Walker H38i Operator's Manual


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Walker H38i 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: 147211
P/N 2000-21
Foreword
Thank you. . .for purchasing a Walker mower. Every effort has been made to provide you with the
most reliable mower on the market, and we are sure you will be among our many satisfied custom­
ers. If for any reason this product does not perform to your expectations, please contact your local
dealer. Every customer is important to us. Your satisfaction is our goal.
Please. . .read this manual thoroughly! This manual is to be used in conjunction with the engine
manufacturer’s manual for the specific engine on the mower model you have purchased. Before
you operate your new mower, please read this entire manual. Some of the information is crucial for
prop­er operation and maintenance of this mower - it will help protect your investment and ensure
that the mower performs to your satisfaction. Some of the information is important to your safety,
and must be read and understood to help prevent possible injury to the operator or others. If any­
thing in this manual is confusing or hard to understand, please contact your local authorized dealer
or call our service department, at (970) 221-5614, for clarification before operating or servicing this
mower.
This manual covers Model H38i with the Kohler Command Pro ECH980 (38 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 pro­
duced for a tractor with standard equipment. Optional equipment is available and may affect the
standard specifications listed.
Walker Mfg. Co. is continually striving to improve the design and performance of its products. We
reserve the right to make changes in specifications and design without thereby incurring any obli­
gation relative to previously manufactured products.
Sincerely,
WALKER MANUFACTURING COMPANY
Bob Walker, President
Table of Contents
General Information_________________ 1
Operating Instructions______________ 28
HIGHLIGHTED INFORMATION______________
GLOSSARY_____________________________
IDENTIFYING NUMBER LOCATIONS_________
ENGINE SERIAL NUMBER LOCATION________
SERVICING OF ENGINE AND
DRIVETRAIN COMPONENTS_______________
BEFORE OPERATING_____________________ 9
OPERATING____________________________ 11
MAINTENANCE_________________________ 13
SAFETY, CONTROL, AND
INSTRUCTION DECALS__________________ 14
CONTROL IDENTIFICATION,
LOCATION, AND FUNCTION ______________
Ignition Switch________________________
Engine Throttle________________________
Body Latch___________________________
Forward Speed Control (FSC)____________
Steering Levers_______________________
Blade Clutch (PTO)_____________________
Parking Brake_________________________
Oil Pressure Warning Light/Horn_________
Engine Service Light___________________
Over Temperature Warning Light/Horn_____
Transaxle Lockout Arms________________
Circuit Breaker________________________
Hourmeter____________________________
Suspension Seat______________________
STARTING THE ENGINE__________________
ADJUSTING GROUND
SPEED AND STEERING___________________
ENGAGING THE BLADE DRIVE____________
STOPPING THE MACHINE________________
FUEL TANK SELECTOR VALVE____________
ADJUSTABLE FOOT RESTS_______________
ADJUSTING CUTTING HEIGHT_____________
Transport Position_____________________
TRANSAXLE LOCKOUT__________________
RECOMMENDATIONS FOR MOWING_______
RECOMMENDATIONS FOR TILT-UP DECK
OPERATION/TRANSPORT________________
Assembly Instructions_______________ 18
Maintenance Instructions___________ 44
1
1
1
2
2
Specifications_________________________ 3
ENGINE_________________________________
ELECTRICAL SYSTEM____________________
TRANSMISSION__________________________
BLADE DRIVE___________________________
TIRE SIZE_______________________________
TIRE PRESSURE_________________________
DIMENSIONS (Tractor and Mower)___________
DRIVE BELTS____________________________
SEAT___________________________________
FRAME/BODY CONSTRUCTION_____________
DECK CHART____________________________
3
3
3
4
4
4
4
5
5
5
5
Component Identification____________ 6
Safety Instructions___________________ 9
SETUP INSTRUCTIONS___________________
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________________________
Measuring Deck Levelness_____________
Deck Leveling Procedure______________
PREOPERATING CHECKLIST______________
18
18
18
19
19
20
20
20
20
21
21
21
21
23
23
24
25
MAINTENANCE SCHEDULE CHART________
IMPORTANT TIPS FOR CARE OF THE
KOHLER ENGINE________________________
Fuel System__________________________
Starting/Stopping______________________
Cooling System_______________________
Air Cleaner System_____________________
Oil__________________________________
LUBRICATION__________________________
Engine Oil____________________________
Engine Break-In Oil____________________
Checking Engine Crankcase Oil Level_____
Changing Engine Crankcase Oil/Oil Filter___
Mower Deck Spindle Lubrication_________
DR52, DS60 or DR64 Mower Deck
Lubrication___________________________
Check Transaxle Fluid Level_____________
Transaxle Oil and Filter Change__________
Grease Fitting and Oil Point Lubrication ___
28
28
29
29
29
29
29
30
31
31
31
32
32
32
33
36
36
38
39
40
40
40
41
41
41
43
44
45
45
45
45
45
45
46
46
46
46
46
47
48
48
48
49
Table of Contents
CLEANING_____________________________
Engine Air Cleaner System______________
Kohler Air Cleaner_____________________
Engine Cooling System_________________
Cooling Air Intake Screen_______________
Cylinder Head Cooling Fins_____________
Grass Buildup in Mower Deck Housing____
Transaxle Housing_____________________
CHECKING/SERVICING___________________
Security of Air Cleaner System___________
Battery_______________________________
Electrolyte Level______________________
Cleaning the Terminals_________________
Charging the Battery___________________
Tire Pressure__________________________
Wheel Nut Torque______________________
Sharpen Mower Blades_________________
Drive Belts____________________________
Spark Plugs___________________________
Ignition Wires_________________________
Fuel Lines and Clamps__________________
PTO U-Joints _________________________
Engine Starter ________________________
Blade Brake Action_____________________
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_____________________
Deck Drive Belt_______________________
Fuel Filter ____________________________
Mower Blades_________________________
52
52
52
54
54
54
55
57
58
58
58
58
59
59
59
59
59
60
60
60
60
60
61
61
61
61
62
62
62
63
63
64
65
66
67
67
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___________
69
69
69
69
70
71
71
72
72
74
74
75
75
76
MAINTENANCE SERVICE
AND RECORDS SHEET___________________ 77
Warranty______________________
79
General Information
HIGHLIGHTED INFORMATION
Walker Manufacturing recommends that any ser­vice
requiring special training or tools be performed by
an authorized Walker Mower dealer. There are sev­
eral general practices to be aware of in the area of
safety. Most accidents associated with the oper­
ation or maintenance of a Walker Mower are caused
by disregarding basic safety precautions or specific
warnings. Such accidents, in most cases, can be
prevented by being aware of the dangers present.
Information of special importance has been high­
lighted in bold type in this manual. Refer to Safety
Instructions for the meanings of DANGER, WARN­
ING, CAUTION, IMPORTANT, and NOTE.
GLOSSARY
There are many terms that are either unique to this
equipment or that are used as acronyms. The fol­
lowing terms and their definitions will help while us­
ing this manual:
●● DECK is the mowing attachment mounted on
the front of the tractor which includes the carrier
frame, deck housing, blade spindles, and cutter
blades.
●● ELECTRONIC CONTROL UNIT (ECU) controls
engine functions such as spark timing, fuel/air
ratio, etc.
●● STEERING LEVERS steer the tractor by con­
trolling the two transaxles.
●● TRACTOR is the prime mover, including the
engine, drivetrain, operator seat, and controls to
operate the mower.
●● TRANSAXLE transmits and controls power
from the ground drive belt to the main drive
wheel.
●● TRANSAXLE LOCKOUT ARMS release the
transaxles to permit freewheeling the tractor.
IDENTIFYING NUMBER LOCATIONS
The tractor serial number plate is affixed to the
tractor body just below the left rear corner of the
seat. The mower deck serial number plate is affixed
alongside the angle iron framing on the LH side of
the LH mower blade drive. Model and serial numbers
are helpful when obtaining replacement parts and
maintenance assistance. For ready reference,
please record these numbers in the space provided.
Tractor Model No. _______________________
Tractor Serial No. _______________________
Deck Serial No.
_______________________
●● FORWARD SPEED CONTROL (FSC) controls
the maximum forward speed of the tractor;
functioning as a cruise control.
Engine Model No. _______________________
●● GROUND DRIVE refers to the dual transaxles
which drive the main wheels.
Date of Purchase _______________________
●● LEFT HAND (LH) refers to the left-hand side of
the tractor when the operator is seated facing
forward in the tractor seat.
Engine Serial No. _______________________
Fill In By Purchaser
●● POWER TAKE-OFF (PTO) transmits engine
power to run the cutter blades.
●● REAR DISCHARGE (RD) discharges mowed
material from the back of the mower deck.
●● 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.
1
General Information
SERVICING OF ENGINE AND DRIVETRAIN
COMPONENTS
Serial Number
Tractor Serial Number Location
The detailed servicing and repair of the engine and
transaxle are not covered in this manual. Only rou­
tine 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 com­
ponent manufacturer. Any unauthorized work
done on these components during the warranty
period may void the warranty. If you have any dif­
ficulty finding an authorized outlet or obtaining
warranty service, please contact our Service Depart­
ment for assistance:
Walker Manufacturing Company
5925 E. Harmony Road
Fort Collins, CO 80528
1-970-221-5614
www.walkermowers.com
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.
Serial Number
Engine Serial Number Location
2
Service manuals are available for each of these
components from their respective manufacturers as
follows:
Kohler Engines
Kohler Company
Kohler, WI 53044
800-544-2444
www.kohlerengines.com
Transaxles
Hydro-Gear
1411 South Hamilton St.
Sullivan, IL 61951
877-728-7410
www.hydro-gear.com
Specifications
MODEL
H38i
ENGINE
Manufacturer/Model
Kohler Command Pro® ECH980, 2 Cyl., OHV, Gasoline
(Air-Cooled), Electronic Fuel Injection (EFI)
Displacement cu. in. (cc)
61 (999)
Max. Power HP (kW)
38.0 (28.3) @ 3600 RPM
Governed RPM
3600
Max. Torque lb·ft (N·m)
53 (71.9)
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
Synthetic or API SJ or Higher Grade Oil Only with 10W-30 Viscosity,
0º to 50º F (-18º to 10º C), or 20W-50 Viscosity Above 32º F (0º C),
or 5W-30 Viscosity Below 32º F (0º C)
Oil Filter
Kohler P/N 52 050 02
Fuel Tank Capacity gal (L)
9.4 (35.6)
Two Independent 4.7 Gallon Tanks with Selector Valve
Fuel
Automotive Grade Unleaded Gasoline
(87 Octane Minimum, 10% Ethanol Maximum)
Cooling System
Air-Cooled
Air Cleaner
Engine Mounted (Kohler)
(Kohler P/N 25-083-01-S Primary / P/N 25-083-04-S Safety Filter)
ELECTRICAL SYSTEM
Battery
12 Volt (340 CCA)
Charging System
Flywheel Alternator
Charging Output
25 Amp DC (Regulated)
System Polarity
Negative Ground
Ignition
Electronic Capacitive Discharge
Starter
12 Volt Electric Ring-Gear Type, Solenoid Operated
Interlock Switches
Ignition Lockout by Seat Switch, Transmission Neutral and Blade
Clutch
Circuit Breakers
Manual Reset (20A), Auto Reset (30A)
TRANSMISSION
Manufacturer/Model
Dual, Independent Hydro-Gear® ZT3400 Integrated Transaxles
Steering
Hand Lever Control / Individual Wheel
Forward Speed Control
Precision Friction Lock Lever, Cruise Control, with
Neutral-Park Position
Service Brake
Dynamic Braking through Transaxles
Parking Brake
Internal Mechanical Cog Lock for each Transaxle
(Single Lever Control)
Neutral
Transmission Release by Manual Dump Valve
Final Drive
Direct Drive Axle from Transaxle
3
Specifications
MODEL
H38i
TRANSMISSION (continued)
Transmission Fluid
Factory Service
20W-50 Multi-Viscosity Motor Oil (Minimum SL Grade Oil)
Transmission Oil Capacity fl oz (L)
77 (2.3)
Transmission Cooling
Cooling Fan Mounted on Drive Pulley
Oil Filter
Hydro-Gear® P/N 52114 (Walker P/N 2026-6)
Ground Travel Speed
Forward MPH (km/h)
Reverse MPH (km/h)
0-10 (0-16) Infinitely Variable
0-5 (0-8) Infinitely Variable
BLADE DRIVE
PTO Shaft
Sliding Spline Shaft with Two (2) High-Speed U-Joints
(Quick Disconnect)
Blade Drive Clutch and Brake
Manual Belt Tightener Clutch and Band Brake
[Stops Blades within Five (5) Seconds of Disengagement]
TIRE SIZE
Deck Caster Wheel
13 x 5.00-6 (Pneumatic 4-Ply)
Drive
22 x 10.50-12 (4-Ply Low-Profile)
Tailwheel
13 x 5.00-6 (Pneumatic 4-Ply)
TIRE PRESSURE PSI (KPA)
Deck Caster Wheel
20 (137)
Drive
15 (103)
Tailwheel
20 (137)
DIMENSIONS (Tractor and Mower)
Length in. (cm)
Tractor Only
69 (175)
Tractor Wheel Base
45 (115)
Tractor with Tilted Deck
(Approximate)
87.75 (223)
Tractor with 64" Rear Discharge
Deck (DR64-3)
107.75 (274)
Width in. (cm)
Tractor Only (Outside Tire)
46.5 (118)
Tractor with 64" Rear Discharge
Deck (DR64-3)
66 (168)
Tread Width
36.5 (93)
Height in. (cm)
4
Tractor
46.5 (118)
With ROPS (Optional)
66.25 (168)
With ROPS (Optional) Lowered
51.25 (130)
Specifications
MODEL
H38i
DIMENSIONS (continued)
Weight lb (kg)
Tractor Only
802 (364)
Tractor with 64" Rear Discharge
Deck (DR64-3)
1239 (562)
DRIVE BELTS
Engine PTO
Walker P/N 2230 (Set of 3)
Ground Drive
Walker P/N 2248-1
SEAT
Full Spring Suspension with Dampening and Adjustments for
Back Angle, Lumbar Support, and Operator Weight.
Includes Adjustable/Retractable Armrests
FRAME/BODY CONSTRUCTION
Frame
All Welded Unitized Steel Chassis
Body
14 Gauge Steel
Deck
11 Gauge Steel
DECK
DR52
DS60
DR64
Type
Belt Driven,
Rear Discharge
Belt Driven,
Side Discharge
Belt Driven,
Rear Discharge
Cutting Width in. (cm)
52 (132)
60 (152)
64 (163)
Cutting Height in. (cm)
1 to 5 (2.5 to 13)
Height Adjustment in. (cm)
Blade Length in. (cm)
1/4 (1) Increments, 17 Positions
18.4 (47)
20.5 (52)
Number of Blades
Direction of Rotation
(Viewed from top of deck)
Deck Suspension
22.2 (56)
3
Clockwise
Torsion-Flex Frame with Caster Wheels and Counterweight Springs
Maximum Blade RPM
3840
3330
3200
Maximum Blade Tip Speed
ft/min (m/min)
18500 (5640)
17870 (5460)
18500 (5639)
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 Tilt-Up
Latch
Deck Support Arm
(Not Visible)
Tilt-Up Latch
Counterweight Springs and
Protective Covers
Adjustable
Footrest
Deck Support Arm
(Not Visible)
Adjustable
Footrest
Deck
Tilt-Up Bar
Forward Speed
Control (FSC)
Friction
Adjustment
Cutting Height Release Lever
(Cutting Height Adjustment)
Deck Lift Foot Pedal
(Raises Deck)
Deck Tilt-Up
Socket
Deck Height
Lift Chain
Tilt-Up
Hook
Front View and Right Side View
6
Deck
Caster Wheels
Component Identification
Oil Fill
Fuel Gauge
Engine Air
Cleaner
Dipstick
(Not Visible)
Body Lift
Handle
Adjustable
Footrest
Muffler Heat
Shield
Tailpipe
Left Hand
Drive Wheel
Fuel Tank
and Cap
Fuel Pickup
Line
Cylinder Head Cooling
Fins (Not Visible)
Muffler
Spread Axle
(Tail Wheel)
Rear View and Left Side View
7
Component Identification
LH Transmission
Control Rod
Steering Lever Spring/
Dampener Assembly
RH Transmission
Control Rod
LH Transaxle
RH Transaxle
LH Transaxle
Lockout Arm
RH Transaxle
Lockout Arm
Clutch
Linkage
Parking Brake
Linkage
PTO Clutch
Lever
Parking Brake
Lever
Transaxle Oil
Expansion
Reservoir
Battery
Fuel Tank Cap
Fuel Filter
Fuel Tank
Selector Valve
EVAP Line
Fuel Gauge
Fuel Tank
Roll Over Valve
Fuel Pickup Line
Oil Filter
ECU
Oil Fill
Dipstick
(Not Visible)
Fuel Pump
(Low Pressure)
Air Filter
Cover
Air Cleaner
Oxygen
Sensor
Rubber Bumpers
(Body Support)
Top View (Body Raised)
8
Muffler Heat
Shield
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 warn-­
ing is ignored and proper safety precau­tions are not taken.
Walker Manufacturing cannot predict every poten­
tially dangerous situation. Therefore, items labeled
as such in this manual do not cover all conceivable
situations. Any person using procedures, tools, or
control techniques not recommended by Walker
Manufacturing must take full responsibility for safety.
The Walker Rider Lawnmower has been designed
with many safety features to protect the operator
from personal harm or injury. However, it is neces­
sary for the operator to use safe operating proce­
dures at all times. Failure to follow safety instructions contained in this manual may result in
personal injury or damage to equipment or property.
If you have any questions concerning setup, opera­
tion, maintenance, or safety, please contact your
authorized Walker Mower dealer or call Walker
Manufacturing Company at (970) 221-5614.
BEFORE OPERATING
WARNING
1.
A POTENTIAL hazard that COULD result in
severe personal injury or DEATH, if warn­
ing is ignored and proper safety precau­
tions are not taken.
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 pre­
cautions are not taken.
IMPORTANT: Identifies mechanical information
demanding special attention, since it deals with the
possibility of damaging a part or parts of the ma­
chine.
NOTE: Identifies information worthy of special
attention.
Read and understand the contents of this
Operator’s Manual before starting and operating the machine. Become thoroughly famil­
iar with all machine controls and how to stop the
machine and disengage the controls quickly.
Replacement Operator’s Manuals are available
by sending the Model and Serial Number to:
Walker Manufacturing Company
5925 East Harmony Road
Fort Collins, CO 80528
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.
7.
Do not wear loose fitting clothing that could get
caught in moving parts. Do not operate this ma­
chine while wearing shorts; always wear adequate protective clothing, including long
pants. Wearing safety glasses, safety shoes,
and a helmet is advisable and required by some
local ordinances and insurance regulations.
Prolonged exposure to loud noise can cause
impairment or loss of hearing. Operator hear­
ing protection is recommended. Wear a suit­
able hearing protective device, such as ear­
muffs or earplugs.
8.
Keep all protective shields and safety devices in place. If a protective shield, safety
device, or decal is damaged, unusable, or miss­
ing, repair or replace it before operating the
machine.
9.
Be sure interlock switches are functioning
correctly, so the engine cannot be started un­
less the Forward Speed Control lever is in the
NEUTRAL-PARK position, and the PTO clutch
is in the DISENGAGED position. Also, the en­
gine should stop if the operator lifts off the seat
with either the Forward Speed Control (FSC)
out of the NEUTRAL-PARK position or the PTO
clutch in the ENGAGED position.
NOTE: There is a 1/2 second time delay func­
tion on the seat switch to avoid engine power
interruption when driving over bumps.
10. Handle gasoline with care. Gasoline is highly
flammable and its vapors are explosive:
10
a.
Use an approved fuel container.
b.
Never add fuel to a running engine or hot
engine (allow hot engine to cool several
minutes).
c.
Keep matches, cigarettes, cigars, pipes,
open flames, or sparks away from the fuel
tanks and fuel container.
d.
Always fill the fuel tank(s) 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(s) and con­
tainer 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.
In case the transmission drive belt breaks dur­
ing 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 ex­
actly the same procedure used to normally stop
and park the machine.
6.
Disengage the blade clutch and put the FSC in
the NEUTRAL-PARK position before starting
the engine (an ignition interlock switch normally
prevents starting of the machine if these con­
trols are in the OPERATING position).
7.
Do not operate machine if the operator presence safety switch system is not working.
Verify proper operation by having the operator
lift off the seat with the engine running and mov­
ing two controls, one at a time; (1) Move the
FSC lever out of the NEUTRAL-PARK position,
and (2) Engage the PTO Clutch. Moving either
control should stop the engine after a 1/2 sec­
ond delay.
8.
Do not run the engine in a confined area
without adequate ventilation. Exhaust fumes
are hazardous and can be deadly.
9.
Do not carry passengers - maximum seating
capacity is one (1) person.
10. Watch for holes, rocks, and roots in the terrain
and for other hidden hazards. When mowing
tall grass, mow higher than desired to expose
any hidden obstacles. Then, clean the area and
mow to the desired height.
11. Avoid sudden starts or stops. Before back­
ing the machine up, look to the rear to be sure
no one is behind the machine. Watch carefully
for traffic when crossing or working near road­
ways.
12. When moving forward, do not suddenly put the
tractor in reverse by rapidly pulling on the steer­
ing levers, especially when going downhill, as
this can lift the tractor tail wheel off the ground
and set up a bucking motion due to operator
overcontrol. If bucking does occur, immediately
stop the bucking action by pulling the Forward
Speed Control (FSC) lever into the NEUTRALPARK position.
13. Disengage the blade drive when transporting
the machine across drives, sidewalks, etc.
Never raise the mower deck while blades are
rotating.
DANGER
Do not mow or drive the tractor within 5
feet (1.5 meters) of an embankment or retaining wall with drop off.
11
Safety Instructions - Operating
14. The maximum recommended slope operating angle is 15 degrees or 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 ma­
chine, avoid sharp turns or sudden changes in
direction. Do not operate the machine on a
slope greater than 15 degrees.
15. Never adjust cutting height with the engine
running. Before adjusting cutting height or
servicing, disengage the blade clutch (PTO),
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 posi­
tion.
17. When using the tilt-up deck, observe the fol­
lowing:
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 un­
clog the system.
c.
Disconnect the spark plug wires.
d.
Never place hands under the deck - use a
stick or similar tool to remove clogged ma­
terial.
19. If the cutting blades strike a solid object or the
machine begins to vibrate abnormally,
immediately disengage the blade clutch
(PTO), 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), 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.
12. Use care when charging the battery or per­
forming maintenance on the battery and electri­
cal system:
a.
Make sure the battery charger is unplugged
before connecting or disconnecting cables
to the battery.
Keep all nuts, bolts, and screws tight to ensure
the machine is in a safe, working condition.
Check the blade mounting bolts frequently,
mak­ing sure they are tight.
b.
Charge the battery in a well-ventilated
space, so gases produced while charging
can dissipate. Make sure the battery vents
in the caps are open.
4.
Perform only maintenance instructions described in this manual. Unauthorized mainte­
nance operations or machine modifications
may result in unsafe operating conditions.
c.
Keep sparks, flames, and smoking materi­als away from the battery at all times. To
avoid sparks, use care when removing
bat­tery 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 mak­
ing 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.
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, fuel lines, and fuel injectors,
contact your Walker dealer or authorized
Kohler service dealer.
8.
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.
9.
Never attempt to disconnect any safety devices
or defeat the purpose of these safety devices.
IMPORTANT: Keep all applicable manuals im­
mediately accessible to anyone who may oper­
ate or service this machine.
10. Do not change the engine governor settings or
overspeed the engine. The governor has been
factory-set for maximum-safe engine operating
speed.
11. Use genuine factory replacement parts.
Sub­stitute parts may result in product malfunc­
tion and possible injury to the operator and/or
others.
13
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
1.
8600-12
Location: Engine
Part Number: 8600-12
2.
1.
8600-28
Location: Each End of Mower Deck
Part Number: 8600-28
Warning – thrown object hazard.
●● Keep bystanders away from the machine
when operating.
●● Clear lawn of debris before operating.
●● Keep any discharge deflector in place and in
the lowest position.
2. Warning – rotating mower blades are a cutting/
dismemberment hazard to hands and feet.
●● Keep all body parts away from rotating mow­
er blades.
●● Do not step on end of deck.
Warning – carbon monoxide (CO) poisoning
hazard.
●● CO emitted by a running engine can be
deadly.
●● Do not operate indoors or in other enclosed
areas.
1.
1.
Location: Deck Carrier Frame
Part Number: 8600-15
1.
Warning – lock deck tilt-up hinge before operat­
ing the machine.
1.
1.
8600-14
Location: Deck Carrier Frame
Part Number: 8600-14
1.
8746-2
Warning – do not operate the machine with the
deck tilted up.
Location: PTO Guard on Deck
Part Number: 8746-2
9804-1
1.
Grease PTO shaft joints every 8 hours.
1.
1.
Location: Chassis Member Behind Transaxles
Part Number: 9804-1
1.
14
Neutral Lock
●● Lift and move back to engage step to unlock transaxle and allow machine to freewheel.
8600-5
Location: Rear Body Near Muffler
Part Number: 8600-5
1.
Warning – hot surface, do not touch.
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.
BELT TWIST
DR64 BELT P/N 2731-5
2749-7
Location: Deck Housing Under Footrest
Part Number: 2749-7
Location: Deck Housing Under Footrest
Part Number: 2749-3
1.
1.
Deck drive belt routing.
Deck drive belt routing.
1.
1.
Location: Deck Discharge Shield (DS60)
Part Number: 5848-3
1.
Warning – thrown object hazard.
●● Always keep the discharge shield in the low­
est position when operating.
●● Do not remove the discharge shield.
Location: Top of Deck Housing
Part Number: 8653-1
1.
Warning – secure deck with straps and engage
parking brake before transporting or trailering
with deck tilted up.
4.75 4.25 3.75 3.25 2.75 2.25 1.75 1.25
121 108
95
83
70
57
44
32
1.
5.0
127
Fuel tank selector valve.
4.0
102
3.5
89
3.0
76
+
Location: Adjacent to Left Fuel Tank
Part Number: 2010-16
1.
4.5
114
2.5
64
2.0
51
1.5
38
inch
mm
1.0
25
1.
2748-1
Location: Deck Height Adjuster
Part Number: 2748-1
1.
Move pin to desired height of cut.
15
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
1.
2.
8600-2
Location: Flex Coupler Guard in Front of Engine
Part Number: 8600-2
1.
Warning – entanglement and cutting/dismem­
berment hazards.
●● Keep away from rotating shafts, belts, and
other components.
3.
4.
5
1.
2.
Location: Underside of Rear Body
Part Number: 2107-5
1.
2.
Ground drive belt routing.
PTO clutch belt routing.
Location: Right Fender
Part Number: 2802-4
1.
2.
3.
Location: Engine Shroud
Part Number: 5855
16
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.
Body Tilt Latch
●● Raise lever to release.
●● Lift at back of body to raise.
Warning – do not engage PTO clutch with PTO
shaft disconnected.
PTO Clutch Lever
●● Move lever forward to engage PTO clutch;
back to disengage.
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
1.
2.
1.
3.
4.
2.
1.
2.
<15°
3.
5.
4.
6.
5.
7.
6.
8.
7.
8.
2802-5
Location: Left Fender
Part Number: 2802-5
Throttle
●● Move lever forward to increase engine
speed; back to idle.
Warning – read Operator’s Manual before oper­
ating the machine.
Warning – wear eye and ear protection when op­
erating the machine.
Warning – read Operator’s Manual before servic­
ing or performing maintenance.
●● Engage parking brake.
●● Remove ignition key.
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 run­
ning.
Parking Brake
●● Move lever forward to engage Parking
Brake; back to disengage.
1.
2.
3.
OIL PRESSURE
CYL HEAD TEMP
SERVICE ENGINE
Location: Front Body Adjacent to
RH Steering Lever
Part Number: 2807-7
1.
2.
3.
Low Engine Oil Pressure Warning Light.
High Oil/Cylinder Head Temperature Light.
Engine Service Light.
17
Assembly Instructions
SETUP INSTRUCTIONS
Walker Mowers are shipped partially assembled to
our distribution network, and are typically assem­
bled by the selling dealer. For any additional as­
sembly besides the following, contact your Walker
dealer.
Battery Service
CAUTION
Battery
Important Battery Service, Installation, and
Charging Tips For Electronic Fuel Injection
Engines:
●● Do not allow the battery cables to touch
opposing terminals. When connecting battery cables attach the positive (+) cable to
positive (+) battery terminal first, followed
by negative (-) cable to negative (-) battery
terminal.
●● Never start the engine when the cables
are loose or poorly connected to the battery terminals.
●● Never disconnect battery while engine
is running.
●● Never use a quick battery charger to
start the engine.
●● Never “jump start” the engine using another source. Electricity fluctuations can
damage the ECU (Electronic Control Unit).
●● Always disconnect negative (-) battery
cable lead before charging battery, and
also unplug harness from ECU before performing any welding on equipment.
Raise mower body up for battery access. Check the
battery for electrolyte level and charge. The electro­
lyte 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 instruc­
tions.
18
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
cre­
ated by damage to critical working parts and
safety systems.
Wet Battery Service
If the battery has been shipped wet, but the electro­
lyte 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.
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.
IMPORTANT: DO NOT overfill the battery.
Electrolyte will overflow through the vented
caps onto parts of the machine and WILL result
in severe corrosion.
Remove the battery hold-down bar, disconnect
the battery cables and lift the battery out of the
tray.
IMPORTANT: Battery must be removed from
the mower before filling with electrolyte.
3.
Install battery.
IMPORTANT: Obtain and use only battery
grade sulfuric acid electrolyte with a 1.265 spe­
cific gravity to activate the battery. DO NOT use
water or any other liquid during initial activation.
2.
Remove the filler caps and carefully fill each cell
until the electrolyte is just above the plates.
3.
After the battery is filled with electrolyte, replace
the filler caps and charge the battery. Refer to
Battery Charging.
19
Assembly Instructions
Battery Installation
Mower Deck Assembly
IMPORTANT: Make sure battery is securely mount­
ed in the frame. A loose battery may cause damage
to the case resulting in acid leakage and severe
damage to the machine. A hazard may be created
by damage to critical working parts and safety sys­
tems.
Deck Caster Wheels Installation
1.
Remove the bolts and washers from each deck
caster wheel.
2.
Install wheel on fork using bolts and washers.
3.
Tighten the bolts and washers.
Install the battery in the mower as shown in Battery
Installation photo. Connect the positive (+) first and
then the negative (-) cable to the proper battery ter­
minal [red cable and boot connects to the Positive (+) terminal]. Slide the rubber boot up and over
the battery post, making sure it covers the post com­
pletely to prevent an electrical short.
WARNING
Make sure the battery cap vents are open.
Improper venting of the battery COULD
cause a battery explosion.
Deck Caster Wheel Installation
Deck Discharge Deflector Shield Installation (DS60)
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.
Battery Clamp
Secured by
Wing Nut(s)
WARNING
(+) Battery Cable
Connection
DO NOT operate the machine without the
grass deflector shield attached and in the
lowest possible position.
Battery Installation
Attach Shield
Deck Discharge Shield Installation
20
Assembly Instructions
PTO Shaft Guard Installation
Mower Deck Installation on Tractor
Position the shaft guard as shown and mount with
two (2) 1/4-20 x 1/2 in. bolts.
Deck Installation
Carrier Frame
Tube Socket
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
Attach
Guard
PTO Shaft Guard Installation
Tilt-Up Roller Wheel Installation
Mount the two (2) tilt-up roller wheels on the brack­
ets on the rear skirt of the deck housing using the
axle spacer tube, 3/8-16 x 3 in. bolt and 3/8-16 Whiz
locknut. Tighten the bolt until the wheel rolls freely,
but is not loose.
Roller
Wheel
Rubber Debris
Guard
Mower Deck Installation
2. First, engage the LH deck carrier frame tube
socket on the LH tractor support arm and then
the RH arm into the RH tube socket. Slide the
deck onto the support arms and install lynch
pins to secure deck. Two (2) lynch pins are in­
cluded in Owner’s Packet of materials.
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 following photos.
NOTE: The Coupler Installation Tool is provided
for convenience, but is not required for installa­
tion.
Roller Wheel Installation (Typical, DS60 Shown)
4. Unhook lower edge of rubber debris guard and
raise for access to the tractor PTO shaft. Refer
to Mower Deck Installation photo for location
of debris guard.
21
Assembly Instructions
Coupler
Installation Tool
PTO Coupler
Tube
Retract Spring-Loaded
Quick Disconnect Ring
PTO Coupler Installation Tool
Coupler
Installation Tool
IMPORTANT: DO NOT operate tractor with
Coupler Installation Tool installed.
Align
Arrows
Tractor
PTO Shaft
PTO Shaft Connection
(Shown with Debris Guard Removed for Clarity)
5. Reaching under the tractor, slide the PTO cou­
pler tube onto the deck drive shaft (align arrow
decals), then install the coupler quick disconnect
onto the tractor PTO drive shaft. Refer to the
PTO Shaft Connection photo.
6. Remove Coupler Installation Tool from quick
disconnect ring and make sure the ring has
“snapped” securely on the spline shaft.
22
Coupler Installation Tool Removal
(Shown with Debris Guard Removed for Clarity)
IMPORTANT: To prevent damage to the mow­
er, make sure the PTO quick disconnect is se­
curely locked on the tractor, with the locking
balls fully seated in the groove and the ring in
the locked position (refer to the Quick Disconnect Ring “Locked” Position illustration). Af­
ter installation, pull on the PTO coupler to check
for security.
Coupler Ring in
Released Position
PTO Drive
Shaft
PTO Coupler
U-Joint
Quick Disconnect Ring “Released” Position
Assembly Instructions
Internal Balls
Locked on Shaft
PTO Coupler
U-Joint
PTO Drive
Shaft
Coupler Ring in
Locked Position
Quick Disconnect Ring “Locked” Position
7. 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.)
8. With the counterweight springs connected, the
weight on the deck caster wheels should be
190 to 230 Ib (86.2 to 104.3 kg); this adjustment
is preset at the factory.
Counterweight Springs
Clip Onto Body
With Body Tilted Up
Deck Leveling
The mower deck and support frame are jig welded
and the deck support linkage is factory adjusted.
Within normal tolerances, very little, if any, adjust­
ment should be required to level the deck. Tire size
and pressure will affect the levelness of the deck.
Assure that all tires (tractor and deck caster
wheels) are properly inflated prior to checking
deck levelness or performing the deck leveling
procedure.
Measuring Deck Levelness
1.
Position the mower on a smooth, level surface,
and set the deck height to the most common
cutting position. Refer to ADJUSTING CUTTING HEIGHT in Operating Instructions.
2.
See the Deck Leveling illustration for side-toside and front-to-back deck level measurement
points. Side-to-side measurements should not
vary more than 1/8 in. (3 mm). Front-to-rear
measurements should have the rear 1/4 in.
(6 mm) to 3/8 in. (10 mm) higher than the front.
If either set of measurements are not within
tolerance, perform the Deck Leveling Procedure.
Lynch Pins
Lock Deck on
Support Arms
(Not Visible)
Deck Counterweight Spring Installation
23
Assembly Instructions
Deck Leveling Procedure
1.
3.
Measure the side-to-side level of the deck by
measuring from the ground to the top of the
deck housing at the front corners of the deck as
shown in the Deck Leveling illustration. The
side-to-side measurements should not vary by
more than 1/8 in. (3 mm). If necessary, raise or
lower the left and/or right front support chain
clevises to level the deck.
4.
Measure the front-to-rear level of the deck using
a straight edge as shown in the Deck Leveling
illustration. The rear measurement should be
1/4 in. (6 mm) to 3/8 in. (10 mm) higher than the
front measurement. If necessary, adjust the
right side height adjustment rod by lengthening
it to lower the back of the deck, or shortening it
to raise the back of the deck.
5.
With the side-to-side and front-to-rear deck
level correct, reattach the left rear support chain
that was removed in step 2. Adjust the left side
height adjustment rod to equalize the left rear
and right rear support chain tension.
6.
Assure that all fasteners are tight and replace
any guards removed during the leveling proce­
dure.
Position the mower on a smooth, level surface,
and set the deck height to the most common
cutting position. Refer to ADJUSTING CUTTING HEIGHT in Operating Instructions.
WARNING
The machine must be shut off during this
procedure.
2.
Place a block of sufficient height under the left
rear corner of the deck housing to remove
tension from the left rear deck support chain.
Detach the left rear deck support chain by
removing the upper bolt from the height adjuster
arm. Remove the block and let the deck hang
from the remaining three support chains.
Right Side
Measurement
Point
Right Height
Adjustment Rod
Left Rear Deck Support
Chain (Remove Upper
Bolt for Leveling)
Approx. 36 in. (914 mm)
Long Straight Edge
Left Height
Adjustment Rod
Rear
Measurement
Point
Right Support
Chain Clevis
Ground
Left Support
Chain Clevis
Front
Measurement Point
Deck Leveling
24
Left Side
Measurement Point
Assembly Instructions
PREOPERATING CHECKLIST
Before operating the mower for the first time, and as
a routine before daily operations, it is important to
make sure the mower is properly prepared and
ready for operation. The following is a list of items
to be checked. (For a mower with frequent opera­
tion, some of these items will not need to be
checked every day, but the operator should be
aware of the condition of each.)
For proper fuel and lubricants refer to Specifications.
FILL FUEL TANKS
Fill the fuel tanks using clean, fresh automotive
grade unleaded gasoline (87 octane minimum, 10%
ethanol maximum).
DANGER
Handle gasoline with care. Gasoline is high­
ly flammable and its vapors are explosive.
Use safe refueling procedures:
●● DO NOT fill fuel tank(s) with the engine
running.
●● If the engine is hot, allow to cool before
refueling.
●● Use an approved fuel container.
●● Fuel the mower outdoors.
●● DO NOT smoke while refueling.
●● Avoid spilling fuel; use a funnel or spout.
●● DO NOT overfill the fuel tank(s); 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 tanks. Wipe dirt from around
the filler cap(s) before removing. Use a clean fuel
storage container and funnel.
IMPORTANT: DO NOT mix oil with gasoline.
Always use fresh, automotive grade unleaded gas­
oline. DO NOT use gasoline containing greater than
10% ethanol. DO NOT use additives, such as
carburetor cleaners, deicers, or moisture removing
agents. DO NOT use gasoline blended with methyl
alcohol.
CHECK ENGINE CRANKCASE OIL LEVEL
Check the engine crankcase oil level before use and
after each 8 hours of continuous operation. Refer
to LUBRICATION for Checking Engine Crankcase
Oil Level in Maintenance Instructions.
CHECK AND SERVICE ENGINE AIR CLEANER SYSTEM
Check condition, cleanliness, and security of the
complete air cleaner system (inspect air filter every
100 hours). For detailed procedures, refer to
CLEANING the Engine Air Cleaner System in
Maintenance Instructions.
CHECK ENGINE COOLING SYSTEM
Check that the engine cooling air intake screen is
free of obstruction by grass clippings or debris and
clean if required. Also, cylinder head cooling fins
should be inspected and cleaned if any build-up of
debris is noted [remove two (2) cylinder head ac­
cess panels to inspect and clean]. Refer to CLEANING the Cylinder Head Cooling Fins in Maintenance
Instructions.
Check performance of the cooling system by start­
ing the engine, holding a hand adjacent to the cylin­
der heads, and feeling the cooling airflow.
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
CHECK SECURITY OF DRIVE TIRE MOUNT­
ING NUTS
The eight (8) Drive Tire mounting nuts should each
be torqued to 75 to 85 lb·ft (102 to 115 N·m).
INSPECT FIVE (5) DRIVE BELTS
Engine/PTO (3), Ground Drive (1) and Deck Drive (1).
25
Assembly Instructions
CHECK HYDROSTATIC TRANSAXLE OIL
LEVEL
Tilt Bar
Refer to LUBRICATION for Check Transaxle Fluid
Level in Maintenance Instructions.
2802-5
5°
<1
2.
1.
CHECK TIRE PRESSURE
Deck Caster Wheel = 20 PSI (137 kPa)
Drive
= 15 PSI (103 kPa)
Tailwheel
= 20 PSI (137 kPa)
CHECK FUNCTIONS OF WARNING LIGHTS
AND WARNING HORN
Turn the ignition key to the ON (RUN) position. Oil
Pressure Warning Light, Engine Service Light, and
Warning Horn should all operate, indicating normal
function.
3.
CHECK FUNCTION OF SAFETY INTERLOCK
SWITCHES
Fit tilt bar into the socket on front of deck hous­
ing and secure with hitch pin.
4.
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 mower blades en­
gaged.
Remove footrest or, if equipped with adjustable
footrests, move the footrest to the full forward
locking position.
5.
Raise deck to tilt-up position using tilt bar and
secure in position by inserting the deck hook in
the tilt-up latch on the tractor body as shown in
the Deck Secured in TILT-UP Position photo.
Before operating the mower, make sure to reengage the locking arms into the LOCKED
position after lowering the deck to the normal
operating position.
CHECK AND CLEAN GRASS
UNDERNEATH MOWER DECK
BUILDUP
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 is secured in the raised position
using the following procedure:
26
1.
Remove the tilt bar from the stowed position on
the carrier frame.
2.
Use the tilt bar to release the two (2) deck lock­
ing arms as shown in the Unlock Deck Arms
for Deck Tilt-Up illustration.
Unlock Deck Arms for Deck Tilt-Up
CAUTION
Do not operate mower with deck tilt-up
pivot joint UNLOCKED. Make sure locking
arms are in the LOCKED position and the
tilt-up joint is rigid (locked).
DANGER
Do not operate the mower with deck in tiltup position. Do not move the tractor with
the deck in the tilt-up position.
Assembly Instructions
Tilt-Up Hook and
Latch Connected
Hitch Pin
Tilt Bar
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 should be
torqued to 70 lb·ft (95 N·m). If blade sharpening is
required, refer to CHECKING/SERVICING for
Sharpen Mower Blades in Maintenance Instruc­
tions.
ADJUST MOWER CUTTING HEIGHT, IF
REQUIRED
Tilt-Up
Latch
Tilt-Up
Hook
Refer to ADJUSTING CUTTING HEIGHT in Oper­
ating Instructions.
PERFORM ANY ADDITIONAL PROCEDURES
called for on the MAINTENANCE SCHEDULE
CHART in Maintenance Instructions.
Deck Secured in TILT-UP Position
27
Operating Instructions
CONTROL IDENTIFICATION, LOCATION, AND
FUNCTION
CAUTION
Before operating the mower, become fa­
miliar with the location and function of all
operator controls. Knowing the location,
function, and operation of these controls
is important for safe and efficient opera­
tion of the mower.
If the engine does not start, return the key to the “O”
position for at least 60 seconds before making a re­
start 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 start­
ing the engine, turn the key clockwise to the “S”
position. Do not hold the key in the “S” position
longer than 10 seconds.
Body Lift Handle
(Not Visible)
START
Ignition Switch
Steering
Levers
Forward Speed
Control (FSC)
Parking
Brake
Throttle
Body
Latch
Blade Clutch
(PTO)
Ignition
Switch
Hourmeter
Circuit
Breaker
Warning
Horn
Warning Lights (3)
Operating Controls
28
Operating Instructions
Engine Throttle
Forward Speed Control (FSC)
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 back­
ward toward the IDLE position decreases engine
speed.
Forward Speed Control (FSC) has two functions:
One is to set forward travel speed, and the other is
to establish the NEUTRAL-PARK position. When
the FSC lever is moved into the FORWARD posi­
tion, a friction lock holds any forward speed setting
from 0 to 10 mph (0 to 16 km/h). The ground speed
is pro­portional to the lever position; the further the
lever is advanced forward, the faster the tractor
moves. It is not necessary to hold the FSC in posi­
tion since the friction lock maintains the selected
lever position. Pulling back on the steering levers
overrides the FSC setting and slows or stops for­
ward travel. Releasing the steering levers allows
the tractor to resume forward travel at the speed set
by the FSC lever. To stop and park the machine, the
FSC lever is moved backward to the NEUTRALPARK position.
Throttle
Steering Levers
Throttle Location
Body Latch
The tractor body hinges forward for maintenance
access and is latched down in the OPERATING po­
sition. To raise the body, pull back and up on body
latch and lift body using the lift handle on the rear
body.
Latch
Each drive wheel is controlled by its own indepen­
dent steering lever, for both steering function and
FORWARD/REVERSE motion. The FSC lever sets
the maximum forward speed, and also sets the for­
ward position of the steering levers. The steering
levers operate only with a backward pulling move­
ment of the lever, which causes the drive wheel for
that lever to first slow down, stop, and then reverse
with a full backward lever stroke. The levers are
released to the FORWARD position for “straightahead” ground travel.
NOTE: Pushing forward on the steering levers will
not cause any change in tractor motion - there will
be no steering lever reaction and there will be no
machine damage.
Blade Clutch (PTO)
Body Latch
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.
29
Operating Instructions
Parking Brake
The parking brake functions by locking a detent arm
to a cog in the hydraulic motor rotor. Moving the
lever FOR­WARD engages the parking brake; mov­
ing the lever BACKWARD releases the brake.
IMPORTANT: Stop the tractor completely before
engaging the parking brake. The parking brake
uses a positive mechanical lock similar to the PARK
posi­tion on an automotive automatic transmission.
If the tractor is moving when the brake is engaged,
it will result in sudden stoppage and possible inter­
nal damage to the transaxle.
Disengaged
Position
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.
Parking Brake Disengaged
Engaged
Position
Parking Brake Engaged
30
Operating Instructions
Oil Pressure Warning Light/Horn
The oil pressure warning light and horn signal indi­
cate that engine oil pressure is below the safe oper­
ating level [below 3 to 5 PSI (21 to 34 kPa)]. This
light (and warning horn) will come on when the
ignition is turned ON, but should go off after the en­
gine is started. If the light fails to come on when the
ignition switch is turned ON, it could indicate a
burned out bulb. If the light comes on during engine
operation, stop the engine immediately and correct
the source of the problem before further engine op­
eration.
IMPORTANT: Continued operation of the engine
with an illuminated oil pressure warning light MAY
cause severe engine damage (if a low oil pressure
condition exists).
Engine Service Light
The engine service light indicates that the engine
Electronic Control Unit (ECU) has detected a fault in
the engine performance. When this light illuminates
during operation, contact an authorized Kohler Ser­
vice dealer to diagnose the fault.
Oil Pressure
Warning Light
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.
Over Temperature Warning Light/Horn
The over temperature warning light and horn signal
indicate that the engine oil temperature is above the
safe operating limit (350° F or 177° C) and the engine is overheating. If this light comes on, there
may be a problem with the engine cooling system
(material packed into cylinder head cooling fins,
clogged air intake screen, etc.). Stop the engine
and correct the source of the problem before further
operation.
IMPORTANT: Continued operation of the engine
with an illuminated over temperature warning light
MAY cause severe engine damage if a high cylinder
head temperature condition exists.
Over Temperature
Warning Light
Engine Service
Light
Warning
Horn
Engine Warning Lights/Horn
31
Operating Instructions
Transaxle Lockout Arms
Hourmeter
The transaxle lockout arms disengage the transax­
les. By lifting the arms up and locking them into
place with the shoulder on the arm in the chassis
notch, the transaxles are released to permit free­
wheeling. By releasing the arms and recessing
them back toward the chassis, the transaxles are
engaged for normal operation. The transaxle arms
in the LOCKOUT position are used to enable mov­
ing the machine without the engine running (e.g., for
service). Refer to TRANSAXLE LOCKOUT in this
section for operating instructions.
The hourmeter, which is located on the right front of
the body, displays operating time accumulated
while the ignition switch is in the ON (RUN) position.
The hourmeter provides maintenance reminders
after certain hours of operation. The hourmeter
screen will start flashing the reminder one hour prior
to the recommended interval and will continue until
one hour after the recommended interval (two
hours). The hourmeter does not have a manual
reset function.
NOTE: The transaxle lockout arms ends should be
completely retracted against the chassis, otherwise
operation of the transaxle may be erratic.
Transaxle
Lockout Arms
Transaxle Lockout Arm Location
Circuit Breaker
One manual reset circuit breaker is located on the
right front of the body. It has a button that pops out
if the circuit breaker trips. The 20 amp circuit break­
er protects the safety circuit and the relays. There
is also a 30 amp master circuit breaker located in the
rear left of the chassis. The 30 amp circuit breaker
protects the starting system and the ignition system.
In addition, there is a 30 amp fuse on the engine to
protect the charging circuit. Refer to the Kohler en­
gine manual included with the Owner’s Packet of
materials for information regarding this fuse.
Procedure
Interval*
Reminder
Oil Change
(Break-In)**
4-6 Hours
C
H
G
Lubricate
and Check
Levels
24-26 Hours
Oil Change
49-51 Hours***
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.
Hourmeter
32
OIL
Operating Instructions
Suspension Seat
A fully adjustable suspension seat is standard on
Model H38i. This seat is adjustable for back pitch,
weight, lumbar support and armrest inclination.
Proper adjustment for each operator is essential to
safe operation and operator comfort.
Read operating instructions in full before you use
the seat.
NOTE: Driver seats that have been adjusted incor­
rectly have little or no vertical travel with the operator
in the seat. To prevent damage to the driver’s back
and to the seat, the seat must be adjusted for the
driver’s weight before use and before every
change of driver. To prevent injury, no objects
should be placed within the moving area of the
driver seat.
CAUTION
To eliminate any risk of accident, the seat
settings must be checked to ensure they
are correctly engaged before the mower
is driven.
Adjustments must not be made while driving.
If you make any changes to the suspension seat
(for example fitting parts which are not original
GRAMMER parts) it may no longer meet the safety
standards to which it is tested. Functions may be
impaired, threatening your safety. For this reason,
any change in design of the seat must be ap­
proved by GRAMMER (Seat Manufacturer).
IMPORTANT: Fasteners must be checked regularly for tightness. If the seat wobbles there may
be loose bolts or other faults.
If you note that the seat does not function correctly
(for example a defective seat suspension; improper
curving of the lumbar support or damaged bellows),
contact your Walker dealer immediately to ar­
range for repairs to be carried out. If you fail to do
so, your health may be affected and the risk of accident increased.
CAUTION: Before the tractor is used, the safety
switch must be checked for proper function. The
operation of the switch is checked by having the op­
erator lift off the seat with the tractor moving forward
and/or the blades engaged -- this action should
cause the machine to stop. If a malfunction is de­
tected the tractor must not be driven, the safety
switch system should be repaired or replaced before
operating the mower.
CAUTION
Except for the driver’s weight during normal use, no loads must be placed on
seats with a built-in switch detecting seat
occupation, as the vehicle may otherwise
start to move by itself.
For armrest inclination adjustment, the inclina­
tion of the armrests can be modified by turning the
adjustment knob. Refer to Figure 1.
Turning the knob to the right lifts the armrest in front,
turning it to the left, lowers it in front.
For weight adjustment, the weight of the respec­
tive driver must be set while sitting on the seat. Fold
out the weight adjustment handle completely, hold it
at the front and move it upwards or downwards (10
movements from minimum to maximum).
Before every new movement, bring the handle back
to the starting position (audible locking sound). The
driver’s weight has been set correctly, when the ar­
row is in the middle of the viewing window. Refer to
Figure 2.
IMPORTANT: To prevent injury to the operator and/
or damage to the seat, the setting for the driver’s
weight must be checked and adjusted as necessary
before the mower is driven.
When the minimum/maximum weight adjustment
has been reached, you will notice an empty move­
ment in the handle.
When you have set the weight, fold the handle com­
pletely into the locking position.
33
Operating Instructions
For Backrest adjustment, moving the adjustment
handle upwards loosens the notching of the back­
rest adjustment. Refer to Figure 3.
After the adjustment, the handle must lock in the
desired position. It should not be possible to move
the backrest into another position when it is locked.
For Armrest height adjustment, the armrests can
be folded back if required and the height individually
adjusted.
For adjusting the height of the armrest, pry out the
round cap (arrow) of the cover and loosen the hexa­
gon nut (size 13 mm) situated behind it. Set the
armrests in the desired position (5 steps) and tighten
the hexagon nut. Replace the cap onto the nut. Re­
fer to Figure 4.
For Lumbar Support adjustment, turning the knob
upwards sets the curve in the upper part of the back
upholstery. Turning the knob downwards sets the
curve in the lower part of the upholstery. Refer to
Figure 5.
IMPORTANT: Dirt can impair the function of the
seat, so make sure you keep your seat clean!
For cleaning, use a standard commercially avail­
able upholstery or plastics cleaning agent. Test
first for compatibility on a small, concealed area.
Figure 5
Figure 1
Remove
Cover
Figure 4
Figure 2
34
Figure 3
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
1.
2.
<15°
THROTTLE
2802-5
Engaged
Position
Engaged
Position
<
Disengaged
Position
PARKING BRAKE
2802-4
Disengaged
Position
BLADE CLUTCH
(PTO)
Operating Controls (Top View from Drivers Point of View)
35
Operating Instructions
STARTING THE ENGINE
CAUTION
Before operating the mower, read and un­
derstand all Safety Instructions and Operat­
ing Instructions.
IMPORTANT: DO NOT crank the engine con­
tinuously for more than 10 seconds at a time. If
the engine does not start, turn the key to the
OFF position and allow a 60 second cool-down
period between starting attempts. Failure to fol­
low these guidelines can damage the starter
motor and shorten battery life. Contact 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, and the
blade clutch and parking brake are DISENGAGED.
NOTE: Release parking brake to prevent extra
load on the starter if the transmission neutral is
slightly out of adjustment.
CAUTION
A Safety interlock switch system PREVENTS CRANKING the engine with either
the Forward Speed Control out of neutral,
or the blade clutch (PTO) engaged. If the
engine cranks otherwise, the safety system is not working and should be repaired
or adjust­ed before operating the mower.
DO NOT disconnect safety switches; they
are for the operator’s protection.
2. 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.
36
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, steering and ground operation should be learned and practiced
until the operator is completely comfortable han­dling the machine BEFORE ATTEMPTING TO MOW.
DANGER
Keep feet on footrest at all times when
the machine is moving. Never operate
the tractor without a deck or implement
in­stalled.
Operating Instructions
1.
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.
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
♦♦ Start maneuvering the mower with SLOW
engine speed and SLOW Forward Speed
Control setting until familiar with all operat­
ing characteristics.
In case 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, immedi­
ately (1) Release the steering levers and
simultaneously (2) Move the FSC to the
NEUTRAL-PARK position. When the ma­
chine is stopped or moving slowly, en­gage
the parking brake.
♦♦ 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.
NOTE: This is exactly the same procedure used
to normally stop and park the machine.
♦♦ Learn to operate the steering levers with
smooth action. Jerky movements are hard
on the transmission and lawn. For sharp
turns, do not allow the inside wheel to stop
and twist on the grass. Pull the steering le­
ver controlling the inside wheel into reverse
for a smooth “rolling” turn (one wheel roll­
ing forward while the other rolls backward).
NOTE: If the FSC lever will not stay in the se­
lected position, the friction lock needs to be ad­
justed. Refer to ADJUSTMENTS for Step 7 Forward Speed Control Friction Adjustment in
the Maintenance Instructions.
CAUTION
♦♦ Practice maneuvering the mower until
you can make it go exactly where you are
aiming.
An operator presence switch (seat switch)
will cause the engine to stop if the FSC is
out of the NEUTRAL-PARK position and
the operator is not in the seat. The function
of this switch should be checked by the
op­
erator raising off the seat with the
tractor moving forward (allow 1/2 second
“off the seat” for the time delay function);
the engine should stop. If the safety sys-­
tem 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.
♦♦ 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.
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.
37
Operating Instructions
5.
Pull Steering
Levers with
Left Hand
Keep Feet on
Footrest when
Moving
Forward Speed Control
(FSC)
Correct Operator Hand Position
on the Controls
3.
Reverse direction of the mower by pulling both
levers backward.
NOTE: Smooth action on the steering levers will
produce smooth mower operation. Remem­ber
to keep the engine and ground speed slow until
learning the control response.
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.
38
The FSC may be adjusted forward for faster
ground speed and backward for slower ground
speed. When mowing, ground speed should be
adjusted to match the load on the cutter blades,
i.e., as the engine pulls down in heavy cutting,
pull back on the FSC lever to reduce ground
speed. Adjusting ground speed helps maintain
a balance between engine power and blade
speed for high-quality cutting action.
Stop ground travel by pulling both steering le­
vers backward to the NEUTRAL position (trac­
tor not moving) and then moving the FSC lever
to the NEUTRAL-PARK position.
NOTE: If the tractor creeps forward or back­ward
with the FSC lever in the NEUTRAL-PARK posi­
tion, the transmission control needs to be ad­
justed. Refer to ADJUSTMENTS for Step 3 Neutral Function Adjustment in the Maintenance
Instructions.
ENGAGING THE BLADE DRIVE
1.
Set the engine throttle at about 1/3 speed. DO
NOT attempt to engage the blade clutch at
high engine speeds. This will drastically short­
en drive belt life. Use only moderate engine
speed when engaging the blade clutch.
2.
Engage the blade clutch by moving the blade
clutch lever forward SLOWLY. For disengage­
ment, move the blade clutch lever backward
SLOWLY.
CAUTION
An operator presence switch (seat switch)
will cause the engine to stop if the blade
clutch is engaged and the operator is not
in the seat. The function of this switch
should be checked by the op­erator raising
off the seat and engaging the blade clutch;
the engine should stop. If the switch is not
working, it should be repaired or replaced
before operating the mower. DO NOT
disconnect the safety switches; they are
for the operator’s protection.
IMPORTANT: DO NOT engage the blade clutch
when transporting the mower across drives, side­
walks, loose materials, etc. DO NOT engage the
blade clutch with the PTO shaft disconnected
(the mower deck removed from tractor).
Operating Instructions
STOPPING THE MACHINE
1.
Pull the steering levers to the NEUTRAL posi­
tion and then move the FSC lever backward to
the NEUTRAL-PARK position.
2.
Slow the engine to a fast idle; put the throttle in
the 1/2 throttle position.
3.
Disengage the blade clutch.
Engaged
Position
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 increased wear of the brake band.
Blade Clutch Engaged
WARNING
A brake stops the cutter blades from free­
wheeling within five (5) seconds after dis­
engaging the clutch. If the brake system
malfunctions and the blades do not stop
within five (5) seconds, the brake should
be repaired or replaced before operating
the mower. Contact your Walker dealer.
Disengaged
Position
4. Turn the ignition switch OFF.
Blade Clutch Disengaged
WARNING
CAUTION
If the cutting blades strike a stationary object while mowing, stop the mower im­
mediately, disconnect the spark plug
wires, lift the deck, and inspect the deck
and blades thoroughly for damage. Also,
make sure the blade retaining bolts are
torqued to 70 lb·ft (95 N·m).
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. Also, engaging the parking brake is
recommended when stopping or parking the
machine in a confined space with little tolerance
for movement.
IMPORTANT: The hydrostatic transaxles 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 transaxles, especially when trans­
mission fluid is warm.
39
Operating Instructions
WARNING
In case 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.
ADJUSTABLE FOOT RESTS
Some carrier frames are outfitted with adjustable
foot rests. To adjust, rotate the footrests upward and
slide to the desired position. Rotate the footrest
down and insert the edge of the footrest into the
nearest notch to lock in position.
NOTE: The emergency stop procedure is ex­
actly the same procedure as used to normally
stop and park the machine.
FUEL TANK SELECTOR VALVE
The tractor is equipped with dual fuel tanks. A fuel
selector valve regulates which tank is being utilized.
The valve is located on the left hand side of the en­
gine. The valve switches between the LH and RH
gas tanks. DO NOT run tank dry before switching
tanks.
Adjustable Footrest
ADJUSTING CUTTING HEIGHT
WARNING
Never adjust cutting height while the
mower is moving.
Before adjusting
cutting height or servicing, move the
Forward Speed Control (FSC) into the
NEUTRAL-PARK position, engage the
parking brake, and disengage the blade
clutch (PTO). Tractor should not be
moving while adjusting cutting height.
Fuel Tank
Selector Valve
Fuel Tank Selector Valve
40
Cutting height is adjusted from operator’s seat using
the deck lift pedal to assist in raising the deck while
adjusting the cutting height hitch pin.
1.
Disengage PTO and stop tractor.
2.
Push down on deck lift pedal until it latches in
the full up (transport) position.
3.
Select the desired cutting height by moving the
hitch pin to the location shown on the cutting
height decal.
4.
Push down on the lift pedal and lift up on the
cutting height release lever. Slowly release the
pedal while lifting the lever until the deck is in
the selected cutting height position.
Operating Instructions
Hitch Pin
LOCKOUT position. The levers must be in the
highest position to completely unlock the trans­
axles.
Cutting Height
Release Lever
Deck Lift Pedal
Transaxle Lockout Arm
Height
Adjustment Decal
Cutting Height Adjustment
Transaxle Lockout Arm - Freewheel Position
4.
Push Deck
Lift Pedal
After moving the mower, release the arms, plac­
ing them down in the normal OPERATING posi­
tion. The lockout arms ends should be com­
pletely retracted against the chassis, otherwise
operation of the transaxle may be erratic.
Transaxle Lockout Arm
Raise Release
Lever
Lowering Deck to Selected Cutting Height
Transport Position
1.
Disengage the PTO.
2.
Push down on deck lift pedal until it latches in
the full up (transport) position.
TRANSAXLE LOCKOUT
IMPORTANT: DO NOT TOW this mower faster than
2 mph (3.2 km/h) with the transaxle lockout en­
gaged. Towing can produce excessive internal
pressure and damage the transaxle(s).
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
back to engage the step that holds the arm in
the UP (unlocked) position.
3.
The mower will “freewheel” with the arms in the
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.
41
Operating Instructions
●● Use a slow setting on the FSC for trimming op­
erations.
●● Make sure the mower is leveled properly for a
smooth cut. Refer to Deck Leveling in Assembly
Instructions.
●● Use an alternating stripe mowing pattern for
best appearance and vary the direction of the stripe
each time the grass is mowed to avoid wear patterns
in the grass.
●● Avoid damage to the grass by slipping and skid­
ding of the drive tires. Use smooth control move­
ments of the steering levers since the transaxles
are “power boosted controls” and jerking the levers
can easily slip the tires. For sharp turns, do not allow
the inside wheel to stop and twist on grass; pull in­
side steering lever into reverse for a smooth “rolling”
turn (one wheel rolling forward while the other rolls
back­ward).
Avoid Low Hanging Branches
IMPORTANT: Operate the engine at full throttle
when mowing, to allow the engine to produce full
horsepower and to increase efficiency of the engine
cooling system.
●● Using the DS60 deck, or other side discharge
decks, the side discharge deflector shield must not
be removed and must be kept in the lowest possi­
ble 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 ob­
jects.
●● 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).
Discharge
Shield
●● It is preferable to cut grass when it is dry and not
too tall. Mow frequently and do not cut grass too
short. (For best appearance, cut off 1/3 or less of
existing grass height.)
●● When mowing, operate the engine at full throttle
for the best cutting action. Mowing with a lower en­
gine 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 - 5 in. (127 mm) - for the first
pass and then make a second pass cutting to the
desired height.
42
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.
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 recommenda­
tions 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.
15°
16 in.
60 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 for­
ward 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 break­
age). 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
43
Maintenance Instructions
CAUTION
Maintenance procedures requiring special training or
tools should be performed by a trained technician.
MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL H38i
Service Item
Daily
25
Hours
100
Hours
200
Hours
400
Hours
Yearly
Every
2 Years
Ref.
Page
Check Engine Crankcase Oil Level
x
46
Check/Clean Engine Air Cooling System*
x
54
Clean Grass Buildup Under Deck
x
55
Service Mower Blades
x
59
Check Security of Air Cleaner System
x
58
Check Function of Warning Lights and Horn
x
26
Lubricate Grease Fittings and Oil Points*
x
49
Check Tire Pressure
x
59
Check Drive Belts
(Engine/PTO, Ground Drive, Blade Drive)
x
60
Check Operation of Safety Interlock Switches
x
61
Check Battery Electrolyte Level
x
58
Check Transaxle Oil Level (in Reservoir)
Change Engine Crankcase Oil**Δ
x
48
x
46
Check Air Filter Element***
x
53
Clean Engine Cooling Fins
x
55
Check Security of Drive Tire
Mounting Nuts (75 to 85 lb·ft)
x
59
Check Blade Brake Action
x
61
Check FSC Friction Lock
x
61
Check/Adjust Blade Clutch
x
74
Clean Transaxle Housing
x
57
Change Engine Oil Filter
x
46
Check/Regap Spark Plugs
x
60
Replace Fuel Filter
x
67
Change Transaxle Oil and FilterΔΔ
x
48
Check Fuel Lines and Clamps
x
60
Replace Air Filter Element ***
x
53
Service Battery
x
58
Service Solenoid Shift Starter
x
ΔΔΔ
Check PTO U-Joints for Wear/Looseness
x
60
Replace Fuel Lines and Clamps
x
60
Replace Ignition Wires
x
60
More often in extremely dusty or dirty conditions (Refer to notes about air cleaner element in
IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE)
** Change engine oil and filter after first 5 hours of operation of a new engine (break-in period)
*** Air cleaner is engine mounted Kohler unit, replace filters every year or when worn or damaged
Δ Change oil every 50 hours when operating in dry, dirty conditions
ΔΔ Change transaxle oil after the initial break-in period of 75-100 hours operation
ΔΔΔ See your Walker dealer for this service or refer to the Walker Service Manual
*
44
Maintenance Instructions
KOHLER TIPS
IMPORTANT TIPS FOR CARE OF THE KOHLER
ENGINE
DANGER
Fuel System
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
●● Fuel must be clean - free from water, dirt, and or­
ganic 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 mod­
ule will void the warranty. Additionally, the fuel
pump module and the fuel lines between it and the
injectors are pressurized. For service of the pres­
surized fuel 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
to a mid-point (1/4 to 1/2) throttle setting. This will
aid starting, especially in cold weather.
●● Keep the battery fully charged.
●● Match crankcase oil viscosity to the ambient tem­
perature, allowing the engine to crank faster and
start easier.
●● Allow engine to run at idle for a few seconds be­
fore stopping engine to avoid run-on or backfiring.
Cooling System
CAUTION
DO NOT use water or a pressure washer to
clean the cooling system on an air-cooled
engine; mud may form under the cooling
shroud on the cylinder head and cooling
fan resulting in engine overheating.
●● Keep engine air intake screen and cylinder head
fins free of grass clippings, chaff, and dirt. Inspect
intake screen and cooling fins for cleanliness and no
damage.
●● Periodically remove two access panels in the en­
gine shroud to inspect and clean cylinder head cool­
ing fins.
●● Operate the engine at full speed when mowing.
This allows the engine to produce full horsepower
and move more cooling air through the engine cool­
ing fins.
Air Cleaner System
●● Use only Kohler air cleaner elements. Aftermar­
ket 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 instruc­
tions).
●● DO NOT overservice or frequently “disturb” the
air filter. A dirty air filter actually cleans better than
a new one. Changing and cleaning the air filter too
often can ac­tually reduce filter efficiency and in­
crease the oppor­tunity for traces of dust to enter the
engine.
●● When the air filter element is removed or re­
placed, make sure all dust is cleaned out of the air
cleaner housing. Use a damp cloth and wipe the
interior of the canister clean, including both the in­
side and outside surfaces of the outlet tube (a lit­tle
dirt left here will be sucked into the engine and re­
duce engine life). When the filter is reinstalled,
make sure the element is held tight and straight
in the canister for proper seating and sealing.
Oil
●● 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.
●● Use only Kohler oil filters. Aftermarket filters
may not seal properly and/or have the incorrect
pressure relief valve for proper lubrication.
●● Check performance of the cooling system by
starting the engine, holding a hand adjacent to the
cylinder head, and feeling the cooling airflow.
45
Maintenance Instructions
LUBRICATION
LUBRICATION
IMPORTANT: DO NOT operate engine without
a sufficient oil supply in the crankcase. DO NOT
operate with 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
procedure. It reduces wear and makes the machine
quieter and easier to operate.
Engine Oil
Engine Break-In Oil
Full
Mark
No special break-in oil is required. The engine is
serviced with 20W-50, 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.
Operating
Range
{
F
L
Checking Engine Crankcase Oil Level
Low
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.
46
5.
Park the mower on a level surface with the
engine stopped. Also, make sure the engine
is cool and oil has had time to drain into the
sump (allow at least five (5) minutes after
stopping the engine).
IMPORTANT: NEVER check or add oil with the
engine running.
2.
Dipstick Operating Range
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).
If additional oil is needed, refer to Specifications
for proper crankcase lubricant. Fill up to, but
not above, the “F” mark on the dipstick.
IMPORTANT: DO NOT overfill the crankcase
(oil above “F” mark) as this CAN result in en­
gine overheating, loss of power, and possi­ble
engine damage.
Changing Engine Crankcase Oil/Oil Filter
Change the engine crankcase oil after every 100
hours of operation and replace the oil filter after
every 200 hours of operation as follows:
1.
Park the mower on a level surface with the
engine stopped. The engine oil should be
warm before draining. If not warm from opera­
tion, start the engine and run a few minutes to
warm the oil.
2.
Before removing the dipstick, and oil fill cap,
clean the area around them to keep any dirt or
debris out of the engine.
Maintenance Instructions
LUBRICATION
3.
Remove the dipstick, oil fill cap, and oil drain
plug, and drain the oil into a suitable container.
Be sure to allow ample time for complete
drainage.
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
2/3 turn.
4.
Before removing the oil filter, clean the area
around the filter to keep dirt and debris out of
the engine.
8.
Reinstall the drain plug. Make sure it is tight­
ened to 10 lb·ft (14 N·m).
5.
Remove the old oil filter and wipe off the filter
mounting surface on the engine.
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 as­
sure proper lubrication in hot weather. Fill up
to, but not above the “F” mark on the dipstick.
Crankcase capacity is 2.0 quarts (1.9 liters)
when changing oil and filter.
Oil Filter
Dipstick
Oil Fill
Dipstick, Oil Fill and Oil Filter Locations
(View from Above Left Side of Tractor)
IMPORTANT: Check the dipstick reading before
adding the last 1/2 pint of oil and fill only to the
“F” mark. The oil level should never be above the
“F” mark on the dipstick; overfilling can result in
engine overheating, loss of power, and possible
engine damage.
10. Start the engine and check for oil leaks around
the oil filter. Stop the engine, recheck the oil
level, and add oil if necessary. (When the en­
gine is first operated with a new oil filter, the oil
level will drop slightly as the filter is filled with
oil.)
Mower Deck Spindle Lubrication
Lubricate each deck spindle grease fitting every 25
hours. Use SAE general purpose lithium or molyb­
denum base grease for grease fittings.
Oil Drain
Plug
Oil Drain Location
(View from Rear of Tractor)
6.
Apply a thin coating of new oil to the rubber gas­
ket on the replacement oil filter.
IMPORTANT: Use ONLY oil filters from the en­
gine manufacturer (Kohler P/N 52 050 02). Aftermarket oil filters may not seal properly and/or
may not have the cor­rect pressure relief valve
for proper lubrication.
47
Maintenance Instructions
LUBRICATION
DR52, DS60 or DR64 Mower Deck Lubrication
Transaxle Oil and Filter Change
Lubricate the U-Joint in the drive shaft every 25
hours with SAE general purpose lithium or molyb­
denum base grease.
Change the transaxle oil after the initial break-in
period of 75-100 hours. Thereafter, change oil
every 400 hours of operation as follows:
Check Transaxle Fluid Level
1.
Thoroughly clean the exterior of the transmis­
sion housing before servicing. Remove expan­
sion tank cap to allow venting. Using a 1/4 in.
hex wrench, remove the plug on the lower in­
side of each transaxle allowing the oil to drain.
2.
Remove the oil filter guard, remove and replace
the oil filter using an oil filter wrench. Tighten
filter by turning filter 3/4 to 1 turn after gasket
contacts the filter base surface. Reinstall the oil
filter guard. (Refer to Transaxle Oil Drain
Plug, Filter, and Guard Location illustration.)
●● The transaxle oil lubrication is SAE 20W-50 (API
Service Class SL or higher) engine oil.
●● Inspect both transaxle cases and hoses after
every 25 hours of operation for visible leaks.
●● The fluid level for the transaxle can be checked
visually by looking at the fluid level in the expansion
reservoir. When the transaxles are cold, the fluid
level in the expansion reservoir should be between
1/4 and 1/2 in. (0.64 cm and 1.27 cm).
Reservoir Cap
Hot
Level
Oil Filter
Hose
Cold
Level
Oil Filter
Guard
Oil Drain
Plug
Expansion Reservoir Location
Transaxle Oil Drain Plug, Filter, and
Guard Location
(Shown with Deck Support Arms
Removed for Clarity)
48
3.
Reinstall drain plug.
4.
Remove the oil reservoir hose attached to the
elbow on top of the transaxle. Remove the el­
bow to access the oil fill opening.
5.
Fill the transaxles with 20W-50 (API Service
Class SL or higher) oil through the opening
where the elbows were. Fill up to the opening.
6.
Before reinstalling the elbows, screw the lock­
ing nut on the elbows down until they are snug
(the o-ring on the elbow will be to the bottom of
the o-ring groove).
Maintenance Instructions
Elbow
Screw Locking
Nut Down
LUBRICATION
Grease Fitting and Oil Point Lubrication
Lubricate the grease fittings and oil points after every 25 hours of operation. Lubricate more often
when operating in dusty or dirty conditions. Use
SAE general purpose lithium or molybdenum base
grease for grease fittings and light machine oil (SAE
10) to lubricate oil points. Lubricate the locations
shown in the Chassis and Deck Lubrication
Points illustration.
NOTE: PTO universal joints (on the deck and trac­
tor) require routine lubrication after every 25 hours
of running time. Remove tractor PTO quick discon­
nect tube assembly for easy access to grease fit­
tings.
Reinstall Transaxle Elbows
7.
Reinstall the elbows. When the elbow begins to
be snug, position the elbow as it was when re­
moved and tighten the locknut. Reinstall reser­
voir hoses to elbows.
8.
Fill reservoir 1/4-1/2 in. (6-13 mm) using
20W-50 (API Service Class SL or higher) oil.
9.
Start and drive the unit for 1- 2 minutes.
NOTE: The best way to lubricate the PTO tube half
of the universal joint assembly is to remove it from
the tractor. See instructions for removing and install­
ing PTO quick coupler, refer to Deck Installation in
Mower Deck Installation on Tractor in the Assem­
bly Instructions.
NOTE: The ball bearings on the PTO drive shaft are
sealed and do not require periodic maintenance.
10. If the transaxles sound noisy or have poor steer­
ing response, there may be air trapped in the
transaxles. Follow purge instructions below.
11. If oil needs to be added refer back to steps 5-10.
12. To purge air from the transaxle, raise tractor and
block with tires off the ground. With engine run­
ning, slowly move Forward Speed Control for­
ward and backward 5 to 6 times. Turn off en­
gine and check oil level and add if needed.
Repeat procedure until transaxles operate at
normal noise levels and move smoothly in for­
ward and reverse.
49
Maintenance Instructions
Ident Lubrication
No.
Location Type
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Deck Caster Wheel Fork Pivot
Grease
Deck Caster Wheel Bearing
Grease
Front Deck Lift Pivot
Grease
Rear Deck Lift Pivot
Grease
Pivot Assembly, Tilt-Up DeckΔ
Grease
Deck Support Arm Socket
Grease
Steering Lever Pivot
Grease
Deck-to-PTO Coupling
Grease
(Grease Spline Slide Area)
Deck Support Arm Pivot
Grease
Universal Joint Tube Assembly
Grease*
FSC Lever Pivot
Grease
Hydro Idler Arm Pivot
Grease
Body Latch Pivot
Oil
PTO Clutch Lever Pivot
Grease
Clutch Arm Pivot
Grease
Transaxle Oil Reservoir
Oil
Throttle Control Cable Ends
Oil
Engine Dipstick
Oil**
LUBRICATION
No.
Places
2
2
2
2
2
2
2
1
2
1
1
1
2
1
1
1
2
1
Ident
No.
Location
Lubrication
Type
19
20
21
22
23
24
25
26
27
28
29
30
Tail Wheel Caster Fork Pivot
Rear Axle Pivot
Rear Wheel Bearing
Engine / Oil Filler
PTO Belt Tightener Pivot
Clutch Actuator Push Rod
Brake Band Pivot Pins (Clevis)
Parking Brake Pivot
Parking Brake Clevis
Throttle Control Pivot
Universal Joint Shaft Assembly
Blade SpindleΔ
*
Grease every twenty-five (25) hours.
Grease
Grease
Grease
Oil**
Grease
Grease
Oil
Grease
Oil
Oil
Grease*
Grease
No.
Places
2
1
2
1
1
1
2
1
3
1
1
3
** Refer to Engine Oil located on page 46.
Δ
Fitting located underside, access with deck in tilt-up position.
NOTE: DR64 Tilt-Up Deck is shown for reference. For other
Deck Lubrication Points, refer to Deck and Carrier Frame Illustrated Parts Manual.
50
Maintenance Instructions
LUBRICATION
1
1
2
2
3
3
30
29
4
4
5
5
6
7
9
27
6
7
9
8
17 & 28
10
27
26
13
11
13
14
25
12
15
24
23
16
17
22
18
19
19
20
21
Chassis and Deck Lubrication Points
51
Maintenance Instructions
CLEANING
CLEANING
IMPORTANT: Use only Kohler air filter elements for
replacement (Kohler 25 083 01-S and 25 083 04-S).
Aftermarket filters may not seal properly or filter ef­
ficiently.
CAUTION
If a pressure washer is used on the exposed working parts, avoid water on the
electrical parts and the engine cooling
system.
Canister
Engine Air Cleaner System
Kohler Air Cleaner
An engine mounted Kohler air cleaner provides the
air filtering function. The primary filter element slides
over an outlet tube inside the air cleaner canister
with radial sealing action, eliminating the possibility
of dust leaks due to improper filter installation.
Intake design and internal baffling provide dust
separation and automatic precleaning action. Daily
or frequent servicing of the air cleaner is not
required.
Intake
Cover
Primary
Filter Element
Air Cleaner Components
(Shown with Cover Removed)
IMPORTANT: The Kohler air cleaner uses a dry
paper-type air filter element. NEVER apply oil to the
paper element.
Kohler
Air Cleaner
Kohler Air
Cleaner Cover
Safety
Filter
Primary Filter
Element
Engine
Engine Air Cleaner System Components
52
Maintenance Instructions
Inspect the primary filter element after every 100
hours of service and replace the element and safe­
ty filter yearly (or when dirty or damaged). More
frequent replacement may be required when operat­
ing in extremely dusty conditions. Service the air
cleaner as follows:
1.
2.
3.
Release the top and bottom cover latches and
remove the air cleaner cover. Wash the cover.
Check that the cover is in good condition.
Remove the primary filter element by pulling it
out of the canister. There will be some initial
resistance as the filter seal breaks loose and
slides off of the outlet tube. Gently move the
end of the filter up and down and side to side or
twist to loosen the seal. Use gentle action to
minimize the amount of dust dislodged as the
filter is removed.
Clean the filter element by GENTLY tapping on
a FLAT, HARD surface.
NOTE: Use care when cleaning the filter ele­
ment. The filter element and/or seal surface
may be damaged by tapping too hard or hitting
on an uneven surface or sharp edge. Washing
the element in water or cleaning solution is not
recommended. Do not try to clean the element
with compressed air. Remember replacing a
filter is less expensive than replacing a dusted
engine.
4.
Use a bright light inside the primary filter 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
primary filter element. Replace the filter if any
cracks, tears, or other damage to the sealing
surface are noted.
6.
Without removing, visually inspect the condi­
tion of the safety filter for damage or holes.
The safety filter should only be removed for replacement YEARLY (or when dirty or dam­
aged).
CLEANING
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.
8.
Check the outside surface of the outlet tube for
smoothness and cleanness (this is the sealing
surface).
9.
Insert and seat the safety filter and primary filter
el­ement carefully into the canister, applying
pres­sure at the outer rim of the filter; not at the
flexible center. Make sure the filter element is
completely in place before installing the cover.
NOTE: DO NOT use petroleum based lubri­
cants on the sealing surfaces of the filter ele­
ments; use tal­cum powder or dry silicone lubri­
cants if required for filter installation.
Outlet Tube
Safety Filter
Canister
Primary
Filter Element
Radial Sealing
Surface
Air Filter Element Replacement
10. Install the cover with the word “Kohler” properly
oriented. Latch the air cleaner cover to the can­
ister. Make sure both the top and bottom cover
latches are securing the cover in place.
11. Release the top and bottom cover latches of the
intake cover. Wash the cover and check and
clean the inlet screen. Reinstall the cover.
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.
53
Maintenance Instructions
CLEANING
Rotating Engine Cooling
Air Intake Screen
Keep Engine Screen Clean
Cover
Latches
Cylinder Head Cooling Fins
Proper Orientation of Air Cleaner Cover
Engine Cooling System
Cooling Air Intake Screen
To prevent engine overheating and possible engine
damage, clean grass clippings, chaff, and dirt from
the rotating engine cooling air intake screen after
every 8 hours of operation. In certain mowing
conditions (dry grass, leaves, tree “cotton”, etc.), it
may be nec­essary to check and clean the screen
several times each day to prevent engine overheat­
ing.
It is essential for performance and longevity of the
air-cooled engine to keep the cylinder head cooling
fins clean and free of obstruction. After every 8
hours of operation, check the performance of the
cooling system by starting the engine, holding a
hand adjacent to the cylinder heads and feeling
the cooling airflow. If there is little or no airflow, clean
the cooling fins as follows:
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
CAUTION
Operating the engine with a blocked air
intake screen, dirty or plugged cooling
fins, and/or cooling shrouds removed will
cause engine damage from overheating.
Check Airflow
with Hand
Check Cooling System Airflow
54
Maintenance Instructions
CLEANING
Every 100 hours, inspect and clean the cooling fins
(more often when operating in extremely dusty, dirty
conditions). Remove the two (2) cylinder head ac­
cess panels in the engine shroud and clean the cool­
ing fins and external surfaces using compressed air.
Also clean the oil cooler fins located on the RH cyl­
inder. Make sure to reinstall the access panels be­
fore oper­ating the engine.
Remove
Access Panel
Oil Line
Oil Cooler
Cooling Fins
Engine Cylinder Head
Access Panels Removed
Grass Buildup in Mower Deck Housing
Remove Three (3)
Screws to Access
Cylinder Head and
Cooling Fins
DANGER
Before raising or removing the mower
deck for cleaning, stop the engine,
remove the ignition key, and disconnect
the spark plug wires.
Remove Cylinder Head Access Panel(s) to
Clean Cooling Fins
IMPORTANT: Yearly, it is good maintenance prac­
tice to remove the engine cooling shroud and clean
the cylinder head cooling fins thoroughly to prevent
overheating and extend engine life. Make sure cool­
ing shroud is reinstalled properly. This procedure
will require removing the engine from the chassis.
Engine Cylinder Head
Access Panels
1.
Remove the tilt bar from the stowed position on
the carrier frame.
2.
Use the tilt bar to release the two (2) deck lock­
ing arms as shown in the Unlock Deck Arms
for Deck Tilt-Up illustration.
Tilt Bar
2802-5
5°
<1
2.
1.
Kohler Engine
Cooling Shroud
Rotating Engine Cooling
Air Intake Screen
Rotating Engine Cooling Air Intake Screen
and Cylinder Head Access Panels
Unlock Deck Arms for Deck Tilt-Up
55
Maintenance Instructions
3.
CLEANING
Fit tilt bar into the socket on front of deck hous­
ing and secure with hitch pin.
Tilt-Up Hook and
Latch Connected
Tilt Bar
Hitch Pin
Use Hitch Pin to
Secure Tilt Bar.
Tilt-Up
Latch
Tilt Bar Installed
4.
Tilt-Up
Hook
Remove footrest or, if equipped with adjustable
footrests, move the footrest to the full forward
locking position.
6-2
874
Deck Secured in TILT-UP Position
6.
NOTE: If the buildup is severe, it may be easier
to clean the deck by removing the deck assem­
bly from the tractor and standing the deck as­
sembly on its “nose”.
Full Forward/
Locked Position
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.
Adjustable Footrest in Full Forward/Locked
Position for Deck Tilt-Up
5.
Clean grass buildup underneath the deck using
a pressure washer (and scraper if required).
Raise deck to tilt-up position using tilt bar and
secure in position by inserting the deck hook in
the tilt-up latch on the tractor body as shown in
the Deck Secured in TILT-UP Position photo.
DANGER
Do not operate the mower with deck in
tilt-up position. Do not move the tractor
with the deck in the tilt-up position.
7.
56
Lower the deck to the normal operating position
and rotate locking arms downward.
Maintenance Instructions
CAUTION
Do not operate mower with deck tilt-up
pivot joint UNLOCKED. Make sure locking arms are in the LOCKED position and
the tilt-up joint is rigid (locked).
8.
Remove tilt bar and stow on carrier frame.
9.
Replace footrests to desired position.
CLEANING
IMPORTANT: In case an oil leak develops on the
input shaft, the cooling fan blowing dusty air and oil
on the transmission will quickly cover the housing
and pack the cooling fins with oily dirt. If this condi­
tion 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.
Transaxle Housing
Keeping the housing on the transaxles clean and
free of obstruction is essential to avoid overheating the transmission fluid and shortening transmis­
sion 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
buildup on the transaxle housings. This may be the
result of an oil leak. If an oil leak is noticed, contact
your local Walker dealer.
Cooling
Fans
Transaxle Cooling Fans
Cooling
Fins
Transaxle Housing and Cooling Fins
57
Maintenance Instructions
CHECKING/SERVICING
CHECKING/SERVICING
CAUTION
DANGER
Important Battery Service, Installation, and
Charging Tips for Electronic Fuel Injected
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.
●● 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.
Security of Air Cleaner System
NOTE: The following inspection is only an external
inspection and should be done without “disturb­
ing” 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 engine air cleaner system. The following
item should be inspected:
●● Never disconnect battery while engine
is running.
1.
●● Never use a quick battery charger to
start the engine.
Check the Kohler air cleaner canister for dam­
age. Make sure both end-cap covers are in
place and the cover latches are secure – do not
run the engine without the air cleaner cover(s)
in place and secure.
●● Never “jump start” the engine using
another source. Electricity fluctuations
can damage the ECU (Electronic Control
Unit).
Battery
●● Always disconnect negative (-) battery
cable lead before charging battery, and
also unplug harness from ECU before performing any welding on equipment.
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 sys­
tems.
Electrolyte Level
The battery electrolyte level should be checked after every 25 hours of operation. To check electro­
lyte level:
1.
Remove battery cell filler caps.
2.
Check the electrolyte level. If the level is below
the bottom of the vent well, fill with distilled wa­
ter to the bottom of the vent wells [1/4 to 1/2 in.
(6 to 13 mm) above the plates].
3.
Replace filler caps.
IMPORTANT: DO NOT overfill the battery. Electro­
lyte will overflow through the vented caps onto parts
of the machine and WILL result in severe corrosion.
58
Maintenance Instructions
Cleaning the Terminals
If battery terminals are corroded, remove battery
from the mower. Using a wire brush, remove corro­
sion with a solution of one part baking soda and
four parts water. Rinse with clean water. Coat the
terminals with petroleum jelly or terminal protector
spray to retard further corrosion.
Charging the Battery
DANGER
BATTERIES PRODUCE EXPLOSIVE GASES
●● Charge the battery in a well-ventilated
area, so that gases produced while charg­
ing can dissipate.
●● Keep sparks, flames, and smoking ma­
terials away from the battery at all times.
●● Make sure the battery cap vents are
open (check manifold vent on each cap).
CHECKING/SERVICING
Wheel Nut Torque
Check the eight (8) Drive Tire mounting nuts. Every
100 hours they should each be torqued to
75 to 85 lb·ft (102 to 115 N·m).
Sharpen Mower Blades
Check mower blade(s) for straightness, sharp­
ness, condition of the cutting edge, and balance
every 10 hours of operation (or more often when
mowing abrasive type grass or operating on sandy
soils). Replace blades if worn, bent, cracked, or
otherwise damaged (refer to REPLACING/REPAIRING the Mower Blades in this section). Use
the following procedure to check and sharpen
blades:
NOTE: Keep blades sharp - cutting with dull blades
not only yields a poor mowing job but slows the cut­
ting 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 Deck Secured in TILT-UP Position photo in CLEANING of Grass Buildup in
Mower Deck Housing in this section).
●● Make sure the battery charger is un­
plugged before connecting or disconnecting cables to the battery.
DANGER
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:
NEVER operate cutter blades with the
deck in the raised position.
IMPORTANT: Always disconnect the negative (-)
battery terminal before charging. Failure to do so
can result in damage to the ECU.
1.
Charge the battery at 15 amps for 10 minutes.
DO NOT exceed 20 amps maximum recom­
mended charging rate. Charge until specific
gravity is at least 1.250. Total charging time
should not exceed one (1) hour.
2.
After charging the battery, use distilled water to
adjust the electrolyte level to the bottom of the
vent wells [1/4 to 1/2 in. (6 to 13 mm) above the
plates].
Tire Pressure
Inflate tires to pressures shown below:
Deck Caster Wheel = 20 PSI (137 kPa)
Drive
= 15 PSI (103 kPa)
Tailwheel
= 20 PSI (137 kPa)
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 replaced.
WARNING
DO NOT try to straighten a blade that is
bent. NEVER weld a broken or cracked
blade. ALWAYS replace with a new blade
to assure safety.
59
Maintenance Instructions
CHECKING/SERVICING
4.
If the blade cutting edge is dull or nicked, it
should be sharpened. Remove blades for
sharpening by grasping the end of the blade us­
ing a rag or a thick, padded glove, while loos­
ening and removing the bolt and 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.
CAUTION
ALWAYS wear eye protection and gloves
when sharpening a blade.
Sharpen at Original
30° Angle
Intersection
Wear Area
30°
Do Not Grind or
Sharpen on Underside
Wing Tip
Mower Blade Profile for Sharpening
6.
Check blade balance by positioning the blade
horizontally on a blade balancer or use a nail
or shaft through the center hole. If either end of
the blade rotates downward, grind (remove)
metal on that end until the blade will balance.
The blade is properly balanced when neither
end drops. Balance of a blade is generally
main­tained by removing an equal amount of
material from each end of the blade when
sharpening.
7.
Mount the blade with wing tips pointing up into
the housing. For gear driven decks reinstall
the blade, washer, lock washer, and nut. Tighten the nut to 60 lb·ft (81 N·m). For belt driven
decks reinstall the spacer (if applicable), blade,
washer, and bolt. Tighten the bolt to 70 lb·ft
(95 N·m).
Drive Belts
Raise the body and inspect the condition of the four
(4) drive belts after every 25 hours of operation –
engine/PTO drive (3) and ground drive (1). Also re­
move the belt cover on the mower deck and check
the blade drive belt. If the belts show signs of
cracking or deteriorating, the belts should be replaced. Refer to REPLACING/REPAIR­­ING the
Drive Belts in this section.
Spark Plugs
Every 200 hours, remove the spark plugs, inspect,
clean, and reset the gap (or replace with a new
plug). Clean spark plug with a wire brush. If the
electrodes are burned short or pitted, replace the
plug (refer to Specifications for the proper type of
replacement plug). Check the spark plug gap with
a wire-type feeler gauge and set the gap to 0.030 in.
(0.76 mm). Reinstall and tighten to 20 lb·ft (27 N·m).
Both spark plugs should be replaced yearly.
Ignition Wires
Good preventive maintenance calls for complete replacement of spark plug wires every two (2) years.
Fuel Lines and Clamps
NOTE: After the fuel injection pump module, the
fuel system is pressurized and should only be ser­
viced by a Walker dealer or authorized Kohler ser­
vice dealer.
Every year, inspect the fuel lines from the tanks to
engine for deterioration or damage. Also, inspect
the fuel line clamps for tightness. Good preven­
tive maintenance calls for complete replacement of
fuel lines and clamps every two (2) years.
PTO U-Joints
Blade Balancer
Blade Balanced on Magnetic
Wall-Mounted Balancer
60
The PTO U-joints should be inspected yearly for
looseness and wear. If either is noticed, the respec­
tive shaft or tube should be replaced. A worn U-joint
can cause vibration and extensive damage to the
PTO and the whole machine.
Maintenance Instructions
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.
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 indi­
cation 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 76.
CHECKING/SERVICING
If any of the following conditions occur during start­
ing or operating, a safety interlock switch may be
malfunctioning. Contact your Walker dealer for trou­
bleshooting and/or replacement.
●● With or without an operator in the seat, the en­
gine starts with the Forward Speed Control (FSC)
and/or the PTO engaged.
●● With an operator in the seat, the engine starts
but dies soon after the Forward Speed Control
(FSC) or PTO is engaged.
●● Without an operator on the seat, the engine
continues to run with the Forward Speed Control
(FSC) and/or PTO engaged.
●● With an operator in the seat, the Forward Speed
Control (FSC) and PTO disengaged and warning
horn sounding, but the starter will not engage.
Forward Speed Control Friction Lock
The FSC friction lock is designed to hold the selected forward travel speed when the steering le­
vers are moved and yet the friction is not too heavy
to make moving the FSC control difficult (too much
friction). The procedure for checking the FSC fric­
tion lock is as follows:
1.
With the engine off, place the FSC in the full
FORWARD position and pull both steering le­
vers back; the FSC lever should not move. If
the FSC lever moves back when the steering
levers are pulled back, the friction needs to be
increased.
2.
With the steering levers held back, move the
FSC lever back from the FORWARD position.
With a proper amount of friction adjusted, the
FSC lever should move back with a slight
amount of resistance (friction). If the FSC lever
movement is “stiff”, the friction needs to be
decreased.
Safety Switch System
WARNING
It is important to check and maintain the
safety switch system for safe operation of
the machine.
There are three (3) safety interlock switches on the
tractor; Seat Switch, FSC Neutral-Park Switch, and
PTO Switch.
NOTE: There is a 1/2 second time delay function on
the seat switch to avoid engine power interruption
when driving over bumps.
If the FSC friction lock needs to be adjusted, refer to
ADJUSTMENTS for Step 7 - Forward Speed Control Friction Adjustment in this section.
61
Maintenance Instructions
Transmission Control Setting
On a yearly interval or when an out-of-adjustment
condition is observed, check the transmission con­
trol 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 operat­
ing speeds. With the FSC in the NEUTRAL-PARK
position, there should be no movement of either­
drive tire. If the tire(s) are “creeping” forward or re­
verse, refer to ADJUSTMENTS for the Neutral
Function Adjustment - Step 3 in this section.
Straight Ground Tracking
Check for straight ground track by driving on a
smooth, level surface with hands off the steering le­
vers. Set the FSC at different speeds and observe if
the mower moves in a straight line (use a cement
joint or other line on the ground for reference). If the
machine is drifting to the right or left, refer to
ADJUSTMENTS for Straight Tracking Adjustment - Step 5 in this section.
62
CHECKING/SERVICING
Maintenance Instructions
REPLACING/REPAIRING
REPLACING/REPAIRING
Drive Belts
There are five (5) individual drive belts on the ma­
chine:
DANGER
To prevent accidental starting of the
engine when replacing parts or repairing
the machine, remove the key from the
ignition switch and disconnect the spark
plug wires.
●● Engine/PTO Belt (Matched Set of 3)
●● Ground Drive Belt
●● Mower Blade Drive
The belts may be removed and replaced using the
procedures described on the following pages.
IMPORTANT: ALWAYS use genuine factory replacement parts. Substitute parts CAN result in
product malfunction and possible injury to the oper­
ator and/or others.
Ground
Drive Belt
Engine/PTO Belts
(Matched Set of 3)
Belt Locations (Engine Hidden for Clarity)
63
Maintenance Instructions
REPLACING/REPAIRING
Engine/PTO Belt
1.
To remove an engine/PTO belt:
a.
Remove Upper LH Belt Guard and RH Belt
Guard by removing two (2) wing nuts.
Wing
Nut
b.
Remove two (2) wire lock pins and open
Lower LH Belt Guard and PTO Belt Guard.
c.
Roll the belt off the pulley( and remove the
belt.
Clutch
Idler Pulley
Upper LH
Guard
Wire Lock Pin
Fixed Idler
Pulley
Right Hand
Guard
Lower LH
Guard
Wing
Nut
Wire Lock Pin
PTO Guard
PTO
Pulley
PTO Belts
(Matched Set)
Engine/PTO Belt (Belt Guards Open) (Engine Hidden for Clarity)
2.
To replace an engine/PTO belt:
a.
Reverse the removal procedure to replace
an engine/PTO belt.
b.
Secure wire on lock pin above tab on lower
PTO guard.
Upper LH
Guard
Right Hand
Guard
Secure
Wing Nut
Lower LH
Guard
Secure
Wing Nut
Wire Lock
Pin
Front View
Secure Wire Above Tab
PTO Guard
Engine/PTO Belt (Belt Guards Closed) (Engine Hidden for Clarity)
64
Maintenance Instructions
REPLACING/REPAIRING
Ground Drive Belt
1.
To remove the ground drive belt:
a.
Remove belt tension by raising the springloaded idler pulley with the deck tilt bar.
b.
Slide belt off pulleys, then release the idler
pulley.
Deck Tilt
Bar
LH Transaxle
Ground Drive
Belt
RH Transaxle
Transmission Belt
Tensioner Arm
Drive Pulley
Raise Idler Pulley to
Relax Belt
Belt Tightener
Idler Pulley
Ground Drive Belt Assembly (Disengaged)
2.
Reverse the procedure to install the ground
drive belt.
Deck Tilt
Bar
RH Transaxle
LH Transaxle
Ground Drive
Belt
Transmission Belt
Tensioner Arm
Drive Pulley
Idler Pulley
Ground Drive Belt Assembly (Engaged)
65
Maintenance Instructions
REPLACING/REPAIRING
d.
Deck Drive Belt
1.
From a position on the LH side of the deck,
grasp belt midsection and pull to compress
the belt tensioner springs and move the
tensioning pulley inward. The belt will then
slip off the LH spindle pulley and can be
completely removed.
To remove the deck drive belt:
a.
Remove deck footrest and two (2) covers
over the RH and LH blade spindles.
b.
Loosen belt tensioner stop bolt and turn in­
ward until retracted 1 in. (2.5 cm) from the
operating position.
c.
Lock drive pulley so that it can not rotate.
2.
Install the deck drive belt by reversing the re­
moval procedure:
a.
Route the belt as shown on the belt routing
decal (located on the deck housing). Leave
the belt loose at the LH spindle and then
install the belt by compressing the belt ten­
sioner as noted above.
b.
After the belt is in place, reset the belt ten­
sioner stop bolt by turning outward until
contacting the pulley bracket and then
making one (1) additional turn.
c.
Reinstall spindle covers and footrest.
* If deck is installed on tractor, the PTO
blade brake will prevent the drive pulley
from rotating.
* If deck is detached from tractor, use pry
bar or large screwdriver positioned
through the drive shaft U-joint to hold
shaft and prevent rotation.
Footrest
Spindle
Cover
Pulley Moves Inward to
Allow Belt to Slip Off
LH Blade Spindle
6
DR
64
BE
LT
N
P/
27
31
-5
874
6-2
BE
LT
TW
IST
2749-
IST
LT
Grasp Belt Here and
Pull from LH Side to
Compress Springs on
Belt Tensioner
RO
860
BE
ING
UT
TW
LT
BE
Use Pry Bar or
Screwdriver Through
U-Joint to
Prevent Rotation
Belt Routing
Decal
Belt Tensioner
Stop Bolt
Deck Drive Belt Replacement
66
0-28
Spindle
Cover
Maintenance Instructions
REPLACING/REPAIRING
Fuel Filter
Mower Blades
Model H38i is equipped with a 10 micron in-line fuel
filter between the fuel tank and the fuel pump (low
pressure pump). Replacement of this filter is recom­
mended every 200 hours of operation or when con­
tamination is suspected or found in the fuel.
Mower blades are removed and remounted as
described in the Sharpen Mower Blades instruc­
tions (refer to CHECKING/SERVICING to Sharpen
Mow­er Blades 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.
Fuel
Pump
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.
DANGER
Gasoline is extremely flammable and can
be highly explosive. To minimize danger:
●● Use only an approved fuel container for
gasoline.
●● DO NOT allow open flames or sparks
near the machine while performing main­
tenance or refueling; DO NOT smoke while
working with fuel.
●● Wipe up spilled gasoline immediately
and completely.
1. Expand and slide clamps on either side of the
filter away from filter and pull fuel lines off filter.
●● Examine ends of the blade carefully, especially
the intersection where the flat section of the blade
turns up to form the “wing tip” (refer to Mower Blade
Pro­file for Sharpening illustration in Sharpen
Mower Blades instructions). Since sand and abra­
sive 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.
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.
67
Maintenance Instructions
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. 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 prod­
uct malfunction and possible
injury to the operator.
68
REPLACING/REPAIRING
Maintenance Instructions
ADJUSTMENTS
ADJUSTMENTS
Transmission Control
IMPORTANT: The proper adjustment of the tran­
saxle control stops is essential for efficient opera­
tion and life of the transaxle. These stops are prop­
erly ad­justed at the factory and should only require
read­justment if the transaxle or related control link­
age is removed or changed.
Stop
Bolt
NOTE: It would not be unusual for a new machine,
after the initial 5 or 10 hours of operation, to begin to
not travel straight (this is due to the break-in of the
tran­saxles). To fine tune tracking, refer to Step 5 Straight Tracking Adjustment in this section.
Step 1 - Steering Lever Position Adjustment
NOTE: For proper operation, the steering levers
should be adjusted to sit evenly using the following
procedure.
1.
Examine the steering levers to make sure they
are parallel front to back in relation to one an­
other. If they are not equal, adjust accordingly.
(The handles may or may not be even at this
point.)
Stop Bolt Location
Step 2 - Steering Handles Adjustment
1.
An adjustment range of approximately 3 in.
(76.2 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.
NOTE: The LH steering lever is non-adjustable. This procedure will require adjustment of
the RH lever to make it even with the LH lever.
Levers should sit
parallel to each other
Adjustment
Slide
Locknut
(Position)
Locknut
(Pivot Point)
Lever Alignment
2.
Adjust the position of the RH lever by turning the
stop bolt in the Speed Control Actuator in or out.
Turning the stop bolt in will make the RH lever
move back, and turning it out will make it move
forward. Tighten the locknut.
Steering Handles Adjustment
69
Maintenance Instructions
ADJUSTMENTS
Step 3 - Neutral Function Adjustment
1.
Control Rods
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.
Control Arm
Tracking Adjustment Nuts
Transmission Control Rod and Arm Location
(Front Body Hidden for Clarity)
Tracking Adjustment Nut
(Adjusts Length of
Control Rod)
Maximum Speed
Adjustment Set Screw
Correct FSC Lever Neutral-Park Position
FWD
REV
Locating/Limit
Stud
Control Rod
Adjust Length of
Rod to Position
FSC Lever
Jam Nut
Ball Joint
Transmission
Control Arm
Tracking Adjustment Components
FSC Lever Position Adjustment
70
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.
Maintenance Instructions
ADJUSTMENTS
WARNING
Maximum
Speed Tracking
Adjustment
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.
5.
6.
7.
T-Handle
Hex Wrench
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.
Lift the body to access the steering adjustment
components.
Transmission
Control Arm
Maximum Speed Tracking Adjustment
(Shown with Parts Removed for Clarity)
Step 5 - Straight Tracking Adjustment
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.
1.
Sit in the seat, start the engine, set throttle at full
speed, and with the FSC in the NEUTRALPARK position check for movement of either
drive wheel (if either wheel moves backward or
for­ward, refer to Step 3 - Neutral Function Adjustment and readjust).
Using a wrench on one tracking adjustment nut,
rotate the control rod clockwise just until the
wheel on that side begins to move forward.
Then, counting the turns required, rotate the
control rod counterclockwise just until the
wheel stops and then begins to move in reverse. Rotate the control rod back clockwise
half the number of turns required to make the
wheel go from moving forward to reverse. The
transmission is now centered in the neutral win­
dow. Tighten the jam nut on the ball joint and
repeat the same procedure on the other trans­
mission.
2.
Check for straight ground tracking on a level
surface (with hands off the steering levers). Set
the FSC at several different speeds and ob­
serve if the machine moves in a straight line
(use cement joint or other line on ground for
reference).
3.
If travel is not straight, shorten the control rod
on the slow side by turning the tracking adjust­
ment nut clockwise. If straight tracking and
neutral can not be achieved, turn the tracking
adjustment nut counterclockwise until neutral is
restored.
Turn off the engine, and then lower the drive
tires onto the ground.
4.
Lengthen the control rod of the faster side by
turning the tracking adjustment nut counter­
clockwise to match the slower side while main­
taining the neutral position.
Step 4 - Full Forward Speed Adjustment
1.
Move the FSC to the full FORWARD speed po­
sition.
2.
Raise the body. The set screws in the left and
right Transmission Control Arms should not be
contacting the locating stud in the transaxle. If
they are, back the set screws out until they do
not touch.
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.
71
Maintenance Instructions
5.
If the forward travel is straight throughout the
speed range, except at maximum speed - place
the FSC in full FORWARD, turn the set screw in
the Transmission Control Arm, of the faster
side, in until it contacts the limit stud. (Turning
the set screw in slows the wheel.) Turn the set
screw in an additional 1/8 turn. Recheck for
equal full for­ward speed. Adjust this set screw
until equal full forward speed is achieved. Tight­
en the jam nut.
Step 6 - FSC Neutral Switch Adjustment
1.
ADJUSTMENTS
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.
Place the FSC lever in the NEUTRAL-PARK
position. Loosen mounting screws and adjust
the neutral switch up or down accordingly.
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
until the starter motor engages. Stop moving
the lever and 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 dis­
tance is greater than 1/8 in. (3 mm), the FSC
Neutral Switch needs to be adjusted downward
for quicker activation.
Step 7 - Forward Speed Control Friction Adjustment
FSC Switch
FSC Neutral Switch Location
Switch Closed
in Neutral
FSC Switch
Actuator Arm
Deck Support
Arm (Ref)
Loosen Screws
NOTE: Adjust the switch downward for quicker
activation. (Switch Open)
FSC Friction Adjustment Test
1.
Place the FSC lever in the full FORWARD
position, and pull both steering levers fully back;
the FSC lever should not move. If the FSC lever
moves back the friction needs to be increased.
2.
With the steering levers held back, move the
FSC lever back from the FORWARD position.
With a proper amount of friction adjusted, the
FSC le­
ver should move back with a slight
amount of re­sistance (friction). If the FSC lever
movement is “stiff”, the friction needs to be
decreased.
FSC Neutral Switch Adjustment
(Side View Through Chassis)
72
Maintenance Instructions
3.
ADJUSTMENTS
The FSC friction is increased or decreased by
tightening or loosening the friction adjustment nut. Loosen or tighten the nut and check
the control function until the conditions of both
steps 1 and 2 (above) are met.
FSC Friction
Adjustment Nut
FSC Friction Adjustment Nut
73
Maintenance Instructions
ADJUSTMENTS
Blade Clutch (PTO)
Adjust the length of the clutch actuator link to
achieve a clutch spring assembly bolt head clear­
ance of 1/4 in. to 5/16 in. (6.35 mm to 7.94 mm)
with the clutch engaged. To adjust length, remove
ball joint from clutch arm and shorten the clutch
actuator link to increase this measurement, or
lengthen the clutch actuator link to decrease this
measurement. If adjustments are needed more
frequently than every 100 hours to maintain dimen­
sions, it may suggest problems with pulley wear or
belt misalignment.
Clutch Engagement/Belt Tension
The clutch engagement and PTO belt tension are
adjusted using the clutch actuator link. After installing
new PTO belts, after 10 hours and every 100 hours
thereafter, check and adjust for the clutch spring as­
sembly bolt head dimension as shown in the PTO
Clutch Engaged illustration. If the clutch actuator
link or clutch spring assembly have been disassem­
bled, first reset them to their factory preset lengths
(as shown in the PTO Clutch Disengaged illustra­
tion) and then proceed with adjustment as follows.
Clutch Actuator
Link
Ball Joint
1/4 in. to 5/16 in.
(6.35 mm to 7.94 mm)
Blade Clutch
Engaged
Clutch Spring Assembly
(Spring Compressed)
Clutch Engagement
Arm
Blade Clutch
Idler Pulley
Clutch Arm
Front of Mower
PTO Clutch Engaged
74
Maintenance Instructions
ADJUSTMENTS
Use the following procedures to check and adjust
clutch disengagement and brake action:
Step 1 - Idler Pulley Maximum Travel Adjustment
6-1/4 in.*
(158.75 mm)
Knuckle Joint
Loosen the brake band adjustment nut allowing
clutch pivot stop arm and stop bolt to make contact
(refer to Blade Brake Band Adjustment illustra­
tion).
1.
To check the pulley travel, first engage the
clutch, then measure the distance the pulley
travels as the clutch is disengaged and the stop
arm contacts the stop bolt.
2.
Adjust the pivot stop bolt to give 1-5/8 in. to
1-3/4 in. (41 mm to 44 mm) pulley travel from
“clutch engaged” to “clutch disengaged”.
2-1/8 in.*
(53.98 mm)
Clutch Actuator
Link
6 in.*
(152.4 mm)
Clutch Spring Assembly
(Spring Uncompressed)
*NOTE: Factory preset dimensions. Reset to
these dimensions prior to adjustment if compo­
nents have been disassembled.
NOTE: This adjustment will prevent excessive
pulley travel that can cause belts to develop too
much slack, causing possible belt derailment
upon disengagement.
1-5/8 in. to 1-3/4 in.
(41 mm to 44 mm)
CLUTCH DISENGAGED
CLUTCH ENGAGED
PTO Clutch Disengaged
Clutch Disengagement/Brake Action
Idler Pulley
WARNING
Clutch Pivot
Stop Arm
Clutch Pivot
Stop Bolt
It is important to check and maintain blade
brake action for safe operation of the machine.
The declutched or disengaged position of the
blade clutch idler pulley is adjustable and is set to
give belt release without excessive slack and to
apply the blade brake. The blade brake is activated
by the brake band connected to the clutch engage­
ment arm. The brake is designed to stop the blades
within five (5) seconds after disengaging the clutch.
Brake Engagement
Arm
Clutch Idler Pulley Travel
75
Maintenance Instructions
ADJUSTMENTS
Step 2 - Blade Brake Band Adjustment
After the maximum pulley travel is set, adjust the
working travel of the clutch idler pulley by adjusting
the brake band nut and make the following adjust­
ment as needed:
1.
Blade Brake
Band
Adjust the blade brake band, using the adjust­
ment nut until pulley travel is approximately
5/8 in. to 3/4 in. (16 mm to 19 mm) from en­
gaged to disengaged.
NOTE: As blade brake band/drum wears, pul­
ley travel will increase and it will be necessary
to adjust the blade brake band nut to maintain
these dimensions.
Blade Brake
Band Adjustment Nut
CLUTCH DISENGAGED
CLUTCH ENGAGED
Chassis Mount
(Ref)
Blade Brake Band Adjustment
2.
5/8 in. to 3/4 in.
(16 mm to 19 mm)
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 ex­
cessive wear is present, it will be necessary
to replace worn parts.
Clutch Idler Pulley Travel Adjustment
76
MAINTENANCE AND SERVICE RECORD SHEET
DATE
SERVICE
ITEM
ENGINE
HOURS
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77
MAINTENANCE AND SERVICE RECORD SHEET
DATE
SERVICE
ITEM
ENGINE
HOURS
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78
LIMITED WARRANTY
FOR
WALKER MODEL H38i
RIDER MOWER
1.
WHAT THIS WARRANTY COVERS, AND FOR HOW LONG:
Walker Manufacturing company will, at its option, repair or replace, without charge, any part covered by this warranty which
is found to be defective in material and/or workmanship within one (1) year* after date of sale to the original retail purchaser
unless the product is used for rental purposes, in which case this warranty is limited to ninety (90) days. At Walker’s request,
customer will make the defective part available for inspection by Walker and/or return the defective part to Walker, transpor­
tation charges prepaid. All parts and components of the Walker Mower are covered by this warranty except the following
components which are warranted separately by their respective manufacturers:
Kohler Engine
Battery
The available warranties covering these items are furnished with each mower. Walker does not assume any warranty obli­
gation, liability or modification for these items, which are covered exclusively by the stated warranty of the respective man­
ufacturers noted above.
* A three (3) year or 3000 hour (whichever comes first) warranty is offered for Hydro-Gear ZT3400 hydrostatic transmissions;
covers full cost of replacement up to 1000 hours of use, and after 1000 hours warranty coverage is prorated against 3000
hours.
2.
3.
WHAT THIS WARRANTY DOES NOT COVER:
A.
This warranty does not cover defects caused by depreciation or damage caused by normal wear, accidents, improper
maintenance, improper use or abuse of the product, alterations, or failure to follow the instructions contained in the
Operator’s Manual for operation and maintenance.
B.
The customer shall pay any charges for making service calls and/or for transporting the mower to and from the place
where the inspection and/or warranty work is performed.
HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:
Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Walker Man­
ufacturing Company, 5925 East Harmony Road, Ft. Collins, CO 80528. Proof of the date of purchase may be required to
verify warranty coverage.
4.
WARRANTY LIMITATION:
A.
THERE IS NO OTHER EXPRESS WARRANTY. ANY WARRANTY THAT MAY BE IMPLIED FROM THIS PURCHASE
INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY LIMITED TO THE
DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED
WARRANTIES ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts, so the
above limitations may not apply to you.
B.
WALKER WILL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, OR SPECIAL DAMAGES AND/OR
EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply
to you.
C.
Only the warranty expressed in this limited warranty shall apply and no dealer, distributor, or individual is authorized to
amend, modify, or extend this warranty in any way. Accordingly, additional statements such as dealer advertising or
presentations, whether oral or written, do not constitute warranties by Walker, and should not be relied upon.
D.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
79
WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, CO 80528 • (970) 221-5614
FORM NO. 042518
PRINTED IN USA
www.walker.com
©2018 WALKER MFG. CO

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