Walker B23i Operator's Manual


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Walker B23i 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: 154037
P/N 4000-23
Foreword
Thank you. . .for purchasing a Walker mower. Every effort has been made to provide you with the
most reliable mower on the market, and we are sure you will be among our many satisfied customers. If for any reason this product does not perform to your expectations, please contact your local
dealer. Every customer is important to us. Your satisfaction is our goal.
Please. . .read this manual thoroughly! This manual is to be used in conjunction with the engine
manufacturer’s manual for the specific engine on the mower model you have purchased. Before
you operate your new mower, please read this entire manual. Some of the information is crucial for
proper operation and maintenance of this mower - it will help protect your investment and ensure
that the mower performs to your satisfaction. Some of the information is important to your safety,
and must be read and understood to help prevent possible injury to the operator or others. If anything in this manual is confusing or hard to understand, please contact your local authorized dealer
or call our service department, at (970) 221-5614, for clarification before operating or servicing this
mower.
This manual covers Model B23i with the Kohler Command Pro ECH730 (23.0 HP) Electronic Fuel
Injection (EFI) gasoline engine.
All shields and guards must be in place for the proper and safe operation of this machine.
Where they are shown removed in this manual, it is for illustration purposes only. Do not operate
this machine unless all shields and guards are in place.
Specifications given are based on the latest information available at the time this manual was produced for a tractor with standard equipment. Optional equipment is available and may affect the
standard specifications listed.
Walker Mfg. Co. is continually striving to improve the design and performance of its products. We
reserve the right to make changes in specifications and design without thereby incurring any obligation relative to previously manufactured products.
Sincerely,
WALKER MANUFACTURING COMPANY
Bob Walker, President
Table of Contents
General Information_________________ 1
Operating Instructions______________ 26
HIGHLIGHTED INFORMATION______________
GLOSSARY_____________________________
IDENTIFYING NUMBER LOCATIONS_________
ENGINE SERIAL NUMBER LOCATION________
SERVICING OF ENGINE AND
DRIVETRAIN COMPONENTS_______________
CONTROL IDENTIFICATION,
LOCATION, AND FUNCTION ______________
Ignition Switch________________________
Engine Throttle________________________
Forward Speed Control (FSC)____________
Steering Levers_______________________
Blade Clutch (PTO)_____________________
Oil Pressure Warning Horn______________
Parking Brake_________________________
Transaxle Lockout Arms________________
Engine Service Light___________________
Circuit Breaker________________________
Body Latch___________________________
Hourmeter____________________________
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_________________________________
ELECTRICAL SYSTEM____________________
TRANSAXLE_____________________________
BLADE DRIVE___________________________
TIRE SIZE_______________________________
TIRE PRESSURE_________________________
MOWER DECK___________________________
DIMENSIONS (Tractor and Mower)___________
DRIVE BELTS____________________________
SEAT___________________________________
FRAME/BODY CONSTRUCTION_____________
3
3
3
4
4
4
4
5
5
5
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
18
18
19
19
19
20
20
20
21
21
23
24
26
26
27
27
27
27
27
28
28
28
29
29
29
31
31
33
34
35
35
36
38
Maintenance Instructions___________ 39
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 or DS62 Mower Deck Lubrication____
Check Transaxle Fluid Level_____________
Transaxle Oil and Filter Change__________
39
40
40
40
40
40
41
41
41
41
41
42
43
43
46
46
46
47
Table of Contents
CLEANING_____________________________
Engine Air Cooling System______________
Cooling Air Intake Screen_______________
Cylinder Head Cooling Fins_____________
Engine Air Cleaner System______________
Donaldson Radialseal ™ 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_______________
REPLACING/REPAIRING__________________
Drive Belts____________________________
Engine/PTO Belt______________________
Ground Drive Belt_____________________
Fuel Filter____________________________
Blade Overload Shear Bolts_____________
Mower Blades_________________________
48
48
48
48
49
49
51
52
53
53
53
53
54
54
54
54
54
55
55
56
56
56
56
56
56
56
57
57
57
57
58
58
59
60
61
61
62
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_____________
63
63
63
64
64
66
66
66
Warranty______________________
71
67
68
68
69
69
70
70
General Information
HIGHLIGHTED INFORMATION
Walker Manufacturing recommends that any service
requiring special training or tools be performed by
an authorized Walker Mower dealer. There are several general practices to be aware of in the area of
safety. Most accidents associated with the operation or maintenance of a Walker Mower are caused
by disregarding basic safety precautions or specific
warnings. Such accidents, in most cases, can be
prevented by being aware of the dangers present.
Information of special importance has been highlighted in bold type in this manual. Refer to Safety
Instructions for the meanings of DANGER, WARNING, CAUTION, IMPORTANT, and NOTE.
GLOSSARY
There are many terms that are either unique to this
equipment or that are used as acronyms. The
following terms and their definitions will help while
using this manual:
●● DECK is the mowing attachment mounted on
the front of the tractor which includes the carrier
frame, deck housing, belt or gear drive components, and cutter blades.
●● TRACTOR is the prime mover, including the engine, drivetrain, operator seat, and controls to
operate the mower.
●● TRANSAXLE transmits and controls power
from the ground drive belt to the main drive
wheel.
●● TRANSAXLE LOCKOUT ARMS release the
transaxles to permit freewheeling the tractor.
IDENTIFYING NUMBER LOCATIONS
The tractor serial number plate is affixed to the tractor body just below the left rear corner of the seat.
The mower deck serial number plate is affixed
alongside the angle iron framing on the LH side of
the LH mower blade drive. Model and serial numbers are helpful when obtaining replacement parts
and maintenance assistance. For ready reference,
please record these numbers in the space provided.
Tractor Model No. _______________________
Tractor Serial No. _______________________
Deck Serial No.
_______________________
●● ELECTRONIC CONTROL UNIT (ECU) controls engine functions such as spark timing,
fuel/air ratio, etc.
Engine Model No. _______________________
●● FORWARD SPEED CONTROL (FSC) controls
the maximum forward speed of the tractor;
functioning as a cruise control.
Date of Purchase _______________________
●● GROUND DRIVE refers to the dual transaxles
which drive the main wheels.
●● LEFT HAND (LH) refers to the left-hand side of
the tractor when the operator is seated facing
forward in the tractor seat.
Engine Serial No. _______________________
Fill In By Purchaser
Serial Number
●● POWER TAKE-OFF (PTO) transmits engine
power to run the cutter blades.
●● 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.
Tractor Serial Number Location
●● STEERING LEVERS steer the tractor by controlling the two transaxles.
1
General Information
Serial Number
Mower Deck Serial Number Location
ENGINE SERIAL NUMBER LOCATION
Refer to the engine manual that accompanies this
manual or the photo below for the location of the
engine serial number.
SERVICING OF ENGINE AND DRIVETRAIN
COMPONENTS
The detailed servicing and repair of the engine,
transaxles, and gearboxes are not covered in this
manual. Only routine maintenance and general service instructions are provided. For the service of
these components during the limited warranty period, it is important to find a local, authorized servicing
agent of the component manufacturer. Any unauthorized work done on these components during
the warranty period may void the warranty. If you
have any difficulty finding an authorized outlet or obtaining warranty service, please contact our Service
Department for assistance:
Walker Manufacturing Company
5925 E. Harmony Road
Fort Collins, CO 80528
1-970-221-5614
www.walker.com
Service manuals are available for each of these
components from their respective manufacturers as
follows:
Kohler Engine
Kohler Company
Kohler, WI 53044
800-544-2444
www.kohlerengines.com
Transaxle
Hydro-Gear
1411 South Hamilton St.
Sullivan, IL 61951
877-728-7410
www.hydro-gear.com
Gearboxes (Deck)
Peerless Gear
1555 South Jackson St.
Salem, IN 47167 USA
866-536-8310
www.peerlessgear.com
Serial Number
Engine Serial Number Location
2
Specifications
MODEL
B23i
ENGINE
Manufacturer/Model
Kohler Command Pro ECH730, V-Twin, 2 Cyl. Gasoline
(Air-Cooled), Electronic Fuel Injection (EFI)
Displacement cu. in. (cc)
45.5 (747)
Max. Power HP (kW)
23.0 (17.2) @ 3600 RPM
Governed RPM
3600
Max. Torque lb·ft (N·m)
38.1 (51.7)
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
Fuel Tank Capacity gal (L)
4.7 (17.8)
Fuel
Automotive Grade Unleaded Gasoline
(87 Octane Minimum, 10% Ethanol Maximum)
Cooling System
Air-Cooled
Air Cleaner
Remote mounted Donaldson Radialseal™ (5”) - S/N 151948 And On
(Walker P/N 5090-8 Primary/5090-7 Safety Filter)
ELECTRICAL SYSTEM
Battery
12 Volt, 300 CCA
Charging System
Flywheel Alternator
Charging Output
20 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, Transaxle Neutral,
Blade Clutch, and Parking Brake
Circuit Breaker(s)
Manual Reset (5A)
Auto Reset (30A)
TRANSAXLE
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
B23i
TRANSAXLE (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
Transaxle Fluid
Factory Service
20W-50 Multi-Viscosity Motor Oil (Minimum SL Grade Oil)
Transaxle Oil Capacity fl oz (L)
79 (2.3)
Transaxle 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
8 x 3.00-4 Semi-Pneumatic (Standard)
8 x 3.00-4 Pneumatic 4-Ply (Optional)
11 x 4.00-5 (Pneumatic 4-Ply, DS52, DS62, DS74 Only)
Drive
18 x 8.50-10 (Pneumatic 4-Ply Low-Profile)
Tailwheel
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 74 in. (91 to 188 cm)
Mulch
36 to 52 in. (91 to 132 cm)
Cutting Height
1.5 to 4 in. (4 to 10 cm) or
1.5 to 4.5 in. (4 to 11.5 cm) (DS52 & DS62 Belt Driven Decks Only)
Deck Suspension
Independent Torsion-Flex Frame with Caster Wheels and
Counterweight Springs
Specifications
MODEL
B23i
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
588 (267)
Tractor with 48" Mulch Deck
(DM48-2)
794 (360)
DRIVE BELTS
Engine PTO
Walker P/N 4230-1 (Matched Pair)
Ground Drive
Walker P/N 4230-2
SEAT
Built-up Seat with Steel Frame, Extra Thick Foam Cushions and
Bolsters, and Removable/Replaceable Nylon Backed Vinyl Covers
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.
Body Lift
Handle
Forward Speed
Control (FSC)
Friction
Adjustment
Tilt-Up Latch
Counterweight Springs and
Protective Covers
Body Tilt-Up Latch
(Not Visible)
Deck Support
Arm
Deck Support
Pins and Height
Adjustment
Hitch Pins
Tilt-Up
Deck Handle
Oil Pressure
Warning Horn
(Not Visible)
Deck
Support Arm
Footrests
Deck Lift Handle
(Cutting Height Adjustment)
Footrests
Tilt-Up
Hook
Front View and Right Side View
6
Deck
Caster Wheels
Component Identification
Fuel
Guage
Fuel Pickup
Line
Oil Fill
Dipstick
Muffler
Tailpipe
Footrests
Muffler
Heat Shield
Left Hand
Drive Wheel
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
LH Transaxle
Control Rod
Steering Lever
Spring / Dampeners
RH Transaxle
Control Rod
LH Transaxle
RH Transaxle
LH Transaxle
Lockout Arm
RH Transaxle
Lockout Arm
Parking Brake
Linkage
Air Cleaner
Cover
Parking Brake
Lever
PTO Clutch
Lever
Fuel Tank Cap
Air Filter
Restriction
Gauge
Fuel Tank
Transaxle Oil
Expansion
Reservoir
Fuel Gauge
Fuel Pump
(Low Pressure)
Roll Over Valve
EVAP Line
Battery Box
and Cover
Fuel Pickup Line
Air Cleaner
Cover Latch
Fuel Filter
30-Amp Master
Circuit Breaker
(Not Visible)
Oil
Cooler
Oil Fill
Oxygen
Sensor
Dipstick
Rubber Bumpers
(Body Support)
Muffler Heat
Shield
Top View (Engine Compartment)
8
Safety Instructions - Before Operating
Pay particular attention to any information labeled
DANGER, WARNING, CAUTION, IMPORTANT,
and NOTE in this manual.
When you see the Safety Alert Symbol (
), read,
understand, and follow the instructions. Fail­ure to
comply with safety instructions may result in personal injury.
The seriousness or degree of importance of each
type of information is defined as follows:
DANGER
An IMMEDIATE hazard that WILL result in
severe personal injury or DEATH, if warning is ignored and proper safety precautions are not taken.
Walker Manufacturing cannot predict every potentially dangerous situation. Therefore, items labeled
as such in this manual do not cover all conceivable
situations. Any person using procedures, tools, or
control techniques not recommended by Walker
Manufacturing must take full responsibility for safety.
The Walker Rider Lawnmower has been designed
with many safety features to protect the operator
from personal harm or injury. However, it is necessary for the operator to use safe operating procedures at all times. Failure to follow safety instructions contained in this manual may result in
personal injury or damage to equipment or property.
If you have any questions concerning setup, operation, maintenance, or safety, please contact your
authorized Walker Mower dealer or call Walker
Manufacturing Company at (970) 221-5614.
BEFORE OPERATING
WARNING
1.
A POTENTIAL hazard that COULD result in
severe personal injury or DEATH, if warning is ignored and proper safety precautions are not taken.
Walker Manufacturing Company
5925 East Harmony Road
Fort Collins, CO 80528
CAUTION
Possible hazards or unsafe practices that
MAY result in MODERATE personal injury
or property damage, or machine damage, if
warning is ignored and proper safety precautions are not taken.
IMPORTANT: Identifies mechanical information
demanding special attention, since it deals with the
possibility of damaging a part or parts of the machine.
NOTE: Identifies information worthy of special
attention.
Read and understand the contents of this
Operator’s Manual before starting and operating the machine. Become thoroughly familiar with all machine controls and how to stop the
machine and disengage the controls quickly.
Replacement Operator’s Manuals are available
by sending the Model and Serial Number to:
2.
Never allow children to operate rider mower.
Do not allow adults to operate without proper
instruction.
3.
Clear the area to be mowed of any foreign
objects which may be picked up and thrown by
cutter blades. Pick up all sticks, stones, wire,
and any other debris.
4.
Keep everyone, especially children and pets, a
safe distance away from the area being mowed.
Do not mow with bystanders in the area.
5.
Do not operate the machine barefoot or wearing
sandals, sneakers, tennis shoes, or similar
lightweight footwear. Wear substantial protective footwear.
9
Safety Instructions - Before Operating
6. Do not wear loose fitting clothing that could get
caught in moving parts. Do not operate this machine while wearing shorts; always wear adequate protective clothing, including long
pants. Wearing safety glasses, safety shoes,
and a helmet is advisable and required by some
local ordinances and insurance regulations.
7.
Prolonged exposure to loud noise can cause
impairment or loss of hearing. Operator hearing protection is recommended. Wear a suitable hearing protective device, such as earmuffs or earplugs.
8.
Keep all protective shields and safety devices in place. If a protective shield, safety
device, or decal is damaged, unusable, or missing, repair or replace it before operating the
machine.
9.
Be sure interlock switches are functioning
correctly, so the engine cannot be started unless the Forward Speed Control lever is in the
NEUTRAL-PARK position, 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 Control (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 container
cap securely and clean up any spilled fuel
before starting the engine.
11. Never attempt to make any adjustments
while the engine is running, except where
specifically instructed to do so.
12. The electrical system battery contains sulfuric
acid. Avoid any contact with skin, eyes, and
clothing. Keep the battery and acid out of reach
of children.
WARNING
This product can expose you to chemicals
including 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 operation, and if the machine is on a slope, the
machine will freewheel down the slope. To
maintain control, immediately (1) Release the
steering levers and simultaneously (2) Move
the FSC to the NEUTRAL-PARK position.
When the machine is stopped or moving slowly,
engage the parking brake.
NOTE: The emergency stop procedure is exactly the same procedure used to normally stop
and park the machine.
6.
Disengage the blade clutch, 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
moving 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 backing the machine up, look to the rear to be sure
no one is behind the machine. Watch carefully
for traffic when crossing or working near roadways.
12. When moving forward, do not suddenly put the
tractor in reverse by rapidly pulling on the steering levers, especially when going downhill, as
this can lift the tractor tail wheel off the ground
and set up a bucking motion due to operator
overcontrol. If bucking does occur, immediately
stop the bucking action by pulling the Forward
Speed Control (FSC) lever into the NEUTRALPARK position.
13. Disengage the blade drive when transporting
the machine across drives, sidewalks, etc.
Never raise the mower deck while blades are
rotating.
DANGER
Do not mow or 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 26% grade. When
operating the machine on a slope, reduce speed
and use caution to start, stop, and maneuver.
To prevent tipping or loss of control of the machine, avoid sharp turns or sudden changes in
direction. Do not operate the machine on a
slope greater than 15 degrees.
15. Never adjust cutting height with the engine
running. Before adjusting cutting height or
servicing, disengage the blade clutch (PTO),
engage parking brake, stop the engine, and remove 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 position.
17. When using the tilt-up deck, observe the following:
a.
Do not move tractor with deck in tilt-up
position.
b.
Never tilt body forward with deck in tilt-up
position.
18. In case of a clogged or plugged mower deck:
12
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 unclog the system.
c.
Disconnect the spark plug wires.
d.
Never place hands under the deck - use a
stick or similar tool to remove clogged material.
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 repair any damage before restarting the engine
and operating the mower. Make sure cutter
blades are in good condition and blade nuts are
torqued to 60 lb·ft (81 N·m) for gear driven
decks, and blade bolts torqued to 70 lb·ft (95
N·m) for belt driven decks.
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.
Safety Instructions - Maintenance
1.
To prevent accidental starting of the engine
when servicing or adjusting the machine, remove the key from the ignition switch and disconnect the spark plug wires.
2.
To reduce fire hazards, keep the engine free
of grass, leaves, excessive grease, and dirt.
3.
11. Use care when charging the battery or per­
forming maintenance on the battery and electrical system:
a.
Make sure the battery charger is unplugged
before connecting or disconnecting cables
to the battery.
Keep all nuts, bolts, and screws tight to ensure
the machine is in a safe, working condition.
Check the blade mounting nuts frequently, mak­
ing sure they are tight.
b.
Charge the battery in a well-ventilated
space, so gases produced while charging
can dissipate. Make sure the battery vents
in the caps are open.
4.
Perform only maintenance instructions described in this manual. Unauthorized maintenance operations or machine modifications
may result in unsafe operating conditions.
c.
Keep sparks, flames, and smoking materi­
als away from the battery at all times. To
avoid sparks, use care when removing bat­
tery cables from posts.
5.
If the engine must be running to perform a main­
tenance adjustment, keep hands, feet, and
clothing away from moving parts. Do not wear
jewelry or loose clothing.
d.
Disconnect both battery cables before unplugging any wiring connectors or making
repairs on the electrical system.
6.
Always use the proper engine service
manual when working on the engine.
Unauthorized maintenance operations or
modifications to the engine may result in unsafe
operating conditions.
7.
Altering the equipment or engine in any manner
which adversely affects its operation, perfor­
mance, durability, or use will VOID the warranty and may cause hazardous conditions.
8.
Never attempt to disconnect any safety devices
or defeat the purpose of these safety devices.
9.
Do not change the engine governor settings or
overspeed the engine. The governor has been
factory-set for maximum-safe engine operating
speed.
12. Do not attempt to service the engine fuel injection system, which contains high pressure fuel
and may cause injury if mishandled. For service of the pressurized fuel system, including
the fuel pump module, fuel lines, and fuel injectors, contact your Walker dealer or authorized
Kohler service dealer.
IMPORTANT: Keep all applicable manuals immediately accessible to anyone who may operate or service this machine.
10. Use genuine factory replacement parts.
Sub­stitute parts may result in product malfunction and possible injury to the operator and/or
others.
13
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
1.
2.
8600-28
Location: Each End of Mower Deck
Part Number: 8600-28
1.
Warning – thrown object hazard.
●● Keep bystanders away from the machine
when operating.
●● Clear lawn of debris before operating.
●● Keep any discharge deflector in place and in
the lowest position.
2. Warning – rotating mower blades are a cutting/
dismemberment hazard to hands and feet.
●● Keep all body parts away from rotating mower blades.
●● Do not step on end of deck.
8600-2
Location: Flex Coupler Guard in Front of Engine
Part Number: 8600-2
1.
Warning – entanglement and cutting/dismemberment hazards.
●● Keep away from rotating shafts, belts, and
other components.
1.
1.
8600-14
Location: Deck Carrier Frame
Part Number: 8600-14
1.
Location: Deck Carrier Frame
Part Number: 8600-15
1.
Warning – lock deck tilt-up hinge before operating 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 transmission and allow machine to freewheel.
5848-3
Location: Deck Discharge Shield
(SD Decks Only)
Part Number: 5848-3
1.
Warning – thrown object hazard.
●● Always keep the discharge shield in the lowest 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.
2.
3.
<15°
4.
1.
2.
3.
5.
4.
6.
5.
7.
Location: LH Fender
Part Number: 8600-47
Location: RH Fender
Part Number: 8600-26
1.
1.
2.
3.
4.
5.
6.
7.
Throttle
●● Move lever forward to increase engine
speed; back to idle.
Warning – read Operator’s Manual before operating 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.
Warning – entanglement hazard.
●● Keep all guards in place while engine is running.
Parking Brake
●● Move lever forward to engage Parking
Brake; back to disengage.
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 servicing 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.
GROUND DRIVE BELT
WALKER P/N 4230-2
Location: Deck Gearbox Cover
Part Number: 8600-39
1.
1.
Warning - stop engine and remove ignition key
before adjusting deck cutting height.
2.
4107-12
60 lb·ft (81 N·m)
1.
8600-9
Location: Gearbox Cover
(Gear Drive Decks Only)
Part Number: 8600-9
1.
ENGINE/PTO BELT
WALKER P/N 4230-1
Location: Rear Body
Part Number: 4107-12
1.
2.
Ground drive belt routing.
Engine/PTO clutch belt routing.
Tighten blade nuts on gear driven decks to
60 lb·ft (81 N·m).
1.
Location: Front Body
Part Number: 5802-4
1.
Engine Service Indicator Light
●● If illuminated during operation contact an
authorized Kohler Service Dealer as soon as
possible.
Location: Body, Left Side
Part Number: 5082-5
1.
8600-5
1.
Location: Rear Body Near Muffler
Part Number: 8600-5
8600-12
Location: Engine
Part Number: 8600-12
1.
16
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.
Warning – hot surface, do not touch.
Location: Engine Shroud
Part Number: 5855
Assembly Instructions
SETUP INSTRUCTIONS
Walker Mowers are shipped partially assembled to
our distribution network, and are typically assembled by the selling dealer. For any additional assembly besides the following, contact your Walker
dealer.
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.
Tire Installation (Tractor)
●● Install the drive tires using the eight (8) mounting
nuts that are supplied with the Owner’s Packet of
materials. Nuts are torqued to 75 to 85 lb·ft
(102 to 115 N·m).
●● Check and adjust the inflation of the tires. The
tire inflation recommendations are:
Drive
Tailwheel
= 15 PSI (103 kPa)
= 20 PSI (137 kPa)
Battery Box
and Cover
Battery Service
CAUTION
Important Battery Service, Installation, and
Charging Tips for Electronic Fuel Injection
Engines:
●● Do not allow the battery cables to touch
opposing terminals. When connecting battery cables attach the positive (+) cable to
positive (+) battery terminal first, followed
by negative (-) cable to negative (-) battery
terminal.
●● Never start the engine when the cables
are loose or poorly connected to the battery terminals.
●● Never disconnect battery while engine
is running.
Battery Location
IMPORTANT:
Make sure battery is securely
mounted in the frame. A loose battery may cause
damage to the case resulting in acid leakage and
severe damage to the machine. A hazard may be
created by damage to critical working parts and
safety systems.
Wet Battery Service
If the battery has been shipped wet, but the electrolyte level is low or the battery needs to be charged
then:
1.
Fill each battery cell with distilled water to the
bottom of the vent wells.
2.
Charge battery. Refer to Battery Charging in
this section.
●● Never use a quick battery charger to
start the engine.
●● Never “jump start” the engine using another source. Electricity fluctuations can
damage the ECU (Electronic Control Unit).
●● Always disconnect negative (-) battery
cable lead before charging battery, and
also unplug harness from ECU before performing any welding on equipment.
17
Assembly Instructions
Dry Battery Service
Battery Charging
DANGER
DANGER
BATTERIES PRODUCE EXPLOSIVE GASES
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.
●● Charge the battery in a well-ventilated
area, so that gases produced while charg­
ing can dissipate.
●● Keep sparks, flames, and smoking mate­
rials away from the battery at all times.
●● Make sure the battery cap vents are
open after the battery is filled with acid
(check manifold vent on each cap).
●● Make sure the battery charger is unplugged before connecting or disconnecting cables to the battery.
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.
●● Neutralize acid spills with baking soda
and water solution.
IMPORTANT: Always disconnect the negative (-)
battery terminal before charging. Failure to do so
can result in damage to the ECU.
1.
Charge the battery at 15 amps for 10 minutes.
DO NOT exceed 20 amps maximum recom­
mended charging rate. Charge until specific
gravity is at least 1.250. Total charging time
should not exceed one (1) hour.
2.
After charging the battery, adjust the electrolyte
level to the bottom of the vent wells [1/4 to 1/2 in.
(6 to 13 mm) above the plates].
To fill (activate) battery with electrolyte (if battery has
been shipped dry):
1.
Remove the battery cover plate and battery
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.
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.
18
2.
Remove the filler caps and carefully fill each cell
until the electrolyte is just above the plates.
3.
After the battery is filled with electrolyte, replace
the filler caps and charge the battery. Refer to
Battery Charging.
IMPORTANT: DO NOT overfill the battery.
Electrolyte will overflow through the vented caps
onto parts of the machine and WILL result in severe corrosion.
3.
Install battery.
Assembly Instructions
Battery Installation
Mower Deck Assembly
IMPORTANT: Make sure battery is securely mounted in the frame. A loose battery may cause damage
to the case resulting in acid leakage and severe
damage to the machine. A hazard may be created
by damage to critical working parts and safety systems.
Deck Caster Wheels Installation
Install the battery in the mower as shown in Battery
Installation photo. Connect the positive (+) first and
then the negative (-) cable to the proper battery terminal [red cable and boot connects to the Positive (+) terminal]. Slide the rubber boot up and over
the battery post, making sure it covers the post completely to prevent an electrical short. Install battery cover using two (2) 10-24 threaded knobs.
1.
Remove the bolt, nut, and axle spacer tube from
each deck caster wheel fork.
2.
Fit the axle spacer tube through the wheel hub
and fit the assembly into the wheel fork.
3.
Insert the 3/8-16 x 4-1/2 in. bolt through the
wheel fork with the bolt head to the outside and
install the 3/8-16 in. Keps nut.
4.
Tighten the bolt and nut until the inner bearing
race bottoms against the inside of the wheel
fork (will not turn) while the wheel spins freely
without binding.
WARNING
Axle Spacer Tube
Make sure the battery cap vents are open.
Improper venting of the battery COULD
cause a battery explosion.
Axle Bolt
(+) Battery
Terminal
Battery Clamp Secured
by Wing Nut(s)
Deck Caster Wheel Installation
5.
Grease the caster pivot bearings - one grease
fitting for each pivot.
Battery Installation
Two (2) 10-24 Threaded
Knobs Mount Cover
Battery Cover
Battery Cover Installation
19
Assembly Instructions
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
Position the shaft guard as shown and mount with
two (2) 1/4-20 x 1/2 in. bolts.
Carrier Frame
Tube Sockets
WARNING
DO NOT operate the machine without the
grass deflector shield attached and in the
lowest possible position.
Attach Shield
Attach
Guard
PTO Shaft Guard Installation
Tilt-Up Roller Wheel Installation
Mount the two (2) tilt-up roller wheels on the brackets on the rear skirt of the deck housing using the
P/N 8490 axle bolt, 3/8 in. wave spring washer and
3/8-16 in. Whiz locknut. Tighten the axle bolt until
the wheel rolls freely, but is not loose.
Deck Discharge Shield Installation
Roller
Wheels
Roller Wheel Installation
20
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.
Deck Support
Arms
Reaching under the tractor, slide the PTO coupler tube onto the deck drive shaft (align arrow
decals), then install the coupler quick disconnect onto the tractor PTO drive shaft.
Arrows on Shaft and Tube
(Used to Align When Sliding Together)
Grease Deck
Support Arm(s)
PTO
Connection
PTO Shaft Connection
IMPORTANT: When installing the DS52 or
DS62 Mower deck, make sure to retract the dolly wheel after mounting the deck on the tractor.
Mower Deck Installation
2.
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 approximately 3 in. (76 mm).
3.
Retract the spring-loaded quick disconnect ring
on the PTO Coupler and insert the Coupler Installation Tool (provided in Owner’s Packet) as
shown in the photo below.
NOTE: The Coupler Installation Tool is provided
for convenience, but is not required for installation.
Coupler
Installation Tool
PTO Coupler
Tube
5.
Remove Installation Tool from quick disconnect
ring and make sure the ring has “snapped” securely on the spline shaft.
IMPORTANT: DO NOT operate tractor with
Coupler Installation Tool installed.
IMPORTANT: To prevent damage to the mower, make sure the PTO quick disconnect is securely locked on the tractor, with the locking
balls fully seated in the groove and the ring in the
locked position (refer to the Quick Disconnect
Ring “Locked” Position illustration). After installation, pull on the PTO coupler to check for
security.
Retract Spring-Loaded
Quick Disconnect Ring
PTO Coupler Installation Tool
21
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 tension can be adjusted by tightening or loosening
the elastic stop nuts located underneath the
lower spring hook, or contact your local dealer
if additional help is required. Refer to Deck
Counterweight Spring Installation photo.
PTO Coupler
U-Joint
Quick Disconnect Ring “Released” Position
Internal Balls
Locked on Shaft
PTO Coupler
U-Joint
PTO Drive
Shaft
Coupler Ring in
Locked Position
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.
22
Raise the mower body (instead of lifting the
front of deck) and clip the counterweight springs
to the receptacle on front of body. Lower the
body to tension the springs. (Refer to Deck
Counterweight Spring Installation photo.)
Spring Tension Adjustment Nut
Located Under Lower
Spring Hook (Not Visible)
Counterweight Springs
Clip Onto Body With
Body Tilted Up
Hitch Pins Lock Deck
on Support Arms
Deck Counterweight Spring Installation
Assembly Instructions
Deck Leveling
The mower deck and support frame are jig welded;
within normal tolerances, very little, if any, shimming
should be required to level the deck. Tire pressure
will influence the levelness of the deck. Check the
tire pressure of all pneumatic tires as a possible
cause of the deck not being level.
1.
WARNING
The machine must be shut off during this
procedure.
2.
Check the side-to-side level. Rotate each
blade sideways and measure the distance
from blade tip to ground on each side. If measurements vary more than 1/8 in. (3 mm), add a
washer shim under the deck support pins on the
low side to level the deck.
3.
Check the front-to-rear level. Rotate the blades
to point forward. Measure the distance from
blade tip to ground on the front and rear. The rear
of the blade should be 1/8 to 1/4 in. (3 to 6 mm)
higher than the front of the blade; shim the rear
(or front) deck support pins equally to achieve at
least 1/8 in. (3 mm) difference.
Position mower on a smooth, level surface. Set
the cutting height to the highest position - 4 in.
(102 mm) - for easy access under the deck to
measure blade height. Refer to ADJUSTING
CUTTING HEIGHT in Operating Instructions.
NOTE: A block of wood cut 4 in. (102 mm) high
is a convenient gauge to measure blade height
above ground during the leveling process.
4 in. (102 mm)
Wood Block
Should be 1/8 in. (3 mm)
to 1/4 in. (6 mm) higher
at the rear of the blade
Should not vary more
than 1/8 in. (3 mm)
side-to-side
NOTE: For 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.
4 in. (102 mm)
Wood Block
Deck Leveling
23
Assembly Instructions
PREOPERATING CHECKLIST
Before operating the mower for the first time, and as
a routine before daily operations, it is important to
make sure the mower is properly prepared and
ready for operation. The following is a list of items
to be checked. (For a mower with frequent operation, some of these items will not need to be checked
every day, but the operator should be aware of the
condition of each.)
For proper fuel and lubricants refer to Specifications.
FILL FUEL TANK
Fill the fuel tank using clean, fresh automotive grade
unleaded gasoline (87 octane minimum, 10% ethanol maximum).
DANGER
Handle gasoline with care. Gasoline is
highly flammable and its vapors are explosive. Use safe refueling procedures:
●● DO NOT fill fuel tank with the engine running.
●● If the engine is hot, allow to cool before
refueling.
●● Use an approved fuel container.
●● Fuel the mower outdoors.
CHECK ENGINE CRANKCASE OIL LEVEL
Check the engine crankcase oil level before use and
after each 8 hours of continuous operation. Refer
to LUBRICATION for Checking Engine Crankcase
Oil Level in Maintenance Instructions.
CHECK AND SERVICE ENGINE AIR CLEANER SYSTEM
●● Check air filter restriction gauge to make sure the
yellow indicator disk is in the safe operating
(green) range.
●● Check condition, cleanliness, and security of the
complete air cleaner system (inspect air filter
paper element every 100 hours). For detailed
procedures, refer to CLEANING the Engine Air
Cleaner System in Maintenance Instructions.
CHECK ENGINE COOLING SYSTEM
Check that the engine cooling air intake screen is
free of obstruction by grass clippings or debris and
clean if required. Also, cylinder head cooling fins
should be inspected and cleaned if any build-up of
debris is noted [remove two (2) cylinder head access panels to inspect and clean]. Refer to CLEANING the Cylinder Head Cooling Fins in the Mainte­
nance Instructions for this procedure.
Check performance of the cooling system by starting the engine, holding a hand adjacent to the cylinder heads, and feeling the cooling airflow.
DANGER
●● DO NOT smoke while refueling.
●● Avoid spilling fuel; use a funnel or spout.
●● DO NOT overfill the fuel tank; fill up to
about 1 in. (25 mm) below the top of tank.
IMPORTANT: DO NOT permit dirt or other foreign
matter to enter the fuel tank. Wipe dirt from around
the filler cap before removing. Use a clean fuel storage container and funnel.
IMPORTANT: DO NOT mix oil with gasoline. Always use fresh, automotive grade unleaded gasoline. DO NOT use gasoline containing greater than
10% ethanol. DO NOT use additives, such as carburetor cleaners, deicers, or moisture removing
agents. DO NOT use gasoline blended with methyl
alcohol.
24
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
CHECK SECURITY OF DRIVE TIRE MOUNTING NUTS
The eight (8) Drive Tire mounting nuts should each
be torqued to 75 to 85 lb·ft (102 to 115 N·m).
INSPECT THREE (3) DRIVE BELTS
Engine/PTO (2) and Ground Drive.
CHECK HYDROSTATIC TRANSAXLE OIL
LEVEL
Refer to LUBRICATION for Check Transaxle Fluid
Level in Maintenance Instructions.
Assembly Instructions
CHECK FUNCTION OF SAFETY INTERLOCK
SWITCHES
Refer to Operating Instructions to check for proper
operation of safety switches, both during engine starting and with the operator leaving the seat with tractor
moving forward or with the mower blades engaged.
CHECK TIRE PRESSURE
Deck Caster Wheel* = 20 PSI (137 kPa)
Drive = 15 PSI (103 kPa)
Tailwheel
= 20 PSI (137 kPa)
* If equipped with optional pneumatic tires
CHECK AND CLEAN GRASS BUILDUP UNDERNEATH MOWER DECK
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 position by unlocking the deck lock levers on each side
of the carrier frame and inserting the deck hook into
the tilt-up latch on the tractor body. Before operating
the tractor, make sure to re-engage the deck lock
levers after lowering the deck to the normal operating position.
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
DANGER
Do not operate the mower with deck in tiltup position. Do not move the tractor with
the deck in the tilt-up position.
CHECK MOWER BLADE CONDITION,
SHARPNESS, AND SECURITY OF MOUNTING
The blade mounting nuts on gear driven decks should
be torqued to 60 lb·ft (81 N·m), and the blade mounting bolts on belt driven decks torqued to 70 lb·ft
(95 N·m). If blade sharpening is required, refer to
CHECKING/SERVICING for Sharpen Mower
Blades in Maintenance Instructions.
ADJUST MOWER CUTTING HEIGHT, IF REQUIRED
Position the hitch pins in the four deck support pins.
Refer to the “Cutting Height Adjustment” decal on
the deck gearbox cover.
PERFORM ANY ADDITIONAL PROCEDURES
called for on the MAINTENANCE SCHEDULE
CHART in Maintenance Instructions.
Tilt-Up
Handle
Tilt-Up Hook and
Latch Connected
Deck Lock
Lever
Tilt-Up
Latch
Tilt-Up
Hook
Deck Secured in TILT-UP Position
25
Operating Instructions
CONTROL IDENTIFICATION, LOCATION, AND
FUNCTION
CAUTION
Before operating the mower, become familiar with the location and function of all operator controls. Knowing the location,
function, and operation of these controls is
important for safe and efficient operation
of the mower.
Do not hold the key in the “S” position longer than
10 seconds. If the engine does not start, return the
key to the “O” position for at least 60 seconds before
making a restart attempt. Prolonged cranking can
damage the starter motor and shorten battery life.
Release the key when the engine starts, and it will
return to the ON (RUN) position. To stop the engine,
rotate the key counterclockwise to the “O” position.
ON
OFF
Ignition Switch
The ignition switch is located on the right front of the
body and is used to start and stop the engine. The
switch has three positions: “O” is the OFF position,
ON (RUN) is the position the key returns to after
starting, and “S” is the START position. When starting the engine, turn the key clockwise to the “S” position.
START
Ignition Switch
Body Lift
Handle
Parking
Brake
Blade Clutch
(PTO)
Parking Brake
Forward Speed
Control (FSC)
Oil Pressure
Warning Horn
(Not Visible)
Throttle
Body Latch
Steering
Levers
Ignition
Switch
Engine
Service Light
Circuit
Breaker
Hourmeter
Operating Controls
26
Operating Instructions
Engine Throttle
Steering Levers
The throttle control lever (red knob) is located on the
left side of the seat and is used to control engine
speed. Moving the lever forward toward the FAST
position increases engine speed; moving it backward toward the IDLE position decreases engine
speed.
Each drive wheel is controlled by its own independent steering lever, for both steering function and
FORWARD/REVERSE motion. The FSC lever sets
the maximum forward speed, and also sets the forward position of the steering levers. The steering
levers operate only with a backward pulling movement of the lever, which causes the drive wheel for
that lever to first slow down, stop, and then reverse
with a full backward lever stroke. The levers are
released to the FORWARD position for “straightahead” ground travel.
Throttle
NOTE: Pushing forward on the steering levers will
not cause any change in tractor motion - there will
be no steering lever reaction and there will be no
machine damage.
Blade Clutch (PTO)
Throttle Location
Forward Speed Control (FSC)
Forward Speed Control (FSC) has two functions:
One is to set forward travel speed, and the other is
to establish the NEUTRAL-PARK position. When
the FSC lever is moved into the FORWARD position, a friction lock holds any forward speed setting
from 0 to 8 mph (0 to 12.9 km/h). The ground speed
is proportional to the lever position; the further the
lever is advanced forward, the faster the tractor
moves. It is not necessary to hold the FSC in position since the friction lock maintains the selected
lever position. Pulling back on the steering levers
overrides the FSC setting and slows or stops forward travel. Releasing the steering levers allows
the tractor to resume forward travel at the speed set
by the FSC lever. To stop and park the machine, the
FSC lever is moved backward to the NEUTRALPARK position.
The blade clutch lever is located on the right side of
the seat behind the right fender and is used to engage and disengage the mower blades. The blade
clutch 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.
Oil Pressure Warning Horn
The oil pressure warning horn indicates that engine
oil pressure is below the safe operating level [below
3 to 5 PSI (21 to 34 kPa)]. This horn will sound when
the ignition is turned ON, but should go off after the
engine is started. If the horn fails to sound when the
ignition switch is turned ON, it could indicate a horn
failure. If the horn sounds during engine operation,
stop the engine immediately and correct the source
of the problem before further engine operation.
IMPORTANT: Continued operation of the engine
with a low oil pressure condition WILL cause severe
engine damage.
Oil Pressure
Warning Horn
Warning Horn Location
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; moving the lever BACKWARD releases the brake.
The transaxle lockout arms disengage the transaxles. By lifting the arms up and locking them into
place with the shoulder on the arm in the chassis
notch, the transaxles are released to permit freewheeling. By releasing the arms and recessing
them back toward the chassis, the transaxles are
engaged for normal operation. The transaxle arms
in the LOCKOUT position are used to enable moving the machine without the engine running (e.g., for
service). Refer to TRANSAXLE LOCKOUTS in this
section for operating instructions.
IMPORTANT: Stop the tractor completely before
engaging the parking brake. The parking brake
uses a positive mechanical lock similar to the PARK
position on an automotive automatic transmission.
If the tractor is moving when the brake is engaged,
it will result in sudden stoppage and possible internal damage to the transaxle.
NOTE: If pressure on the parking brake (e.g.,
parked on a hill) makes it impossible to release the
parking brake with the parking brake lever, move the
mower gently forward or backward to allow the
brake detent to release.
NOTE: The transaxle lockout arms ends should be
completely retracted against the chassis, otherwise
operation of the transaxle may be erratic.
Transaxle
Lockout Arms
Engaged
Position
Transaxle Lockout Arm Location
Engine Service Light
Parking Brake Engaged
Disengaged
Position
Parking Brake Disengaged
28
The engine service light indicates that the engine
Electronic Control Unit (ECU) has detected a fault in
the engine performance. When this light illuminates
during operation, contact an authorized Kohler Service dealer to diagnose the fault.
IMPORTANT: Continued operation of the engine
with an illuminated engine service light will result in
sub-standard performance and MAY cause engine
damage if not corrected as soon as possible.
Operating Instructions
Circuit Breaker
A 5 amp, manual-reset 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. An auto-reset 30 amp
master circuit breaker is located in the rear left of the
chassis, and protects the charging system. In addition, there are two (2) 10 amp fuses, and one (1) 30
amp fuse included on the engine to protect the ECU,
ignition switch, and charging system. Refer to the
Kohler engine manual included with the Owner’s
Packet of materials for information regarding these
fuses.
Body Latch
The tractor body hinges forward for maintenance access and is latched down in the OPERATING position. To raise the body, pull back on body latch and
lift body using the lift handle on the rear of the body.
Body
Latch
Procedure
Interval*
Reminder
Oil Change
(Break-In)**
4-6 Hours
C
H
G
Lubricate
and Check
Levels
Oil Change
24-26 Hours
49-51 Hours***
OIL
LUBE
C
H
G
OIL
*
These intervals reflect the actual time that the
reminder will flash (one hour prior to and one
hour after the recommended interval).
**
This reminder is only used one time.
*** In normal operating conditions, oil changes in
100-hour intervals are acceptable. Walker and
the engine manufacturers recommend engine
oil changes every 50 hours in extremely dirty or
dusty conditions or for units with less than 100
hours annual use.
NOTE: The blinking hour glass on the display
means that the meter is operating properly.
Body Latch
Hourmeter
The hourmeter, which is located on the right front of
the body, displays operating time accumulated
when the PTO (blade drive) is engaged.
The hourmeter provides maintenance reminders after certain hours of operation. The hourmeter screen
will start flashing the reminder one hour prior to the
recommended interval and will continue until one
hour after the recommended interval (two hours).
The hourmeter does not have a manual reset
function.
Hourmeter
29
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
<15°
1.
2.
THROTTLE
Engaged
Position
Engaged
Position
8600-5
Disengaged
Position
Disengaged
Position
PARKING
BRAKE
BLADE CLUTCH
(PTO)
Operating Controls (Top View from Drivers Point of View)
30
Operating Instructions
STARTING THE ENGINE
CAUTION
Before operating the mower, read and un­
derstand all Safety Instructions and Operat­
ing Instructions.
IMPORTANT: If the engine fails to start after
approximately 10 seconds of cranking, the engine should be checked before further crank­ing.
Turn the key to the OFF position and allow a 60
second cool-down period between starting attempts. Failure to follow these guidelines can
damage the starter motor and shorten battery
life. Consult your Walker dealer or authorized
Kohler dealer for additional help.
ADJUSTING GROUND SPEED AND STEERING
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.
IMPORTANT: If the DS52 or DS62 mower deck
is in­stalled on the tractor, make sure the dolly
wheel is retracted BEFORE moving.
CAUTION
Learn to START, STOP, and MANEUVER
the mower in a large, open area.
If the operator has not operated a ma­chine
with LEVER STEERING OR DUAL TRANSAXLES, steer­
ing and ground operation
should be learned and practiced until the
operator is completely comfortable handling the ma­chine BEFORE ATTEMPTING
TO MOW.
DANGER
Keep feet on footrests at all times when
the machine is moving. Never operate the
tractor without a deck or implement installed.
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.
31
Operating Instructions
1.
Move the FSC out of NEUTRAL-PARK position
to the desired forward speed. DO NOT hold
for­ward on steering levers. It is not necessary
to hold the FSC lever in position since a friction
lock maintains the selected lever position (and
forward travel speed).
WARNING
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.
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 op­
erator 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.
32
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.
Beginning Recommendations are:
♦♦ Learn operation of the mower in an open
area away from buildings, fences, and ob­
structions. Learn operation on flat ground
BEFORE operating on slopes.
♦♦ Start maneuvering the mower with SLOW
engine speed and SLOW Forward Speed
Control setting until familiar with all operat­
ing characteristics.
♦♦ Remember it is not necessary to hold the
steering levers forward (a unique Walker
feature); always PULL on the levers for
steering or for reverse motion of the mower.
♦♦ Learn to operate the mower with your left
hand on the steering levers and right hand
on Forward Speed Control. The use of two
hands on the steering levers tends to cause
overcontrol.
♦♦ Learn to operate the steering levers with
smooth action. Jerky movements are hard
on the transmission and lawn. For sharp
turns, do not allow the inside wheel to stop
and twist on the grass. Pull the steering 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.
Operating Instructions
Pull Steering
Levers With
Left Hand
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 NEUTRAL-PARK
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
Forward Speed Control
(FSC)
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 disengagement, move the blade clutch lever backward
SLOWLY.
Keep Feet On Footrest
When Moving
Correct Operator Hand Position on the Controls
3.
Reverse direction of the mower by pulling both
levers backward.
NOTE: Smooth action on the steering levers
will produce smooth mower operation. Remem­
ber to keep the engine and ground speed slow
until learning the control response.
WARNING
When moving forward, DO NOT suddenly
put the tractor in reverse by rapidly pulling
on the steering levers, especially when going downhill, as this can lift the tractor tail
wheel off the ground and set up a bucking
motion due to operator overcontrol. If
bucking does occur, immediately stop the
bucking action by pulling the Forward
Speed Control (FSC) lever into the NEUTRAL-PARK position.
4.
The FSC may be adjusted forward for faster
ground speed and backward for slower ground
speed. When mowing, ground speed should be
adjusted to match the load on the cutter blades,
i.e., as the engine pulls down in heavy cutting,
pull back on the FSC lever to reduce ground
speed. Adjusting ground speed helps maintain
a balance between engine power and blade
speed for high-quality cutting action.
CAUTION
An operator presence switch (seat switch)
will cause the engine to stop if the blade
clutch is engaged and the operator is not in
the seat. The function of this switch should
be checked by the operator raising off the
seat and engaging the blade clutch; the engine should stop. If the switch is not working, it should be repaired or replaced before operating the mower.
DO NOT
disconnect the safety switches; they are
for the operator’s protection.
IMPORTANT: DO NOT engage the blade clutch
when transporting the mower across drives, side­
walks, loose materials, etc. DO NOT engage the
blade clutch with the PTO shaft disconnected
(the mower deck removed from tractor).
33
Operating Instructions
STOPPING THE MACHINE
1.
Pull the steering levers to the NEUTRAL position 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.
Engaged
Position
Blade Clutch Engaged
WARNING
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.
Disengaged
Position
Blade Clutch Disengaged
4.
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).
34
Slow the engine to idle, put throttle in IDLE position; turn the ignition switch OFF.
WARNING
Remove the key from the ignition switch
when leaving the mower unattended. This
will prevent children and inexperienced
operators from starting the engine.
5.
Engage the parking brake by moving the lever
forward.
Operating Instructions
IMPORTANT: The hydrostatic transmissions
lock to prevent the mower from rolling freely
with the engine stopped. However, if the mower
is parked on a slope, it is necessary to ENGAGE
the parking BRAKE to prevent the mower from
creeping. This is due to a small amount of slip­
page in the hydrostatic transmissions, especially when transmission fluid is warm. Also, engaging the parking brake is recommended when
stopping or parking the machine in a confined
space with little tolerance for movement.
Lift Handle
Deck Support
Pin
Washer
Hitch Pin
WARNING
If the transaxle 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.
Cutting Height Adjustment
TRANSAXLE LOCKOUT
IMPORTANT: DO NOT TOW this mower faster than
2 mph (3.2 km/h) with the transaxle lockout engaged. Towing can produce excessive internal
pressure and damage the transaxle(s).
To move the mower with the engine NOT running
(dead battery, maintenance, etc.), the transaxles
need to be unlocked (released).
1.
Raise the body.
2.
Pull up on each transaxle lockout arm and move
toward the center of the machine to engage the
step that holds the arm in the UP (unlocked)
position.
3.
The mower will “freewheel” with the arms in the
LOCKOUT position. The levers must be in the
highest position to completely unlock the transaxles.
ADJUSTING CUTTING HEIGHT
WARNING
The engine must be stopped before
ad­justing 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.
Transaxle Lockout Arm
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.
Transaxle Lockout Arm - Freewheel Position
35
Operating Instructions
4.
After moving the mower, release the arms, placing them down in the normal OPERATING position. The transaxle lockout arm ends should be
completely retracted against the chassis, otherwise operation of the transaxle may be erratic.
Transaxle Lockout Arm
Transaxle Lockout Arm - Normal Operating
Position
RECOMMENDATIONS FOR MOWING
DANGER
Do not mow around overhanging tree
branches or bushes at the same height as
the operator’s torso and head where inadvertent contact may cause injury.
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).
●● It is preferable to cut grass when it is dry and not
too tall. Mow frequently and do not cut grass too
short. (For best appearance, cut off 1/3 or less of
existing grass height.)
●● When mowing, operate the engine at full throttle
for the best cutting action. 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.
36
Operating Instructions
●● Make sure the mower is leveled properly for a
smooth cut. Refer to Deck Leveling in Assembly In­
structions.
●● Use an alternating stripe mowing pattern for
best appearance and vary the direction of the stripe
each time the grass is mowed to avoid wear patterns
in the grass.
●● Avoid damage to the grass by slipping and skid­
ding of the drive tires. Use smooth control move­
ments of the steering levers since the transaxles
are “power boosted controls” and jerk­ing the levers
can easily slip the tires. For sharp turns, do not allow
the inside wheel to stop and twist on grass; pull inside steering lever into reverse for a smooth “rolling”
turn (one wheel rolling forward while the other rolls
backward).
●● 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
Side Discharge Deflector Shield in
Lowest Position
●● When operating on a slope, reduce speed and
use caution to start, stop, and maneuver. Avoid
sharp turns or sudden changes in direction. The
maximum recommended slope operating angle
is 15 degrees or 26% grade.
37
Operating Instructions
Maximum
Recommended
Slope Do Not Operate
on Steep Slopes
RECOMMENDATIONS FOR TILT-UP DECK
OPERATION/TRANSPORT
To avoid potential deck and/or tractor damage while
using the tilt-up deck, the following recommendations are offered:
●● Do not move the tractor with the deck in the tiltup position since both the roller wheels (on the back
of the deck) may be damaged by moving the tractor.
The tilt-up configuration should only be used when
the tractor is parked.
8600-14
60 lb·ft
(81 N·m)
8600-9
15°
16 in.
52 in.
Maximum Recommended Slope
DANGER
Do not mow or drive the tractor within 5 feet
(1.5 meters) of an embankment or retaining
wall with drop off.
●● The tractor body should never be tilted forward with the deck in the tilt-up position. This can
cause the deck to unhook from the tractor and fall
with considerable force, potentially causing deck or
tractor damage and/or bodily injury.
●● When transporting a tractor with the deck in the
tilt-up position (on a truck or trailer), the deck should
be secured to the vehicle with a strap or rope (stop
vertical movement). This will prevent the deck from
bouncing on the rear roller wheels (causing breakage). This will also prevent the deck from unhooking
from the tractor and falling, potentially causing deck
or tractor damage. Damage to other items parked
in front of the deck may also occur.
5 FT
MINIMUM
No Driving Zone
38
Maintenance Instructions
CAUTION
Maintenance procedures requiring special training or
tools should be performed by a trained technician.
MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL B23i
Service Item
Daily
25
Hours
100
Hours
200
Hours
400
Hours
Yearly
Every
2 Years
Ref.
Page
Check Engine Crankcase Oil Level
x
41
Check/Clean Engine Air Cooling System*
x
48
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
43
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
56
Clean Transaxle Housing
x
52
Clean Engine Cooling Fins
x
48
Check Air Filter Element***
x
50
Change Engine Crankcase Oil**
x
42
Check/Adjust Blade Clutch
x
68
Check/Regap Spark Plugs
x
56
Change Engine Oil Filter
x
42
Replace Fuel Filter
x
61
Change Transaxle Oil and FilterΔ
x
47
Replace Air Filter Element, and Safety Filter***
x
50
Check/Adjust FSC Friction Lock
x
57
Check Fuel Lines and Clamps
x
56
Service Solenoid Shift Starter
x
56
Check PTO U-Joints for Wear/Looseness
x
56
Service Battery
x
53
Check Transmission Control Setting
x
57
Replace Fuel Lines and Clamps
x
56
Replace Dust Ejection Valve***
x
50
Replace Ignition Wires
x
56
*
**
***
Δ
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 Donaldson Radialseal™ 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
39
Maintenance Instructions
IMPORTANT TIPS FOR CARE OF THE KOHLER
ENGINE
Fuel System
KOHLER TIPS
●● Check performance of the cooling system by
starting the engine, holding a hand adjacent to the
cylinder head, and feeling the cooling airflow.
DANGER
●● Fuel must be clean – free from water, dirt, and
or­ganic material.
●● Change fuel filter on a regular basis and when
contamination is suspected or found in the fuel.
●● The fuel injection pump module is a sealed unit
and is not serviceable; opening the fuel pump
module will void the warranty. Additionally, the fuel
pump module and the fuel lines between it and
the injectors are pressurized. For service of the
pressurized fuel injection system including the fuel
pump module, fuel lines, and fuel injectors contact
your Walker dealer or authorized Kohler service
dealer.
Starting/Stopping
●● Start engine with the throttle advanced off idle
(1/4 to 1/2 throttle). This will aid starting, especially
in cold weather.
●● Keep the battery fully charged.
●● Match crankcase oil viscosity to the ambient
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 backfiring.
Cooling System
CAUTION
DO NOT use water or a pressure washer to
clean the cooling system on an air-cooled
engine; mud may form under the cooling
shroud on the cylinder head and cooling
fan resulting in engine overheating.
●● Keep engine air intake screen and cylinder head
fins free of grass clippings, chaff, and dirt. Inspect
intake screen and cooling fins for cleanliness and no
damage.
●● Periodically remove two access panels in the
en­gine shroud to inspect and clean cylinder head
cool­ing fins.
40
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
●● Operate the engine at full speed when mowing.
This allows the engine to produce full horsepower
and move more cooling air through the engine cool­ing fins.
Air Cleaner System
●● Use only Donaldson® air cleaner elements.
Aftermarket elements may not seal in the air cleaner
housing, allowing dirt to enter the engine. Also, aftermarket filters often skimp on the filtration media and
require more frequent replacement (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 efficiency and increase the oppor­tunity for traces of dust to enter
the engine. Wait until the element really needs
servicing as indicated by the air filter restriction
gauge.
●● When the air filter element is removed or replaced, make sure all dust is cleaned out of
­
the air cleaner housing and hose. Use a damp
cloth and wipe the interior of the canister and hose
clean (a lit­tle dirt left here will be sucked into the
engine and reduce engine life). When the filter is
reinstalled, make sure the element is held tight
and straight in the canister for proper seating and
sealing.
●● Periodically check the air intake hose for cuts,
nicks, etc., and the hose clamps for tightness.
Maintenance Instructions
KOHLER TIPS/LUBRICATION
Oil
2.
●● Use only multi-viscosity oils as specified with the
viscosity matching ambient temperatures for the en­
gine operating conditions. This will aid starting in
cold weather and assure proper lubrication in hot
weather.
Before removing the dipstick, clean the area
around the dipstick to keep any dirt or debris out
of the engine.
3.
Remove the dipstick, wipe off with a clean rag,
then reinsert the dipstick into the tube and press
all the way down.
4.
Remove the dipstick again and check the oil
lev­el on the dipstick. The oil level should be
within the “Operating Range” on the dipstick
(between the “L” mark and the “F” mark).
●● Use only Kohler oil filters. Aftermarket filters
may not seal properly and/or have the incorrect
pressure relief valve for proper lubrication.
LUBRICATION
IMPORTANT: DO NOT operate engine without
a sufficient oil supply in the crankcase. DO NOT
operate with the oil level below the “L” mark or
above the “F” mark on the dipstick.
WARNING
DO NOT attempt to lubricate the machine
with the engine running. Disengage the
PTO clutch, shut off the machine, and re­
move the ignition key.
Proper lubrication is an important maintenance pro­
cedure. It reduces wear and makes the machine
quieter and easier to operate.
5.
If additional oil is needed, refer to Specifications
for proper crankcase lubricant. Fill up to, but
not above, the “F” mark on the dipstick.
IMPORTANT: DO NOT overfill the crankcase
(oil above “F” mark) as this CAN result in engine overheating, loss of power, and possible
en­gine damage.
Engine Oil
Engine Break-In Oil
No special break-in oil is required. The engine is
serviced with 10W-30, Service Class SJ oil from the
factory. Change the oil after the initial engine breakin period of 5 hours. Thereafter, change oil after
every 100 hours of operation.
Checking Engine Crankcase Oil Level
Full Mark
Check the engine crankcase oil level before use and
after each 8 hours of continuous operation.
IMPORTANT: The importance of checking and
maintaining the proper crankcase oil level cannot be
overemphasized. Check the oil level BEFORE
EACH USE.
1.
Park the mower on a level surface with the
en­gine stopped. Also, make sure the engine
is cool and oil has had time to drain into the
sump [allow at least five (5) minutes after
stopping the engine].
Operating
Range
{
F
L
Low Mark
Dipstick Operating Range
IMPORTANT: NEVER check or add oil with the
engine running.
41
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 operation, start the engine and run a few minutes to
warm the oil.
2.
Before removing the dipstick, clean the area
around it to keep any dirt or debris out of the
en­gine.
3.
Remove the dipstick and open oil drain valve
and drain the oil into a suitable container. Be
sure to allow ample time for complete drainage.
Dipstick
Oil Fill
Oil Drain
Oil Drain Location
(View from the Rear Left 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.
Dipstick and Oil Fill
(View from Above Right Side of Tractor)
Oil Filter
Oil Filter Location
(View from the Rear Right Side of Tractor)
42
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.
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 engine is first operated with a new oil filter, the oil
level will drop slightly as the filter is filled with
oil.)
Grease Fitting and Oil Point Lubrication
Lubricate the grease fittings and oil points after ev­ery 25 hours of operation. Lubricate more often
when operating in dusty or dirty conditions. Use
SAE general purpose lithium or molybdenum base
grease for grease fittings and light machine oil (SAE
10) to lubricate oil points. Lubricate the locations
shown in the Chassis and Deck Lubrication
Points illustration.
LUBRICATION
Mower Deck Gearbox Lubrication
NOTE: These instructions apply to all mower decks
with gear-driven blades. Refer to DS52 or DS62
Mower Deck Lubrication in this section for the
DS52 or DS62 deck with belt-driven blades. Refer
to Mower Deck Spindle Lubrication in this section
for the DS42 Belt Drive deck with belt-driven blades.
On gear driven decks, the mower deck gearboxes
(tee gearbox and blade drive gearboxes) are connected as a unitized assembly, and oil flows freely
between them. The gearboxes are permanently lubricated (oil filled) and sealed requiring no scheduled lubrication. However, the gearbox oil seals
should be checked every 25 hours for indication of
an oil leak; particularly the lower seals on the
blade drive gearboxes should be inspected, since
they operate in a dirty environment. If an oil leak is
noted, replace the oil seal and relubricate the gearbox assembly as follows:
1.
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.
Remove gearbox cover (footrest). Deck orientation should be the normal operating position.
Blade Drive
Gearboxes
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.
Tee
Gearbox
NOTE: The ball bearings on the PTO drive shaft
are sealed and do not require periodic maintenance.
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).
Continued page 46
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
No.
Places
Deck Caster Wheel Fork Pivot
Grease
Deck Caster Wheel Bearing
Grease
Blade Spindle
GreaseΔ
Pivot Assembly, Tilt-Up Deck
Grease
Deck Support Arm Socket
Grease
Right Angle Gearbox
Oil*Δ
Universal Joint Shaft Assembly Grease**
Dolly Wheel Retract
OilΔ
Lever and Linkage
Dolly Wheel Pivot
GreaseΔ
Idler Arm Pivot
GreaseΔ
Tee Gearbox, Deck
Oil*
Blade Drive Gearbox
Oil*
Steering Lever Pivot
Grease
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
2
Ident
No.
2
2
3
4
2
1
1(2Δ)
1
1
1
1
2
2
1
24
25
26
27
28
29
30
31
32
33
*
Tail Wheel Caster Fork Pivot
Rear Axle Pivot
Rear Wheel Bearing
Throttle Control Cable Ends
Engine Oil Filler
Brake Band Pivot Pins
PTO Belt Tightener Pivot
Parking Brake Clevis
Parking Brake Lever
Throttle Control Pivot
1
2
1
** Grease every twenty-five (25) hours.
Grease
Grease
Grease
Oil
Oil***
Oil
Grease
Oil
Grease
Oil
1
1
1
1
1
1
Δ
5
9
8
2
1
2
2
1
2
1
2
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.
1
3
2
3
4
No.
Places
*** Refer to Engine Oil located on page 41.
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
27 & 33
14
15
16
16
17
31
32
31
30
19
18
20
21
20
29
22
28
27
23
24
24
25
26
Chassis and Deck Lubrication Points (DS42 Shown)
45
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.
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).
Dolly Wheel
Pivot
U-Joints
Gearbox, Dolly Wheel, and U-Joint Lubrication
Check Transaxle Fluid Level
Mower Deck Spindle Lubrication
●● The transaxle oil lubrication is SAE 20W-50 (API
Service Class SL or higher) engine oil.
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.
●● Inspect both transaxle cases and hoses after every 25 hours of operation for visible leaks.
DS52 or DS62 Mower Deck Lubrication
There are several special lubrication requirements
for the DS52 or DS62 mower deck in addition to the
require­
ments detailed in the Chassis and Deck
Lubrica­tion Points illustration. Lubricate the locations shown in the Gearbox, Dol­ly Wheel, and UJoint Lubrication photo and check and maintain oil
in the belt drive gearbox.
1.
46
Belt Drive
Gearbox
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.
●● The fluid level for the transaxles can be checked
visually by looking at the fluid level in the expansion
reservoir. When the transaxles are cold, the fluid
level in the expansion reservoir should be between
1/4 in. and 1/2 in. (0.64 cm and 1.27 cm).
Reservoir
Cap
Hose to
Transaxles
Hot Level
Cold Level
Expansion Reservoir Location
Maintenance Instructions
LUBRICATION
Transaxle Oil and Filter Change
Elbow
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 inside of each transaxle allowing the oil to drain.
2.
Remove the oil filter guard, remove and replace
the oil filter using an oil filter wrench. Tighten
filter by turning filter 3/4 to 1 turn after gasket
contacts the filter base surface. Reinstall the oil
filter guard. (Refer to Transaxle Oil Drain
Plug, Filter, and Guard Location illustration.)
Screw Locking
Nut Down
Reinstall Transaxle Elbows
7. Reinstall the elbows. When the elbow begins to
be snug, position the elbow as it was when removed and tighten the locknut. Reinstall reservoir hoses to elbows.
Oil Filter
Oil Filter
Guard
Oil Drain
Plug
Transaxle Oil Drain Plug, Filter, and
Guard Location
3.
Reinstall drain plugs.
4.
Remove the oil reservoir hose attached to the
elbow on top of the transaxles. Remove the
elbow 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 locking 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).
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 steering 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.
12. To purge air from transaxle, raise tractor and
block with tires off the ground. With engine running, slowly move Forward Speed Control forward and backward 5 to 6 times. Turn off engine and check oil level and add if needed.
Repeat procedure until transaxles operate at
normal noise levels and move smoothly in forward and reverse.
47
Maintenance Instructions
CLEANING
CLEANING
Cylinder Head Cooling Fins
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 overheating. Also, visually check inside cylinder head shroud
and between cylinder head fins for material packed
in this area which would prevent cooling airflow; remove shroud and clean as required.
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
Check Cooling System Airflow
Rotating Engine Cooling
Air Intake Screen
Keep Rotating Engine Cooling
Air Intake Screen Clean
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.
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.
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.
48
Maintenance Instructions
CLEANING
IMPORTANT: Yearly, it is good maintenance practice to remove the engine cooling shroud and clean
the cylinder head cooling fins thoroughly to prevent
overheating and extend engine life. Make sure cooling shroud is reinstalled properly. This procedure
will require removing the engine from the chassis.
Engine Air Cleaner System
Donaldson Radialseal™ Air Cleaner
A remote mounted Donaldson Radialseal™ air
cleaner provides the air filtering function. The paper filter element slides over an outlet tube inside
the air cleaner canister with radial sealing action,
reducing the possibility of dust leaks due to improper filter installation. Intake design, internal
baffling, and a dust ejection valve provide dust
separation and automatic precleaning action.
Daily or frequent servicing of the air cleaner is not
required. Use the air filter restriction gauge on the
air cleaner outlet to indicate when the air filter needs
servicing -- a yellow indicator will show when the
filter is overly restricting airflow into the engine.
Engine Cooling
Fin Access Panels
Rotating Engine Cooling
Air Intake Screen
IMPORTANT: Use only Donaldson air filter elements for replacement (Donaldson P821575 or
Walker 5090-8 Primary/Donaldson P822858 or
5090-7 Safety Filter). Aftermarket filters may not
seal properly or filter efficiently.
Kohler Engine
Shroud
Engine Cooling Air Intake Screen
and Cooling Fin Access Panels
Air Intake
Hose
Hose
Clamp
Hose
Clamp
2
Donaldson
Air Cleaner
8600-1
Engine
2
8600-1
Safety
Filter
Donaldson
Air Cleaner Cover
Air Filter
Restriction Gauge
Mounting
Band
Primary Filter
Element
Cover Latch
Dust Ejection
Valve
Engine Air Cleaner System Components
49
Maintenance Instructions
Cover Latch
CLEANING
2.
Remove the filter element by pulling it out of the
canister. There will be some initial resistance
as the filter seal breaks loose and slides off of
the outlet tube. Gently move the end of the
filter up and down and side to side or twist to
loosen the seal. Use gentle action to minimize
the amount of dust dislodged as the filter is removed.
3.
Discard the filter element if excessive air flow
restriction has been indicated by the air filter
restriction gauge and proceed to Step 6. Clean
the filter element by gently tapping on a flat,
hard surface. If excessive restriction still exists
after cleaning the element, it should be replaced.
Canister
Primary Filter
Element
Cover
Dust Ejection
Valve
Air Cleaner Components
(Shown with Cover Being Removed)
NOTE: Use care when cleaning the filter element. The filter element and/or seal surface
may be damaged by tapping too hard or hitting
on an uneven surface or sharp edge. Washing
the element in water or cleaning solution is not
recommended. Do not try to clean the element
with compressed air. Remember replacing a
filter is less expensive than replacing a dusted
engine.
IMPORTANT: The Donaldson air cleaner uses a dry
paper-type air filter element. NEVER apply oil to the
paper element.
Air Filter
Restriction Gauge
Push Button to Reset
Indicator After Service
4.
Use a bright light inside the element to inspect
for damage. Check the element very carefully
for pin holes or other damage that will allow
dirt to leak through the paper media. Replace
element if necessary.
5.
Check the condition and resilience of the radial
sealing surface (inside of the open end) of the
filter. Replace the filter if any cracks, tears, or
other damage to the sealing surface are noted.
6.
Without removing, visually inspect the condition
of the safety filter for damage or holes. The
safety filter should only be removed for replacement every 400 hours (or when dirty or damaged).
Air Filter Restriction Gauge Location
Inspect the paper element after every 100 hours of
service and replace the element and safety filter
every 400 hours (or when dirty or damaged). More
frequent replacement may be required when operating in extremely dusty conditions as indicated by the
air filter restriction gauge. Service the air cleaner as
follows:
1.
50
Release the top and bottom cover latches and
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 deterioration
and should be inspected carefully and replaced
every two years or when damaged. The lips of
the valve should close and fit together; any
cracks, deformation, or wear in the valve is
cause for replacement.
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 cleaner canister clean. Use special care to clean
both the inside and outside surfaces of the
outlet tube.
IMPORTANT: Any dust left on the inside of the
outlet tube will go into the engine and cause
wear.
Maintenance Instructions
8.
Check the outside surface of the outlet tube for
smoothness and cleanness (this is the sealing
surface).
9.
Insert and seat the safety filter and primary filter
el­
ement 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.
CLEANING
11. Check the air intake hose for cuts, nicks, cracks,
etc., and the hose clamps for tightness.
12. Reset the air filter restriction gauge (press button on the end of the indicator).
Grass Buildup in Mower Deck Housing
DANGER
IMPORTANT: DO NOT use the cover latches
to force the filter into the canister–the cover
should fit on with no extra force.
Before raising or removing the mower
deck for cleaning, stop the engine, re­
move the ignition key, and disconnect the
spark plug wires.
NOTE: DO NOT use petroleum based lubri­
cants on the sealing surfaces of the filter; use
tal­cum powder or dry silicone lubricants if required for filter installation.
Primary
Filter Element
Canister
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.
Radial Sealing
Surface
Outlet Tube
Tilt-Up Handle
Tilt-Up Hook and
Latch Connected
Safety Filter
Air Filter Element Replacement
10. Install the cover with the word “TOP” properly
oriented to the top of the canister. Give the
cover a slight twist as it reaches the canister to
make sure the tab inside the cover goes into a
slot, otherwise the cover will not fit properly.
Make sure both the top and bottom cover
latches are securing the cover in place.
Cover Latch
Deck Lock
Lever
Tilt-Up
Latch
Orient to Top
of Canister
Tilt-Up
Hook
Deck Secured in TILT-UP Position
Dust Ejection
Valve
Cover Latch
Proper Orientation of Air Cleaner Cover
51
Maintenance Instructions
CLEANING
DANGER
Cooling
Fins
Do not operate the mower with deck in tiltup position. Do not move the tractor with
the deck in the tilt-up position.
3.
Clean grass buildup underneath the deck using
a pressure washer (and scraper if required).
NOTE: If the buildup is severe, it may be easier to clean the deck by removing the deck assembly from the tractor and standing the deck
assembly on its “nose”.
NOTE: While some degree of material buildup
in the mower deck housing can be tolerated, a
point is finally reached where cutting quality
deteriorates and clogging begins to occur
because of too much buildup on the baffling and
housing.
4.
Lower the deck to the normal operating position
and re-engage the deck lock levers.
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.
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
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.
52
Cooling
Fans
Transaxle Cooling Fans
Maintenance Instructions
CHECKING/SERVICING
CHECKING/SERVICING
CAUTION
DANGER
Important Battery Service, Installation, and
Charging Tips for Electronic Fuel Injection
Engines:
To prevent accidental starting of the en­
gine when servicing or adjusting the ma­
chine, remove the key from the ignition
switch and disconnect the spark plug
wires.
Security of Air Filtration Components
●● Do not allow the battery cables to touch
opposing terminals. When connecting battery cables attach the positive (+) cable to
positive (+) battery terminal first, followed
by negative (-) cable to negative (-) battery
terminal.
NOTE: The following inspection is only an exter­
nal inspection and should be done without “dis­
turbing” the filtration components.
●● Never start the engine when the cables
are loose or poorly connected to the battery terminals.
On a daily basis, visually inspect the external condi­
tion of the complete air cleaner system. The following items should be inspected:
●● Never disconnect battery while engine
is running.
1.
Check the Donaldson Radialseal™ air cleaner
canister for damage. Make sure the cover is in
place and the cover latches are secure - do not
run the engine without the air cleaner cover in
place and secure.
2.
Inspect the air intake hose for cracks, nicks,
cuts, etc., and check the hose clamps for tightness.
3.
Check to make sure the air filter restriction
gauge is in place and hose connections are
secure.
Battery
NOTE: For initial battery service during setup, re­fer
to Battery Service in Assembly Instructions.
IMPORTANT: Make sure battery is securely mount­
ed in the frame. A loose battery may cause damage
to the case resulting in acid leakage and severe
dam­age to the machine. A hazard may be created
by damage to critical working parts and safety systems.
●● Never use a quick battery charger to
start the engine.
●● Never “jump start” the engine using another source. Electricity fluctuations can
damage the ECU (Electronic Control Unit).
●● Always disconnect negative (-) battery
cable lead before charging battery, and
also unplug harness from ECU before performing any welding on equipment.
Electrolyte Level
The battery electrolyte level should be checked after every 25 hours of operation. To check electrolyte level:
1.
Remove battery cell filler caps.
2.
Check the electrolyte level. If the level is below
the bottom of the vent well, fill with distilled water to the bottom of the vent wells [1/4 to 1/2 in.
(6 to 13 mm) above the plates].
3.
Replace filler caps.
IMPORTANT: DO NOT overfill the battery. Electrolyte will overflow through the vented caps onto parts
of the machine and WILL result in severe corrosion.
53
Maintenance Instructions
Cleaning the Terminals
Tire Pressure
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.
Inflate tires to pressures shown below:
Charging the Battery
Wheel Nut Torque
DANGER
BATTERIES PRODUCE EXPLOSIVE GASES
●● Charge the battery in a well-ventilated
area, so that gases produced while charg­
ing can dissipate.
●● Keep sparks, flames, and smoking materials away from the battery at all times.
●● Make sure the battery cap vents are
open (check manifold vent on each cap).
●● Make sure the battery charger is un­
plugged before connecting or disconnecting cables to the battery.
Check the battery charge by measuring the specific
gravity of electrolyte; if specific gravity is less than
1.225, the battery will need to be charged as follows:
IMPORTANT: Always disconnect the negative (-)
battery terminal before charging. Failure to do so
can result in damage to the ECU.
1.
2.
54
CHECKING/SERVICING
Deck Caster Wheel* = 20 PSI (137 kPa)
Drive
= 15 PSI (103 kPa)
Tailwheel
= 20 PSI (137 kPa)
* If equipped with optional pneumatic tires
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).
Sharpen Mower Blades
Check mower blade(s) for straightness, sharp­
ness, condition of the cutting edge, and balance
every 10 hours of operation (or more often when
mowing abrasive type grass or operating on sandy
soils). Replace blades if worn, bent, cracked, or
otherwise damaged (refer to REPLACING/RE­
PAIRING the Mower Blades in this section). Use
the following procedure to check and sharpen
blades:
NOTE: Keep blades sharp - cutting with dull blades
not only yields a poor mowing job but slows the
cutting speed of the mower and causes extra wear
on the engine and blade drive by pulling hard.
1.
Stop the engine, remove ignition key, and dis­
connect the spark plug wires before raising the
mower deck to service blades.
2.
Raise the deck and secure it in the TILT-UP
po­sition. Refer to CLEANING the Grass Buildup in Mower Deck Housing in this section for
deck rais­ing instructions.
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, 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].
DANGER
NEVER operate cutter blades with the
deck in the raised position.
NOTE:
PTO shaft must be disconnected
be­fore checking blades for straightness.
3.
Check the blades for straightness by marking
the blade tip position inside the deck housing,
and then rotating the opposite end of the blade
to the same position and comparing. If the dif­
ference in blade tip track is more than 1/8 in.
(3 mm), the blade is bent and should be re­
placed.
Maintenance Instructions
CHECKING/SERVICING
WARNING
DO NOT try to straighten a blade that is
bent. NEVER weld a broken or cracked
blade. ALWAYS replace with a new blade
to assure safety.
Blade Balancer
4.
If the blade cutting edge is dull or nicked, it
should be sharpened. Remove blades for
sharpening by grasping the end of the blade using a rag or a thick, padded glove, while loosening and removing the nut, lock washer, and flat
washer that mounts the blade.
5. Grind cutting edge at the same bevel as the
original. Sharpen only the top of the cutting
edge to maintain sharpness.
NOTE: Blades can be sharpened with an electric blade sharpener, conventional electric grinder, or a hand file.
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
CAUTION
ALWAYS wear eye protection and gloves
when sharpening a blade.
Raise the body and inspect the condition of the
three (3) drive belts after every 25 hours of operation -- engine/PTO drive and ground drive. If the
belts show signs of cracking or deteriorating, the
belts should be replaced. Refer to REPLACING/
REPAIRING the Drive Belts in this section.
Sharpen at
Original 30° Angle
Mower Deck Gearbox Oil Seals
Intersection
Wear Area
Wing
Tip
30°
Do Not Grind or
Sharpen on Underside
Mower Blade Profile for Sharpening
6.
Blade Balanced on Magnetic
Wall-Mounted Balancer
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.
The mower deck gearbox seals should be inspected
every 25 hours for evidence of oil leaking; particularly the lower oil seal on the blade drive gearbox.
This seal is protected by the trash guard on the blade
hub and seal protector plate on the housing, but is
still vulnerable to seal damage due to operating in
an adverse environment. The mower blade must
be removed for inspection of the seal, so it is recommended to inspect the gearbox seals when
blades are removed for sharpening. If an oil leak
is noted, the seal should be replaced and the
gearbox assembly relubricated. Refer to LUBRICATION for Mower Deck Gearbox Lubrication
in this section.
55
Maintenance Instructions
Spark Plugs
PTO U-Joints
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).
The PTO U-joints should be inspected yearly for
looseness and wear. If either is noticed, the respective shaft or tube should be replaced. A worn U-joint
can cause vibration and extensive damage to the
PTO and the whole machine.
Ignition Wires
Safety Switch System
Good preventive maintenance calls for complete replacement of spark plug wires every two (2) years.
Fuel Lines and Clamps
NOTE: The engine fuel injection system is pressurized and should only be serviced by a Walker dealer
or authorized Kohler service dealer.
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 engaging the blade clutch (PTO), operating the engine
at full throttle, then disengaging the clutch and measuring how quickly the blades stop. Watch the rotation of the blade drive shaft as a visual indication that
movement has stopped. If the brake is working
properly, all rotation will stop five (5) seconds
after disengagement of the clutch. If the brake system malfunctions - blades do not stop in five (5) seconds - adjust or repair the brake before operating
the mower. Refer to ADJUSTMENTS for Clutch
Disengagement/Brake Action, Step 2 - Blade Brake
Band Adjustment on page 70.
56
CHECKING/SERVICING
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.
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.
If any of the following conditions occur during starting or operating, a safety interlock switch may be
malfunctioning. Contact your Walker dealer for troubleshooting and/or replacement.
●● With or without an operator in the seat, the
engine starts with the Forward Speed Control
(FSC) and/or the PTO engaged, or the parking brake
disengaged.
●● 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 engaged.
●● 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, and Oil Pressure Warning Horn
sounding, but the starter will not engage.
Maintenance Instructions
CHECKING/SERVICING
Forward Speed Control Friction Lock
The FSC friction lock is designed to hold the selected forward travel speed when the steering levers are moved and yet the friction is not too heavy
to make moving the FSC control difficult (too much
friction). The procedure for checking the FSC friction lock is as follows:
1.
With the engine off, place the FSC in the full
FORWARD position and pull both steering levers back; the FSC lever should not move. If
the FSC lever moves back when the steering
levers are pulled back, the friction needs to be
increased.
2.
With the steering levers held back, move the
FSC lever back from the FORWARD position.
With a proper amount of friction adjusted, the
FSC lever should move back with a slight
amount of resistance (friction). If the FSC lever
movement is “stiff”, the friction needs to be
decreased.
If the FSC friction lock needs to be adjusted, refer to
ADJUSTMENTS for Step 7 - Forward Speed Control Friction Adjustment in this section.
Transmission Control Setting
On a yearly interval or when an out-of-adjustment
condition is observed, check the transmission control for proper function as follows:
Neutral-Park
With the mower parked on level ground, start and
run the engine, first at idle and then normal operating speeds. With the FSC in the NEUTRAL-PARK
position, there should be no movement of eitherdrive tire. If the tire(s) are “creeping” forward or reverse, refer to ADJUSTMENTS for the Neutral
Function Adjustment - Step 3 in this section.
Straight Ground Tracking
Check for straight ground track by driving on a
smooth, level surface with hands off the steering levers. Set the FSC at different speeds and observe if
the mower moves in a straight line (use a cement
joint or other line on the ground for reference). If the
machine is drifting to the right or left, refer to
ADJUSTMENTS for Straight Tracking Adjustment - Step 5 in this section.
57
Maintenance Instructions
REPLACING/REPAIRING
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.
IMPORTANT: ALWAYS use genuine factory replacement parts. Substitute parts CAN result in
product malfunction and possible injury to the operator and/or others.
Drive Belts
There are three (3) individual belts on the machine:
●● 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.
Ground
Drive Belt
Engine/PTO Belts
(Matched Set of 2)
Belt Locations (Engine Hidden for Clarity)
58
REPLACING/REPAIRING
Maintenance Instructions
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.
Upper LH
Guard
REPLACING/REPAIRING
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
Fixed Idler
Pulley
Clutch Idler
Pulley
Lower LH
Guard
Right Hand
Guard
Wire Lock Pins
Wing Nut
Engine/PTO Belt
(Matched Set)
PTO
Pulley
2.
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
an engine/PTO belt.
Secure
Wing Nut
Upper LH
Guard
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)
59
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
Belt Tightener
Idler Pulley
Drive Pulley
Depress Idler Pulley to
Relax Belt
Ground Drive Belt Assembly (Disengaged)
2.
Reverse the procedure to install the ground
drive belt.
LH Transaxle
Ground Drive
Belt
RH Transaxle
Drive Pulley
Ground Drive Belt Assembly (Engaged)
60
Idler Pulley
Maintenance Instructions
Fuel Filter
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.
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.
Blade Overload Shear Bolts
NOTE: Blade shear bolts are not used on belt driven decks.
On gear driven decks each cutting blade is keyed to
the blade hub by two (2) shear bolts (10-24 x 5/8 in.
stainless steel machine screws). These bolts are
designed to shear and protect the blade drive gearbox from damage if the blade encounters a shock
load.
●● Wipe up spilled gasoline immediately
and completely.
Model B23i is equipped with an inline fuel filter between the fuel tank and the fuel pump (low pressure
fuel pump). Visually inspect the filter periodically,
and replace the filter every 400 hours. Use Walker
P/N 5020-3 or Kohler P/N 24-050-13, 9-12 microns
for replacement filter.
In-Line
Fuel Filter
Fuel Filter Location
IMPORTANT: Replace the fuel filter only in a clean
area where the fuel line and connections will not be
contaminated by any dust and dirt.
1.
Expand and slide clamps on either side of the
filter away from filter and pull fuel lines off filter.
Cutting Blade
Shear Bolts
Cutting Blade Shear Bolts
NOTE: Tightening the 5/8-18 blade mounting nut
to 60 lb·ft (81 N·m) is also important for proper
shock load protection. It is important to not overtighten the mounting nut since this defeats (overrides) the function of the shear bolts.
If these bolts shear, remove the blade and install
new bolts. Refer to CHECKING/SERVICING in
this section for Sharpen Mower Blades which describes the blade removal and installation procedure.
After reinstalling the blade, check blade timing (on
gear driven decks) by moving blades through one
(1) complete revolution. Make sure blade tips
pass clear of each other. If timing is incorrect, contact your Walker dealer.
61
Maintenance Instructions
Mower Blades
Mower blades are removed and remounted as described in Sharpen Mower Blades instructions (refer to CHECKING/SERVICING in this section). During the course of sharpening and inspecting mower
blades, if there are any of the following conditions
of wear or damage, blades should be replaced
for reasons of safety and performance of the machine:
●● An excessive amount of the flat section of the
blade has been ground away (removed) when the
blade is sharpened. Replace the blade when less
than a 3/4 in. (19 mm) flat section remains at the
blade tip.
●● Examine ends of the blade carefully, especially
the intersection where the flat section of the blade
turns up to form the “wing tip” (refer to CHECKING/
SERVICING for Mower Blade Profile for Sharpening illustration in Sharpen Mower Blades instructions). Since sand and abrasive material can wear
metal away in this area, the blade should be replaced when metal thickness has worn to
1/16 in. (1.6 mm) or less.
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.
62
REPLACING/REPAIRING
WARNING
DO NOT try to straighten a blade that is
bent. NEVER weld a broken or cracked
blade. ALWAYS replace with a new blade
to assure safety.
Reinstall the blades following procedure from
Sharpen Mower Blades instructions in CHECKING/SERVICING in this section. If blades are replaced, always use Walker original equipment
blades to ensure safety and optimum performance.
The quality and performance of replacement
blades offered by other manufacturers cannot be
guaranteed, they could be dangerous.
CAUTION
ALWAYS use genuine factory replacement parts. Substitute parts CAN result
in product malfunction and possible injury to the operator.
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 read­
justment if the transaxle or related
control linkage is removed or changed.
Adjust the position of the RH lever by turning the
stop bolt in the Speed Control Actuator in or out.
Turning the stop bolt in will make the RH lever
move back, and turning it out will make it move
forward. Tighten the locknut.
Stop
Bolt
NOTE: It would not be unusual for a new machine,
after the initial 5 or 10 hours of operation, to begin to
not travel straight (this is due to the break-in of the
transmissions). To fine tune tracking, refer to Step 5
- Straight Tracking Adjustment in this section.
Step 1 - Steering Lever Position Adjustment
NOTE: For proper operation, the steering levers
should be adjusted to sit evenly using the following
procedure.
1.
Stop Bolt Location
Examine the steering levers to make sure they
are parallel front to back in relation to one an­
other. If they are not equal, adjust accordingly.
(The handles may or may not be even at this
point.)
NOTE: The LH steering lever is non-adjust­
able. This procedure will require adjustment of
the RH lever to make it even with the LH lever.
Levers should sit
parallel to each other
Lever Alignment
63
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 depending on the arm length of the operator. The handles can be adjusted by loosening the locknut
at the pivot point and the locknut holding the
handle in position in the adjustment slide.
Adjust the han­dles into the most comfortable
position and tighten both locknuts.
Adjustment
Slide
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)
Correct FSC Lever NEUTRAL-PARK Position
Locknut
(Pivot Point)
Steering Handles Adjustment
Adjust Length of
Rod to Position
FSC Lever
FSC Lever Position Adjustment
64
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, rotate the control rod clockwise just until the
wheel stops and then begins to move in reverse. Rotate the control rod back counterclockwise half the number of turns required to
make the wheel go from moving forward to reverse. The transmission is now centered in the
neutral window. Tighten the jam nut on the ball
joint and repeat the same procedure on the
other transmission.
6.
Turn off the engine, and then lower the drive
tires onto the ground.
Tracking Adjustment Nuts
Transmission Control Rod and Arm Location
(Components Hidden for Clarity)
Ball Joint
Maximum Speed
Adjustment Set Screw
Jam Nut
Control Rod
FWD
REV
Locating/Limit
Stud
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.
Transmission
Control Arm
Tracking Adjustment Nut
(Adjusts Length of Control Rod)
Tracking Adjustment Components
65
Maintenance Instructions
ADJUSTMENTS
Step 4 - Full Forward Speed Adjustment
1.
Move the FSC to the full FORWARD speed
position.
2.
Raise the body. The maximum speed tracking
adjustment set screw in both transmission
control arms should not be contacting the limit
stud on the transaxle. If they are, back the set
screws out until they do not touch.
T-Handle
Hex Wrench
Maximum Speed Tracking Adjustment
(Shown with Parts Removed for Clarity)
Step 5 - Straight Tracking Adjustment
2.
3.
4.
66
5.
If the machine is tracking straight throughout
the speed range except at maximum speed,
use the following adjustment procedure:
a.
With the engine off, place the FSC in full
FORWARD. On the faster transmission,
loosen the jam nut and turn the maximum
speed tracking adjustment set screw in until it just contacts the limit stud, and then
turn it in an additional 1/8 turn (turning the
set screw in slows the drive wheel).
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
1.
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.
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, re­
fer to Step 3 - Neutral Function
Adjustment and readjust).
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).
If tracking is not straight, shorten the control rod
on the faster side by turning the tracking
adjustment nut clockwise. If straight tracking
and neutral are both achieved, proceed to the
next step. If straight tracking and neutral cannot both be achieved, turn the tracking adjustment nut on the faster side counterclockwise
until neutral is restored.
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
Maintenance Instructions
NOTE: Adjust the bolt
downward for quicker
activation (Switch Open).
FSC Switch
Actuator Arm
ADJUSTMENTS
Step 7 - Forward Speed Control Friction Adjustment
FSC Full
Forward Position
Switch Closed
in Neutral
Switch Adjustment
Bolt
Jam Nut
FSC Friction Nut
Pull Steering
Levers Back to
Check Friction
Lock
Front of Mower
FSC Neutral Switch Adjustment
(Side View Through Chassis)
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.
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 position. 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 greater than 1/8 in. (3 mm) turn the adjustment bolt
down slightly and recheck switch operation.
When finished adjusting, tighten the jam nut
and reconnect the spark plug wires.
FSC Friction
Adjustment Nut
FSC Friction Adjustment Nut
67
Maintenance Instructions
ADJUSTMENTS
Blade Clutch (PTO)
Clutch Engagement/Belt Tension
The clutch engagement and PTO belt tension are adjusted 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 assembly bolt head dimension as shown in the PTO
Clutch Engaged illustration. If the clutch actuator
link or clutch spring assembly have been disassembled, 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 mm to 8 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 mm to 8 mm)
Ball Joint
Blade Clutch
Engaged
Clutch Spring Assembly
(Spring Compressed)
Clutch Engagement
Arm
Clutch Arm
Safety
Switch
Front of Mower
PTO Clutch Engaged
68
Blade Clutch
Idler Pulley
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 components have been disassembled.
Loosen the brake band adjustment nut allowing
clutch pivot stop arm and stop bolt to make contact
(refer to Blade Brake Band Adjustment illustration).
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 engaged” 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
PTO Clutch Disengaged
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 engagement 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
69
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 adjustment as needed:
1.
Adjust the blade brake band, using the adjustment nut until pulley travel is approximately
5/8 in. to 3/4 in. (16 mm to 19 mm) from engaged 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.
CLUTCH DISENGAGED
CLUTCH ENGAGED
5/8 in. to 3/4 in.
(16 mm to 19 mm)
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 loosen­
ing the set screws on the Deck Mount
Pivot Brack­ets. Retighten the jam nut when the
adjustment is complete.
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
70
LIMITED WARRANTY
FOR
WALKER MODEL B23i
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, transportation charges prepaid. All parts and components of the Walker Mower are covered by this warranty except the following
components which are warranted separately by their respective manufacturers:
Kohler Engine
Battery
The available warranties covering these items are furnished with each mower. Walker does not assume any warranty obligation, liability or modification for these items, which are covered exclusively by the stated warranty of the respective manufacturers noted above.
* Extended warranties are offered for the following powertrain components:
• A 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 Manufacturing Company, 5925 East Harmony Road, Ft. Collins, CO 80528. Proof of the date of purchase may be required to verify warranty coverage.
4.
WARRANTY LIMITATION:
A.
THERE IS NO OTHER EXPRESS WARRANTY. ANY WARRANTY THAT MAY BE IMPLIED FROM THIS PURCHASE
INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY LIMITED TO THE
DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED
WARRANTIES ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts, so the
above limitations may not apply to you.
B.
WALKER WILL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, OR SPECIAL DAMAGES AND/OR
EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply
to you.
C.
Only the warranty expressed in this limited warranty shall apply and no dealer, distributor, or individual is authorized to
amend, modify, or extend this warranty in any way. Accordingly, additional statements such as dealer advertising or
presentations, whether oral or written, do not constitute warranties by Walker, and should not be relied upon.
D.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
71
WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, CO 80528 • (970) 221-5614
FORM NO. 092518
PRINTED IN USA
www.walker.com
©2018 WALKER MFG. CO

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