
the cooling fins as follows:
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
Check Airflow
with Hand
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.
IMPORTANT: Yearly, it is good maintenance prac­
tice to remove the engine cooling shroud and clean
the cylinder head cooling fins thoroughly to prevent
overheating and extend engine life. Make sure cool­
ing shroud is reinstalled properly. This procedure
will require removing the engine from the chassis.
Engine Cooling
Fin Access Panels
Rotating
Engine Cooling
Air Intake
Screen
Kohler Engine
Shroud
Engine Cooling Air Intake Screen
and Cooling Fin Access Panels
Check Cooling System Airflow
Every 100 hours, inspect and clean the cooling fins
(more often when operating in extremely dusty, dirty
conditions). Remove the two (2) cooling fin access
panels in the engine shroud and clean the cooling
fins and external surfaces using compressed air.
Make sure to reinstall the access panels before oper­ating the engine.
48
Maintenance Instructions
CLEANING
Engine Air Cleaner System
Primary
Filter Element
Cummins/Fleetguard OptiAir™ Air Cleaner
Cover
A remote mounted Cummins/Fleetguard OptiAir™
air cleaner provides the air filtering function. The
paper filter element slides over an outlet tube in­
side the air cleaner canister with radial sealing
action, reducing the possibility of dust leaks due
to improper filter installation. Intake design, inter­
nal baffling, and a dust ejection valve provide dust
separation and automatic precleaning action.
Daily or frequent servicing of the air cleaner is not
required. Use the air filter restriction gauge con­
nected to 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.
Dust Ejection
Valve
Canister
Air Cleaner Components
(Shown with Cover Being Removed)
IMPORTANT: The Cummins/Fleetguard air cleaner
uses a dry paper-type air filter element. NEVER
apply oil to the paper element.
IMPORTANT: Use only Cummins/Fleetguard air
filter elements for replacement (Walker 2090-1 and
2090-3). Aftermarket filters may not seal properly or
filter efficiently.
Primary Filter
Element
Mounting
Band
Cummins/Fleetguard
Air Cleaner
Safety
Filter
Cummins/Fleetguard
Air Cleaner Cover
Hose
Clamps
Dust Ejection
Valve
Engine
8600
Air Filter
Restriction Gauge
-12
Flex
Hose
Engine Air Cleaner System Components
49
Maintenance Instructions
CLEANING
NOTE: Use care when cleaning the filter ele­
ment. 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.
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 necessary.
5.
Check the condition and resilience of the radial
sealing surface (inside of the open end) of the
filter. Replace the filter if any cracks, tears, or
other damage to the sealing surface are noted.
6.
Without removing, visually inspect the condition
of the safety filter for damage or holes. The
safety filter should only be removed for replace­
ment every 400 hours (or when dirty or dam­
aged).
Push Button to Reset
Indicator After Service
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 operat­
ing in extremely dusty conditions as indicated by the
air filter restriction gauge. Service the air cleaner as
follows:
1.
2.
3.
50
Lift Mono Latch Twist Lock™ and twist the
OptiAir™ cover to the left into the “open” posi­
tion to remove the air cleaner cover. Wash the
cover and dust ejection valve. Check that these
components are in good condition. The dust
ejection valve is subject to wear and deteriora­
tion and should be inspected carefully and re­
placed every two (2) years or when damaged.
The lips of the valve should close and fit togeth­
er; any cracks, deformation, or wear in the valve
is cause for replacement.
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 re­
moved.
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 re­
placed.
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.
7.
After removing the safety filter, use a clean,
damp cloth and wipe the interior of the air clean­
er canister clean. Use special care to clean
both the inside and outside surfaces of the
outlet tube.
IMPORTANT: Any dust left on the inside of the
outlet tube will go into the engine and cause
wear.
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 OptiAir™
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 re­
quired for filter installation.
Maintenance Instructions
Grass Buildup in Mower Deck Housing
Canister
Safety Filter
CLEANING
Outlet Tube
DANGER
Before raising or removing the mower
deck for cleaning, stop the engine, re­
move the ignition key, and disconnect the
spark plug wires.
Radial Sealing
Surface
OptiAir™
Filter Element
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.
Air Filter Element Replacement
10. Install the cover with the word “DOWN” prop­
erly oriented to the bottom of the canister. Twist
the OptiAir™ cover to the right and put into the
“closed” position.
Tilt-Up Handle
Mono Latch
Twist Lock™
2
Tilt-Up Hook and
Latch Connected
3
Tilt-Up
Latch
Deck Lock
Lever
DOWN
Orient to Bottom
of Canister
Dust Ejection
Valve
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 but­
ton on the end of the indicator).
Tilt-Up
Hook
Deck Secured in TILT-UP Position
DANGER
Do not operate the mower with deck in tiltup position. Do not move the tractor with
the deck in the tilt-up position.
51
Maintenance Instructions
3.
Clean grass buildup underneath the deck using
a pressure washer (and scraper if required).
NOTE: If the buildup is severe, it may be easi­
er to clean the deck by removing the deck as­
sembly from the tractor and standing the deck
assembly on its “nose”.
NOTE: While some degree of material buildup
in the mower deck housing can be tolerated, a
point is finally reached where cutting quality
deteriorates and clogging begins to occur
because of too much buildup on the baffling and
housing.
4.
Lower the deck to the normal operating position
and re-engage the deck lock levers.
CAUTION
CLEANING
Transaxle Housing
Keeping the housing on the transaxles clean and
free of obstruction is essential to avoid overheating the transaxle fluid and short­ening transaxle life.
The housing should be checked every 100 hours
and cleaned if neces­sary.
To clean the housing, use compressed air and/or a
pressure washer. Pay close attention to any oily dirt
build up on the transaxle housings. This may be the
result of an oil leak. If an oil leak is noticed, contact
your local Walker dealer.
Cooling
Fins
Do not operate machine with deck tilt-up
pivot joint unlocked.
Transaxle Housing and Cooling Fins
IMPORTANT: In case an oil leak develops on the
input shaft, the cooling fan blowing dusty air and oil
on the transaxle will quickly cover the housing and
pack the cooling fins with oily dirt. If this condition
occurs, contact your dealer immediately to avoid
overheating and dam­aging the transaxle.
An additional procedure in maintaining transaxle
cooling is to inspect the cooling fans. Replace the
fan(s) if blades are missing or damaged.
Cooling
Fans
Transaxle Cooling Fans
52
Maintenance Instructions
CHECKING/SERVICING
CHECKING/SERVICING
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.
DANGER
To prevent accidental starting of the en­
gine when servicing or adjusting the ma­
chine, remove the key from the ignition
switch and disconnect the spark plug
wires.
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
Security of Air Filtration Components
NOTE: The following inspection is only an exter­nal
inspection and should be done without “dis­
turbing” the filtration components.
On a daily basis, visually inspect the external condi­
tion of the complete air cleaner system. The follow­
ing items should be inspected:
1.
If battery terminals are corroded, remove battery
from the mower. Using a wire brush, remove corro­
sion with a solution of one part baking soda and
four parts water. Rinse with clean water. Coat the
terminals with petroleum jelly or terminal protector
spray to retard further corrosion.
Charging the Battery
Check the Cummins/Fleetguard OptiAir™ air
cleaner canister for damage. Make sure the
cover is in place and the cover latch is 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 se­
cure.
DANGER
BATTERIES PRODUCE EXPLOSIVE GASES
●● Charge the battery in a well-ventilated
area, so that gases produced while
charg­ing can dissipate.
●● Keep sparks, flames, and smoking ma­
terials away from the battery at all
times.
●● Make sure the battery cap vents are
open (check manifold vent on each
cap).
Battery
NOTE: For initial battery service during setup, re­fer
to Battery Service in Assembly Instructions.
●● Make sure the battery charger is un­
plugged before connecting or disconnecting cables to the battery.
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
dam­age to the machine. A hazard may be created
by damage to critical working parts and safety sys­
tems.
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:
Electrolyte Level
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].
The battery electrolyte level should be checked after every 25 hours of operation. To check electro­
lyte level:
1.
Remove battery cell filler caps.
53
Maintenance Instructions
CHECKING/SERVICING
Tire Pressure
WARNING
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 Nut Torque
Check the eight (8) nuts that mount the drive tires.
Every 100 hours they should be torqued to 75 to 85
lb·ft (102 to 115 N·m).
DO NOT try to straighten a blade that is
bent. NEVER weld a broken or cracked
blade. ALWAYS replace with a new blade
to assure safety.
4.
If the blade cutting edge is dull or nicked, it
should be sharpened. Remove blades for
sharpening by grasping the end of the blade us­
ing a rag or a thick, padded glove, while loosen­
ing 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.
Sharpen Mower Blades
Check mower blade(s) for straightness, sharp­
ness, condition of the cutting edge, and balance
every 10 hours of operation (or more often when
mowing abrasive type grass or operating on sandy
soils). Replace blades if worn, bent, cracked, or
otherwise damaged (refer to REPLACING/RE­
PAIRING the Mower Blades in this section). Use
the following procedure to check and sharpen
blades:
NOTE: Blades can be sharpened with an elec­
tric blade sharpener, conventional electric grind­
er, or a hand file.
CAUTION
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.
ALWAYS wear eye protection and gloves
when sharpening a blade.
1. Stop the engine, remove ignition key, and dis­
connect the spark plug wires before raising the
mower deck to service blades.
Sharpen at
Original 30° Angle
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.
Do Not Grind or
Sharpen on Underside
NEVER operate cutter blades with the
deck in the raised position.
3. Check the blades for straightness by marking
the blade tip position inside the deck housing,
and then rotating the opposite end of the blade
to the same position and comparing. If the dif­
ference in blade tip track is more than 1/8 in.
(3 mm), the blade is bent and should be re­
placed.
54
Wing
Tip
30°
DANGER
NOTE: PTO shaft must be disconnected be­
fore checking blades for straightness.
Intersection
Wear Area
Mower Blade Profile for Sharpening
6.
Check blade balance by positioning the blade
horizontally on a blade balancer or use a nail
or shaft through the center hole. If either end of
the blade rotates downward, grind (remove)
metal on that end until the blade will balance.
The blade is properly balanced when neither
end drops. Balance of a blade is generally
maintained by removing an equal amount of
material from each end of the blade when
sharpening.
Maintenance Instructions
CHECKING/SERVICING
Spark Plugs
Blade Balancer
Blade Balanced on Magnetic
Wall-Mounted Balancer
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).
Drive Belts
Raise the body and inspect the condition of the
three (3) drive belts after every 25 hours of opera­
tion—engine/PTO drive and ground drive. If the
belts show signs of cracking or deteriorating, the
belts should be replaced. Refer to REPLACING/
REPAIRING the Drive Belts in this section.
Mower Deck Gearbox Oil Seals
The mower deck gearbox seals should be inspected
every 25 hours for evidence of oil leaking; particularly the lower oil seal on the blade drive gearbox. This seal is protected by the trash guard on the
blade hub and seal protector plate on the housing,
but is still vulnerable to seal damage due to operat­
ing 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 gear­
box assembly relubricated. Refer to LUBRICATION
for Mower Deck Gearbox Lubrication in this sec­
tion.
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 wiretype 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).
Ignition Wires
Good preventive maintenance calls for complete replacement of spark plug wires every two (2) years.
Fuel Lines and Clamps
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.
Blade Brake Action
WARNING
It is important to check and maintain blade
brake action for safe operation of the machine.
Check the function of the cutter blade brake by en­
gaging the blade clutch (PTO), operating the engine
at full throttle, then disengaging the clutch and mea­
suring how quickly the blades stop. Watch the rota­
tion of the blade drive shaft 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 sys­
tem malfunctions - blades do not stop in five (5) sec­
onds - adjust or repair the brake before operating
the mower. Refer to ADJUSTMENTS for Clutch
Disengagement/Brake Action, Step 2 - Blade Brake
Band Adjustment, on page 69.
55
Maintenance Instructions
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 respec­
tive 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 le­
vers 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 fric­
tion lock is as follows:
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.
Safety Switch System
WARNING
It is important to check and maintain the
safety switch system for safe operation of
the machine.
There are four (4) safety interlock switches on the
tractor; Seat Switch, FSC Neutral-Park Switch, PTO
Switch, and Parking Brake Switch.
1.
With the engine off, place the FSC in the full
FORWARD position and pull both steering le­
vers back; the FSC lever should not move. If
the FSC lever moves back when the steering
levers are pulled back, the friction needs to be
increased.
2.
With the steering levers held back, move the
FSC lever back from the FORWARD position.
With a proper amount of friction adjusted, the
FSC lever should move back with a slight
amount of resistance (friction). If the FSC lever
movement is “stiff”, the friction needs to be
decreased.
If the FSC friction lock needs to be adjusted, refer to
ADJUSTMENTS for Step 7 - Forward Speed Control Friction Adjustment in this section.
Transmission Control Setting
If any of the following conditions occur during start­
ing or operating, a safety interlock switch may be
malfunctioning. Contact your Walker dealer for trou­
bleshooting and/or replacement.
On a yearly interval or when an out-of-adjustment
condition is observed, check the transmission con­
trol for proper function as follows:
●● With or without an operator in the seat, the
engine starts with the Forward Speed Control
(FSC) and/or the PTO engaged, or the parking
brake disengaged.
With the mower parked on level ground, start and
run the engine, first at idle and then normal operat­
ing 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 re­
verse, refer to ADJUSTMENTS for the Neutral
Function Adjustment - Step 3 in this section.
●● With an operator in the seat and the parking
brake engaged, the engine starts but dies soon
after the parking brake is disengaged and the
Forward Speed Control (FSC) or PTO is en­
gaged.
●● Without an operator in the seat, the engine
starts and continues to run with the Forward
Speed Control (FSC) and/or PTO engaged, or
the parking brake disengaged.
●● With an operator in the seat, the Forward Speed
Control (FSC) and PTO disengaged, the parking
brake engaged, but the starter will not engage.
56
CHECKING/SERVICING
Neutral-Park
Straight Ground Tracking
Check for straight ground track by driving on a
smooth, level surface with hands off the steering le­
vers. 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 Tracking Adjustment - Step 5 in this section.
Maintenance Instructions
REPLACING/REPAIRING
REPLACING/REPAIRING
Drive Belts
There are three (3) individual belts on the ma­
chine:
DANGER
To prevent accidental starting of the engine when replacing parts or repairing the
machine, remove the key from the ignition
switch and disconnect the spark plug
wires.
●● Engine/PTO Belt (Matched Set of 2)
●● Ground Drive Belt
The belts may be removed and replaced using the
procedures described on the following pages.
IMPORTANT: ALWAYS use genuine factory re­
placement parts. Substitute parts CAN result in
product malfunction and possible injury to the op­
erator and/or others.
Ground
Drive Belt
Engine/PTO Belts
(Matched Set of 2)
Belt Locations
57
Maintenance Instructions
REPLACING/REPAIRING
Engine/PTO Belt
1.
To remove the engine/PTO belt:
a.
Remove Upper LH Belt Guard and RH Belt
Guard by removing two (2) wing nuts.
b.
Remove two (2) wire lock pins and open
Lower LH Belt Guard and PTO Belt Guard.
c.
Roll the belt off the pulley(s) and remove
the belt.
Wing Nut
Upper LH
Guard
Clutch Idler Pulley
Fixed Idler
Pulley
Lower LH
Guard
Wire Lock Pins
Right Hand
Guard
Engine/PTO Belt
(Matched Set)
PTO
Pulley
2.
Wing Nut
PTO Guard
Engine/PTO Belt (Belt Guards Open) (Engine Hidden for Clarity)
To replace the engine/PTO belt:
a.
Reverse the removal procedure to replace
the engine/PTO belt.
Upper LH
Guard
Secure
Wing Nut
b.
Secure wire on lock pin above tab on lower
PTO guard.
Right Hand
Guard
Lower LH
Guard
Front View
Secure Wire Above Tab
Secure
Wing Nut
PTO Guard
Engine/PTO Belt (Belt Guards Closed) (Engine Hidden for Clarity)
58
Maintenance Instructions
REPLACING/REPAIRING
Ground Drive Belt
1.
To remove the ground drive belt:
a.
b.
Depress the spring-loaded idler pulley to
relax belt.
LH Transaxle
Ground Drive
Belt
Slide belt off pulleys, then release the idler
pulley.
RH Transaxle
Drive Pulley
Depress Idler Pulley to
Relax Belt
Belt Tightener
Idler Pulley
Ground Drive Belt Assembly (Disengaged)
2.
Reverse the procedure to install the ground
drive belt.
LH Transaxle
Ground Drive
Belt
Drive Pulley
RH Transaxle
Belt Tightener
Idler Pulley
Ground Drive Belt Assembly (Engaged)
59
Maintenance Instructions
Fuel Filter
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.
REPLACING/REPAIRING
2.
Replace filter, making sure that the arrow on the
filter is aligned with the fuel flow through the
filter.
3.
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 driv­
en 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
Model B19 is equipped with a 10 micron in-line fuel
filter between the fuel tank and the fuel pump. Re­
placement of this filter is recommended every 400
hours of operation or when contamination is sus­
pected or found in the fuel.
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 dust and dirt.
1.
60
Expand and slide clamps on either side of the
filter away from filter and pull fuel lines off filter.
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 (over­
rides) the function of the shear bolts.
If these bolts shear, remove the blade and install
new bolts. Refer to CHECKING/SERVICING in
this section for Sharpen Mower Blades which de­
scribes the blade removal and installation proce­
dure.
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, con­
tact your Walker dealer.
Maintenance Instructions
Mower Blades
Mower blades are removed and remounted as de­
scribed in Sharpen Mower Blades instructions (re­
fer to CHECKING/SERVICING in this section). Dur­
ing 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 ma­
chine:
●● 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 re­
placed, 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.
61
Maintenance Instructions
ADJUSTMENTS
ADJUSTMENTS
2.
Transmission Control
IMPORTANT:
The proper adjustment of the
transmission control stops is essential for efficient
operation and life of the transaxle. These stops are
properly adjusted at the factory and should only
require read­justment if the transaxle 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). To fine tune tracking, refer to Step 5 Straight Tracking Adjustment in this section.
Adjust the position of the RH lever by turning the
stop bolt in the Speed Control Actuator in or out.
Turning the stop bolt in will make the RH lever
move back, and turning it out will make it move
forward. Tighten the locknut.
Stop
Bolt
Step 1 - Steering Lever Position Adjustment
NOTE: For proper operation, the steering levers
should be adjusted to sit evenly using the following
procedure.
1.
Examine the steering levers to make sure they
are parallel front to back in relation to one an­
other. If they are not equal, adjust accordingly.
(The handles may or may not be even at this
point.)
NOTE: The LH steering lever is non-adjust­able.
This procedure will require adjustment of the RH le­
ver to make it even with the LH lever.
Levers should sit
parallel to each other
Lever Alignment
62
Stop Bolt Location
Maintenance Instructions
ADJUSTMENTS
Step 2 - Steering Handles Adjustment
Step 3 - Neutral Function Adjustment
1.
1.
An adjustment range of approximately 3 in.
(76 mm) is available on the steering handles - the
han­dles can be adjusted forward or aft depend­
ing on the arm length of the operator. The han­
dles can be adjusted by loosening the locknut
at the pivot point and the locknut holding the
handle in position in the adjustment slide. Ad­
just han­dles into most comfortable position and
tighten both locknuts.
With the Forward Speed Control (FSC) in NEU­
TRAL-PARK, the lever should be straight up.
Adjust by loosening the jam nuts on the FSC
Rod and turn the rod to attain the straight up
position. Tighten the jam nuts.
Locknut
(Position)
Adjustment
Slide
Correct FSC Lever NEUTRAL-PARK Position
Locknut
(Pivot Point)
Steering Handle Adjustment
Adjust Length of
Rod to Position
FSC Lever
FSC Lever Position Adjustment
63
Maintenance Instructions
2.
Securely block the tractor up so the drive tires
are off the ground.
3.
Adjust the tracking adjustment nuts at the front
of both control rods so that 2 or 3 threads are
visible, then loosen the jam nuts on the ball joints
at the back of the control rods.
Control Rods
Control Arm
ADJUSTMENTS
WARNING
The following adjustments are made with
the engine running. Keep all body parts
and tools away from rotating and hot components, and secure all loose clothing.
4.
With the body lowered and the FSC in NEUTRAL-PARK, start the engine. With the engine
at normal operating speed, check for movement
of the drive wheels.
5.
Using a wrench on one tracking adjustment
nut, rotate the control rod counterclockwise
just until the wheel on that side begins to move
forward. Then, counting the turns required, ro­
tate the control rod clockwise just until the
wheel stops and then begins to move in reverse. Rotate the control rod back counter­
clockwise half the number of turns required to
make the wheel go from moving forward to re­
verse. The transmission is now centered in the
neutral window. Tighten the jam nut on the ball
joint and repeat the same procedure on the
other transmission.
6.
Turn off the engine, and then lower the drive
tires onto the ground.
Tracking Adjustment Nuts
Transmission Control Rod and Arm Location
(Shown with Parts Removed for Clarity)
Ball Joint
Maximum Speed
Adjustment Set Screw
Jam Nut
Control Rod
NOTE: It may be necessary to tighten the FSC
friction adjustment if the transmissions are
moved out of neutral when the body is raised.
Refer to Step 7 - Forward Speed Control Friction
Adjustment later in this section for location of
the FSC friction adjustment nut.
FWD
REV
Locating/Limit
Stud
Transmission
Control Arm
Tracking Adjustment Nut
(Adjusts Length of Control Rod)
Tracking Adjustment Components
64
Step 4 - Full Forward Speed Adjustment
1.
Move the FSC to the full FORWARD speed
position.
2.
Raise the body. The maximum speed tracking
adjustment set screw in both transmission
control arms should not be contacting the limit
stud on the transaxle. If they are, back the set
screws out until they do not touch.
Maintenance Instructions
T-Handle
Hex Wrench
ADJUSTMENTS
With the engine off, place the FSC in full
FORWARD. On the faster transmission,
loosen the jam nut and turn the maximum
speed tracking adjustment set screw in un­
til it just contacts the limit stud, and then
turn it in an additional 1/8 turn (turning the
set screw in slows the drive wheel).
b.
Recheck maximum speed tracking, and if
necessary continue adjusting the set screw
in small increments until straight travel is
achieved.
c.
Tighten the jam nut.
Maximum
Speed Tracking
Adjustment
Transmission
Control Arm
Maximum Speed Tracking Adjustment
(Shown with Parts Removed for Clarity)
Step 5 - Straight Tracking Adjustment
1.
a.
Sit in the seat, start the engine, set throttle at full
speed, and with the FSC in the NEUTRALPARK po­sition check for movement of either
drive wheel (if either wheel moves backward or
forward, re­fer to Step 3 - Neutral Function
Adjustment and readjust).
2.
Check for straight ground tracking on a level
surface (with hands off the steering levers). Set
the FSC at several different speeds and ob­serve
if the machine moves in a straight line (use
cement joint or other line on ground for refer­
ence).
3.
If tracking is not straight, shorten the control rod
on the faster side by turning the tracking adjust­
ment nut clockwise. If straight tracking and
neutral are both achieved, proceed to the next
step. If straight tracking and neutral cannot
both be achieved, turn the tracking adjustment
nut on the faster side counterclockwise until
neutral is restored.
4.
Lengthen the control rod on the slower side by
turning the tracking adjustment nut counterclockwise until straight tracking and neutral are
both achieved.
Step 6 - FSC Neutral Switch Adjustment
1.
Place the FSC lever in the NEUTRAL-PARK
position. Raise the body and adjust the switch
adjustment bolt up until it just makes contact
with the FSC switch plunger, and then turn the
switch adjustment bolt up an additional two (2)
turns and tighten the jam nut.
NOTE: It may be necessary to tighten the FSC
friction adjustment if the transmissions are
moved out of neutral when the body is raised.
Refer to Step 7 - Forward Speed Control Friction Adjustment later in this section for location
of the FSC friction adjustment nut.
FSC Switch
Switch Adjustment
Bolt
FSC Neutral Switch Location
IMPORTANT: After tracking adjustments are
complete, confirm that there is at least one (1)
thread visible on both control rods past the
tracking adjustment nuts.
5.
If the machine is tracking straight throughout
the speed range except at maximum speed,
use the following adjustment procedure:
65
Maintenance Instructions
NOTE: Adjust the bolt
downward for quicker
activation (Switch Open).
FSC Switch
Actuator Arm
ADJUSTMENTS
Step 7 - Forward Speed Control Friction Adjustment
Pull Steering Levers
Back To Check
Friction Lock
Switch Closed
in Neutral
Switch Adjustment
Bolt
Jam Nut
FSC Friction Nut
Front of Mower
FSC Full
Forward Position
FSC Neutral Switch Adjustment
(Side View Through Chassis)
CAUTION
Before testing the FSC Neutral Switch,
disconnect the spark plug wires from the
engine and engage the parking brake to
prevent accidental starting and inadvertent machine movement.
2.
Check operation of the FSC Neutral Switch by
placing the FSC lever in the full FORWARD po­
sition. While holding the ignition switch in the
START position, slowly move the FSC lever
back towards the NEUTRAL-PARK position
and stop when the starter motor engages. Note
the position of the FSC lever where it passes
through the slot in the body. The FSC lever
should be within 1/8 in. (3 mm) of the NEUTRAL-PARK position. If this distance is great­
er than 1/8 in. (3 mm), turn the adjustment bolt
down slightly and recheck switch operation.
When finished adjusting, tighten the jam nut
and reconnect the spark plug wires.
FSC Friction Adjustment Test
(Checking Friction Lock)
1.
Place the FSC lever in the full FORWARD
position, and pull both steering levers fully back;
the FSC lever should not move. If the FSC lever
moves back the friction needs to be increased.
2.
With the steering levers held back, move the
FSC lever back from the FORWARD position.
With a proper amount of friction adjusted, the
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 the conditions of both
steps 1 and 2 (above) are met.
FSC Friction
Adjustment Nut
FSC Friction Adjustment Nut
66
Maintenance Instructions
ADJUSTMENTS
Blade Clutch (PTO)
Clutch Engagement/Belt Tension
The clutch engagement and PTO belt tension are ad­
justed using the clutch actuator link. After installing
new PTO belts, after 10 hours and every 100 hours
thereafter, check and adjust for the clutch spring as­
sembly bolt head dimension as shown in the PTO
Clutch Engaged illustration. If the clutch actuator
link or clutch spring assembly have been disassem­
bled, first reset them to their factory preset lengths (as
shown in the PTO Clutch Disengaged illustration)
and then proceed with adjustment as follows.
Adjust the length of the clutch actuator link to achieve
a clutch spring assembly bolt head clearance of
1/4 in. to 5/16 in. (6.35 mm to 7.94 mm) with the clutch
engaged. To adjust length: remove ball joint from
clutch arm and shorten the clutch actuator link to
increase this measurement, or lengthen the clutch
actuator link to decrease this measurement. If
adjustments are needed more frequently than every
100 hours to maintain dimensions, it may suggest
problems with pulley wear or belt misalignment.
Clutch Actuator
Link
1/4 in. to 5/16 in.
(6.35 mm to 7.94 mm)
Ball Joint
Blade Clutch
Engaged
Clutch Spring Assembly
(Spring Compressed)
Clutch Engagement
Arm
Clutch Arm
Safety
Switch
Blade Clutch
Idler Pulley
Front of Mower
PTO Clutch Engaged
67
Maintenance Instructions
Knuckle Joint
ADJUSTMENTS
Use the following procedures to check and adjust
clutch disengagement and brake action:
Step 1 - Idler Pulley Maximum Travel Adjustment
2-1/8 in.*
(53.98 mm)
6-1/2 in.*
(165.1 mm)
Clutch Actuator
Link
6 in.*
(152.4 mm)
Clutch Spring Assembly
(Spring Uncompressed)
*NOTE: Factory preset dimensions. Reset to
these dimensions prior to adjustment if compo­
nents have been disassembled.
PTO Clutch Disengaged
Loosen the brake band adjustment nut allowing
clutch pivot stop arm and stop bolt to make contact
(refer to Blade Brake Band Adjustment illustra­
tion).
1.
To check the pulley travel, first engage the
clutch, then measure the distance the pulley
travels as the clutch is disengaged and the stop
arm contacts the stop bolt.
2.
Adjust the pivot stop bolt to give 1 in. to 1-1/8 in.
(25 mm to 29 mm) pulley travel from “clutch en­
gaged” to “clutch disengaged”.
NOTE: This adjustment will prevent excessive
pulley travel that can cause belts to develop too
much slack, causing possible belt derailment
upon disengagement.
1 in. to 1-1/8 in.
(25 mm to 29 mm)
CLUTCH DISENGAGED
CLUTCH ENGAGED
Clutch Disengagement/Brake Action
WARNING
It is important to check and maintain
blade brake action for safe operation of
the machine.
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 band connected to the clutch engage­
ment arm. The brake is designed to stop the blades
within five (5) seconds after disengaging the clutch.
Idler Pulley
Clutch Pivot
Stop Arm
Clutch Pivot
Stop Bolt
Brake Engagement
Arm
Clutch Idler Pulley Travel
68
Maintenance Instructions
Step 2 - Blade Brake Band Adjustment
After the maximum pulley travel is set, adjust the
working travel of the clutch idler pulley by adjusting
the brake band nut and make the following adjust­
ment as needed:
1.
Adjust the blade brake band, using the adjust­
ment nut until pulley travel is approximately
5/8 in. to 3/4 in. (16 mm to 19 mm) from en­
gaged to disengaged.
NOTE: As blade brake band/drum wears,
pulley travel will increase and it will be necessary to adjust the blade brake band nut to
maintain these dimensions.
ADJUSTMENTS
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.
Make sure clutch and brake linkage are
working freely (no binding).
b.
Check the brake band lining for wear.
c.
Check the brake drum on the pulley. If
excessive wear is present, it will be necessary to replace worn parts.
Tilt-Up Deck Adjustable Stop
When the carrier frame hinge joint is properly ad­
justed, 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 com­
plete.
CLUTCH DISENGAGED
CLUTCH ENGAGED
Clutch Idler Pulley Travel Adjustment
Jam Nut
Blade Brake
Band
Set Screw
Tilt-Up Deck Adjustable Stop
Blade Brake
Band Adjustment Nut
Chassis Mount
(Ref)
Blade Brake Band Adjustment
69
MAINTENANCE AND SERVICE RECORD SHEET
DATE
SERVICE
ITEM
ENGINE
HOURS
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70
LIMITED WARRANTY
FOR
WALKER MODEL B19
RIDER MOWERS
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, transpor­
tation 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 obliga­
tion, liability or modification for these items, which are covered exclusively by the stated warranty of the respective manufac­
turers noted above.
* Extended warranties are offered for the following powertrain components:
• A two (2) year or 2000 hour (whichever comes first) warranty is offered for Hydro-Gear ZT3100 Hydrostatic transaxle;
covers full cost of replacement up to 1000 hours of use, and after 1000 hours warranty coverage is prorated against
2000 hours.
2.
3.
WHAT THIS WARRANTY DOES NOT COVER:
A.
This warranty does not cover defects caused by depreciation or damage caused by normal wear, accidents, improper
maintenance, improper use or abuse of the product, alterations, or failure to follow the instructions contained in the
Operator’s Manual for operation and maintenance.
B.
The customer shall pay any charges for making service calls and/or for transporting the mower to and from the place
where the inspection and/or warranty work is performed.
HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:
Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Walker Manu­
facturing Company, 5925 East Harmony Road, Ft. Collins, CO 80528. Proof of the date of purchase may be required to veri­
fy 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.
71
WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, CO 80528 • (970) 221-5614
FORM NO. 052119
PRINTED IN USA
www.walker.com
©2019 WALKER MFG. CO

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