Walker B19 Operator's Manual

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Walker B19 Operator's Manual | Manualzz

Operator’s Manual

Safety, Assembly, Operating, and Maintenance Instructions

Please Read and Save These Instructions

For Safety, Read All Safety and Operation

Instructions Prior to Operating Machine

Beginning S/N: 161698

P/N 4000-33

Foreword

Thank you. . .

for purchasing a Walker mower. Every effort has been made to provide you with the most reliable mower on the market, and we are sure you will be among our many satisfied custom ­ ers. If for any reason this product does not perform to your expectations, please contact your local dealer. Every customer is important to us. Your satisfaction is our goal.

Please. . .

read this manual thoroughly! This manual is to be used in conjunction with the engine manufacturer’s manual for the specific engine on the mower model you have purchased. Before you operate your new mower, please read this entire manual. Some of the information is crucial for proper operation and maintenance of this mower - it will help protect your investment and ensure that the mower performs to your satisfaction. Some of the information is important to your safety, and must be read and understood to help prevent possible injury to the operator or others. If any ­ thing in this manual is confusing or hard to understand, please contact your local authorized dealer or call our service department, at (970) 221-5614, for clarification before operating or servicing this mower.

This manual covers Model B19 with the Kohler Command CH620 (19 HP) gasoline engine.

All shields and guards must be in place for the proper and safe operation of this machine.

Where they are shown removed in this manual, it is for illustration purposes only.

Do not operate this machine unless all shields and guards are in place.

Specifications given are based on the latest information available at the time this manual was pro ­ duced for a tractor with standard equipment. Optional equipment is available and may affect the standard specifications listed.

Walker Mfg. Co. is continually striving to improve the design and performance of its products. We reserve the right to make changes in specifications and design without thereby incurring any obliga ­ tion relative to previously manufactured products.

Sincerely,

WALKER MANUFACTURING COMPANY

Bob Walker, Chairman

Table of Contents

General Information

________________ 1

HIGHLIGHTED INFORMATION

_____________ 1

GLOSSARY

____________________________ 1

IDENTIFYING NUMBER LOCATIONS

________ 1

ENGINE SERIAL NUMBER LOCATION

_______ 2

SERVICING OF ENGINE AND

DRIVETRAIN COMPONENTS

______________ 2

Specifications

________________________ 3

ENGINE

_______________________________ 3

ELECTRICAL SYSTEM

__________________ 3

TRANSMISSION

________________________ 3

BLADE DRIVE

__________________________ 4

TIRE SIZE

______________________________ 4

TIRE PRESSURE

_______________________ 4

MOWER DECK

_________________________ 4

DIMENSIONS (Tractor and Mower)

_________ 5

DRIVE BELTS

__________________________ 5

SEAT

__________________________________ 5

FRAME/BODY CONSTRUCTION

__________ 5

Component Identification

___________ 6

Safety Instructions

__________________ 9

BEFORE OPERATING

____________________ 9

OPERATING

___________________________ 11

MAINTENANCE

________________________ 13

SAFETY, CONTROL,

AND INSTRUCTION DECALS

_____________ 14

Assembly Instructions

______________ 17

SETUP INSTRUCTIONS

__________________ 17

Tire Installation (Tractor)

_______________ 17

Battery Service

_______________________ 17

Wet Battery Service

__________________ 17

Dry Battery Service

___________________ 17

Battery Charging

_____________________ 18

Battery Installation

___________________ 18

Mower Deck Assembly

_________________ 18

Deck Caster Wheels Installation

_________ 18

Deck Discharge Deflector

Shield Installation

____________________ 19

PTO Shaft Guard Installation

___________ 19

Tilt-Up Roller Wheel Installation

_________ 19

Mower Deck Installation on Tractor

_______ 20

Deck Installation

_____________________ 20

Deck Leveling

_______________________ 22

PREOPERATING CHECKLIST

_____________ 23

Operating Instructions

_____________ 25

CONTROL IDENTIFICATION,

LOCATION, AND FUNCTION

_____________ 25

Engine Choke

________________________ 25

Engine Throttle

_______________________ 26

Forward Speed Control (FSC)

___________ 26

Steering Levers

_______________________ 26

Blade Clutch (PTO)

____________________ 26

Body Latch

__________________________ 26

Parking Brake

________________________ 28

Transaxle Lockout Arms

_______________ 28

Hourmeter

___________________________ 29

Ignition Switch

_______________________ 29

Circuit Breakers

______________________ 29

STARTING THE ENGINE

_________________ 30

ADJUSTING GROUND

SPEED AND STEERING

__________________ 30

ENGAGING THE BLADE DRIVE

___________ 33

STOPPING THE MACHINE

_______________ 33

ADJUSTING CUTTING HEIGHT

____________ 34

TRANSAXLE LOCKOUT

_________________ 35

RECOMMENDATIONS FOR MOWING

______ 36

RECOMMENDATIONS FOR TILT-UP DECK

OPERATION/TRANSPORT

_______________ 37

Maintenance Instructions

__________ 38

MAINTENANCE SCHEDULE CHART

_______ 38

IMPORTANT TIPS FOR CARE

OF THE KOHLER ENGINE

________________ 39

Fuel System

_________________________ 39

Starting/Stopping

_____________________ 39

Cooling System

______________________ 39

Air Cleaner System

____________________ 39

Oil

__________________________________ 39

LUBRICATION

_________________________ 40

Engine Oil

___________________________ 40

Engine Break-In Oil

___________________ 40

Checking Engine Crankcase Oil Level

____ 40

Changing Engine Crankcase Oil/Oil Filter

__ 41

Grease Fitting and Oil Point Lubrication

__ 42

Mower Deck Gearbox Lubrication

________ 43

Mower Deck Spindle Lubrication

________ 43

DS52 Mower Deck Lubrication

__________ 46

Check Transaxle Fluid Level

____________ 46

Transaxle Oil and Filter Change

_________ 46

Table of Contents

CLEANING

____________________________ 47

Engine Air Cooling System

_____________ 47

Cooling Air Intake Screen

______________ 47

Cylinder Head Cooling Fins

____________ 48

Engine Air Cleaner System

_____________ 49

Cummins/Fleetguard OptiAir™

Air Cleaner

_________________________ 49

Grass Buildup in Mower Deck Housing

___ 51

Transaxle Housing

____________________ 52

CHECKING/SERVICING

__________________ 53

Security of Air Filtration Components

____ 53

Battery

______________________________ 53

Electrolyte Level

_____________________ 53

Cleaning the Terminals

________________ 53

Charging the Battery

__________________ 53

Tire Pressure

_________________________ 54

Wheel Nut Torque

_____________________ 54

Sharpen Mower Blades

________________ 54

Drive Belts

___________________________ 55

Mower Deck Gearbox Oil Seals

__________ 55

Spark Plugs

__________________________ 55

Ignition Wires

________________________ 55

Fuel Lines and Clamps

_________________ 55

Blade Brake Action

____________________ 55

PTO U-Joints

________________________ 56

Engine Starter

________________________ 56

Safety Switch System

__________________ 56

Forward Speed Control Friction Lock

_____ 56

Transmission Control Setting

___________ 56

Neutral-Park

________________________ 56

Straight Ground Tracking

______________ 56

REPLACING/REPAIRING

_________________ 57

Drive Belts

___________________________ 57

Engine/PTO Belt

_____________________ 58

Ground Drive Belt

____________________ 59

Fuel Filter

___________________________ 60

Blade Overload Shear Bolts

_____________ 60

Mower Blades

________________________ 61

ADJUSTMENTS

________________________ 62

Transmission Control

__________________ 62

Steering Lever Position Adjustment

______ 62

Steering Handle Adjustment

____________ 63

Neutral Function Adjustment

____________ 63

Full Forward Speed Adjustment

_________ 64

Straight Tracking Adjustment

___________ 65

FSC Neutral Switch Adjustment

_________ 65

Forward Speed Control

Friction Adjustment

___________________ 66

Blade Clutch (PTO)

____________________ 67

Clutch Engagement/Belt Tension

________ 67

Clutch Disengagement/Brake Action

_____ 68

Idler Pulley Maximum Travel Adjustment

__ 68

Blade Brake Band Adjustment

__________ 69

Tilt-Up Deck Adjustable Stop

____________ 69

MAINTENANCE AND SERVICE

RECORD SHEET

_______________________ 70

Warranty

___________________________ 71

General Information

HIGHLIGHTED INFORMATION

Walker Manufacturing recommends that any service requiring special training or tools be performed by an authorized Walker Mower dealer. There are sev ­ eral general practices to be aware of in the area of safety. Most accidents associated with the opera ­ tion or maintenance of a Walker Mower are caused by disregarding basic safety precautions or specific warnings. Such accidents, in most cases, can be prevented by being aware of the dangers present.

Information of special importance has been high ­ lighted in bold type in this manual. Refer to

Safety

Instructions

for the meanings of

DANGER, 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 following terms and their definitions will help while using this manual:

DECK

is the mowing attachment mounted on the front of the tractor which includes the carrier frame, deck housing, belt or gear drive compo ­ nents, and cutter blades.

FORWARD SPEED CONTROL (FSC)

controls the maximum forward speed of the tractor; functioning as a cruise control.

GROUND DRIVE

refers to the dual transaxles which drive the main wheels.

LEFT HAND (LH)

refers to the left-hand side of the tractor when the operator is seated facing forward in the tractor seat.

POWER TAKE-OFF (PTO)

transmits engine power to run the cutter blades.

RIGHT HAND (RH)

refers to the right-hand side of the tractor when the operator is seated facing forward in the tractor seat.

SIDE DISCHARGE (SD)

discharges mowed material from the right side of the mower deck .

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 trac ­ tor body just below the left rear corner of the seat.

The mower deck serial number plate is affixed alongside the angle iron framing on the LH side of the LH mower blade drive. Model and serial num ­ bers are helpful when obtaining replacement parts and maintenance assistance. For ready reference, please record these numbers in the space provided.

Tractor Model No. ______________________

Tractor Serial No. ______________________

Deck Serial No. ______________________

Engine Model No. ______________________

Engine Serial No. ______________________

Date of Purchase ______________________

Fill In By Purchaser

Serial Number

Tractor Serial Number Location

1

2

General Information

Serial Number

Mower Deck Serial Number Location

ENGINE SERIAL NUMBER LOCATION

Refer to the engine manual that accompanies this manual or photo below for the location of the engine serial number.

Serial Number

Engine Serial Number Location

SERVICING OF ENGINE AND DRIVETRAIN

COMPONENTS

The detailed servicing and repair of the engine, transaxles, and gearboxes are not covered in this manual. Only routine maintenance and general ser ­ vice instructions are provided. For the service of these components during the limited warranty period, it is important to find a local, authorized ser ­ vicing agent of the component manufacturer.

Any unauthorized work done

on these components during the warranty period

may void the warranty.

If you have any difficulty finding an authorized outlet or obtaining warranty service, please contact our Service Department for assistance:

Walker Manufacturing Company

5925 E. Harmony Road

Fort Collins, CO 80528

1-970-221-5614 www.walker.com

Service manuals are available for each of these components from their respective manufacturers as follows:

Kohler Engines

Kohler Company

Kohler, WI 53044

800-544-2444

www.kohlerengines.com

Transaxles

Hydro-Gear

1411 South Hamilton St.

Sullivan, IL 61951

877-728-7410 www.hydro-gear.com

Gearboxes (Deck)

Peerless Gear

1555 South Jackson St.

Salem, IN 47167 USA

866-536-8310

www.peerlessgear.com

Specifications

MODEL

ENGINE

Manufacturer/Model

Displacement cu. in. (cc)

Max. Power HP (kW)

Governed RPM

Max. Torque lb

· ft (N

· m)

Idle RPM

Spark Plug Type

Spark Plug Gap in. (mm)

Crankcase Capacity qt (L)

Crankcase Lubricant

Oil Filter

Cooling System

Fuel Tank Capacity gal (L)

Fuel

Air Cleaner

ELECTRICAL SYSTEM

Battery

Charging System

Charging Output

System Polarity

Ignition

Starter

Interlock Switches

Circuit Breaker(s)

TRANSMISSION

Manufacturer/Model

Steering

Forward Speed Control

Service Brake

B19

Kohler Command CH620, V-Twin, 2 Cyl., Gasoline (Air-Cooled)

41.1 (674)

19 (14.2) @ 3600 RPM

3600

35 (47.5)

1200

Champion

®

RC12YC

.030 (0.76)

1.8 (1.7)

API SJ or Higher Grade Oil Only with 10W-30 Viscosity Above 0° F

(-18° C), or 5W-20 or 5W-30 Viscosity Below 32° F (0° C)

Kohler P/N 12-050-01

Air-Cooled

4.0 (15.1)

Automotive Grade Unleaded Gasoline

(87 Octane Minimum, 10% Ethanol Maximum)

Remote Mounted Cummins/Fleetguard OptiAir

TM

(Walker P/N 2090-1 Primary/2090-3 Safety Filter)

12 Volt, 300 CCA (Interstate SP-35)

Flywheel Alternator

15 Amp DC (Regulated)

Negative Ground

Electronic Capacitive Discharge

12 Volt Electric, Key Operated, Solenoid Shift

Ignition Lockout by Seat Switch, Transmission Neutral,

Blade Clutch, and Parking Brake

Manual Reset (5A)

Auto Reset (30A)

Dual, Independent Hydro-Gear

®

ZT3100 Integrated Transaxles

Hand Lever Control / Individual Wheel

Precision Friction Lock Lever, Cruise Control, with

Neutral-Park Position

Dynamic Braking through Transaxles

3

4

Specifications

MODEL

TRANSMISSION (continued)

Parking Brake

B19

Neutral

Final Drive

Transmission Fluid

Factory Service

Transmission Oil Capacity fl oz (L)

Transmission Cooling

Oil Filter

Ground Travel Speed

Forward MPH (km/h)

Reverse MPH (km/h)

BLADE DRIVE

PTO Shaft

Blade Drive Clutch and Brake

Internal Mechanical Cog Lock for each Transaxle

(Single Lever Control)

Transmission Release by Manual Dump Valve

Transaxle Direct to Drive Wheel

20W-50 Multi-Viscosity Motor Oil (Minimum SL Grade Oil)

77 (2.3)

Cooling Fan Mounted on Drive Pulley

Hydro-Gear

®

P/N 52114 (Walker P/N 2026-6)

0-8 (0-13) Infinitely Variable

0-5 (0-8) Infinitely Variable

Quick Disconnect Splined Shaft with Two (2) High-Speed U-Joints

Manual Belt Tightener Clutch and Band Brake

[Stops Blades within Five (5) Seconds of Disengagement]

TIRE SIZE

Deck Caster Wheel

Drive

8 x 3.00-4 Semi-Pneumatic (Standard)

8 x 3.00-4 Pneumatic 4-Ply (Optional)

11 x 4.00-5 (Pneumatic 6-Ply, DS52 Only)

18 x 8.50-10 (Pneumatic 4-Ply, Low-Profile)

18 x 7.00-8 (Pneumatic 4-Ply, Optional)

20 x 10.00-10 (Pneumatic 4-Ply, Optional Big Tire Kit, P/N 5076-10)

11 x 4.00-5 (Pneumatic 6-Ply)

Tailwheel

TIRE PRESSURE PSI (KPA)

Deck Caster Wheel*

Drive

20 (137)

15 (103)

Tailwheel 20 (137)

* If equipped with optional pneumatic tires

MOWER DECK

Recommended Cut Width

Side Discharge

Mulch

Cutting Height

Deck Suspension

36 to 56 in. (91 to 142 cm)

36 to 48 in. (91 to 122 cm)

1.5 to 4 in. (4 to 10 cm) or

1.5 to 4.5 in. (4 to 11.5 cm) (DS52 Belt Driven Deck Only)

Independent Torsion-Flex Frame with Caster Wheels and

Counterweight Springs

Specifications

MODEL

DIMENSIONS (Tractor and Mower)

Length in. (cm)

Tractor Only

Tractor Wheel Base

Tractor with Tilted Deck

(Approximate)

Tractor with 48" Mulch Deck

(DM48-2)

Width in. (cm)

Tractor Only (Outside Tire)

Tractor with 48" Mulch Deck

(DM48-2)

Height in. (cm)

Tractor

Weight lb (kg)

Tractor Only

Tractor with 48" Mulch Deck

(DM48-2)

B19

63 (160)

40 (102)

72 (183)

90.75 (230)

38.5 (98)

49 (125)

39.5 (100)

583 (264)

789 (358)

DRIVE BELTS

Engine PTO

Ground Drive

Walker P/N 4230-1 (Matched Pair)

Walker P/N 4230-2

SEAT

Contour-Molded, with Nylon Backed Vinyl Cover and Integral

Foam Cushion

FRAME/BODY CONSTRUCTION

Frame

Body

Deck

All Welded Unitized Steel Chassis

14 Gauge Steel

11 Gauge Steel

NOTE:

The manufacturer reserves the right to make changes in specifications shown herein at any time without notice or obligation. The specifications listed are for a standard configuration tractor, and may change with the addition of optional equipment.

5

6

Component Identification

NOTE:

Control Identification shown in

Operating

Instructions

section.

Body Lift

Handle

Forward Speed

Control (FSC)

Friction

Adjustment

Negative (-)

Battery Cable

Positive (+)

Battery Cable

Body Tilt-Up Latch

(Not Visible)

Deck Support

Arm

Deck Lift Handle

(Cutting Height Adjustment)

Footrests

Tilt-Up Latch

Counterweight Springs and

Protective Covers

Deck Support

Arm

Deck Support

Pins and Height

Adjustment

Hitch Pins

Tilt-Up

Deck Handle

Footrests

Tilt-Up

Hook

Deck

Caster Wheels

Front View and Right Side View

Component Identification

Footrests

Fuel Gauge

Fuel Pickup

Line

Oil Dipstick /

Oil Fill

Muffler

Tailpipe

Muffler Heat

Shield

Left Hand

Drive Wheel

Fuel Tank and Cap

Cylinder Head

Cooling Fins

Spread Axle

(Tail Wheel)

Tailwheel Fork and Wheel

Rear View and Left Side View

7

8

Component Identification

LH Transmission

Control Rod

Steering Levers

Spring / Dampener

RH Transmission

Control Rod

LH Transaxle

LH Transaxle

Lockout Arm

Parking Brake

Linkage

Parking Brake

Lever

Fuel Tank Cap

Parking Brake

Linkage

Fuel Gauge

Fuel Tank

Roll Over Valve

EVAP Line

Fuel Pickup Line

Fuel Filter

(Not Visible)

30 Amp Circuit

Breaker

(Not Visible)

Oil Dipstick /

Oil Fill

Rubber Bumpers

(Body Support)

Top View (Engine Compartment)

RH Transaxle

RH Transaxle

Lockout Arm

Transaxle Oil

Expansion

Reservoir

PTO Clutch

Lever

Air Filter

Restriction Gauge

Fuel Pump

OptiAir

TM

Air Cleaner

Air Cleaner

Cover Latch

Air Cleaner Cover

Throttle and

Choke Linkage

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. Fail ure to comply with safety instructions may result in per ­ sonal injury.

The seriousness or degree of importance of each type of information is defined as follows:

DANGER

An IMMEDIATE hazard that WILL result in severe personal injury or DEATH, if warning is ignored and proper safety precautions are not taken.

WARNING

A POTENTIAL hazard that COULD result in severe personal injury or DEATH, if warning is ignored and proper safety precautions 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 precautions are not taken.

IMPORTANT:

Identifies mechanical information demanding special attention, since it deals with the possibility of damaging a part or parts of the ma ­ chine.

NOTE:

Identifies information worthy of special attention.

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

1.

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. Do not wear loose fitting clothing that could get caught in moving parts. Do not operate this ma ­ chine while wearing shorts;

always wear adequate protective clothing,

including long pants. Wearing safety glasses, safety shoes, and a helmet is advisable and required by some local ordinances and insurance regulations.

7. Prolonged exposure to loud noise can cause impairment or loss of hearing.

Operator hearing protection is recommended.

Wear a suit ­ able hearing protective device, such as ear ­ muffs or earplugs.

8.

Keep all protective shields and safety devices in place.

If a protective shield, safety device, or decal is damaged, unusable, or miss ­ ing, repair or replace it

before

operating the machine.

9.

Be sure interlock switches are functioning correctly,

so the engine cannot be started un ­ less the Forward Speed Control lever is in the

NEUTRAL-PARK

position, the PTO clutch is in the

DISENGAGED

position, and the Parking

Brake is in the

ENGAGED

position. Also, the engine should stop if the operator lifts off the seat with any one or more of these controls in the operating position: (1) Forward Speed Con ­ trol (FSC) out of

NEUTRAL-PARK,

(2) PTO

Clutch

ENGAGED,

or (3) Parking Brake

DIS-

ENGAGED.

10.

Handle gasoline with care.

Gasoline is highly flammable and its vapors are explosive: a. Use an approved fuel container.

b. Never add fuel to a running engine or hot engine (allow hot engine to cool several minutes).

c. Keep matches, cigarettes, cigars, pipes, open flames, or sparks away from the fuel tank and fuel container.

d. Always fill the fuel tank outdoors using care. Fill to about one inch from the top of the tank. Use a funnel or spout to prevent spilling.

e. Replace the machine fuel cap and contain ­ er cap securely and clean up any spilled fuel before starting the engine.

11.

Never attempt to make any adjustments while the engine is running,

except where specifically instructed to do so.

12. The electrical system battery contains sulfuric acid. Avoid any contact with skin, eyes, and clothing. Keep the battery and acid out of reach of children.

WARNING

This product can expose you to chemicals including Di-(2-ethylhexyl) phthalate which is known to the State of California to cause cancer, and Di-(2-ethylhexyl) phthalate, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

10

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 op erating 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 implement 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. Remember, for an emergency stop, the forward motion of the tractor can always be stopped by pulling the Forward Speed Control (FSC) into the

NEUTRAL-PARK

position.

5. If the transmission drive belt breaks during op­ eration, and if the machine is on a slope, the machine will freewheel down the slope.

To maintain control,

immediately (1) Release the steering levers and simultaneously (2) Move the FSC to the

NEUTRAL-PARK

position.

When the machine is stopped or moving slowly, engage the parking brake.

NOTE:

The emergency stop procedure is ex ­ actly the same procedure as used to normally stop and park this machine.

6. Disengage the blade clutch, put the FSC in the

NEUTRAL-PARK

position, and engage the

Parking Brake before starting the engine (an ignition interlock switch normally prevents starting of the machine if these controls are in the

OPERATING

position).

7.

Do not operate machine if the operator presence safety switch system is not working.

Verify proper operation by having the operator lift off the seat with the engine running and mov ­ ing three controls, one at a time; (1) Move the

FSC lever out of the

NEUTRAL-PARK

position,

(2) Engage the PTO Clutch, and (3) Disengage the Parking Brake. Moving any of these controls should stop the engine immediately.

8.

Do not run the engine in a confined area without adequate ventilation.

Exhaust fumes are hazardous and can be deadly.

9.

Do not carry passengers

- maximum seating capacity is one (1) person.

10. Watch for holes, rocks, and roots in the terrain and for other hidden hazards. When mowing tall grass, mow higher than desired to expose any hidden obstacles. Then, clean the area and mow to the desired height.

11.

Avoid sudden starts or stops.

Before back ­ ing the machine up, look to the rear to be sure no one is behind the machine. Watch carefully for traffic when crossing or working near road ­ ways.

12. When moving forward,

do not

suddenly put the tractor in reverse by rapidly pulling on the steer ­ ing levers, especially when going downhill, as this can lift the tractor tail wheel off the ground and set up a bucking motion due to operator overcontrol. If bucking does occur, immediately stop the bucking action by pulling the Forward

Speed Control (FSC) lever into the

NEUTRAL-

PARK

position.

13. Disengage the blade drive when transporting the machine across drives, sidewalks, etc.

Never raise the mower deck while blades are rotating.

DANGER

Do not mow or drive the tractor within

5 feet (1.5 meters) of an embankment or retaining wall with drop off.

11

Safety Instructions - Operating

14.

The maximum recommended slope operating angle is 15 degrees or 27% grade.

When operating the machine on a slope, reduce speed and use caution to start, stop, and maneuver.

To prevent tipping or loss of control of the ma ­ chine, avoid sharp turns or sudden changes in direction.

Do not operate the machine on a slope greater than 15 degrees.

15.

Never adjust cutting height with the engine running. Before

adjusting cutting height or servicing, disengage the blade clutch (PTO), engage parking brake, stop the engine, and re ­ move the ignition key. Wait for all movement to stop before getting off the seat.

NOTE:

The blade/PTO brake should normally stop drive line rotation within five (5) seconds of disengaging the PTO clutch.

16. For side discharge mower decks,

do not operate with the grass deflector shield removed.

Keep the deflector in the lowest possible posi ­ tion.

17. When using the tilt-up deck,

observe the following:

a. Do not move tractor with deck in tilt-up position.

b. Never tilt body forward with deck in tilt-up position.

18.

In case of a clogged or plugged mower deck:

a. Disengage the blade clutch (PTO), engage the parking brake, and turn the engine off before leaving the seat.

b.

LOOK

to make sure blade drive shaft movement has stopped before trying to un ­ clog the system.

c. Disconnect the spark plug wires.

d. Never place hands under the deck - use a stick or similar tool to remove clogged ma ­ terial.

19. If the cutting blades strike a solid object or the machine begins to vibrate abnormally,

immediately disengage the blade clutch (PTO), engage the parking brake, stop the engine, and wait for all moving parts to stop.

To prevent accidental starting, disconnect the spark plug wires. Thoroughly inspect the mower and re ­ pair any damage before restarting the engine and operating the mower. Make sure cutter blades are in good condition and blade nuts are torqued to 60 lb decks, and blade bolts torqued to 70 lb

N

·

· ft (81 N m) for belt driven decks.

· m) for gear driven

· ft (95

20.

Do not touch the engine or muffler while the engine is running

or immediately after stopping the engine. These areas may be hot enough to cause serious burns.

21. When leaving the machine unattended,

disengage the blade clutch (PTO), engage the parking brake, stop the engine, and remove the key.

12

Safety Instructions - Maintenance

1. To prevent accidental starting of the engine when servicing or adjusting the machine, re ­ move the key from the ignition switch and dis ­ connect the spark plug wires.

2.

To reduce fire hazards,

keep the engine free of grass, leaves, excessive grease, and dirt.

3. Keep all nuts, bolts, and screws tight to ensure the machine is in a safe, working condition.

Check the blade mounting nuts frequently, making sure they are tight.

4.

Perform only maintenance instructions described in this manual.

Unauthorized mainte ­ nance operations or machine modifications may result in unsafe operating conditions.

5. If the engine must be running to perform a maintenance adjustment, keep hands, feet, and clothing away from moving parts.

Do not wear jewelry or loose clothing.

6.

Always use the proper engine service manual when working on the engine.

Unauthorized maintenance operations or modifications to the engine may result in unsafe operating conditions.

7. Altering the equipment or engine in any manner which adversely affects its operation, performance, durability, or use will

VOID the warranty

and may cause hazardous conditions.

8. Never attempt to disconnect any safety devices or defeat the purpose of these safety devices.

9. Do not change the engine governor settings or overspeed the engine. The governor has been factory-set for maximum-safe engine operating speed.

10.

Use genuine factory replacement parts.

Sub stitute parts may result in product malfunc ­ tion and possible injury to the operator and/or others.

11.

Use care when charging the battery

or per­ forming maintenance on the battery and electri ­ cal system: a. Make sure the battery charger is unplugged before connecting or disconnecting cables to the battery.

b. Charge the battery in a well-ventilated space, so gases produced while charging can dissipate. Make sure the battery vents in the caps are open.

c. Keep sparks, flames, and smoking materials away from the battery at all times. To avoid sparks, use care when removing battery cables from posts.

d. Disconnect both battery cables before un ­ plugging any wiring connectors or making repairs on the electrical system.

IMPORTANT:

Keep all applicable manuals im ­ mediately accessible to anyone who may oper ­ ate or service this machine.

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.

Location: Each End of Mower Deck

Part Number: 8600-28

1. Warning – thrown object hazard.

8600-28

1.

2.

● Keep bystanders away from the machine when operating.

● Clear lawn of debris before operating.

● Keep any discharge deflector in place and in the lowest position.

2. Warning – rotating mower blades are a cutting/ dismemberment hazard to hands and feet.

● Keep all body parts away from rotating mow ­ er blades.

● Do not step on end of deck.

1.

1.

8600-14

Location: Deck Carrier Frame

Part Number: 8600-14

1. Warning – do not operate the machine with the deck tilted up.

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.

1.

Location: Deck Carrier Frame

Part Number: 8600-15

1. Warning – lock deck tilt-up hinge before operat ­ ing the machine.

1.

1.

Location: Chassis Member Behind Transaxles

Part Number: 9804-1

1. Neutral Lock

● Lift and move into slot to unlock transmis ­ sion and allow machine to freewheel.

Location: Deck Discharge Shield

(SD Decks Only)

Part Number: 5848-3

1. Warning – thrown object hazard.

● Always keep the discharge shield in the low ­ est position when operating.

● Do not remove the discharge shield.

14

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.

5.

7.

2.

3.

4.

8.

<15°

1.

6.

1.

2.

1.

2.

3.

4.

5.

Location: LH Fender

Part Number: 8600-46

1. Throttle

● Move lever forward to increase engine speed; back to idle.

2. Warning – read Operator’s Manual before oper ­ ating the machine.

3. Warning – wear eye and ear protection when operating the machine.

4. Warning – roll-over hazard.

● Do not operate on slopes greater than 15 degrees.

5. Warning – thrown object hazard.

● Keep bystanders away from the machine when operating.

6. Choke

7. Warning – entanglement hazard.

● Keep all guards in place while engine is run ­ ning.

8. Parking Brake

● Move lever forward to engage Parking

Brake; back to disengage.

Location: RH Fender

Part Number: 8600-26

1. Warning – do not operate the machine without a deck or other implement attached.

2. Forward Speed Control

● Move lever forward to increase speed; back to stop.

3. Warning – read Operator’s Manual before ser ­ vicing or performing maintenance.

● Engage parking brake.

● Remove ignition key.

4. Warning – do not engage PTO clutch with PTO shaft disconnected.

5. PTO Clutch Lever

● Move lever forward to engage PTO clutch; back to disengage.

15

Safety Instructions

SAFETY, CONTROL, AND INSTRUCTION DECALS

Safety, Control, and Instruction Decals are installed on the machine; if any are missing, illegible, or damaged, a replacement should be ordered and installed before putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.

BELT ROUTING

1.

Location: Deck Gearbox Cover

Part Number: 8600-39

1. Warning - stop engine and remove ignition key before adjusting deck cutting height.

60 lb·ft (81 N·m)

1.

8600-9

Location: Gearbox Cover

(Gear Drive Decks Only)

Part Number: 8600-9

1. Tighten blade nuts on gear driven decks to

60 lb

· ft (81 N

· m ).

GROUND DRIVE BELT

WALKER P/N 4230-2

1.

ENGINE/PTO BELT

WALKER P/N 4230-1

4107-12

Location: Rear Body

Part Number: 4107-12

1. Ground drive belt routing.

2. Engine/PTO clutch belt routing.

2.

1.

8600-12

Location: Engine

Part Number: 8600-12

1. Warning – carbon monoxide (CO) poisoning hazard.

● CO emitted by a running engine can be deadly.

● Do not operate indoors or in other enclosed areas.

Location: Engine Shroud

Part Number: 5855

1.

8600-5

Location: Rear Body Near Muffler

Part Number: 8600-5

1. Warning – hot surface, do not touch.

16

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.

Tire Installation (Tractor)

● Install the drive tires using the eight (8) mount ­ ing nuts supplied with the Owner’s Packet of materials. Nuts are torqued to 75 to 85 lb

(102 to 115 N

· m ).

· ft

● Check and adjust the inflation of the tires.

The tire inflation recommendations are:

Drive = 15 PSI (103 kPa)

Tailwheel = 20 PSI (137 kPa)

Battery Service

NOTE:

Disregard the following instructions to ser ­ vice the battery with electrolyte if equipped with a sealed, maintenance-free battery.

Check the battery for electrolyte level and charge.

The electrolyte level should be at the bottom of the vent wells [1/4 to 1/2 in. (6 to 13 mm) above plates].

If the specific gravity is less than 1.225, the battery needs charging. If the battery has been shipped dry, or is wet but needs service, refer to the following instructions.

Battery Clamp and Cover

Battery Location

IMPORTANT:

Make sure battery is securely mount ­ ed in the frame. A loose battery may cause damage to the case resulting in acid leakage and severe damage to the machine. A hazard may be created by damage to critical working parts and safety sys ­ tems.

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.

Dry Battery Service

DANGER

Activating a battery can be dangerous.

The battery should be taken to a reliable service station, battery store, or power equipment dealer where a trained technician can activate the battery safely. DO

NOT attempt to activate the battery unless you are experienced in battery service work. The following activation and charging instructions are provided for use by a trained battery technician.

DANGER

Battery electrolyte is a poisonous and corrosive sulfuric acid solution.

Avoid spillage and contact with skin, eyes, and clothing - causes severe burns.

To prevent accidents, wear safety goggles and rubber gloves when working with electrolyte.

Neutralize acid spills with baking soda and water solution.

To fill (activate) battery with electrolyte (if battery has been shipped dry):

1. Remove the battery cover and hold-down clamp, disconnect the battery cables and lift the battery out of the tray.

IMPORTANT:

Battery must be removed from the mower before filling with electrolyte.

17

Assembly Instructions

IMPORTANT:

Obtain and use only battery grade sulfuric acid electrolyte with a 1.265 specific gravity to activate the battery.

DO NOT

use water or any other liquid during initial activation.

2. Remove the filler caps and carefully fill each cell until the electrolyte is just above the plates.

3. After the battery is filled with electrolyte, replace the filler caps and charge the battery. Refer to

Battery Charging.

Battery Charging

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 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.

1. Charge the battery at 15 amps for 10 minutes.

DO NOT

exceed 20 amps maximum recommended charging rate. Charge until specific gravity is at least 1.250. Total charging time should not exceed one (1) hour.

2.

After charging the battery, adjust the electrolyte level to the bottom of the vent wells [1/4 to 1/2 in.

(6 to 13 mm) above the plates].

IMPORTANT: DO NOT

overfill the battery.

Electrolyte will overflow through the vented caps onto parts of the machine and

WILL

result in severe corrosion.

3. Install battery.

Battery Installation

IMPORTANT:

Make sure battery is securely mount ­ ed in the frame. A loose battery may cause damage to the case resulting in acid leakage and severe damage to the machine. A hazard may be created by damage to critical working parts and safety sys ­ tems.

Install the battery in the mower as shown in

Battery

Installation

photo. Connect the positive (+) first and then the negative (-) cable to the proper battery ter ­ minal

[red cable and boot connects to the Positive (+) terminal].

Slide the rubber boot up and over the battery post, making sure it covers the post com ­ pletely

to prevent an electrical short.

WARNING

Make sure the battery cap vents are open.

Improper venting of the battery COULD cause a battery explosion.

(+) Battery Cable

Connection

Battery Clamp

Secured by

Wing Nut(s)

Battery Installation

Mower Deck Assembly

Deck Caster Wheels Installation

1. Remove the bolt and nut from each deck caster wheel fork.

2. Fit a bearing cup on the outside of each wheel bearing and slide the wheel assembly into the wheel fork.

3. Insert the 3/8-16 x 4-1/2 in. bolt through the wheel fork with the bolt head to the outside and install the 3/8-16 in. Keps nut.

18

Assembly Instructions

4. Tighten the bolt and nut until the axle spacer tube and inner bearing race bottom against the inside of the wheel fork (will not turn) while the wheel spins freely without binding.

Axle Spacer

Tube

PTO Shaft Guard Installation

Position the shaft guard as shown and mount with two (2) 1/4-20 x 1/2 in. bolts.

Carrier Frame

Tube Sockets

Bearing

Cup

Axle Bolt

Deck Caster Wheel Installation

5. Grease the caster wheel bearings and caster pivot bearings - two (2) grease fittings for each wheel.

Deck Discharge Deflector Shield Installation

(Side Discharge Models Only)

Attach the side discharge deflector shield using two

(2) 3/8-16 x 1-1/4 in. bolts, 3/8-16 ESNA nuts, and

3/8 in. wave spring washers. The wave washers fit between the two hinging surfaces. Tighten the nuts until the shield moves freely but is not loose.

WARNING

DO NOT operate the machine without the grass deflector shield attached and in the lowest possible position.

Attach Shield

Attach

Guard

PTO Shaft Guard Installation

Tilt-Up Roller Wheel Installation

Mount the two (2) tilt-up roller wheels on the brack ­ ets on the rear skirt of the deck housing using the

P/N 8490 axle bolt, 3/8 in. plain washer, 3/8 in. wave spring washer (between bracket and wheel) and 3/8-16 Whiz locknut. Tighten the axle bolt until the wheel rolls freely, but is not loose.

Roller Wheel Installation

Roller

Wheels

Deck Discharge Shield Installation

19

Assembly Instructions

Mower Deck Installation on Tractor

Deck Installation

1. Lightly grease each deck support arm (2) on the tractor. Refer to

Mower Deck Installation

photo for location of deck support arm.

4. Reaching under the tractor, slide the PTO cou ­ pler tube onto the deck drive shaft (align arrow decals), then install the coupler quick discon ­ nect onto the tractor PTO drive shaft.

IMPORTANT:

When installing the DS52

Mower deck, make sure to retract the dolly wheel after mounting the deck on the tractor.

Arrows on Shaft and Tube

(Used to Align When Sliding Together)

PTO

Connection

Deck Support

Arms

Mower Deck Installation

2. Engage the deck carrier frame tube sockets on the tractor support arms (refer to

PTO Shaft

Guard Installation

photo for socket location), slide the deck onto the support arms approxi ­ mately 3 in. (76 mm).

3. Retract the spring-loaded quick disconnect ring on the PTO Coupler and insert the Coupler In ­ stallation Tool (provided in Owner’s Packet) as shown in the photo below.

NOTE:

The Coupler Installation Tool is provid ­ ed for convenience, but is not required for in ­ stallation.

Coupler

Installation Tool

Grease Deck

Support Arms

PTO Shaft Connection

5. Remove Installation Tool from quick disconnect ring and make sure the ring has “snapped” se ­ curely on the spline shaft.

IMPORTANT: DO NOT

operate tractor with

Coupler Installation Tool installed.

IMPORTANT:

To prevent damage to the mow ­ er, make sure the PTO quick disconnect is se­ curely locked on the tractor, with the locking balls fully seated in the groove and the ring in the locked position (refer to the

Quick Disconnect

Ring “Locked” Position

illustration). After in ­ stallation, pull on the PTO coupler to check for security.

20

PTO Coupler

Tube

Retract Spring-Loaded

Quick Disconnect Ring

PTO Coupler Installation Tool

Assembly Instructions

Coupler Ring in

Released Position

PTO Drive

Shaft

9. With the counterweight springs connected, the weight on the deck caster wheels should be

15 to 25 Ib (6.8 to 11.3 kg); this adjustment is preset at the factory. If required, the spring ten ­ sion can be adjusted by tightening or loosening the elastic stop nuts located underneath the lower spring hook, or contact your local dealer if additional help is required. Refer to

Deck

Counterweight Spring Installation

photo.

PTO Coupler

U-Joint

Quick Disconnect Ring “Released” Position

Internal Balls

Locked on Shaft

PTO Drive

Shaft

Spring Tension Adjustment Nut

Located Under Lower

Spring Hook (Not Visible)

PTO Coupler

U-Joint

Coupler Ring in

Locked Position

Quick Disconnect Ring “Locked” Position

6. Slide the deck the rest of the way on the deck arms.

7. Install the hitch pin through the hole on the end of each support arm to lock the deck in place

(refer to

Deck Counterweight Spring Installation

photo). Two (2) hitch pins are included in the Owner’s Packet of materials.

8. Raise the mower body to the tilt-up position, and then raise the front of the deck and clip the counterweight springs to the receptacle on front of body. Lower the body to tension the springs.

(Refer to

Deck Counterweight Spring Installation

photo.)

Counterweight Springs

Clip Onto Body

With Body Tilted Up

Hitch Pins

Lock Deck on

Support Arms

Deck Counterweight Spring Installation

21

Assembly Instructions

Deck Leveling

The mower deck and support frame are jig welded; within normal tolerances, very little, if any, shimming should be required to level the deck. Tire pressure will influence the levelness of the deck. Check the tire pressure of all pneumatic tires as a possible cause of the deck not being level.

1. Position mower on a smooth, level surface. Set the cutting height to the highest position - 4 in.

(102 mm) - for easy access under the deck to measure blade height. Refer to

ADJUSTING

CUTTING HEIGHT

in

Operating Instructions .

NOTE:

A block of wood cut

4 in. (102 mm)

high is a convenient gauge to measure blade height above ground during the leveling process.

WARNING

The machine must be shut off during this procedure.

2. Check the side-to-side level.

Rotate each blade sideways

and measure the distance from blade tip to ground on each side. If mea ­ surements vary more than 1/8 in. (3 mm), add a washer shim under the deck support pins on the low side to level the deck.

3. Check the front-to-rear level.

Rotate the blades to point forward.

Measure the distance from blade tip to ground on the front and rear. The rear of the blade should be 1/8 to 1/4 in. (3 to 6 mm) higher than the front of the blade; shim the rear

(or front) deck support pins equally to achieve

at least

1/8 in. (3 mm) difference.

4 in. (102 mm)

Wood Block

Should be 1/8 in. (3 mm) to 1/4 in. (6 mm) higher at the rear of the blade

Should not vary more than 1/8 in. (3 mm) side-to-side

4 in. (102 mm)

Wood Block

22

NOTE:

For DS52 and DS62 decks with three (3) staggered blades, the front-to-rear level should be set using the middle blade pointing forward, and either outside blade pointing back.

Deck Leveling

Assembly Instructions

PREOPERATING CHECKLIST

Before operating the mower for the first time, and as a routine before daily operations, it is important to make sure the mower is properly prepared and ready for operation. The following is a list of items to be checked. (For a mower with frequent opera ­ tion, some of these items will not need to be checked every day, but the operator should be aware of the condition of each.)

For proper fuel and lubricants refer to

Specifications.

FILL FUEL TANK

Fill the fuel tank using clean, fresh automotive grade

unleaded

gasoline (87 octane minimum, 10% etha ­ nol maximum).

DANGER

Handle gasoline with care. Gasoline is highly flammable and its vapors are explo sive. Use safe refueling procedures:

DO NOT fill fuel tank with the engine running.

If the engine is hot, allow to cool before refueling.

Use an approved fuel container.

Fuel the mower outdoors.

DO NOT smoke while refueling.

Avoid spilling fuel; use a funnel or spout.

DO NOT overfill the fuel tank; fill up to about 1 in. (25 mm) below the top of tank.

IMPORTANT: DO NOT

permit dirt or other foreign matter to enter the fuel tank. Wipe dirt from around the filler cap before removing. Use a clean fuel stor ­ age container and funnel.

IMPORTANT: DO NOT mix oil with gasoline.

Al­ ways use fresh, automotive grade unleaded gaso ­ line.

DO NOT

use gasoline containing greater than

10% ethanol.

DO NOT

use additives, such as car ­ buretor cleaners, deicers, or moisture removing agents.

DO NOT

use gasoline blended with methyl alcohol.

CHECK ENGINE CRANKCASE OIL LEVEL

Check the engine crankcase oil level before use and

after each 8 hours

of continuous operation. Refer to

LUBRICATION

for

Checking Engine Crankcase

Oil Level

in

Maintenance Instructions.

CHECK AND SERVICE ENGINE AIR CLEAN ­

ER SYSTEM

● Check air filter restriction gauge to make sure the yellow indicator disk is in the safe operating

(green) range .

● Check condition, cleanliness, and security of the complete air cleaner system (inspect air filter paper element

every 100 hours

). For detailed procedures, refer to

CLEANING

the

Engine Air

Cleaner System

in

Maintenance Instructions.

CHECK ENGINE COOLING SYSTEM

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

CLEAN-

ING

the

Cylinder Head Cooling Fins

in the

Mainte­ nance Instructions

for this procedure.

Check performance of the cooling system by start ­ ing the engine, holding a hand adjacent to the cylin ­ der heads, and feeling the cooling airflow.

DANGER

Make sure to keep hands clear of exhaust pipe, muffler, and moving parts when checking airflow.

CHECK HYDROSTATIC TRANSAXLE OIL

LEVEL

Refer to

LUBRICATION

for

Check Transaxle Fluid

Level

in

Maintenance Instructions.

INSPECT THREE (3) DRIVE BELTS

Engine/PTO (2) and Ground Drive.

23

Assembly Instructions

CHECK FUNCTION OF SAFETY INTERLOCK

SWITCHES

Refer to

Operating Instructions

to check for proper operation of safety switches, both during engine starting and with the operator leaving the seat with tractor moving forward or with the mower blades en ­ gaged.

CHECK TIRE PRESSURE

Deck Caster Wheel* = 20 PSI (137 kPa)

Drive

Tailwheel

= 15 PSI (103 kPa)

= 20 PSI (137 kPa)

* If equipped with optional pneumatic tires

CHECK SECURITY OF DRIVE TIRE MOUNT ­

ING NUTS

The eight (8) Drive Tire mounting nuts should each be torqued to 75 to 85 lb

· ft (102 to 115 N

· m ).

ADJUST MOWER CUTTING HEIGHT, IF RE ­

QUIRED

Position the hitch pins in the four deck support pins.

Refer to the “Cutting Height Adjustment” decal on the deck gearbox cover.

CHECK AND CLEAN GRASS BUILDUP UN ­

DERNEATH MOWER DECK

Refer to

CLEANING

the

Grass Buildup in Mower

Deck Housing

in

Maintenance Instructions

for deck tilt-up and deck cleaning information.

DANGER

Never operate cutter blades with deck in raised position because it is hazardous.

The tilt-up deck can be secured in the raised posi ­ tion by unlocking the deck lock levers on each side of the carrier frame and inserting the deck hook into the tilt-up latch on the tractor body. Before operating the tractor, make sure to re-engage the deck lock levers after lowering the deck to the normal operat ­ ing position.

Tilt-Up

Latch

Tilt-Up Handle

Tilt-Up Hook and

Latch Connected

Tilt-Up

Hook

Deck Lock

Lever

Deck Secured in TILT-UP Position

CAUTION

Do not operate machine with deck tilt-up pivot joint unlocked.

DANGER

Do not operate the mower with deck in tiltup position. Do not move the tractor with the deck in the tilt-up position.

CHECK MOWER BLADE CONDITION,

SHARPNESS, AND SECURITY OF MOUNT ­

ING

The blade mounting nuts on gear driven decks should be torqued to 60 lb blade mounting bolts on belt driven decks torqued to

70 lb

· ft (95 N

·

· ft (81 N

· m), and the m). If blade sharpening is required, refer to

CHECKING/SERVICING

for

Sharpen Mower Blades

in

Maintenance Instructions.

PERFORM ANY ADDITIONAL PROCEDURES called for in the

MAINTENANCE SCHEDULE

CHART

in

Maintenance Instructions.

24

Operating Instructions

CONTROL IDENTIFICATION, LOCATION, AND

FUNCTION

CAUTION

Before operating the mower, become familiar with the location and function of all operator controls. Knowing the location, function, and operation of these controls is important for safe and efficient operation of the mower.

Engine Choke

The choke control lever (black knob) is located on the left side of the seat. To start a cold engine, move the choke control forward to the

ON

position. After engine starts, move the choke control toward the

OFF

position, keeping enough choke to allow the engine to run smoothly as it warms up. As soon as possible, move the choke to the

OFF

position. A warm engine requires little or no choke for starting.

Body Lift

Handle

IMPORTANT:

Make sure the choke is in the

OFF

position during normal engine operation; running with the choke in the

ON

position

CAN

damage the engine.

Parking

Brake

Throttle Choke

Choke and Throttle Location

Blade Clutch

(PTO)

Forward Speed

Control (FSC)

Steering

Levers

Choke

Throttle

Body Latch

Ignition

Switch

Hourmeter

Operating Controls

Circuit

Breaker

25

Operating Instructions

Engine Throttle

The throttle control lever (red knob) is located on the left side of the seat and is used to control engine speed. Moving the lever

forward

toward the

FAST

position

increases

engine speed; moving it

backward

toward the

IDLE

position

decreases

engine speed.

Forward Speed Control (FSC)

Forward Speed Control (FSC) has two functions:

One is to set forward travel speed, and the other is to establish the

NEUTRAL-PARK

position. When the FSC lever is moved into the

FORWARD

posi­ tion, a friction lock holds any forward speed setting from 0 to 8 mph (0 to 13 km/h). The ground speed is proportional to the lever position; the further the lever is advanced forward, the faster the tractor moves. It is not necessary to hold the FSC in posi ­ tion since the friction lock maintains the selected lever position. Pulling back on the steering levers overrides the FSC setting and slows or stops for ­ ward travel. Releasing the steering levers allows the tractor to resume forward travel at the speed set by the FSC lever. To stop and park the machine, the

FSC lever is moved backward to the

NEUTRAL-

PARK

position.

Steering Levers

Each drive wheel is controlled by its own indepen ­ dent steering lever, for both steering function and

FORWARD/REVERSE

motion. The FSC lever sets the maximum forward speed, and also sets the for ­ ward position of the steering levers. The steering levers operate

only with a backward pulling

move­ ment of the lever, which causes the drive wheel for that lever to first slow down, stop, and then reverse with a full backward lever stroke. The levers are released to the

FORWARD

position for “straightahead” ground travel.

NOTE:

Pushing forward on the steering levers will not cause

any

change in tractor motion - there will be no steering lever reaction and there will be no machine damage.

Blade Clutch (PTO)

The blade clutch lever is located on the right side of the seat behind the right fender and is used to en ­ gage and disengage the mower blades. The blade clutch lever has two positions. Pushing the lever

DOWN engages

the PTO that drives the mower blades. Pulling the lever

UP disengages

the PTO and engages the blade brake.

Body Latch

The tractor body hinges forward for maintenance ac ­ cess and is latched down in the

OPERATING

posi­ tion. To raise the body, pull back on body latch and lift body using the lift handle on the rear of the body.

Body Latch

Body

Latch

26

Operating Instructions

The Forward Speed Control also Establishes the

Neutral-Park

Position of the Steering Levers

LEFT WHEEL

STEERING LEVER

RIGHT WHEEL

STEERING LEVER

FORWARD SPEED

CONTROL LEVER (FSC)

Forward Position

(No Control Change)

Full Forward

Position

Ground Speed

Neutral-Park

Position

Intermediate

Ground Speed

Position

Reverse Drive

Wheel Motion

Position

Neutral-Park

Position

Fast

Throttle

Position

Idle

Position

<15°

1.

2.

ON

Position

THROTTLE

OFF

Position

CHOKE

Engaged

Position

Engaged

Position

PARKING

BRAKE

Disengaged

Position

Disengaged

Position

Operating Controls (Top View from Drivers Point of View)

BLADE CLUTCH

(PTO)

27

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.

NOTE:

If pressure on the parking brake (e.g., parked on a hill) makes it impossible to release the parking brake with the parking brake lever, move the mower gently forward or backward to allow the brake detent to release.

Transaxle Lockout Arms

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.

Engaged

Position

Parking Brake Engaged

Transaxle Lockout

Arms

Transaxle Lockout Arm Location

NOTE:

The transaxle lockout arms ends should be completely retracted against the chassis, otherwise operation of the transaxle may be erratic.

Disengaged

Position

Parking Brake Disengaged

28

Operating Instructions

Hourmeter

The hourmeter, which is located on the right front of the body, displays

operating time

accumulated while the PTO (blade drive) clutch is

engaged.

The hourmeter provides maintenance reminders af ­ ter certain hours of operation. The hourmeter screen will start flashing the reminder one hour prior to the recommended interval and will continue until one hour after the recommended interval (two hours).

The hourmeter

does not have a manual reset function.

Procedure Interval*

Oil Change

(Break-In)**

4-6 Hours

Reminder

C

H

G

OIL

Lubricate and Check

Levels

24-26 Hours

LUBE

Oil Change 49-51 Hours***

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.

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 that the key returns to after starting, and “S” is the

START

position. When start ­ ing the engine, turn the key clockwise to the “S” position. Do not hold the key in the “S” position longer than 10 seconds. If the engine does not start, return the key to the “O” position for at least 60 sec ­ onds before making a restart attempt. Prolonged cranking can damage the starter motor and shorten battery life. Release the key when the engine starts, and it will return to the

ON (RUN)

position. To stop the engine, rotate the key counterclockwise to the

“O” position.

OFF

ON

START

Ignition Switch

Circuit Breakers

A manual reset 5 amp circuit breaker is located on the right front of the body. The button pops out if the circuit breaker trips. This circuit breaker protects the safety circuits and relays. In addition, an auto reset

30 amp master circuit breaker is located in the rear left of the chassis, and protects the charging system.

Hourmeter

29

Operating Instructions

STARTING THE ENGINE

CAUTION

Before operating the mower, read and understand all Safety Instructions and Operat­ ing Instructions .

WARNING

NEVER run the engine in an enclosed or poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

1. Before attempting to start the engine, make sure the operator is in the seat, the Forward

Speed Control is in

NEUTRAL-PARK

position, the parking brake is

ENGAGED,

and the blade clutch is

DISENGAGED.

CAUTION

A safety interlock switch system PRE-

VENTS CRANKING the engine with any one of these three controls in the OPERATING position: (1) Forward Speed Control out of neutral, (2) blade clutch (PTO) engaged, or

(3) parking brake disengaged. If the engine cranks otherwise, the safety system is not working and should be repaired or ad justed before operating the mower. DO NOT disconnect safety switches; they are for the operator’s protection.

2. Move the choke lever to the

ON

position and move the throttle 1/4 to 1/2 open (toward

FAST

).

Turn the ignition switch to the

START

position to start the engine. Release the key to

ON

(RUN)

position as soon as the engine starts.

NOTE:

The choke may not be required if the engine is warm.

IMPORTANT: DO NOT

crank the engine con ­ tinuously for more than 10 seconds at a time. If the engine does not start, turn the key to the

OFF

position and allow a 60 second cool-down period between starting attempts. Failure to fol ­ low these guidelines can damage the starter motor and shorten battery life. Consult your

Walker dealer or authorized Kohler dealer for additional help.

3. After the engine starts, gradually move the choke to the

OFF

position, keeping enough choke on to allow the engine to run smoothly as it warms up. As soon as possible, move the choke to the

OFF

position.

IMPORTANT:

Make sure the choke is in the

OFF

position during normal engine operation; running with the choke in the

ON

position

CAN

damage the engine.

ADJUSTING GROUND SPEED AND STEERING

IMPORTANT:

If the DS52 mower deck is installed on the tractor, make sure the dolly wheel is retracted

BEFORE

moving.

CAUTION

Learn to START, STOP, and MANEUVER the mower in a large, open area.

If the operator has not operated a ma chine with LEVER STEERING OR DUAL HYDROing and ground operation should be learned and practiced until the operator is completely chine BE-

FORE ATTEMPTING TO MOW.

DANGER

Keep feet on footrests at all times when the machine is moving. Never operate the tractor without a deck or implement installed.

30

Operating Instructions

1. Move the FSC out of

NEUTRAL-PARK

position to the desired forward speed.

DO NOT

hold for ward on steering levers. It is not necessary to hold the FSC lever in position since a friction lock maintains the selected lever position (and forward travel speed).

2. Steer by pulling the lever on the side of desired direction of turn, e.g., pull the

LH

lever to

turn left.

To minimize the possibility of overcontrol, use only one hand on both steering levers .

CAUTION

An operator presence switch (seat switch) will cause the engine to stop if the parking brake is in the DISENGAGED position and/ or the FSC is out of the NEUTRAL-PARK position (tractor stationary or moving forward) and the operator is not in the seat.

The function of this switch should be checked by the op erator raising off the seat, first with the parking brake DISEN -

GAGED, and then with the tractor moving forward; the engine should stop. In each case, 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.

NOTE:

If the FSC lever will not stay in the selected position, the friction lock needs to be adjusted. Refer to

ADJUSTMENTS

for

Step 7 -

Forward Speed Control Friction Adjustment

in the

Maintenance Instructions.

Pull Steering

Levers With

Left Hand

Keep Feet On

Footrest When

Moving

Forward Speed Control

(FSC)

Correct Operator Hand Position on the Controls

31

Operating Instructions

Beginning Recommendations are:

♦ Learn operation of the mower in an open area away from buildings, fences, and ob structions. Learn operation on flat ground BEFORE operating on slopes.

♦ Start maneuvering the mower with

SLOW engine speed and SLOW Forward Speed Control setting until familiar with all operat ing characteristics.

♦ Remember it is not necessary to hold the steering levers forward (a unique

Walker feature); always PULL on the levers for steering or for reverse motion of the mower.

♦ Learn to operate the mower with your left hand on the steering levers and right hand on Forward Speed Control. The use of two hands on the steering levers tends to cause overcontrol.

♦ Learn to operate the steering levers with smooth action. Jerky movements are hard on the transmission and lawn.

For sharp turns, do not allow the inside wheel to stop and twist on the grass.

Pull the steering le ver controlling the inside wheel into reverse for a smooth

“rolling” turn (one wheel roll ing forward while the other rolls backward).

♦ Practice maneuvering the mower until you can make it go exactly where you are aiming.

♦ Remember, for an emergency stop, or in case of loss of control, machine movement can always be stopped quickly by pulling the Forward Speed Control into the NEU TRAL-PARK position.

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 NEU-

TRAL-PARK position.

4. The FSC may be adjusted forward for faster ground speed and backward for slower ground speed. When mowing, ground speed should be adjusted to match the load on the cutter blades, i.e., as the engine pulls down in heavy cutting, pull back on the FSC lever to reduce ground speed. Adjusting ground speed helps maintain a balance between engine power and blade speed for high-quality cutting action.

5. Stop ground travel by pulling both steering le vers backward to the

NEUTRAL

position

(trac tor not moving) and then moving the FSC lever to the

NEUTRAL-PARK

position.

NOTE:

If the tractor creeps forward or back ward with the FSC lever in the

NEUTRAL-

PARK

position, the transmission control needs to be adjusted. Refer to

ADJUSTMENTS

for

Transmission Control, Step 3 -

Neutral Function Adjustment

in the

Maintenance Instructions.

WARNING

If the transmission drive belt breaks during operation, and if the machine is on a slope, the machine will freewheel down the slope. To maintain control, immediately

(1) Release the steering levers and simultaneously (2) Move the FSC to the NEUTRAL-

PARK position. When the machine is stopped or moving slowly, engage the parking brake.

NOTE:

This is exactly the same procedure used to normally stop and park the machine.

32

Operating 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 shorten 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.

Engaged

Position

Blade Clutch Engaged

Disengaged

Position

Blade Clutch Disengaged

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, sidewalks, loose materials, etc.

DO NOT engage the blade clutch with the PTO shaft disconnected

(the mower deck removed from tractor).

CAUTION

If the cutting blades strike a stationary object while mowing, stop the mower immediately, disconnect the spark plug wires, lift the deck, and inspect the deck and blades thoroughly for damage. Make sure that the blade timing has not been dis turbed (the blades should be at 90 degrees to each other). Refer to REPLACING/RE PAIRING the Blade Overload Shear Bolts in

Mainte­ nance Instructions

if blades are out of time.

Also, make sure the blade retain ing nuts are torqued to 60 lb·ft (81 N·m).

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.

IMPORTANT: DO NOT

disengage the blade clutch with high engine speed (above 1/2 throttle) since the brake action on the blade drive will cause premature wear of the brake band.

33

Operating Instructions

34

WARNING

A brake stops the cutter blades from freewheeling within five (5) seconds after disengaging the clutch. If the brake system malfunctions and the blades do not stop within five (5) seconds, the brake should be adjusted or repaired before further op eration of the mower. Contact your

Walker dealer, or refer to ADJUSTMENTS of

Clutch Disengagement/Brake Action

in

Maintenance Instructions.

4. Turn the ignition switch

OFF.

When stopping the engine, do not reduce the throttle below 1/2 speed. Since the engine is equipped with a fuel shutoff solenoid, stopping at low idle may cause engine run-on or backfiring.

WARNING

Remove the key from the ignition switch when leaving the mower unattended. This will prevent children and inexperienced operators from starting the engine.

5. Engage the parking brake by moving the lever forward.

IMPORTANT:

The hydrostatic transmissions lock to prevent the mower from rolling freely with the engine stopped. However, if the mow ­ er is parked on a slope, it is necessary to

EN-

GAGE

the parking

BRAKE

to prevent the mower from creeping. This is due to a small amount of slippage in the hydrostatic transmis ­ sions, especially when transmission fluid is warm. Also, engaging the parking brake is rec ­ ommended when stopping or parking the ma ­ chine in a confined space with little tolerance for movement.

WARNING

If the transmission drive belt breaks during operation, and if the machine is on a slope, the machine will freewheel down the slope. To maintain control, immediately

(1) Release the steering levers and simultaneously (2) Move the FSC to the NEUTRAL-

PARK position. When the machine is stopped or moving slowly, engage the parking brake.

NOTE:

The emergency stop procedure is exactly the same procedure used to normally stop and park the machine.

ADJUSTING CUTTING HEIGHT

WARNING

The engine must be stopped before adjusting cutting height. Disengage the blade clutch (PTO), engage the parking brake, stop the engine, and remove the ignition key. Wait for all move ment to stop before getting off the seat.

Cutting height is adjusted by positioning the four (4) re tainer hitch pins in a series of six vertical holes on the deck support pins. Lift handles have been provided on each end of the deck to assist in raising the deck while positioning the hitch pins. Cutting heights range from 1.5 in. (38 mm) [top holes] to 4 in. (102 mm) [bottom holes] in 1/2 in. (13 mm) incre ments.

Lift Handle

Deck Support

Pin

Washer

Hitch Pin

Cutting Height Adjustment

Operating Instructions

TRANSAXLE LOCKOUT

IMPORTANT: DO NOT TOW

this mower faster than

2 mph (3.2 km/h) with the transaxle lockout en ­ gaged. Towing can produce excessive internal pressure and damage the transaxle(s).

To move the mower with the engine

NOT

running

(dead battery, maintenance, etc.), the transaxles need to be unlocked (released).

1. Raise the body.

2. Pull up on each transaxle lockout arm and move toward the center of the machine to engage the step that holds the arm in the UP (unlocked) position.

3. The mower will “freewheel” with the arms in the

LOCKOUT

position. The levers must be in the highest position to completely unlock the trans ­ axles.

Transaxle Lockout Arm

Transaxle Lockout Arm

Transaxle Lockout Arm - Normal Operating

Position

Transaxle Lockout Arm - Freewheel Position

4. After moving the mower, release the arms, plac ­ ing them down in the normal

OPERATING

posi­ tion. The transaxle lockout arm ends should be completely retracted against the chassis, other ­ wise operation of the transaxle may be erratic.

35

Operating Instructions

RECOMMENDATIONS FOR MOWING

DANGER

Do not mow around overhanging tree branches or bushes at the same height as the operator’s torso and head where inadvertent contact may cause injury.

Avoid Low Hanging Branches

IMPORTANT:

Operate the engine at

full throttle

when mowing, to allow the engine to produce full horsepower and to increase efficiency of the engine cooling system.

● Keep the mower deck and discharge shield clean.

● Mow with

sharp blades.

A dull blade tears the grass (resulting in poor lawn appearance) and uses extra power (slowing the mowing speed).

● It is preferable to cut grass when it is

dry

and

not too tall.

Mow frequently and do not cut grass too short. (For best appearance, cut off

1/3 or less of existing grass height.)

● When mowing, operate the engine at

full throttle

for the best cutting action. Mowing with a lower engine RPM causes the mowing blade to not cut clean and tear the grass. The engine is

designed to be operated at full speed.

● When mowing in adverse conditions (tall and/or wet grass), mow the grass twice. Raise the mower to the highest setting - 4 in. (102 mm) - for the first pass and then make a second pass cutting to the desired height.

● Use a

slow

setting on the FSC for

trimming

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 skidding of the drive tires. Use

smooth control move ments

of the steering levers since the transaxles are “power boosted controls” and jerk ing the levers can easily slip the tires. For sharp turns, do not allow the inside wheel to stop and twist on grass; pull inside steering lever into reverse for a smooth “rolling” turn (one wheel rolling forward while the other rolls back ­ ward).

● When using a side discharge mower deck, the side discharge deflector shield

must not be removed

and must be kept in the lowest possible position to deflect grass clippings and thrown objects down ward. Orient the side discharge away from side walks or streets to minimize cleanup of clippings. When mowing close to obstacles, orient the side dis charge away from obstacles to reduce the chance of damage to property by thrown objects.

Discharge

Shield

Side Discharge Deflector

Shield in Lowest Position

36

Operating Instructions

● When operating on a slope,

reduce speed and use caution

to start, stop, and maneuver. Avoid sharp turns or sudden changes in direction. The

maximum recommended slope operating angle is 15 degrees or 27% grade.

Maximum

Recommended

Slope -

Do Not Operate on Steep Slopes

8600-1

60 lb·ft

(81 N· m)

8600-9

15°

14 in.

52 in.

Maximum Recommended Slope

DANGER

Do not mow or drive the tractor within 5 feet

(1.5 meters) of an embankment or retaining wall with drop off.

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 tilt-up position since both the roller wheels (on the back of the deck) may be damaged by mov ­ ing the tractor. The tilt-up configuration should only be used when the tractor is parked.

● The tractor

body should never be tilted forward

with the deck in the tilt-up position. This can cause the deck to unhook from the tractor and fall with considerable force, potentially causing deck or tractor damage and/or bodily injury.

● When transporting a tractor with the deck in the tilt-up position (on a truck or trailer), the

deck should be secured

to the vehicle with a strap or rope (stop vertical movement). This will pre ­ vent the deck from bouncing on the rear roller wheels (causing breakage). This will also pre ­ vent the deck from unhooking from the tractor and falling, potentially causing deck or tractor damage. Damage to other items parked in front of the deck may also occur.

5 FT

MINIMUM

No Driving Zone

37

Maintenance Instructions

CAUTION

Maintenance procedures requiring special training or tools should be performed by a trained technician.

MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL B19

Service Item

Check Engine Crankcase Oil Level

Check/Clean Engine Air Cooling System*

Clean Grass Buildup Under Deck

Service Mower Blades

Check Security of Air Filtration Components

Check Air Filter Restriction Gauge

Daily

x x x x x x

25

Hours

100

Hours

200

Hours

400

Hours Yearly

Every

2 Years

Lubricate Grease Fittings and Oil Points*

Check Battery Electrolyte Level

Check Transaxle Fluid x x x x

Check Tire Pressure

Check Drive Belts

(Engine/PTO, Ground Drive)

Check Deck Gearbox Oil Seals x

Check Safety Switch System

Check Security of Drive Tire

Mounting Nuts (75 to 85 lb · ft)

Check Blade Brake Action x x x

Clean Transaxle Housing

Clean Engine Cooling Fins

Check Air Filter Element***

Change Engine Crankcase Oil**

Check/Adjust Blade Clutch x x x x x x

Check/Regap Spark Plugs

Change Engine Oil Filter x x

Replace Fuel Filter

Change Transaxle Oil and Filter

Δ

Replace Air Filter Element and Safety Filter*** x x x

Check/Adjust FSC Friction Lock

Check Fuel Lines and Clamps

Service Solenoid Shift Starter

Check PTO U-Joints for Wear/Looseness

Service Battery

Check Transmission Control Settings x x x x x x

Replace Fuel Lines and Clamps

Replace Dust Ejection Valve***

Replace Ignition Wires

*

More often in extremely dusty or dirty conditions

**

Change engine oil and filter after first 5 hours of operation of a new engine (break-in period)

***

Air cleaner is remote mounted Cummins/Fleetguard OptiAir™ unit, replace filter(s) every 400 hours and dust ejection valve every two years or when worn or damaged

Δ

Change transaxle oil after the initial break-in period of 75-100 hours operation

x x x

55

56

54

46

50

56

55

41

60

49

41

67

55

52

48

53

56

55

55

56

56

50

55

Ref.

Page

54

53

49

40

47

51

42

53

46

54

55

38

Maintenance Instructions

IMPORTANT TIPS FOR CARE OF THE KOHLER

ENGINE

Fuel System

● Fuel must be clean - free from water, dirt, and or ganic material.

● Change fuel filter on a regular basis or when con tamination is suspected or found in the fuel.

Starting/Stopping

● Start engine with the throttle advanced off idle

(1/4 to 1/2 throttle). This will aid starting, espe ­ cially in cold weather.

● Keep the battery fully charged.

● Match crankcase oil viscosity to the ambient 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 back ­ firing.

Cooling System

CAUTION

DO NOT use water or a pressure washer to clean the cooling system on an air-cooled engine; mud may form under the cooling shroud on the cylinder head and cooling fan resulting in engine overheating.

● Keep engine air intake screen and cylinder head fins free of grass clippings, chaff, and dirt. In ­ spect intake screen and cooling fins for cleanli ­ ness and no damage.

● Periodically remove two access panels in the en gine shroud to inspect and clean cylinder head cooling fins.

● Check performance of the cooling system by starting the engine, holding a hand adjacent to the cylinder head, and feeling the cooling air ­ flow.

KOHLER TIPS

DANGER

Make sure to keep hands clear of exhaust pipe, muffler, and moving parts when checking airflow.

● Operate the engine at full speed when mowing.

This allows the engine to produce full horse ­ power and move more cooling air through the engine cool ing fins.

Air Cleaner System

● Use

only

Cummins/Fleetguard air cleaner ele­ ments. Aftermarket elements may not seal in the air cleaner housing, allowing dirt to enter the en ­ gine. Also, aftermarket filters often skimp on the filtration media and require more frequent re ­ placement (see following instructions).

● Use the air filter restriction gauge to indicate the need to service the air filter.

DO NOT overservice or frequently “disturb” the air filter.

A dirty air filter actually cleans bet ­ ter than a new one. Changing and cleaning the air filter too often can ac tually reduce filter effi ­ ciency and increase the oppor tunity for traces of dust to enter the engine. Wait until the element really needs servicing as indicated by the air fil ­ ter restriction gauge.

● When the air filter element is removed or re- placed, make sure all

dust is cleaned out

of the

air cleaner housing and hose.

Use a damp cloth and wipe the interior of the canister and hose clean (a lit tle dirt left here will be sucked into the engine and reduce engine life). When the filter is reinstalled, make sure the

element is held tight and straight

in the canister for proper seating and sealing.

● Periodically check the air intake hose for cuts, nicks, etc., and the hose clamps for tightness.

Oil

● Use only multi-viscosity oils as specified with the viscosity matching ambient temperatures for the 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 incor ­ rect pressure relief valve for proper lubrication.

39

Maintenance Instructions

LUBRICATION

WARNING

DO NOT attempt to lubricate the machine with the engine running. Disengage the

PTO clutch, shut off the machine, and remove the ignition key.

Proper lubrication is an important maintenance procedure. It reduces wear and makes the machine quieter and easier to operate.

Engine Oil

Engine Break-In Oil

No special break-in oil is required. The engine is ser viced with 10W-30, Service Class SJ oil from the factory. Change the oil after the initial engine

breakin period

of

5 hours.

Thereafter, change oil

after every 100 hours

of operation.

Checking Engine Crankcase Oil Level

Check the engine crankcase oil level before use and

after each 8 hours

of continuous operation.

IMPORTANT:

The importance of checking and maintaining the proper crankcase oil level cannot be overemphasized. Check the oil level

BEFORE

EACH USE.

1. Park the mower on a

level surface with the engine stopped.

Also, make sure the engine is cool and oil has had time to drain into the sump

[allow

at least five (5) minutes

after stopping the engine].

IMPORTANT: NEVER

check or add oil with the engine running.

2. Before removing the dipstick, clean the area around the dipstick to keep any dirt or debris out of the engine.

3. Remove the dipstick, wipe off with a clean rag, then reinsert the dipstick into the tube and hold all the way down. For correct oil level measure ­ ment, do not turn cap on threads.

LUBRICATION

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).

IMPORTANT: DO NOT

operate engine without a sufficient oil supply in the crankcase.

DO NOT

operate with the oil level below the “L” mark or above the “F” mark on the dipstick.

5. If additional oil is needed, refer to

Specifications

for proper crankcase lubricant.

Fill up to, but not above, the “F” mark on the dipstick.

IMPORTANT: DO NOT

overfill the crankcase

(oil above “F” mark) as this

CAN

result in en ­ gine overheating, loss of power, and possible en gine damage.

Full Mark

Operating

Range

Low Mark

Dipstick Operating Range

40

Maintenance Instructions

Changing Engine Crankcase Oil/Oil Filter

Change the engine crankcase oil

after every 100 hours

of operation and replace the oil filter every other oil change (

every 200 hours

of operation).

1. Park the mower on a

level surface with the en gine stopped.

The engine oil should be warm before draining. If not warm from opera ­ tion, start the engine and run a few minutes to warm the oil.

2. Before removing the dipstick, clean the area around the dipstick to keep any dirt or debris out of the en gine.

3. Remove the dipstick and open oil drain valve and drain the oil into a suitable container. Be sure to allow ample time for complete drainage.

Oil Dipstick/

Oil Fill

Oil Dipstick/Oil Fill Location

(View from Above Left Side of Tractor)

Oil Drain

LUBRICATION

Oil Filter

Oil Filter Location

(View from the Rear Right Side of Tractor)

4. Before removing the oil filter, clean the area around the filter to keep dirt and debris out of the engine.

5. Remove the old oil filter and wipe off the filter mounting surface on the engine.

6. Apply a thin coating of clean oil to the rubber gasket on the replacement oil filter.

IMPORTANT:

Use

ONLY

oil filters from the engine manufacturer (Kohler 12-050-01). Aftermarket oil filters may not seal properly and/or may not have the correct pressure relief valve for proper lubrication.

7. Install the new oil filter on the engine. Turn the filter clockwise until the rubber gasket contacts the sealing surface, then tighten an additional

3/4 to 1 turn.

8. Close the oil drain valve and tighten until snug .

Do not overtighten.

9. Fill the crankcase with new, clean oil. Use only crankcase lubricants recommended by the engine manufacturer. Refer to

Specifications

in this manual or the engine owner’s manual. Use the recommended oil viscosity for the expected ambient temperature. Oil with the correct viscosity will aid starting in cold weather and assure proper lubrication in hot weather.

Fill up to, but not above, the “F” mark

on the dipstick.

Crankcase capacity is 1.8 quarts (1.7 liters) plus

1/2 pint (0.24 liters) for the new oil filter.

Oil Drain Location

(View from the Rear of Tractor)

41

Maintenance Instructions

IMPORTANT:

Check the dipstick reading before adding the last 1/2 pint of oil and

fill only to the “F” mark.

DO NOT

overfill the crankcase

(oil above “F” mark) as this

CAN

result in engine overheating, loss of power, and possible engine damage.

10. Start the engine and check for oil leaks around the oil filter. Stop the engine, recheck the oil level, and add oil if necessary. (When the en ­ gine is first operated with a new oil filter, the oil level will drop slightly as the filter is filled with oil.)

LUBRICATION

Grease Fitting and Oil Point Lubrication

Lubricate the grease fittings and oil points

after every 25 hours

of operation. Lubricate

more often

when operating in

dusty or dirty conditions.

Use

SAE general purpose lithium or molybdenum base grease for grease fittings and light machine oil

(SAE 10) to lubricate oil points.

Lubricate the locations shown in the Chassis and Deck

Lubrication Points illustration.

NOTE:

PTO universal joints (on the deck and tractor) require routine lubrication

after every 25 hours

of running time. Remove tractor PTO quick disconnect tube assembly for easy access to grease fittings.

NOTE:

The best way to lubricate the PTO tube half of the universal joint assembly is to remove it from the tractor. See instructions for removing and installing PTO quick coupler, refer to

Deck Installation

in

Mower Deck Installation on Tractor

in the

Assem­ bly Instructions.

NOTE:

The ball bearings on the PTO drive shaft are sealed and do not require periodic maintenance.

42

Maintenance Instructions

Mower Deck Gearbox Lubrication

NOTE:

These instructions apply to all mower decks with gear-driven blades. Refer to

DS52 Mower

Deck Lubrication

in this section for the DS52 deck with belt-driven blades. Refer to

Mower

Deck Spindle Lubrication

in this section for mower decks with belt-driven blades.

On gear driven decks, the mower deck gearboxes

(tee gearbox and blade drive gearboxes) are con ­ nected as a unitized assembly, and oil flows freely between them. The gearboxes are permanently lu ­ bricated (oil filled) and sealed requiring no sched ­ uled lubrication. However, the gearbox oil seals should be checked

every 25 hours

for indication of an oil leak;

particularly the lower seals

on the blade drive gearboxes should be inspected, since they operate in a dirty environment. If an oil leak is noted, replace the oil seal and relubricate the gear ­ box assembly as follows:

1. Remove gearbox cover (footrest). Deck orien ­ tation should be the normal operating position.

Blade Drive

Gearboxes

LUBRICATION

NOTE:

In case the gearboxes are completely drained of oil, approximately 5 fl. oz. (15 cl) of oil per gearbox is required to refill the gear drive assembly.

NOTE:

Since the gearboxes are connected as a unit by connector tubes, it is necessary to add oil slowly. Allow a few minutes after adding oil for the oil to flow throughout the assembly and the oil level to stabilize before reassembly.

IMPORTANT: DO NOT

overfill the deck gearboxes. The gearbox assembly is not vented, and overfilling with oil will cause excessive pressure and result in oil leaks.

5. Check condition of the cover gasket and replace if worn or damaged. Reinstall gearbox cover plates; torque screws to 24 lb

· in.

(3 N

· m).

Mower Deck Spindle Lubrication

For mower decks with belt-driven blades, lubricate each deck spindle grease fitting

every 25 hours.

Use SAE general purpose lithium or molybdenum base grease for grease fittings.

Tee

Gearbox

Mower Deck Gearboxes

(Shown with Gearbox Cover

Removed for Clarity)

2. Clean the area around the individual gearbox cover plates to prevent contaminants from entering the gearcase.

3. Remove the screws securing the cover plates on the blade drive gearboxes.

4. Check the level of lubricant in the gearboxes. If the lubricant is low, add SAE E.P. (Extreme

Pressure) 80W-90 (API GL-5) gear lube until the oil level is up to (submerges) the horizontal shaft in the gearbox (shaft parallel to cover plate).

43

Maintenance Instructions

Ident

No. Location

Lubrication No.

Type Places

1 Deck Caster Wheel Fork Pivot Grease

2 Deck Caster Wheel Bearing

3 Blade Spindle

4

5

6

Pivot Assembly, Tilt-Up Deck

Deck Support Arm Socket

Right Angle Gearbox

Grease

Grease

Grease

Grease

Oil

*

Δ

Δ

Δ

)

8 Dolly Wheel Retract

Lever and Linkage

9 Dolly Wheel Pivot

10 Idler Arm Pivot

11 Tee Gearbox, Deck

12 Blade Drive Gearbox

13

14

Steering Lever Pivot

Deck-to-PTO Coupling

(Grease Spline Slide Area)

Grease

15 Universal Joint Tube Assembly Grease

**

1

2

1

2

1

16 Deck Support Arm Pivot Grease

17 Universal Joint Quick Connect Grease

Spline (Grease Slide Area)

18 FSC Lever Pivot

19

20

21

22

23

Body Latch Pivot

Clutch Actuator Push Rod

Ground Drive Idler Pivot

PTO Clutch Lever Pivot

Transaxle Oil Reservoir

Grease

Oil

Grease

Grease

Grease 1

Oil/20W-50 1

1

1

1

1

2

2

3

Oil

Δ

Grease

Grease

Δ

1

Δ

1

Oil

*

1

Oil

*

2

Grease

4

2

1

7 Universal Joint Shaft Assembly Grease

**

1(2

1

2 1

10

3

1

LUBRICATION

Ident

No. Location

Lubrication

Type

No.

Places

24 Tail Wheel Caster Fork Pivot

25 Rear Axle Pivot

26 Engine Dipstick / Oil Fill

27 Throttle Control Cable Ends

28 Choke Control Cable Ends

29 Brake Band Pivot Pins

30 PTO Belt Tightener Pivot

31 Parking Brake Clevis

32 Parking Brake Lever

33 Choke Control Pivot

34 Throttle Control Pivot

Grease

Grease

Oil

***

1

Oil

2

1

Oil

Oil

Grease

Oil

Grease

Oil

Oil

1

1

2

1

2

1

2

2

*

Gearboxes are permanently lubricated and sealed requiring no scheduled lubrication. Oil level should be checked only when an oil leak is noted. Refer to

Mower Deck Gearbox Lubrication

in this section.

**

Grease every twenty-five (25) hours.

***

Refer to

Engine Oil

located on page 40.

Δ

Belt Driven Decks Only

NOTE:

DS42 and DS52 Tilt-Up Decks are shown for reference.

For other Deck Lubrication Points,

Refer to Deck and

Carrier Frame Illustrated Parts Manual.

2

3

3

44

4 5 9 8 7 6 5 4

Lubrication Points for Optional Belt Driven Decks (DS52 Shown)

Maintenance Instructions

12

2

1

2

1

20

29

28

27

26

24

30

27 & 34

16

28 & 33

31

32

31

5

4

4

Chassis and Deck Lubrication Points (DS42 Shown)

24

25

18

19

20

21

22

23

45

LUBRICATION

13

14

15

16

17

5

4

4

7

11

12

Maintenance Instructions

DS52 Mower Deck Lubrication

There are several special lubrication requirements for the DS52 mower deck in addition to the requirements detailed in the

Chassis and Deck Lubrication Points

illustration. Lubricate the locations shown in the

Gearbox, Dol ly Wheel, and U-Joint

Lubrication

photo and check and maintain oil in the belt drive gearbox.

1. Check the oil level in the belt drive gearbox

every 100 hours

(or sooner if a visible oil leak has developed). With the deck in the normal operating position, remove the level plug in the side of the gearcase. Add SAE E.P. (Extreme Pressure) 80W-90 (API GL-5) gear lube to maintain the oil level to the plug. If the oil level is low, check the gear box for any indication of an oil leak. If an oil leak is noted, the gearbox will need to be removed and rebuilt.

2. Lubricate the dolly wheel pivot

every 25 hours

with general purpose grease.

3. Lubricate both drive shaft u-joints

every 25 hours

with SAE general purpose lithium or molybdenum base grease.

Belt Drive

Gearbox

LUBRICATION

Reservoir Cap

Hot Level

Cold Level

Hose to

Transaxles

Expansion Reservoir Location

Transaxle Oil and Filter Change

Change the transaxle oil after the initial

break-in period

of

75-100 hours.

Thereafter, change oil

every 400 hours

of operation as follows:

1. Thoroughly clean the exterior of the transaxle housing before servicing. Remove expansion reservoir cap to allow venting. Using a 1/4 in. hex wrench, remove the plug on the lower in ­ side of each transaxle allowing the oil to drain.

2. Remove the oil filter guard, remove and replace the oil filter using an oil filter wrench. Tighten filter by turning filter 3/4 to 1 turn after gasket contacts the filter base surface. Reinstall the oil filter guard. (Refer to

Transaxle Oil Drain

Plug, Filter, and Guard Location

illustration.)

Oil Filter

46

Dolly Wheel

Pivot

U-Joints

Gearbox, Dolly Wheel, and U-Joint Lubrication

Check Transaxle Fluid Level

● The transaxle oil lubrication is SAE 20W-50 (API

Service Class SL or higher) engine oil.

● Inspect both transaxle cases and hoses

after every 25 hours

of operation for visible leaks.

● The fluid level of the transaxles can be checked visually by looking at the fluid level in the expan ­ sion reservoir. When the transaxles are cold, the fluid level in the expansion reservoir should be between 1/4 in. and 1/2 in. (0.64 cm and 1.27 cm).

Oil Filter

Guard

Oil Drain

Plug

Transaxle Oil Drain Plug, Filter, and

Guard Location

3. Reinstall drain plugs.

Maintenance Instructions

4. Remove the oil reservoir hose attached to the elbow on top of the transaxles. Remove the elbows to access the oil fill opening.

5. Fill the transaxles with 20W-50 (API Service

Class SL or higher) oil through the opening

(where the elbows were). Fill up to the opening.

6. Before reinstalling the elbows, screw the lock ­ ing nut on the elbows down until they are snug

(the o-ring on the elbow will be to the bottom of the o-ring groove).

Elbow

Screw Locking

Nut Down

LUBRICATION/CLEANING

CLEANING

CAUTION

If a pressure washer is used on the exposed working parts, avoid water on the electrical parts and the engine cooling system.

Engine Air Cooling System

Cooling Air Intake Screen

To prevent engine overheating and possible engine damage, clean grass clippings, chaff, and dirt from the rotating engine cooling air intake screen

after every 8 hours of operation.

In certain mowing conditions (dry grass, leaves, tree “cotton”, etc.) it may be necessary to check and clean the screen several times each day to prevent engine overheat ­ ing. Also, visually check inside cylinder head shroud and between cylinder head fins for material packed in this area which would prevent cooling airflow; remove shroud and clean as required.

Reinstall Transaxle Elbows

7. Reinstall the elbows. When the elbow begins to be snug, position the elbow as it was when re ­ moved and tighten the locknut. Reinstall reser ­ voir hoses to elbows.

8. Fill reservoir to 1/4-1/2 in. (6-13 mm) with

20W-50 (API Service Class SL or higher) oil.

9. Start and drive the unit for 1-2 minutes.

10. If the transaxles sound noisy or have poor steer ­ ing response, there may be air trapped in the transaxles. Follow purge instructions below.

11. If oil needs to be added, refer back to steps

4-10.

12. To purge air from transaxle, raise tractor and block with tires off the ground. With engine run ­ ning, slowly move Forward Speed Control for ­ ward and backward 5 to 6 times. Turn off en ­ gine and check oil level and add if needed.

Repeat procedure until transaxles operate at normal noise levels and move smoothly in for ­ ward and reverse.

Rotating Engine Cooling

Air Intake Screen

Keep Rotating Engine Cooling

Air Intake Screen Clean

47

Maintenance Instructions

CLEANING

CAUTION

Operating the engine with a blocked air intake screen, dirty or plugged cooling fins, and/or cooling shrouds removed will cause engine damage from overheating.

Cylinder Head Cooling Fins

It is essential for performance and longevity of the air-cooled engine to keep the cylinder head cooling fins clean and free of obstruction. After

every 8 hours

of operation, check the performance of the cooling system by starting the engine, holding a hand adjacent to the cylinder head, and feeling the cooling airflow. If there is little or no airflow, clean the cooling fins as follows:

DANGER

Make sure to keep hands clear of exhaust pipe, muffler, and moving parts when checking airflow.

Check Airflow with Hand

CAUTION

DO NOT use a pressure washer to clean the cooling system on an air-cooled engine, mud may form under the cooling shroud on the cylinder head and cooling fan.

NOTE:

If dirt is packed into the cooling fins it may be necessary to remove the engine shroud in order to thoroughly clean the cooling fins.

IMPORTANT:

Yearly, it is good maintenance prac ­ tice to remove the engine cooling shroud and clean the cylinder head cooling fins and cooling fan thor ­ oughly to prevent overheating and extend engine life. Make sure cooling shroud is reinstalled prop ­ erly. This procedure will require removing the en ­ gine from the chassis.

Engine Cooling

Fin Access Panels

Rotating

Engine Cooling

Air Intake

Screen

Kohler Engine

Shroud

Engine Cooling Air Intake Screen and Cooling Fin Access Panels

Check Cooling System Airflow

Every 100 hours,

inspect and clean the cooling fins

(more often when operating in extremely dusty, dirty conditions). Remove the two (2) cooling fin access panels in the engine shroud and clean the cooling fins and external surfaces using compressed air.

Make sure to reinstall the access panels before oper ating the engine.

48

Maintenance Instructions

Engine Air Cleaner System

Cummins/Fleetguard OptiAir™ Air Cleaner

A remote mounted Cummins/Fleetguard OptiAir™ air cleaner provides the air filtering function. The paper filter element slides over an outlet tube in ­ side the air cleaner canister with

radial

sealing action, reducing the possibility of dust leaks due to improper filter installation. Intake design, inter ­ nal baffling, and a dust ejection valve provide dust separation and automatic precleaning action.

Daily or frequent servicing of the air cleaner

is not required.

Use the air filter restriction gauge con ­ nected to the air cleaner outlet to indicate when the air filter needs servicing–a yellow indicator will show when the filter is overly restricting airflow into the engine.

IMPORTANT:

Use

only

Cummins/Fleetguard air filter elements for replacement (Walker 2090-1 and

2090-3). Aftermarket filters may not seal properly or filter efficiently.

Cover

Primary

Filter Element

CLEANING

Dust Ejection

Valve

Canister

Air Cleaner Components

(Shown with Cover Being Removed)

IMPORTANT:

The Cummins/Fleetguard air cleaner uses a dry paper-type air filter element.

NEVER

apply oil to the paper element.

Mounting

Band

Cummins/Fleetguard

Air Cleaner

Primary Filter

Element

Safety

Filter

Hose

Clamps

Cummins/Fleetguard

Air Cleaner Cover

Dust Ejection

Valve

Engine

Air Filter

Restriction Gauge

Flex

Hose

Engine Air Cleaner System Components

860 0-1

49

Maintenance Instructions

Air Filter

Restriction Gauge

Push Button to Reset

Indicator After Service

Air Filter Restriction Gauge Location

Inspect the paper element

after every 100 hours

of service and

replace

the element and safety filter

every 400 hours

(or when dirty or damaged). More frequent replacement may be required when operat ­ ing in extremely dusty conditions as indicated by the air filter restriction gauge. Service the air cleaner as follows:

1. Lift Mono Latch Twist Lock™ and twist the

OptiAir™ cover to the left into the “open” posi ­ tion to remove the air cleaner cover. Wash the cover and dust ejection valve. Check that these components are in good condition. The dust ejection valve is subject to wear and deteriora ­ tion and should be inspected carefully and re ­ placed

every two (2) years

or when damaged.

The lips of the valve should close and fit togeth ­ er; any cracks, deformation, or wear in the valve is cause for replacement.

2. Remove the filter element by pulling it out of the canister. There will be some initial resistance as the filter seal breaks loose and slides off of the outlet tube.

Gently

move the end of the filter up and down and side to side or twist to loosen the seal. Use gentle action to minimize the amount of dust dislodged as the filter is re ­ moved.

3. Discard the filter element if excessive air flow restriction has been indicated by the air filter restriction gauge and proceed to Step 6. Clean the filter element by

gently tapping

on a

flat, hard surface.

If excessive restriction still exists after cleaning the element, it should be re ­ placed .

CLEANING

NOTE:

Use care when cleaning the filter ele ­ ment. The filter element and/or seal surface may be damaged by tapping too hard or hitting on an uneven surface or sharp edge. Washing the element in water or cleaning solution is

not recommended.

Do not try to clean the element with compressed air. Remember, replacing a filter is less expensive than replacing a dusted engine.

4. Use a bright light inside the element to inspect for damage. Check the element very carefully for

pin holes or other damage

that will allow dirt to leak through the paper media. Replace filter element if necessary.

5. Check the condition and resilience of the radial sealing surface (inside of the open end) of the filter. Replace the filter if any cracks, tears, or other damage to the sealing surface are noted.

6. Without removing, visually inspect the condition of the safety filter for damage or holes. The safety filter should only be removed for replace ­ ment

every 400 hours

(or when dirty or dam ­ aged).

IMPORTANT:

Prior to removing the safety filter, make sure the inside surface of the air cleaner canister is clean. This will minimize the risk of dirt entering the outlet tube which can cause premature engine wear.

7. After removing the safety filter, use a clean, damp cloth and wipe the interior of the air clean ­ er canister clean. Use special care to clean

both the inside and outside

surfaces of the outlet tube.

IMPORTANT:

Any dust left on the inside of the outlet tube will go into the engine and cause wear.

8. Check the outside surface of the outlet tube for smoothness and cleanness (this is the sealing surface).

9. Insert and seat the safety filter and OptiAir™ el ement carefully into the canister, applying pres sure 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 lubricants on the sealing surfaces of the filter; use tal cum powder or dry silicone lubricants if re ­ quired for filter installation.

50

Maintenance Instructions

Safety Filter

Canister

Outlet Tube

Radial Sealing

Surface

OptiAir™

Filter Element

Air Filter Element Replacement

10. Install the cover with the word “DOWN” prop ­ erly oriented to the bottom of the canister. Twist the OptiAir™ cover to the right and put into the

“closed” position.

Mono Latch

Twist Lock™

2 3

CLEANING

Grass Buildup in Mower Deck Housing

DANGER

Before raising or removing the mower deck for cleaning, stop the engine, remove the ignition key, and disconnect the spark plug wires.

1.

Raise

the deck lock lever handle on each side of the carrier frame

and pull out

to release carrier frame for tilting action.

2. Using the carrier frame lift handle, raise deck to the

TILT-UP

position and insert the deck hook into the tilt-up latch on the tractor body.

Tilt-Up Handle

Tilt-Up Hook and

Latch Connected

Tilt-Up

Latch

DOWN

Deck Lock

Lever

Tilt-Up

Hook

Orient to Bottom of Canister

Dust Ejection

Valve

Proper Orientation of Air Cleaner Cover

11. Check the air intake hose for cuts, nicks, cracks, etc., and the hose clamps for tightness.

12. Reset the air filter restriction gauge (press but ­ ton on the end of the indicator).

Deck Secured in TILT-UP Position

DANGER

Do not operate the mower with deck in tiltup position. Do not move the tractor with the deck in the tilt-up position.

51

Maintenance Instructions

3. Clean grass buildup underneath the deck using a pressure washer (and scraper if required).

NOTE:

If the buildup is severe, it may be easi ­ er to clean the deck by removing the deck as ­ sembly from the tractor and standing the deck assembly on its “nose”.

NOTE:

While some degree of material buildup in the mower deck housing can be tolerated, a point is finally reached

where cutting quality deteriorates and clogging begins to occur

because of too much buildup on the baffling and housing.

4. Lower the deck to the normal operating position and re-engage the deck lock levers.

CAUTION

Do not operate machine with deck tilt-up pivot joint unlocked.

CLEANING

Transaxle Housing

Keeping the housing on the transaxles clean and free of obstruction is

essential to avoid overheating

the transaxle fluid and short ening transaxle life.

The housing should be checked

every 100 hours

and cleaned if neces sary.

To clean the housing, use compressed air and/or a pressure washer . Pay close attention to any oily dirt build up on the transaxle housings. This may be the result of an oil leak. If an oil leak is noticed, contact your local Walker dealer.

Cooling

Fins

Transaxle Housing and Cooling Fins

IMPORTANT:

In case an oil leak develops on the input shaft, the cooling fan blowing dusty air and oil on the transaxle will

quickly

cover the housing and pack the cooling fins with

oily dirt.

If this condition occurs, contact your dealer immediately to avoid overheating and dam aging the transaxle.

An additional procedure in maintaining transaxle cooling is to inspect the cooling fans. Replace the fan(s) if blades are missing or damaged.

Cooling

Fans

Transaxle Cooling Fans

52

Maintenance Instructions

CHECKING/SERVICING

DANGER

To prevent accidental starting of the engine when servicing or adjusting the machine, remove the key from the ignition switch and disconnect the spark plug wires.

Security of Air Filtration Components

NOTE:

The following inspection is

only an exter nal inspection

and should be done without

“disturbing”

the filtration components.

On a daily basis, visually inspect the external condition of the complete air cleaner system. The follow ­ ing items should be inspected:

1. Check the Cummins/Fleetguard OptiAir™ air cleaner canister for damage. Make sure the cover is in place and the cover latch is secure— do not run the engine without the air cleaner cover in place and secure.

2. Inspect the air intake hose for cracks, nicks, cuts, etc., and check the hose clamps for tight ­ ness.

3. Check to make sure the air filter restriction gauge is in place and hose connections are se ­ cure.

Battery

NOTE:

For initial battery service during setup, re fer to

Battery Service

in

Assembly Instructions .

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 dam age to the machine. A hazard may be created by damage to critical working parts and safety sys ­ tems.

NOTE:

Checking electrolyte level is not required if equipped with a sealed, maintenance-free battery.

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.

CHECKING/SERVICING

2. Check the electrolyte level. If the level is below the bottom of the vent well, fill with distilled wa ­ ter to the bottom of the vent wells [1/4 to 1/2 in.

(6 to 13 mm) above the plates].

3. Replace filler caps.

IMPORTANT: DO NOT

overfill the battery. Electro ­ lyte will overflow through the vented caps onto parts of the machine and

WILL

result in severe corrosion.

Cleaning the Terminals

If battery terminals are corroded,

remove battery

from the mower. Using a wire brush, remove corrosion with a solution of

one part baking soda and four parts water.

Rinse with clean water. Coat the terminals with petroleum jelly or terminal protector spray to retard further corrosion.

Charging the Battery

DANGER

BATTERIES PRODUCE EXPLOSIVE GASES

Charge the battery in a well-ventilated area, so that gases produced while charg ing can dissipate.

Keep sparks, flames, and smoking materials away from the battery at all times.

Make sure the battery cap vents are open (check manifold vent on each cap).

Make sure the battery charger is unplugged before connecting or disconnecting cables to the battery.

Check the battery charge by measuring the specific gravity of electrolyte; if specific gravity is less than

1.225, the battery will need to be charged as follows:

1. Charge the battery at 15 amps for 10 minutes.

DO NOT

exceed 20 amps maximum recommended charging rate. Charge until specific gravity is at least 1.250. Total charging time should not exceed one (1) hour.

2. After charging the battery, 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].

53

Maintenance Instructions

Tire Pressure

Inflate tires to pressures shown below:

Deck Caster Wheel* = 20 PSI (137 kPa)

Drive

Tailwheel

= 15 PSI (103 kPa)

= 20 PSI (137 kPa)

* If equipped with optional pneumatic tires

Wheel Nut Torque

Check the eight (8) nuts that mount the drive tires.

Every 100 hours

they should be torqued to 75 to 85 lb

· ft (102 to 115 N

· m).

Sharpen Mower Blades

Check mower blade(s) for

straightness, sharpness, condition of the cutting edge,

and

balance every 10 hours

of operation (or more often when mowing abrasive type grass or operating on sandy soils).

Replace blades if worn, bent, cracked, or otherwise damaged

(refer to

REPLACING/RE-

PAIRING

the

Mower Blades

in this section). Use the following procedure to check and sharpen blades:

NOTE: Keep blades sharp

—cutting with dull blades not only yields a poor mowing job but slows the cutting speed of the mower and causes extra wear on the engine and blade drive by pulling hard.

1. Stop the engine, remove ignition key, and disconnect the spark plug wires

before

raising the mower deck to service blades.

2. Raise the deck and

secure

it in the

TILT-UP

position. Refer to

CLEANING

the

Grass Buildup in Mower Deck Housing

in this section for deck raising instructions.

DANGER

NEVER operate cutter blades with the deck in the raised position.

NOTE:

PTO shaft must be

disconnected

before checking blades for straightness.

3. Check the blades for

straightness

by marking the blade tip position inside the deck housing, and then rotating the opposite end of the blade to the same position and comparing. If the difference in blade tip track is

more than 1/8 in.

(3 mm),

the blade is bent and

should be replaced.

54

CHECKING/SERVICING

WARNING

DO NOT try to straighten a blade that is bent. NEVER weld a broken or cracked blade. ALWAYS replace with a new blade to assure safety.

4. If the blade cutting edge is

dull or nicked,

it should be sharpened. Remove blades for sharpening by grasping the end of the blade us ­ ing a rag or a thick, padded glove, while loosen ­ ing and removing the nut, lock washer, and flat washer that mounts the blade.

5. Grind cutting edge at the same bevel as the original. Sharpen only the top of the cutting edge to maintain sharpness.

NOTE:

Blades can be sharpened with an elec ­ tric blade sharpener, conventional electric grind ­ er, or a hand file.

CAUTION

ALWAYS wear eye protection and gloves when sharpening a blade.

Sharpen at

Original 30° Angle

Intersection

Wear Area

30°

Wing

Tip

Do Not Grind or

Sharpen on Underside

Mower Blade Profile for Sharpening

6. Check blade balance by positioning the blade

horizontally

on a blade balancer or use a nail or shaft through the center hole. If either end of the blade rotates downward, grind (remove) metal on that end until the blade will balance.

The blade is properly balanced when neither end drops. Balance of a blade is generally maintained by removing an equal amount of material from each end of the blade when sharpening.

Maintenance Instructions

Blade Balancer

Blade Balanced on Magnetic

Wall-Mounted Balancer

7. Mount the blade with wing tips pointing up into the housing. For

gear driven decks

reinstall the blade, washer, lock washer, and nut.

Tighten the nut to 60 lb·ft (81 N·m).

For

belt driven decks

reinstall the spacer (if applicable), blade, washer, and bolt.

Tighten the bolt to 70 lb·ft

(95 N·m).

Drive Belts

Raise the body and inspect the condition of the three (3) drive belts after

every 25 hours

of opera­ tion—engine/PTO drive and ground drive. If the belts show

signs of cracking or deteriorating,

the belts should be

replaced.

Refer to

REPLACING/

REPAIRING

the

Drive Belts

in this section.

Mower Deck Gearbox Oil Seals

The mower deck gearbox seals should be inspected

every 25 hours

for evidence of oil leaking;

particularly the lower oil seal on the blade drive gearbox.

This seal is protected by the trash guard on the blade hub and seal protector plate on the housing, but is still vulnerable to seal damage due to operat ­ ing in an adverse environment. The mower blade must be removed for inspection of the seal, so it is recommended to

inspect the gearbox seals when blades are removed for sharpening.

If an oil leak is noted, the seal should be replaced and the gear ­ box assembly relubricated. Refer to

LUBRICATION

for

Mower Deck Gearbox Lubrication

in this sec ­ tion.

CHECKING/SERVICING

Spark Plugs

Every 200 hours

of operation, remove the spark plugs, inspect, clean, and reset the gap (or replace with

new plugs

). Before removing the spark plugs, clean the area around the base of the plugs to keep dirt and debris out of the engine. Clean spark plugs with a wire brush. DO NOT use an abrasive grit type cleaner. If the electrodes are burned short or pitted, replace plugs with Champion

®

type RC12YC

(or equivalent). Check spark plug gap with a wiretype feeler gauge and set the gap at 0.030 in.

(0.76 mm). Reinstall and tighten to between 18 and

22 lb·ft (24 to 30 N·m).

Ignition Wires

Good preventive maintenance calls for complete

replacement

of spark plug wires

every two (2) years.

Fuel Lines and Clamps

Every year,

inspect the fuel supply line from the tank to engine for deterioration or damage. Also, inspect the fuel line

clamps for tightness.

Good preventive maintenance calls for complete

replacement

of fuel lines and clamps

every two (2) years.

Blade Brake Action

WARNING

It is important to check and maintain blade brake action for safe operation of the machine.

Check the function of the cutter blade brake by en ­ gaging the blade clutch (PTO), operating the engine at full throttle, then disengaging the clutch and mea ­ suring how quickly the blades stop. Watch the rota ­ tion of the blade drive shaft as a visual indication that movement has stopped. If the brake is

working properly, all rotation will stop five (5) seconds after disengagement

of the clutch. If the brake sys ­ tem malfunctions - blades do not stop in five (5) sec ­ onds - adjust or repair the brake before operating the mower. Refer to

ADJUSTMENTS

for

Clutch

Disengagement/Brake Action,

Step 2 -

Blade Brake

Band Adjustment,

on page 69.

55

Maintenance Instructions

PTO U-Joints

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.

Engine Starter

Yearly or every 500 hours

disassemble and clean the solenoid shift starter. Refer to the Kohler Service

Manual for this procedure or contact an authorized

Kohler engine dealer to perform this service.

Safety Switch System

WARNING

It is important to check and maintain the safety switch system for safe operation of the machine.

There are four (4) safety interlock switches on the tractor; Seat Switch, FSC Neutral-Park Switch, PTO

Switch, and Parking Brake Switch.

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

engine starts

with the Forward Speed Control

(FSC) and/or the PTO engaged, or the parking brake disengaged.

● With an operator in the seat and the parking brake engaged,

the engine starts but dies

soon after the parking brake is disengaged and the

Forward Speed Control (FSC) or PTO is en ­ gaged.

Without

an operator in the seat, the engine starts and

continues to run

with the Forward

Speed Control (FSC) and/or PTO engaged, or the parking brake disengaged.

● With an operator in the seat, the Forward Speed

Control (FSC) and PTO disengaged, the parking brake engaged, but the

starter will not engage.

CHECKING/SERVICING

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.

If the FSC friction lock needs to be adjusted, refer to

ADJUSTMENTS

for

Step 7 -

Forward Speed Control Friction Adjustment

in this section .

Transmission Control Setting

On a

yearly

interval or when an out-of-adjustment condition is observed, check the transmission 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 Adjust- ment - Step 5

in this section.

56

Maintenance Instructions

REPLACING/REPAIRING

DANGER

To prevent accidental starting of the engine when replacing parts or repairing the machine, remove the key from the ignition switch and disconnect the spark plug wires.

IMPORTANT: ALWAYS

use genuine factory re ­ placement parts. Substitute parts

CAN

result in product malfunction and possible injury to the op ­ erator and/or others.

REPLACING/REPAIRING

Drive Belts

There are

three (3) individual belts

on the ma ­ chine:

● Engine/PTO Belt (Matched Set of 2)

● Ground Drive Belt

The belts may be removed and replaced using the

procedures described on the following pages.

Ground

Drive Belt

Engine/PTO Belts

(Matched Set of 2)

Belt Locations

57

Maintenance Instructions

REPLACING/REPAIRING

Engine/PTO Belt

1. To remove the engine/PTO belt: a. Remove Upper LH Belt Guard and RH Belt

Guard by removing two (2) wing nuts.

Upper LH

Guard

Fixed Idler

Pulley

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(s) and remove the belt.

Clutch Idler Pulley

Lower LH

Guard

Wire Lock Pins

Right Hand

Guard

58

Engine/PTO Belt

(Matched Set)

PTO

Pulley

PTO Guard

Engine/PTO Belt (Belt Guards Open) (Engine Hidden for Clarity)

2. To replace the engine/PTO belt:

Wing Nut a. Reverse the removal procedure to replace the 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

Front View

Secure

Wing Nut

Secure Wire Above Tab

PTO Guard

Engine/PTO Belt (Belt Guards Closed) (Engine Hidden for Clarity)

Maintenance Instructions

REPLACING/REPAIRING

Ground Drive Belt

1. To remove the ground drive belt: a. Depress the spring-loaded idler pulley to relax belt.

LH Transaxle

Ground Drive

Belt b. Slide belt off pulleys, then release the idler pulley.

RH Transaxle

Drive Pulley

Depress Idler Pulley to

Relax Belt

Belt Tightener

Idler Pulley

Ground Drive Belt Assembly (Disengaged)

2. Reverse the procedure to install the ground drive belt.

LH Transaxle

Ground Drive

Belt

RH Transaxle

Drive Pulley Belt Tightener

Idler Pulley

Ground Drive Belt Assembly (Engaged)

59

Maintenance Instructions

Fuel Filter

DANGER

Gasoline is extremely flammable and can be highly explosive. To minimize danger:

Before servicing the fuel system:

1) Disconnect the spark plug leads.

2) Disconnect the negative (-) battery cable from battery.

Use only an approved fuel container for gasoline.

DO NOT allow open flames or sparks near the machine while performing maintenance or refueling; DO NOT smoke while working with fuel.

Wipe up spilled gasoline immediately and completely.

Model B19 is equipped with a 10 micron in-line fuel filter between the fuel tank and the fuel pump. Re ­ placement of this filter is recommended

every 400 hours

of operation or when contamination is sus ­ pected or found in the fuel.

In­Line

Fuel Filter

REPLACING/REPAIRING

2. Replace filter, making sure that the arrow on the filter is aligned with the fuel flow through the filter.

3. Verify that the fuel lines and clamps are securely attached, and that no fuel leaks are present.

Blade Overload Shear Bolts

NOTE:

Blade shear bolts are not used on belt driv ­ en decks.

On gear driven decks, each cutting blade is keyed to the blade hub by

two (2) shear bolts

(10-24 x

5/8 in. stainless steel machine screws). These bolts are designed to shear and protect the blade drive gearbox from damage if the blade encounters a shock load.

Cutting Blade

Shear Bolts

Fuel Filter Location

IMPORTANT:

Replace the fuel filter only in a clean area where the fuel line and connections will not be contaminated by dust and dirt.

1. Expand and slide clamps on either side of the filter away from filter and pull fuel lines off filter.

Cutting Blade Shear Bolts

NOTE:

Tightening the

5/8-18 blade mounting nut to 60 lb·ft (81 N·m)

is also important for proper shock load protection. It is important to

not overtighten

the mounting nut since this defeats (over ­ rides) the function of the shear bolts.

If these bolts shear, remove the blade and install new bolts. Refer to

CHECKING/SERVICING

in this section for

Sharpen Mower Blades

which de ­ scribes the blade removal and installation proce ­ dure.

After reinstalling the blade, check blade timing (on gear driven decks) by moving blades through

one

(1) complete revolution.

Make sure blade tips pass clear of each other. If timing is incorrect, con ­ tact your Walker dealer.

60

Maintenance Instructions

REPLACING/REPAIRING

Mower Blades

Mower blades are removed and remounted as de ­ scribed in

Sharpen Mower Blades

instructions (re ­ fer to

CHECKING/SERVICING

in this section). Dur ­ ing the course of sharpening and inspecting mower blades, if there are

any of the following conditions of wear or damage, blades should be replaced

for reasons of safety and performance of the ma ­ chine:

● An excessive amount of the

flat section

of the blade has been

ground away

(removed) when the blade is sharpened. Replace the blade

when less than a 3/4 in. (19 mm) flat section remains

at the blade tip.

● Examine ends of the blade carefully, especially the intersection where the flat section of the blade turns up to form the “wing tip” (refer to

CHECKING/SERVICING

for

Mower Blade

Profile for Sharpening

illustration in

Sharpen

Mower Blades

instructions). Since sand and abrasive material can wear metal away in this area, the blade should be

replaced when metal thickness has worn to 1/16 in. (1.6 mm) or less.

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.

WARNING

DO NOT try to straighten a blade that is bent. NEVER weld a broken or cracked blade. ALWAYS replace with a new blade to assure safety.

Reinstall the blades following procedure from

Sharpen Mower Blades

instructions in

CHECK-

ING/SERVICING

in this section. If blades are re ­ placed, always use

Walker original equipment blades

to ensure safety and optimum performance.

The quality and performance of

replacement blades offered by other manufacturers

cannot be guaranteed, they

could be dangerous.

CAUTION

ALWAYS use genuine factory replacement parts. Substitute parts CAN result in product malfunction and possible injury to the operator.

61

Maintenance Instructions

ADJUSTMENTS

Transmission Control

IMPORTANT:

The proper adjustment of the transmission control stops is

essential

for efficient operation and life of the transaxle. These stops are properly adjusted at the factory and should only require read justment if the transaxle or related control linkage is removed or changed.

NOTE:

It would not be unusual for a new machine, after initial 5 or 10 hours of operation, to begin to not travel straight (this is due to the break-in of the transmissions). To fine tune tracking, refer to

Step 5 -

Straight Tracking Adjustment

in this section.

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 another. If they are not equal, adjust accordingly.

(The handles may or may not be even at this point.)

NOTE:

The

LH steering lever is non-adjust able.

This procedure will require adjustment of the RH le ­ ver to make it even with the LH lever.

Levers should sit parallel to each other

ADJUSTMENTS

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.

Stop

Bolt

Stop Bolt Location

62

Lever Alignment

Maintenance Instructions

Step 2 -

Steering Handle Adjustment

An adjustment range of approximately 3 in. (76 mm) is available on the steering handles–the han dles 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 adjust ­ ment slide. Adjust han dles into most comfortable po ­ sition and tighten both locknuts.

ADJUSTMENTS

Step 3 -

Neutral Function Adjustment

1. With the Forward Speed Control (FSC) in

NEU-

TRAL-PARK,

the lever should be straight up.

Adjust the angle of the FSC lever by removing the ball joint on the lever end of the FSC Rod, loosen the jam nut, adjust the rod length. Once it is the correct length, tighten the jam nut and reinstall the ball joint.

Locknut

(Position)

Adjustment

Slide

Correct FSC Lever NEUTRAL-PARK Position

Locknut

(Pivot Point)

Steering Handle Adjustment

Adjust Length of

Rod to Position

FSC Lever

FSC Lever Position Adjustment

63

Maintenance Instructions

2. Securely block the tractor up so the drive tires are off the ground.

3. Adjust the tracking adjustment nuts at the front of both control rods so that 2 or 3 threads are visible, then loosen the jam nuts on the ball joints at the back of the control rods.

Control Arm

Control Rods

Tracking Adjustment Nuts

Transmission Control Rod and Arm Location

(Shown with Parts Removed for Clarity)

Ball Joint

Jam Nut

Control Rod

Maximum Speed

Adjustment Set Screw

FWD

REV

Locating/Limit

Stud

Transmission

Control Arm

Tracking Adjustment Nut

(Adjusts Length of Control Rod)

ADJUSTMENTS

WARNING

The following adjustments are made with the engine running. Keep all body parts and tools away from rotating and hot components, and secure all loose clothing.

4. With the body lowered and the FSC in

NEU-

TRAL-PARK,

start the engine. With the engine at normal operating speed, check for movement of the drive wheels.

5. Using a wrench on one tracking adjustment nut, rotate the control rod

counterclockwise

just until the wheel on that side begins

to move forward.

Then, counting the turns required, ro ­ tate the control rod

clockwise

just until the wheel stops and then begins

to move in reverse.

Rotate the control rod back counter ­ clockwise half the number of turns required to make the wheel go from moving forward to re ­ verse. The transmission is now centered in the neutral window. Tighten the jam nut on the ball joint and repeat the same procedure on the other transmission.

6. Turn off the engine, and then lower the drive tires onto the ground.

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.

Step 4 -

Full Forward Speed Adjustment

1. Move the FSC to the full

FORWARD

speed position.

2. Raise the body. The maximum speed tracking adjustment set screw in both transmission control arms should not be contacting the limit stud on the transaxle. If they are, back the set screws out until they do not touch.

Tracking Adjustment Components

64

Maintenance Instructions

T-Handle

Hex Wrench

Maximum

Speed Tracking

Adjustment

Transmission

Control Arm

Maximum Speed Tracking Adjustment

(Shown with Parts Removed for Clarity)

Step 5 -

Straight Tracking Adjustment

1. Sit in the seat, start the engine, set throttle at full speed, and with the FSC in the

NEUTRAL-

PARK

po sition check for movement of either drive wheel (if either wheel moves backward or forward, re fer to

Step 3 -

Neutral Function

Adjustment

and readjust).

2. Check for straight ground tracking on a level surface (with hands off the steering levers). Set the FSC at several different speeds and ob serve if the machine moves in a straight line (use cement joint or other line on ground for reference).

3. If tracking is not straight, shorten the control rod on the faster side by turning the tracking adjust ­ ment nut clockwise. If straight tracking and neutral are both achieved, proceed to the next step. If straight tracking and neutral cannot both be achieved, turn the tracking adjustment nut on the faster side counterclockwise until neutral is restored.

4. Lengthen the control rod on the slower side by turning the tracking adjustment nut counterclockwise until straight tracking and neutral are both achieved.

IMPORTANT:

After tracking adjustments are complete, confirm that there is at least one (1) thread visible on both control rods past the tracking adjustment nuts.

5. If the machine is tracking straight throughout the speed range except at maximum speed, use the following adjustment procedure:

ADJUSTMENTS

a. With the engine off, place the FSC in full

FORWARD.

On the faster transmission, loosen the jam nut and turn the maximum speed tracking adjustment set screw in un ­ til it just contacts the limit stud, and then turn it in an additional 1/8 turn (turning the set screw in slows the drive wheel).

b. Recheck maximum speed tracking, and if necessary continue adjusting the set screw in small increments until straight travel is achieved.

c. Tighten the jam nut.

Step 6 -

FSC Neutral Switch Adjustment

1. Place the FSC lever in the

NEUTRAL-PARK

position. Raise the body and adjust the switch adjustment bolt up until it just makes contact with the FSC switch plunger, and then turn the switch adjustment bolt up an additional two (2) turns and tighten the jam nut.

NOTE:

It may be necessary to tighten the FSC friction adjustment if the transmissions are moved out of neutral when the body is raised.

Refer to

Step 7 -

Forward Speed Control Friction Adjustment

later in this section for location of the FSC friction adjustment nut.

FSC Switch

Switch Adjustment

Bolt

FSC Neutral Switch Location

65

Maintenance Instructions

NOTE:

Adjust the bolt downward for quicker activation (Switch Open).

Switch Closed in Neutral

Switch Adjustment

Bolt

Jam Nut

FSC Switch

Actuator Arm

FSC Friction Nut

ADJUSTMENTS

Step 7 -

Forward Speed Control Friction Adjustment

Pull Steering Levers

Back To Check

Friction Lock

Front of Mower

FSC Neutral Switch Adjustment

(Side View Through Chassis)

CAUTION

Before testing the FSC Neutral Switch, disconnect the spark plug wires from the engine and engage the parking brake to prevent accidental starting and inadvertent machine movement.

2. Check operation of the FSC Neutral Switch by placing the FSC lever in the full

FORWARD

po­ sition. While holding the ignition switch in the

START

position, slowly move the FSC lever back towards the

NEUTRAL-PARK

position and stop when the starter motor engages. Note the position of the FSC lever where it passes through the slot in the body. The FSC lever should be within 1/8 in. (3 mm) of the

NEU-

TRAL-PARK

position. If this distance is great ­ er than 1/8 in. (3 mm), turn the adjustment bolt down slightly and recheck switch operation.

When finished adjusting, tighten the jam nut and reconnect the spark plug wires.

FSC Full

Forward Position

FSC Friction Adjustment Test

(Checking Friction Lock)

1. Place the FSC lever in the full

FORWARD

position, and pull both steering levers fully back; the FSC lever should not move. If the FSC lever moves back the

friction needs to be increased.

2. With the steering levers held back, move the

FSC lever back from the

FORWARD

position.

With a proper amount of friction adjusted, the

FSC le ver should move back with a slight amount of re sistance (friction). If the FSC lever movement is “stiff”, the

friction needs to be decreased.

3. The FSC friction is

increased

or

decreased

by

tightening

or

loosening

the

friction adjustment nut.

Loosen or tighten the nut and check the control function until the conditions of both steps 1 and 2 (above) are met.

FSC Friction

Adjustment Nut

FSC Friction Adjustment Nut

66

Maintenance Instructions

Blade Clutch (PTO)

Clutch Engagement/Belt Tension

The clutch engagement and PTO belt tension are ad ­ justed using the clutch actuator link. After installing new PTO belts,

after 10 hours and every 100 hours

thereafter, check and adjust for the clutch spring as ­ sembly bolt head dimension as shown in the

PTO

Clutch Engaged

illustration. If the clutch actuator link or clutch spring assembly have been disassem ­ bled, first reset them to their factory preset lengths (as shown in the

PTO Clutch Disengaged

illustration) and then proceed with adjustment as follows.

Clutch Actuator

Link

ADJUSTMENTS

Adjust the length of the clutch actuator link to achieve a clutch spring assembly bolt head clearance of

1/4 in. to 5/16 in. (6.35 mm to 7.94 mm) with the clutch engaged. To adjust length: remove ball joint from clutch arm and

shorten

the clutch actuator link to

increase

this measurement, or

lengthen

the clutch actuator link to

decrease

this measurement. If adjustments are needed more frequently than every

100 hours to maintain dimensions, it may suggest problems with pulley wear or belt misalignment.

Ball Joint

Clutch Spring Assembly

(Spring Compressed)

Clutch Engagement

Arm

1/4 in. to 5/16 in.

(6.35 mm to 7.94 mm)

Safety

Switch

Blade Clutch

Engaged

Clutch Arm

Blade Clutch

Idler Pulley

Front of Mower

PTO Clutch Engaged

67

Maintenance Instructions

6-1/2 in.

*

(165 mm)

Knuckle Joint

2-1/8 in.

*

(54 mm)

Clutch Actuator

Link

6 in.

*

(152 mm)

Clutch Spring Assembly

(Spring Uncompressed)

*NOTE:

Factory preset dimensions. Reset to these dimensions prior to adjustment if compo ­ nents have been disassembled.

PTO Clutch Disengaged

Clutch Disengagement/Brake Action

WARNING

It is important to check and maintain blade brake action for safe operation of the machine.

The

declutched or disengaged position

of the blade clutch idler pulley is adjustable and is set to give belt release

without excessive slack

and to apply the blade brake. The blade brake is activated by the brake band connected to the clutch engage ­ ment arm. The brake is designed to stop the blades within five (5) seconds after disengaging the clutch.

ADJUSTMENTS

Use the following procedures to check and adjust clutch disengagement and brake action:

Step 1 -

Idler Pulley Maximum Travel Adjustment

Loosen the brake band adjustment nut allowing clutch pivot stop arm and stop bolt to make contact

(refer to

Blade Brake Band Adjustment

illustra ­ tion).

1. To check the pulley travel, first engage the clutch, then measure the distance the pulley travels as the clutch is disengaged and the stop arm contacts the stop bolt.

2. Adjust the pivot stop bolt to give 1 in. to 1-1/8 in.

(25 mm to 29 mm) pulley travel from “clutch en ­ gaged” to “clutch disengaged”.

NOTE:

This adjustment will prevent excessive pulley travel that can cause belts to develop too much slack, causing possible belt derailment upon disengagement.

1 in. to 1-1/8 in.

(25 mm to 29 mm)

CLUTCH DISENGAGED

CLUTCH ENGAGED

Idler Pulley

Clutch Pivot

Stop Bolt

Brake Engagement

Arm

Clutch Idler Pulley Travel

Clutch Pivot

Stop Arm

68

Maintenance Instructions

Step 2 -

Blade Brake Band Adjustment

After the maximum pulley travel is set, adjust the working travel of the clutch idler pulley by adjusting the brake band nut and make the following adjust ­ ment as needed:

1. Adjust the blade brake band, using the adjust ­ ment nut until pulley travel is approximately

5/8 in. to 3/4 in. (16 mm to 19 mm) from en ­ gaged to disengaged.

NOTE:

As blade brake band/drum wears, pulley travel will increase and it will be necessary to adjust the blade brake band nut to maintain these dimensions.

CLUTCH DISENGAGED

CLUTCH ENGAGED

ADJUSTMENTS

2. After adjustments are complete, check blade brake action as described in

CHECKING/SER-

VICING

the

Blade Brake Action

in this section.

If blades do not stop within five (5) seconds, check the following: a. Make sure clutch and brake linkage are working freely (no binding).

b. Check the brake band lining for wear.

c. Check the brake drum on the pulley. If excessive wear is present, it will be necessary to replace worn parts.

Tilt-Up Deck Adjustable Stop

When the carrier frame hinge joint is properly adjusted, the deck lock levers should move in and out of the engaged and disengaged positions freely. All four (4) hitch pins used for height adjustment should sit flush on the washers above the deck pin bushing.

On a level surface, if any pin is sticking up (likely the front pins), tighten the opposite side or loosen the same side to lower the pin. Adjustments are made by loosening the jam nut and tightening or loosen ing the set screws on the Deck Mount Pivot Brack ets.

Retighten the jam nut when the adjustment is com ­ plete.

Clutch Idler Pulley Travel Adjustment

Jam Nut

Blade Brake

Band

Set Screw

Tilt-Up Deck Adjustable Stop

Blade Brake

Band Adjustment Nut

Chassis Mount

(Ref)

Blade Brake Band Adjustment

69

MAINTENANCE AND SERVICE RECORD SHEET

DATE SERVICE ENGINE

ITEM HOURS

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70

LIMITED WARRANTY

FOR

WALKER MODEL B19

RIDER MOWERS

1. WHAT THIS WARRANTY COVERS, AND FOR HOW LONG:

Walker Manufacturing company will, at its option, repair or replace, without charge, any part covered by this warranty which is found to be defective in material and/or workmanship within two (2) years* after the date of sale to the original retail pur ­ chaser unless the product is used for rental purposes, in which case this warranty is limited to ninety (90) days. At Walker’s request, customer will make the defective part available for inspection by Walker and/or return the defective part to Walker, transportation charges prepaid. All parts and components of the Walker Mower are covered by this warranty

except

the fol ­ lowing components which are warranted separately by their respective manufacturers:

Kohler Engine

Battery

The available warranties covering these items are furnished with each mower. Walker does not assume any warranty obliga ­ tion, liability or modification for these items, which are covered exclusively by the stated warranty of the respective manufac ­ turers noted above.

* Extended warranties are offered for the following powertrain components:

A two (2) year or 2000 hour (whichever comes first) warranty is offered for Hydro-Gear ZT3100 Hydrostatic transaxle; covers full cost of replacement up to 1000 hours of use, and after 1000 hours warranty coverage is prorated against

2000 hours.

2. 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.

3. HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:

Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Walker

Manufacturing Company, 5925 East Harmony Road, Ft. Collins, CO 80528. Proof of the date of purchase may be required to verify warranty coverage.

4. WARRANTY LIMITATION:

A.

THERE IS NO OTHER EXPRESS WARRANTY. ANY WARRANTY THAT MAY BE IMPLIED FROM THIS PURCHASE

INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY LIMITED TO THE

DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED

WARRANTIES ARE EXCLUDED.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

B.

WALKER WILL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, OR SPECIAL DAMAGES AND/OR

EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply to you.

C. Only the warranty expressed in this limited warranty shall apply and no dealer, distributor, or individual is authorized to amend, modify, or extend this warranty in any way. Accordingly, additional statements such as dealer advertising or presentations, whether oral or written, do not constitute warranties by Walker, and should not be relied upon.

D. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

71

WALKER MFG. CO.

5925 E. HARMONY ROAD, FORT COLLINS, CO 80528

(970) 221-5614

FORM NO. 082720 PRINTED IN USA www.walker.com

©

2020 WALKER MFG. CO

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