Walker B23i Operator's Manual

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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: 124998

Eective Date: 10.14.13

P/N 4000-14

Foreword

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

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

This manual covers Model B23i with the Kohler Command Pro ECH730 (23.0 HP) Electronic Fuel Injection (EFI) gasoline engine.

All shields and guards must be in place for the proper and safe operation of this machine. Where they are shown removed in this manual, it is for illustration purposes only. Do not operate this machine unless all shields and guards are in place.

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

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

Sincerely, WALKER MANUFACTURING COMPANY

Bob Walker, President

Table of Contents

General Information ________________ 1

HIGHLIGHTED INFORMATION _____________ 1 GLOSSARY ____________________________ 1 IDENTIFYING NUMBER LOCATIONS ________ 1 ENGINE SERIAL NUMBER LOCATION _______ 2 SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS ______________ 2

Specications ________________________ 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 Identication ___________ 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 _________________ 19

Deck Caster Wheels Installation _________ 19 Deck Discharge Deector Shield Installation ____________________ 19 PTO Shaft Guard Installation ___________ 19 Tilt-Up Roller Wheel Installation _________ 20

Mower Deck Installation on Tractor _______ 20

Deck Installation _____________________ 20 Deck Leveling _______________________ 22

PREOPERATING CHECKLIST _____________ 23

Operating Instructions _____________ 25

CONTROL IDENTIFICATION, LOCATION, AND FUNCTION _____________ 25

Ignition Switch _______________________ 25 Engine Throttle _______________________ 26 Forward Speed Control (FSC) ___________ 26 Blade Clutch (PTO) ____________________ 26 Steering Levers_______________________ 26 Oil Pressure Warning Horn _____________ 26 Parking Brake ________________________ 27 Transaxle Lockout Arms _______________ 27 Engine Service Light __________________ 27 Circuit Breaker _______________________ 27 Body Latch __________________________ 28 Hourmeter ___________________________ 28

STARTING THE ENGINE _________________ 30 ADJUSTING GROUND SPEED AND STEERING __________________ 30 ENGAGING THE BLADE DRIVE ___________ 32 STOPPING THE MACHINE _______________ 33 ADJUSTING CUTTING HEIGHT ____________ 34 TRANSAXLE LOCKOUT _________________ 34 RECOMMENDATIONS FOR MOWING ______ 35 RECOMMENDATIONS FOR TILT-UP DECK OPERATION/TRANSPORT _______________ 36

Maintenance Instructions __________ 37

MAINTENANCE SCHEDULE CHART _______ 37 IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE _______________________ 38

Fuel System _________________________ 38 Starting/Stopping _____________________ 38 Cooling System ______________________ 38 Air Cleaner System ____________________ 38 Oil__________________________________ 39

LUBRICATION _________________________ 39

Engine Oil ___________________________ 39

Engine Break-In Oil ___________________ 39 Checking Engine Crankcase Oil Level ____ 39 Changing Engine Crankcase Oil/Oil Filter __ 40

Mower Deck Gearbox Lubrication ________ 41 Grease Fitting and Oil Point Lubrication __ 41 DS52 or DS62 Mower Deck Lubrication ___ 44 Transaxle Oil and Filter Change _________ 44 Mower Deck Spindle Lubrication ________ 45 Transaxle Lubrication _________________ 45

Table of Contents

CLEANING ____________________________ 45

Engine Air Cooling System _____________ 45

Cylinder Head Cooling Fins ____________ 46

Engine Air Cleaner System _____________ 47

Turbine Precleaner ___________________ 47 Enginaire™ VLR Air Cleaner ___________ 47

Grass Buildup in Mower Deck Housing ___ 49 Transaxle Housing ____________________ 50

CHECKING/SERVICING __________________ 51

Security of Air Cleaner System __________ 51 Battery ______________________________ 51

Electrolyte Level _____________________ 51 Cleaning the Terminals ________________ 52 Charging the Battery __________________ 52

Tire Pressure _________________________ 52 Wheel Nut Torque _____________________ 52 Sharpen Mower Blades ________________ 52 Drive Belts ___________________________ 53 Mower Deck Gearbox Oil Seals __________ 53 Spark Plugs __________________________ 54 Ignition Wires ________________________ 54 Fuel Lines and Clamps _________________ 54 Blade Brake Action ____________________ 54 PTO U-Joints ________________________ 54 Engine Starter ________________________ 54 Safety Switch System__________________ 54 Forward Speed Control Friction Lock _____ 55

REPLACING/REPAIRING _________________ 55

Drive Belts ___________________________ 55

Engine/PTO Belt _____________________ 56 Ground Drive Belt ____________________ 57

Fuel Filter ___________________________ 58 Blade Overload Shear Bolts_____________ 59 Shear Pin (If Equipped) ________________ 59 Mower Blades ________________________ 60

ADJUSTMENTS ________________________ 61

Transmission Control__________________ 61

Steering Lever Position Adjustment ______ 61 Steering Handles Adjustment ___________ 62 Neutral Position Adjustment ____________ 62 Full Forward Speed Adjustment _________ 64 Straight Tracking Adjustment ___________ 64 FSC Neutral Switch Adjustment _________ 64 Forward Speed Control Friction Adjustment 65

Blade Clutch (PTO) ____________________ 66

Clutch Engagement/Belt Tension ________ 66 Clutch Disengagement/Brake Action _____ 67 Idler Pulley Maximum Travel Adjustment __ 67 Blade Brake Band Adjustment __________ 68

Tilt-Up Deck Adjustable Stop ____________ 68

Operator’s Notes _______________ 69

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 several general practices to be aware of in the area of safety. Most accidents associated with the operation or maintenance of a Walker Mower are caused by disregarding basic safety precautions or specific warnings. Such accidents, in most cases, can be prevented by being aware of the dangers present.

Information of special importance has been highlighted in bold type in this manual. Refer to Safety

Instructions for the meanings of DANGER, 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 components, and cutter blades.

• ELECTRONIC CONTROL UNIT (ECU) con-

trols engine functions such as spark timing, fuel/air ratio, etc.

• FORWARD SPEED CONTROL (FSC) controls

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

• TRACTOR is the prime mover, including the en-

gine, drivetrain, operator seat, and controls to operate the mower.

• TRANSAXLE transmits and controls power

from the ground drive belt to the main drive wheel.

• TRANSAXLE LOCKOUT ARMS release the

transaxles to permit freewheeling the tractor.

IDENTIFYING NUMBER LOCATIONS

The tractor serial number plate is affixed to the tractor body just below the left rear corner of the seat. The mower deck serial number plate is affixed alongside the angle iron framing on the LH side of the LH mower blade drive. Model and serial numbers are helpful when obtaining replacement parts and maintenance assistance. For ready reference, please record these numbers in the space provided.

Tractor Model No. ______________________

Tractor Serial No. ______________________

Deck Serial No. ______________________

Engine Model No. ______________________

Engine Serial No. ______________________

Date of Purchase ______________________

• GROUND DRIVE refers to the dual transaxles

which drive the main wheels.

• LEFT HAND (LH) refers to the left-hand side of

the tractor when the operator is seated facing forward in the tractor seat.

• 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.

Fill In By Purchaser

Serial Number

Tractor Serial Number Location

General Information

Serial Number

Mower Deck Serial Number Location

SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS

The detailed servicing and repair of the engine, transaxle, and gearboxes are not covered in this manual. Only routine maintenance and general service instructions are provided. For the service of these components during the limited warranty period, it is important to find a local, authorized servicing agent of the component manufacturer. Any unauthorized work done on these components during the warranty period may void the warranty. If you have any difficulty finding an authorized outlet or obtaining warranty service, please contact our Service Department for assistance:

ENGINE SERIAL NUMBER LOCATION

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

Serial Number

Engine Serial Number Location

Walker Manufacturing Company

5925 E. Harmony Road

Fort Collins, CO 80528

1-970-221-5614

www.walkermowers.com

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

Kohler Engine Kohler Company Kohler, WI 53044 800-544-2444 www.kohlerengines.com

Transaxle Hydro-Gear 1411 South Hamilton St. Sullivan, IL 61951 877-728-7410 www.hydro-gear.com

Gearboxes (Deck) Peerless Gear 1555 South Jackson St. Salem, IN 47167 USA 866-536-8310 www.peerlessgear.com

Specications

MODEL B23i

ENGINE

Manufacturer/Model

Displacement cu. in. (cc) 45.5 (747)

Max. Power HP (kW) 23.0 (17.2) @ 3600 RPM

Governed RPM 3600

Kohler Command Pro ECH730, V-Twin, 2 Cyl. (Air Cooled), Electronic Fuel Injection (EFI)

Max. Torque lb

·ft (N·m)

36.1 (48.9)

Idle RPM 1200

Spark Plug Type

Champion

RC12YC

Spark Plug Gap in. (mm) .030 (0.75)

Crankcase Capacity qt (L) 2.0 (1.9)

Crankcase Lubricant API SJ or higher Grade Oil Only with 10W-30 Viscosity above

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

Oil Filter Kohler P/N 12-050-01

Fuel Tank Capacity gal (L) 4.7 (17.79)

Fuel

Automotive Grade Unleaded Gasoline (87 Octane Minimum, 10% Ethanol Maximum)

Cooling System Air Cooled

Air Cleaner Remote mounted Enginaire

- S/N 133533 and prior (Walker P/N 5090-1 Primary/5090-3 Safety Filter) Remote mounted Enginaire

VLR - S/N 133534 to Current

(Walker P/N 5090-4 Primary/5090-5 Safety Filter)

ELECTRICAL SYSTEM

Battery 12 Volt, 300 CCA

Charging System Flywheel Alternator

Charging Output 15 Amp DC (Regulated)

System Polarity Negative Ground

Ignition Electronic Capacitive Discharge

Starter 12 Volt Electric, Key Operated, Solenoid Shift

Interlock Switches Ignition Lockout by Seat Switch, Transmission Neutral and

Circuit Breaker Manual Reset (20A)

TRANSMISSION

Manufacturer/Model Dual, Independent Hydro-Gear

Steering Hand Lever Control / Individual Wheel

Forward Speed Control Precision Friction Lock Lever, Cruise Control, with

Service Brake Dynamic Braking Though Transaxles

Blade Clutch

Neutral-Park Position

ZT3100 Integrated Transaxles

Specications

MODEL B23i

TRANSMISSION (continued)

Parking Brake

Neutral Transmission Release by Manual Dump Valve

Final Drive Transaxle Direct to Drive Wheel

Transmission Fluid

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

Transmission Oil Capacity fl oz (L) 79 (2.3)

Transmission Cooling Cooling Fan Mounted on Drive Pulley

Oil Filter Hydro-Gear

Ground Travel Speed

Forward MPH (km/h) Reverse MPH (km/h)

BLADE DRIVE

Internal Mechanical Cog Lock for each Transaxle (Single Lever Control)

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

0-8 (0-13) Infinitely Variable 0-5 (0-8) Infinitely Variable

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

Blade Drive Clutch and Brake

TIRE SIZE

Deck Caster

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

Tailwheel 11 x 4.00-5 (Pneumatic)

TIRE PRESSURE PSI (KPA)

Deck Caster Wheel 20 (137)

Drive 15 (103)

Tailwheel 20 (137)

MOWER DECK

Recommended Cut Width Side Discharge

Mulch 36 to 52 in. (91 to 132 cm)

Cutting Height

Deck Suspension

Manual Belt Tightener Clutch and Band Brake [Stops Blades within Five (5) Seconds of Disengagement]

8 x 3.00-4 (Pneumatic 4-Ply, All Decks Except DS52, DS62, DS74) 11 x 4.00-5 (Pneumatic 4-Ply, DS52, DS62, DS74 Only)

36 to 74 in. (91 to 188 cm)

1 to 4 in. (2.5 to 10 cm) or 1.5 to 4.5 in. (4 to 11.5 cm) (DS52 and DS62 Belt Driven SD Decks Only)

Independent Torsion-Flex Frame with Caster Wheels and Counterweight Springs

Specications

MODEL B23i

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)

DRIVE BELTS

Engine PTO Walker P/N 4230-1

Ground Drive

58-1/4 (148) Tail Wheels Forward - Muffler is Most Rear Point

40 (102)

72 (183)

90-3/4 (230)

38 (97)

49 (125)

39-1/2 (100)

594 (269) With PTO Quick Disconnect Coupling

800 (363)

Walker P/N 4230-2

SEAT Contour-Molded, with Nylon Backed Vinyl Cover and

Integral Foam Cushion

FRAME/BODY CONSTRUCTION

Frame All Welded Unitized Steel Chassis

Body 14 Gauge Steel

Deck 11 Gauge Steel

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

Component Identication

Forward Speed

Control (FSC)

Oil Pressure

Warning Horn

(Not Visible)

Friction

Adjustment

NOTE: Control Identification

shown in Operating Instructions section.

Body Tilt-Up Latch

(Not Visible)

Deck Support Arm

(Not Visible)

Deck Lift Handle

(Cutting Height Adjustment)

Footrests

Tilt-Up Latch

Counterweight Springs and

Tilt-Up Hook (Not Visible)

Protective Covers

Deck Support

Arm

Footrests

Deck

Caster Wheels

Deck Support

Pins and Height

Adjustment

Hitch Pins

Tilt-Up

Deck Handle

Front View and Right Side View

Component Identication

Footrests

Fuel Pickup

Line

DipstickOil Fill

Tailpipe

Muffler

Left Hand

Drive Wheel

Fuel Tank

and Cap

Cylinder Head

Cooling Fins

Rear View and Left Side View

Spread Axle

Tail Wheel

Tailwheel Fork

and Wheel

Component Identication

LH Transmission

Control Arm

Steering Lever

Dampening Springs

RH Transmission

Control Arm

LH Transaxle

Lockout Arm

Parking Brake

Linkage

Parking Brake

Lever

Turbine Precleaner

Fuel Tank Cap

Fuel Tank

Fuel Gauge

Roll Over Valve

EVAP Line

Fuel Pickup Line

Fuel Filter

RH Transaxle

Lockout Arm

Air Cleaner

Cover

PTO Clutch

Lever

Transaxle Oil

Expansion

Reservoir

Fuel Pump

Air Cleaner

Cover Latch

Oil Fill

Dipstick

Rubber Bumpers

(Body Support)

Top View (Engine Compartment)

Oil

Cooler

Oxygen

Sensor

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 personal injury.

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

DANGER

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

WARNING

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

Walker Manufacturing cannot predict every potentially dangerous situation. Therefore, items labeled as such in this manual do not cover all conceivable situations. Any person using procedures, tools, or control techniques not recommended by Walker Manufacturing must take full responsibility for safety.

The Walker Rider Lawnmower has been designed with many safety features to protect the operator from personal harm or injury. However, it is necessary for the operator to use safe operating procedures at all times. Failure to follow safety instructions con-

tained in this manual may result in personal injury or damage to equipment or property.

If you have any questions concerning setup, operation, maintenance, or safety, please contact your authorized Walker Mower dealer or call Walker Manufacturing Company at (970) 221-5614.

BEFORE OPERATING

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

CAUTION

Possible hazards or unsafe practices that MAY result in MODERATE personal injury or property damage, or machine damage, if warning is ignored and proper safety precautions are not taken.

IMPORTANT: Identifies mechanical information

demanding special attention, since it deals with the possibility of damaging a part or parts of the machine.

NOTE: Identifies information worthy of special attention.

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 pro-

tective footwear.

Safety Instructions - Before Operating

6. Do not wear loose fitting clothing that could get caught in moving parts. Do not operate this machine while wearing shorts; always wear ade- quate 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 hear- ing protection is recommended. Wear a suitable hearing protective device, such as earmuffs or earplugs.

8. Keep all protective shields and safety de- vices in place. If a protective shield, safety device, or decal is damaged, unusable, or missing, repair or replace it before operating the machine.

9. Be sure interlock switches are functioning correctly, so the engine cannot be started unless the Forward Speed Control lever is in the NEUTRAL-PARK position, and the PTO clutch is in the DISENGAGED position. Also, the engine should stop if the operator lifts off the seat with either the Forward Speed Control (FSC) out of the NEUTRAL-PARK position or the PTO clutch in the ENGAGED position.

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

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

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 container

cap securely and clean up any spilled fuel before starting the engine.

11. Never attempt to make any adjustments while the engine is running, except where specifically instructed to do so.

Safety Instructions - Operating

1. Operate the mower only in daylight or in good artificial light with good visibility of the area being mowed.

2. Sit on the seat when starting the engine and operating the machine. Keep feet on the deck footrests at all times when the tractor is moving and/or mower blades are operating. Never op-

erate 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.

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

Verify proper operation by having the operator lift off the seat with the engine running and moving two controls, one at a time; (1) Move the FSC lever out of the NEUTRAL-PARK position, and (2) Engage the PTO Clutch. Moving either control should stop the engine immediately.

8. Do not run the engine in a conned area without adequate ventilation. Exhaust fumes are hazardous and can be deadly.

9. Do not carry passengers - maximum seating capacity is one (1) person.

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

11. Avoid sudden starts or stops. Before backing the machine up, look to the rear to be sure no one is behind the machine. Watch carefully for traffic when crossing or working near roadways.

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 either of the transmission drive belts break during slope operation, the machine will free-

wheel down the slope. To maintain control, immediately (1) Release the steering levers and simultaneously (2) Move the FSC to the NEU- TRAL-PARK position. When the machine is stopped or moving slowly, engage the parking brake.

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

6. Disengage the blade clutch and put the FSC in the NEUTRAL-PARK position before starting the engine (an ignition interlock switch normally prevents starting of the machine if these controls are in the OPERATING position).

12. When moving forward, do not suddenly put the tractor in reverse by rapidly pulling on the steering levers, especially when going downhill, as this can lift the tractor tail wheel off the ground and set up a bucking motion due to operator overcontrol. If bucking does occur, immediately stop the bucking action by pulling the Forward Speed Control (FSC) lever into the 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.

Safety Instructions - Operating

14. The maximum recommended slope operating angle is 15 degrees or 26% grade. When

operating the machine on a slope, reduce speed and use caution to start, stop, and maneuver. To prevent tipping or loss of control of the machine, avoid sharp turns or sudden changes in direction. Do not operate the machine on a

slope greater than 15 degrees.

15. Never adjust cutting height with the engine running. Before adjusting cutting height or

servicing, disengage the blade clutch (PTO), stop the engine, and remove the ignition key. Wait for all movement to stop before getting off the seat.

NOTE: 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 oper- ate with the grass deector shield removed. Keep the deflector in the lowest possible position.

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

immediately disengage the blade clutch (PTO), stop the engine, and wait for all moving parts to stop. To prevent accidental

starting, disconnect the spark plug wires. Thoroughly inspect the mower and repair any damage before restarting the engine and operating the mower. Make sure cutter blades are in good condition and blade nuts are torqued to 60 lb·ft (81 N·m) for gear driven decks, and blade bolts torqued to 70 lb·ft (90 N·m) for belt driven decks.

20. Do not touch the engine or mufer 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, disen-

gage the blade clutch (PTO), stop the engine, and remove the key.

17. When using the tilt-up deck, observe the fol-

lowing:

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

position.

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

position.

18. In case of a clogged or plugged mower deck:

a. Disengage the blade clutch (PTO) and turn

the engine off before leaving the seat.

b. LOOK to make sure blade drive shaft

movement has stopped before trying to unclog the system.

c. Disconnect the spark plug wires.

d. Never place hands under the deck - use a

stick or similar tool to remove clogged material.

Safety Instructions - Maintenance

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

2. To reduce re 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 de- scribed in this manual. Unauthorized maintenance 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. Unauthor-

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

11. Use care when charging the battery or per- forming maintenance on the battery and electrical system:

a. Make sure the battery charger is unplugged

before connecting or disconnecting cables to the battery.

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 materi-

als 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 immediately accessible to anyone who may operate or service this machine.

7. Altering the equipment or engine in any manner which adversely affects its operation, performance, durability, or use will VOID the war- ranty 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 malfunction and possible injury to the operator and/or others.

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.

8600-28

Location: Each End of Mower Deck Part Number: 8600-28

1. Warning – thrown object hazard.

• Keep bystanders away from the machine when operating.

• Clear lawn of debris before operating.

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

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

• Keep all body parts away from rotating mower blades.

• Do not step on end of deck.

8600-14

Location: Deck Carrier Frame Part Number: 8600-14

8600-2

Location: Flex Coupler Guard in Front of Engine Part Number: 8600-2

1. Warning – entanglement and cutting/dismemberment hazards.

• Keep away from rotating shafts, belts, and other components.

Location: Deck Carrier Frame Part Number: 8600-15

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

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

9804-1

Location: Chassis Member Behind Transaxles Part Number: 9804-1

1. Neutral Lock

• Lift and move into slot to unlock transmission and allow machine to freewheel.

5848-2

1. Location: Deck Discharge Shield

(SD Decks Only) Part Number: 5848-2

1. Warning – thrown object hazard.

• Always keep the discharge shield in the lowest position when operating.

• Do not remove the discharge shield.

Safety Instructions

SAFETY, CONTROL, AND INSTRUCTION DECALS

Safety, Control, and Instruction Decals are installed on the machine;

if any are missing, illegible, or damaged, a replacement should be ordered and installed before

putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.

Location: LH Fender Part Number: 8600-25

<15°

1. 2.

Location: RH Fender Part Number: 8600-26

1. Throttle

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

2. Warning – read Operator’s Manual before operating 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. Warning – entanglement hazard.

• Keep all guards in place while engine is running.

7. Parking brake

• Move lever forward to engage Parking Brake; back to disengage.

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 servicing 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.

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

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)

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).

Location: Engine Shroud Part Number: 5855

GROUND DRIVE BELT

WALKER P/N 4230-2

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.

Location: Front Body Part Number: 5802-3

1. Engine Service Indicator Light

• If illuminated during operation contact an authorized Kohler Service Dealer as soon as possible.

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.

8600-5

Location: Rear Body Near Mufer Part Number: 8600-5

1. Warning – hot surface, do not touch.

Assembly Instructions

SETUP INSTRUCTIONS

Walker Mowers are shipped partially assembled to our distribution network, and are typically assembled by the selling dealer. For any additional assembly besides the following, contact your Walker dealer.

Tire Installation (Tractor)

• Install the drive tires using the eight (8) mounting

nuts that are supplied with the owner’s packet of materials. Nuts are torqued to 75 to 85 lb·ft (102 to 115 N·m).

• Check and adjust the inflation of the tires. The

tire inflation recommendations are:

Drive = 15 PSI (103 kPa) Tailwheel = 20 PSI (137 kPa)

Battery Service

Check the battery for electrolyte level and charge. The electrolyte level should be at the bottom of the vent wells [1/4 to 1/2 in. (6 to 13 mm) above plates]. If the specific gravity is less than 1.225, the battery needs charging. If the battery has been shipped dry, or is wet but needs service, refer to the following instructions.

Wet Battery Service

If the battery has been shipped wet, but the electrolyte level is low or the battery needs to be charged then:

1. Fill each battery cell with distilled water to the bottom of the vent wells.

2. Charge battery. Refer to Battery Charging in this section.

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.

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 systems.

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 gog-

gles 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 plate, disconnect the battery cables and lift the battery out of the tray.

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

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 charging can dissipate.

• Keep sparks, ames, and smoking mate

rials away from the battery at all times.

Battery Installation

IMPORTANT: Make sure battery is securely mounted in the frame. A loose battery may cause damage to the case resulting in acid leakage and severe damage to the machine. A hazard may be created by damage to critical working parts and safety systems.

Install the battery in the mower as shown in Battery Installation photo. Connect the positive (+) first and then the negative (-) cable to the proper battery terminal [red cable and boot connects to the Posi- tive (+) terminal]. Slide the rubber boot up and over the battery post, making sure it covers the post completely to prevent an electrical short.

WARNING

Make sure the battery cap vents are open. Improper venting of the battery COULD cause a battery explosion.

• Make sure the battery cap vents are

open after the battery is lled with acid (check manifold vent on each cap).

• Make sure the battery charger is un-

plugged before connecting or disconnecting cables to the battery.

 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 Clamp

Secured by

Wing Nut(s)

Battery Installation

Assembly Instructions

Mower Deck Assembly

Deck Caster Wheels Installation

1. Remove the bolt, nut, axle spacer tube, and spacer washers from each deck caster wheel fork.

NOTE: Spacer washers are used only when the optional semi-pneumatic deck wheels are installed.

2. Fit the axle spacer tube through the wheel hub, position the spacer washer on each side of the hub (if used), and fit the assembly into the wheel fork.

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

4. Tighten the bolt and nut until the axle spacer tube bottoms against the inside of the wheel fork (will not turn) while the wheel and spacer washers (if used) spin freely without binding.

Deck Discharge Deector 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 deector shield attached and in the

lowest possible position.

Attach Shield

Axle Spacer Tube

Spacer Washer

Axle Bolt

Deck Caster Wheel Installation

5. Grease the caster wheel bearings and caster pivot bearings - one grease fitting for each wheel and each pivot.

Deck Discharge Shield Installation

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

Attach Guard

PTO Shaft Guard Installation

Assembly Instructions

Tilt-Up Roller Wheel Installation

Mount the two (2) tilt-up roller wheels on the brackets on the rear skirt of the deck housing using the P/N 8490 axle bolt, 3/8 in. wave spring washer and 3/8-16 in. Whiz locknut. Tighten the axle bolt until the wheel rolls freely, but is not loose.

Roller Wheels

Roller Wheel Installation

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.

Coupler

Installation Tool

PTO Coupler

Tube

PTO Coupler Installation Tool

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

Arrows on Shaft and Tube

(Used to Align When Sliding Together)

Grease Deck

Support Arm

Retract Spring-Loaded Quick Disconnect Ring

2. Engage the deck carrier frame tube sockets on the tractor support arms (refer to PTO Shaft Guard Installation photo for socket location), slide the deck onto the support arms approximately 3 in. (76 mm).

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

NOTE: The Coupler Installation Tool is provided for convenience, but is not required for installation.

PTO

Connection

Mower Deck Installation

(PTO Shaft Connection)

IMPORTANT: When installing the DS52 or

DS62 Mower deck, make sure to retract the dolly wheel after mounting the deck on the tractor.

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

IMPORTANT: DO NOT operate tractor with Coupler Installation Tool installed.

IMPORTANT: To prevent damage to the mower, make sure the PTO quick disconnect is securely locked on the tractor, with the locking balls fully seated in the groove and the ring in the locked position (refer to the Quick Disconnect Ring “Locked” Position illustration). After installation, pull on the PTO coupler to check for security.

Assembly Instructions

Coupler Ring in

Released Position

PTO Coupler

U-Joint

Quick Disconnect Ring “Released” Position

Internal Balls

Locked on Shaft

PTO Drive

Shaft

PTO Drive

Shaft

9. With the counterweight springs connected, the weight on the deck caster wheels should be 15 to 25 Ib (6.8 to 11.3 kg); this adjustment is preset at the factory. If required, the spring tension can be adjusted by tightening or loosening the elastic stop nuts located underneath the lower spring hook, or contact your local dealer if additional help is required. Refer to Deck Counterweight Spring Installation photo.

Spring Tension Adjustment Nut

Located Under Lower

Spring Hook (Not Visible)

Counterweight Springs

Clip Onto Body With

Forward Body Tilted Up

PTO Coupler

U-Joint

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

8. Raise the mower body (instead of lifting the front of deck) and clip the counterweight springs to the receptacle on front of body. Lower the body to tension the springs. (Refer to Deck Counterweight Spring Installation photo.)

Coupler Ring in

Locked Position

Hitch Pins Lock Deck on Support Arms

Deck Counterweight Spring Installation

Assembly Instructions

Deck Leveling

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 measurements vary more than 1/8 in. (3 mm), add a washer shim under the deck support pins on the low side to level the deck.

3. Check the front-to-rear level. Rotate the blades to point forward. Measure the distance from blade tip to ground on the front and rear. The rear of the blade should be 1/8 to 1/4 in. (3 to 6 mm) higher than the front of the blade; shim the rear (or front) deck support pins equally to achieve at

least 1/16 in. (2 mm) difference.

NOTE: 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 as a possible cause of the deck not being level.

4 in. (102 mm)

Wood Block

Should not vary more

than 1/8 in. (3 mm)

side-to-side

NOTE: For the 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.

Should be 1/8 in. (3 mm)

to 1/4 in. (6 mm) higher

at the rear of the blade

4 in. (102 mm)

Wood Block

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 operation, some of these items will not need to be checked every day, but the operator should be aware of the condition of each.)

For proper fuel and lubricants refer to Specications.

FILL FUEL TANK

Fill the fuel tank using clean, fresh automotive grade unleaded gasoline (87 octane minimum, 10% ethanol maximum).

DANGER

Handle gasoline with care. Gasoline is highly ammable and its vapors are explosive. Use safe refueling procedures:

• DO NOT ll fuel tank with the engine run-

ning.

• If the engine is hot, allow to cool before

refueling.

• Use an approved fuel container.

• Fuel the mower outdoors.

CHECK ENGINE CRANKCASE OIL LEVEL

Check the engine crankcase oil level before use and after each 8 hours of continuous operation. Refer to LUBRICATION for Checking Engine Crankcase Oil Level in Maintenance Instructions.

CHECK AND SERVICE ENGINE AIR 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 every 100 hours). For detailed procedures, refer to CLEANING the Engine Air Cleaner Sys- tem 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. Refer to CLEANING the Cylinder Head Cooling Fins in the Maintenance Instructions for this procedure.

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).

• DO NOT smoke while refueling.

• Avoid spilling fuel; use a funnel or spout.

• DO NOT overll the fuel tank; ll up to

about 1 in. (25 mm) below the top of tank.

IMPORTANT: DO NOT permit dirt or other foreign

matter to enter the fuel tank. Wipe dirt from around the filler cap before removing. Use a clean fuel storage container and funnel.

IMPORTANT: DO NOT mix oil with gasoline. Always use fresh, automotive grade unleaded gasoline. DO NOT use gasoline containing greater than 10% ethanol. DO NOT use additives, such as carburetor cleaners, deicers, or moisture removing agents. DO NOT use gasoline blended with methyl alcohol.

INSPECT THREE (3) DRIVE BELTS

Engine/PTO (2) and Ground Drive.

CHECK HYDROSTATIC TRANSAXLE OIL

LEVEL

Refer to LUBRICATION for Transaxle Lubrication in Maintenance Instructions.

CHECK FUNCTION OF SAFETY INTERLOCK

SWITCHES

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

Assembly Instructions

CHECK TIRE PRESSURE

Deck Caster Wheel = 20 PSI (137 kPa) Drive = 15 PSI (103 kPa) Tailwheel = 20 PSI (137 kPa)

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 position by unlocking the deck lock levers on each side of the carrier frame and inserting the deck hook into the tilt-up latch on the tractor body. Before operating the tractor, make sure to re-engage the deck lock levers after lowering the deck to the normal operating position.

CAUTION

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

DANGER

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

CHECK MOWER BLADE CONDITION,

SHARPNESS, BALANCE, AND SECURITY OF MOUNTING

The blade mounting nuts on gear driven decks should be torqued to 60 lb·ft (81 N·m), and the blade mounting bolts on belt driven decks torqued to 70 lb·ft (95 N·m). If blade sharpening is required, refer to

CHECKING/SERVICING for Sharpen Mower Blades in Maintenance Instructions.

ADJUST MOWER CUTTING HEIGHT, IF RE-

QUIRED

Tilt-Up Hook and

Latch Connected

Tilt-Up

Latch

Tilt-Up

Hook

Deck Secured in TILT-UP Position

Tilt Bar

Position the hitch pins in the four deck support pins. Refer to the “Cutting Height Adjustment” decal on the deck gearbox cover.

PERFORM ANY ADDITIONAL PROCEDURES

called for on the MAINTENANCE SCHEDULE CHART in Maintenance Instructions.

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 efcient operation

of the mower.

Ignition Switch

The ignition switch is located on the right front of the body and is used to start and stop the engine. The switch has three positions: “O” is the OFF position, ON (RUN) is the position the key returns to after starting, and “S” is the START position. When start- ing the engine, turn the key clockwise to the “S” position.

Do not hold the key in the “S” position longer than 10 seconds. If the engine does not start, return the key to the “O” position for at least 60 seconds before making a restart attempt. Prolonged cranking can damage the starter motor and shorten battery life. Release the key when the engine starts, and it will return to the ON (RUN) position. To stop the engine, rotate the key counterclockwise to the “O” position.

OFF

Ignition Switch

START

Blade Clutch

(PTO)

Body Latch

(Not Visible)

Forward Speed

Control (FSC)

Ignition

Switch

Engine

Service Light

Parking

Brake

Parking Brake

Throttle

Steering

Levers

Circuit

Breaker

Hourmeter

Operating Controls

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 back- ward toward the IDLE position decreases engine speed.

Throttle

Throttle Location

Forward Speed Control (FSC)

Forward Speed Control (FSC) has two functions: One is to set forward travel speed, and the other is to establish the NEUTRAL-PARK position. When the FSC lever is moved into the FORWARD posi- tion, a friction lock holds any forward speed setting from 0 to 8 mph (0 to 12.9 km/h). The ground speed is proportional to the lever position; the further the lever is advanced forward, the faster the tractor moves. It is not necessary to hold the FSC in position since the friction lock maintains the selected lever position. Pulling back on the steering levers overrides the FSC setting and slows or stops forward travel. Releasing the steering levers allows the tractor to resume forward travel at the speed set by the FSC lever. To stop and park the machine, the FSC lever is moved backward to the NEUTRAL-

PARK position.

Steering Levers

Each drive wheel is controlled by its own independent steering lever, for both steering function and FORWARD/REVERSE motion. The FSC lever sets the maximum forward speed, and also sets the forward position of the steering levers. The steering levers operate only with a backward pulling movement of the lever, which causes the drive wheel for that lever to first slow down, stop, and then reverse with a full backward lever stroke. The levers are released to the FORWARD position for “straight- ahead” 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.

Oil Pressure Warning Horn

The oil pressure warning horn indicates that engine oil pressure is below the safe operating level [below 3 to 5 PSI (21 to 34 kPa)]. This horn will sound when the ignition is turned ON, but should go off after the engine is started. If the horn fails to sound when the ignition switch is turned ON, it could indicate a horn failure. If the horn sounds during engine operation, stop the engine immediately and correct the source of the problem before further engine operation.

IMPORTANT: Continued operation of the engine with a low oil pressure condition WILL cause severe engine damage.

Oil Pressure

Warning Horn

Blade Clutch (PTO)

The blade clutch lever is located on the right side of the seat behind the right fender and is used to engage and disengage the mower blades. The blade clutch lever has two positions. Pushing the lever DOWN engages the PTO that drives the mower blades. Pulling the lever UP disengages the PTO and engages the blade brake.

Warning Horn Location

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 internal damage to the transaxle.

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

Transaxle Lockout Arms

The transaxle lockout arms disengage the transaxles. By lifting the arms up and locking them into place with the shoulder on the arm in the chassis notch, the transaxles are released to permit freewheeling. By releasing the arms and recessing them back toward the chassis, the transaxles are engaged for normal operation. The transaxle arms in the LOCKOUT position are used to enable moving the machine without the engine running (e.g., for service). Refer to TRANSAXLE LOCKOUTS in this section for operating instructions.

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

Parking Brake Engaged

Parking Brake Disengaged

Hydro Lockout

Arms

Hydro Lockout Arm Location

Engine Service Light

The engine service light indicates that the engine Electronic Control Unit (ECU) has detected a fault in the engine performance. When this light illuminates during operation, contact an authorized Kohler Service dealer to diagnose the fault.

IMPORTANT: Continued operation of the engine with an illuminated service engine soon light will result in sub-standard performance and MAY cause engine damage if not corrected as soon as possible.

Circuit Breaker

One manual reset circuit breaker is located on the right front of the body. It has a button that pops out if the circuit breaker trips. The 20 amp circuit breaker protects the safety and ignition switch circuits.

Operating Instructions

Body Latch

The front portion of the tractor body hinges forward for maintenance access and is latched down in the OPERATING position. To raise the body, move the latch release backward.

Body

Latch

Body Latch

Hourmeter

The hourmeter, which is located on the right front of the body, displays operating time accumulated when the PTO is in the ENGAGED position.

Procedure Interval* Reminder

Oil Change (Break-In)**

Lubricate and Check Levels

Oil Change

4-6 Hours

24-26 Hours

49-51 Hours***

C H G

OIL

LUBE

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.

The hourmeter provides maintenance reminders after certain hours of operation. The hourmeter screen will start flashing the reminder one hour prior to the recommended interval and will continue until one hour after the recommended interval (two hours). The hourmeter does not have a manual reset

function.

Hourmeter

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)

Neutral-Park

Position

Reverse Drive

Wheel Motion

Position

THROTTLE

Fast

Throttle

Position

Idle

Position

Full Forward

Ground Speed

Position

Intermediate

Ground Speed

Position

Neutral-Park

Position

<15°

1. 2.

PARKING

BRAKE

Operating Controls (Top View from Drivers Point of View)

Engaged

Position

Disengaged

Position

Engaged

Position

8600-5

Disengaged

Position

BLADE CLUTCH

(PTO)

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, and the blade clutch and parking brake are DIS-

ENGAGED.

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 follow these guidelines can damage the starter motor and shorten battery life. Contact your Walker dealer or authorized engine dealer for additional help.

ADJUSTING GROUND SPEED AND STEERING

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 TRANSAXLES, steer ing and ground operation should be learned and practiced until the operator is completely comfortable handling the ma chine BEFORE ATTEMPTING TO MOW.

NOTE: Release parking brake to prevent extra

load on the starter if the transmission neutral is slightly out of adjustment.

CAUTION

A safety interlock switch system PREVENTS CRANKING the engine with either the Forward Speed Control out of neutral or the blade clutch (PTO) engaged. If the engine cranks otherwise, the safety system is not working and should be repaired or adjusted before operating the mower. DO NOT disconnect safety switches; they are for the operator’s protection.

2. Move the throttle 1/4 to 1/2 open (toward FAST) and turn the ignition switch to the START posi- tion to start the engine. Release the key to ON (RUN) position as soon as the engine starts.

DANGER

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

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).

Operating Instructions

Beginning Recommendations are:

♦ Learn operation of the mower in an open area away from buildings, fences, and ob-

structions. Learn operation on at ground

BEFORE operating on slopes.

♦ Start maneuvering the mower with SLOW engine speed and SLOW Forward Speed Control setting until familiar with all operating characteristics.

♦ Remember it is not necessary to hold the steering levers forward (a unique Walker feature); always PULL on the levers for steering or for reverse motion of the mower.

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

♦ Learn to operate the steering levers with smooth action. Jerky movements are hard on the transmission and lawn. For sharp turns, do not allow the inside wheel to stop and twist on the grass. Pull the steering lever controlling the inside wheel into reverse for a smooth “rolling” turn (one wheel 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 TRALPARK position.

NOTE: This is exactly the same procedure

used to normally stop and park the machine.

CAUTION

An operator presence switch (seat switch) will cause the engine to stop if the FSC is out of the NEUTRAL-PARK position and the operator is not in the seat. The function of this switch should be checked by the operator raising off the seat with the tractor moving forward; the engine should stop. If the safety sys tem is not working, it should be repaired or replaced before operating the mower. DO NOT disconnect the safety switches; they are for the operator’s protection.

NOTE: If the FSC lever will not stay in the se-

lected position, the friction lock needs to be adjusted. Refer to ADJUSTMENTS for Step 7 - Forward Speed Control Friction Adjustment in the Maintenance Instructions.

2. Steer by pulling the lever on the side of desired direction of turn, e.g., pull the LH lever to turn left. To minimize the possibility of overcontrol, use only one hand on both steering levers.

Pull Steering

Levers With

Left Hand

WARNING

If either of the transmission drive belts break during slope operation, 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.

Forward Speed Control

(FSC)

Correct Operator Hand Position on the Controls

3. Reverse direction of the mower by pulling both levers backward.

Keep Feet On Footrest

When Moving

Operating Instructions

NOTE: Smooth action on the steering levers will produce smooth mower operation. Remember to keep the engine and ground speed slow until learning the control response.

WARNING

When moving forward, DO NOT suddenly put the tractor in reverse by rapidly pulling on the steering levers, especially when going downhill, as this can lift the tractor tail wheel off the ground and set up a bucking motion due to operator overcontrol. If bucking does occur, immediately stop the bucking action by pulling the Forward Speed Control (FSC) lever into the NEUTRAL-PARK position.

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

CAUTION

An operator presence switch (seat switch) will cause the engine to stop if the blade clutch is engaged and the operator is not in the seat. The function of this switch should be checked by the operator raising off the seat and engaging the blade clutch; the engine should stop. If the switch is not working, it should be repaired or replaced before operating the mower. DO NOT disconnect the safety switches; they are for the operator’s protection.

IMPORTANT: DO NOT engage the blade clutch

when transporting the mower across drives, sidewalks, loose materials, etc. DO NOT engage the

blade clutch with the PTO shaft disconnected

(the mower deck removed from tractor).

5. Stop ground travel by pulling both steering levers backward to the NEUTRAL-PARK 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 po- sition, the transmission control needs to be adjusted. Refer to ADJUSTMENTS for Step 3 - Neutral Position Adjustment in the Maintenance

Instructions.

ENGAGING THE BLADE DRIVE

1. Set the engine throttle at about 1/3 speed. Do not attempt to engage the blade clutch at high engine speeds. This will drastically short-

en drive belt life. Use only moderate engine speed when engaging the blade clutch.

2. Engage the blade clutch by moving the blade clutch lever forward SLOWLY. For disengage- ment, move the blade clutch lever backward

SLOWLY.

Engaged

Position

Blade Clutch Engaged

Disengaged

Position

Blade Clutch Disengaged

Operating Instructions

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

nance Instructions

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-PARK position and then move the FSC lever backward to the NEUTRAL-PARK position.

2. Slow the engine to a fast idle; put the throttle in the 1/2 throttle position.

if blades are out of time.

Mainte-

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. Also, engaging the parking brake is recommended when stopping or parking the machine in a confined space with little tolerance for movement.

IMPORTANT: The hydrostatic transaxles lock to prevent the mower from rolling freely with the engine stopped. However, if the mower is parked on a slope, it is necessary to ENGAGE the parking BRAKE to prevent the mower from creeping. This is due to a small amount of slippage in the transaxles, especially when transmission fluid is warm.

WARNING

3. Disengage the blade clutch.

NOTE: Reducing engine speed prior to disengaging the blade clutch will reduce wear on the brake band and brake drum, increasing the life of these components.

WARNING

A brake stops the cutter blades from

freewheeling within ve (5) seconds after

disengaging the clutch. If the brake system malfunctions and the blades do not

stop within ve (5) seconds, the brake

should be repaired or replaced before operating the mower. Contact your Walker dealer.

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 shutdown solenoid, stopping at low idle may cause engine run-on or backfiring.

NOTE: The emergency stop procedure is ex-

actly the same procedure as used to normally stop and park the machine.

Operating Instructions

ADJUSTING CUTTING HEIGHT

WARNING

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

Cutting height is adjusted by positioning the four (4) retainer hitch pins in a series of seven vertical holes on the deck support pins. Lift handles have been pro vided on each end of the deck to assist in raising the deck while positioning the hitch pins. Cutting heights range from 1 in. (25 mm) [top holes] to 4 in. (102 mm) [bottom holes] in 1/2 in. (13 mm) increments.

Deck Support

Hitch Pin

3. The mower will “freewheel” with the arms in the LOCKOUT position. The levers must be in the highest position to completely unlock the transmissions.

Hydro Lockout Arm

Hydro Lockout Arm - Freewheel Position

4. After moving the mower, release the arms, placing them in the normal OPERATING position. The transmission arm ends should be completely retracted against the chassis, otherwise operation of the transmission maybe erratic.

Lift Handle

Cutting Height Adjustment

TRANSAXLE LOCKOUT

IMPORTANT: DO NOT TOW this mower faster than

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

To move the mower with the engine NOT running (dead battery, maintenance, etc.), the transaxles need to be unlocked (released).

1. Raise the body.

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

Hydro Lockout Arm

Hydro Lockout Arm - Normal Operating Position

Operating Instructions

RECOMMENDATIONS FOR MOWING

DANGER

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

• When mowing 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 skid-

ding of the drive tires. Use smooth control movements 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 backward).

Avoid Low Hanging Branches

IMPORTANT: Operate the engine at full throttle

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

• 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 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 Deector Shield in

Lowest Position

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 26% grade.

Maximum

Recommended

Slope -

Do Not Operate

on Steep Slopes

60 lb·ft (81 N·m)

8600-9

8600-14

15°

16 in.

52 in.

Maximum Recommended Slope

DANGER

RECOMMENDATIONS FOR TILT-UP DECK OPERATION/TRANSPORT

To avoid potential deck and/or tractor damage while using the tilt-up deck, the following recommendations are offered:

• Do not move the tractor with the deck in the tilt-

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

• The tractor body should never be tilted for-

ward with the deck in the tilt-up position. This can

cause the deck to unhook from the tractor and fall with considerable force, potentially causing deck or tractor damage and/or bodily injury.

• When transporting a tractor with the deck in the

tilt-up position (on a truck or trailer), the deck should be secured to the vehicle with a strap or rope (stop

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

Do not mow or drive the tractor within 5 feet (1.5 meters) of an embankment or retaining wall with drop off.

5 FT

MINIMUM

No Driving Zone

Maintenance Instructions

MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL B23i

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 Cleaner System

Check Air Filter Restriction Gauge

Check Battery Electrolyte Level

Lubricate Grease Fittings and Oil Points*

Check Transaxle Fluid

Check Tire Pressure

Check Drive Belts (Engine/PTO, Ground Drive)

Check Deck Gearbox Oil Seals

Check Safety Switch System

Check Security of Drive Tire Mounting Nuts (75 to 85 lb·ft)

Check Blade Brake Action

Clean Transaxle Housing

Clean Engine Cooling Fins

Check Air Filter Element***

Check/Regap Spark Plugs

Change Engine Crankcase Oil**

Change Engine Oil Filter

Replace Fuel Filter

Change Transaxle Oil and Filter

Replace Air Filter Element***

Check FSC Friction Lock

Check Fuel Lines and Clamps

Service Solenoid Shift Starter

Check PTO U-Joints for Wear/Looseness

Service Battery

Replace Fuel Lines and Clamps

Replace Ignition Wires

CAUTION

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

Daily

x 39

x 45

x 49

x 52

x 51

x 47

Hours

100

Hours

200

Hours

400

Hours Yearly

Every

2 Years

x 51

x 41

x 45

x 52

x 53

x 54

x 52

x x 54

x 50

x 46

x 48

x 54

x 40

x 58

x 44

x 48

x 55

x 54

x 51

x 54

Ref.

Page

∗ More often in extremely dusty or dirty conditions

∗∗ Change engine oil and lter after rst 58 hours of operation of a new engine (break-in period)

∗∗∗ Air cleaner is remote mounted Enginaire™ unit, replace lter(s) every 400 hours or when worn or damaged

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

Maintenance Instructions KOHLER TIPS

IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE

Fuel System

• Fuel must be clean - free from water, dirt, and or-

ganic material.

• Change fuel filter on a regular basis and when con-

tamination is suspected or found in the fuel.

• The fuel pump module is a sealed unit and is not

serviceable; opening the fuel pump module will void the warranty. Additionally, the fuel pump module and the fuel lines between it and the injectors are pressurized. For service of the pressurized fuel system including the fuel pump module, fuel lines, and fuel injectors contact your Walker dealer or authorized Kohler service dealer.

Starting/Stopping

• Start engine with the throttle advanced off idle

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

• Keep the battery fully charged.

• Match crankcase oil viscosity to the ambient tem-

perature, allowing the engine to crank faster and start easier.

• Allow engine to run at idle for a few seconds be fore

stopping engine to avoid run-on or backfiring.

• Check performance of the cooling system by start-

ing the engine, holding a hand adjacent to the cylinder head, and feeling the cooling airflow.

DANGER

Make sure to keep hands clear of exhaust

pipe, mufer, and moving parts when checking airow.

• Operate the engine at full speed when mowing.

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

Air Cleaner System

• Use only Enginaire

Aftermarket elements may not seal in the air cleaner housing, allowing dirt to enter the engine. Also, aftermarket filters often skimp on the filtration media and require more frequent replacement (see following instructions).

air cleaner elements.

• Use the air filter restriction gauge to indicate the

need to service the air filter.

• Do frequently check the Turbine Precleaner (lo-

cated in the end cap of the air cleaner assembly) for free movement of the internal fan. Shine light into end cap to verify movement of fan with engine running.

Cooling System

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.

• Keep engine air intake screen and cylinder head

fins free of grass clippings, chaff, and dirt. Inspect intake screen and cooling fins for cleanliness and no damage.

• Periodically remove two access panels in the en-

gine shroud to inspect and clean cylinder head cool ing fins.

• DO NOT overservice or frequently “disturb” the

air lter. A dirty air filter actually cleans better than a new one. Changing and cleaning the air filter too often can ac tually reduce filter efficiency 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 filter restriction gauge.

• When the air filter element is removed or re placed,

make sure all dust is cleaned out of the air cleaner housing and hose. Use a damp cloth and wipe the

interior of the canister and hose clean (a 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.

Maintenance Instructions KOHLER TIPS/LUBRICATION

Oil

• Use only multi-viscosity oils as specified with the

viscosity matching ambient temperatures for the engine operating conditions. This will aid starting in cold weather and assure proper lubrication in hot weather.

• Use only Kohler oil filters. Aftermarket filters may

not seal properly and/or have the incorrect pressure relief valve for proper lubrication.

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.

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 press all the way down.

4. Remove the dipstick again and check the oil lev el on the dipstick. The oil level should be within the “Operating Range” on the dipstick (between the “L” mark and the “F” mark).

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 Specications for proper crankcase lubricant. Fill up to, but

not above, the “F” mark on the dipstick.

IMPORTANT: DO NOT overfill the crankcase

(oil above “F” mark) as this CAN result in engine overheating, loss of power, and possible en gine damage.

Engine Oil

Engine Break-In Oil

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

in period of 5 hours. Thereafter, change oil after every 100 hours of operation.

Checking Engine Crankcase Oil Level

Check the engine crankcase oil level before use and

after each 8 hours of continuous operation.

IMPORTANT: The importance of checking and

maintaining the proper crankcase oil level cannot be overemphasized. Check the oil level BEFORE

EACH USE.

1. Park the mower on a level surface with the en gine stopped. Also, make sure the engine

is cool and oil has had time to drain into the sump (allow at least ve (5) minutes after stopping the engine).

Operating

Range

Dipstick Operating Range

{

IMPORTANT: NEVER check or add oil with the engine running.

Maintenance Instructions LUBRICATION

Changing Engine Crankcase Oil/Oil Filter

Change the engine crankcase oil after every 100 hours of operation and replace the oil filter every

other oil change (every 200 hours of operation).

1. Park the mower on a level surface with the en gine stopped. The engine oil should be warm before draining. If not warm from operation, start the engine and run a few minutes to warm the oil.

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

Dipstick Oil Fill

Oil Drain Location

(View from the Rear Left Side of Tractor)

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

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

Oil Drain

Dipstick and Oil Fill

(View from Above Right Side of Tractor)

Oil Filter

Oil Filter Location

(View from the Rear Right Side of Tractor)

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 this manual or the engine owner’s manual. Use the recommended oil viscosity for the expected ambient temperature. Oil with the correct viscosity will aid starting in cold weather and assure proper lubrication in hot weather. Fill up to, but not above, the “F” mark on the dipstick. Crankcase capacity is 1.85 quarts (1.75 liters) plus 1/2 pint (0.24 liters) for the new oil filter.

Specications in

Maintenance Instructions LUBRICATION

IMPORTANT: Check the dipstick reading before adding the last 1/2 pint of oil and ll 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 engine is first operated with a new oil filter, the oil level drops slightly as the filter is filled with oil.)

Mower Deck Gearbox Lubrication

On gear driven decks, the mower deck gearboxes (tee gearbox and blade drive gearboxes) are connected as a unitized assembly, and oil flows freely between them. The gearboxes are permanently lubricated (oil filled) and sealed requiring no scheduled lubrication. However, the gearbox oil seals should be checked every 25 hours for indication of an oil leak; particularly the lower seals on the blade drive gearboxes should be inspected, since they operate in a dirty environment. If an oil leak is noted, replace the oil seal and relubricate the gearbox assembly as follows:

4. Check the level of lubricant in the gearboxes. If the lubricant is low, add SAE E.P. (Extreme Pressure) 80W-90 (API GL-5) gear lube until the oil level is up to (submerges) the horizontal shaft in the gearbox (shaft parallel to cover plate).

NOTE: 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

Grease Fitting and Oil Point Lubrication

·in. (3 N·m).

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

Blade Drive Gearboxes

Tee

Gearboxes

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.

Lubricate the grease fittings and oil points after ev ery 25 hours of operation. Lubricate more often when operating in dusty or dirty conditions. Use SAE general purpose lithium or molybdenum base grease for grease fittings and light machine oil (SAE 10) to lubricate oil points. Lubricate the locations shown

in the Chassis and Deck Lubrication Points illustration.

NOTE: PTO universal joints (on the deck and trac-

tor) require routine lubrication after every 25 hours of running time. Remove tractor PTO quick disconnect tube assembly for easy access to grease fittings.

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

Mower Deck Installation on Tractor in the Assem bly Instructions.

Maintenance Instructions LUBRICATION

Ident Lubrication No. No. Location Type Places

1 Deck Caster Wheel Fork Pivot Grease 2 2 Deck Caster Wheel Bearing Grease 2 3 Blade Spindle GreaseΔ 3 4 Pivot Assembly, Tilt-Up Deck Grease 4 5 Deck Support Arm Socket Grease 2 6 Right Angle Gearbox Oil*Δ 1 7 Universal Joint Shaft Assembly Grease** 1(2Δ) 8 Dolly Wheel Retract OilΔ 1 Lever and Linkage

9 Dolly Wheel Pivot GreaseΔ 1 10 Idler Arm Pivot GreaseΔ 1 11 Tee Gearbox, Deck Oil* 1 12 Blade Drive Gearbox Oil* 2 13 Steering Lever Pivot Grease 2 14 Deck-to-PTO Coupling Grease 1 (Grease Spline Slide Area) 15 Universal Joint Tube Assembly Grease** 1 16 Deck Support Arm Pivot Grease 2 17 FSC Lever Pivot Grease 1 18 Body Latch Pivot Oil 1 19 Clutch Actuator Spring Assembly Grease 1 20 Hydro Idler Pivot Grease 1 21 PTO Clutch Lever Pivot Grease 1 22 Transaxle Oil Reservoir Oil/20W-50 1

Ident Lubrication No. No. Location Type Places

23 Tail Wheel Caster Fork Pivot Grease 2 24 Rear Axle Pivot Grease 1 25 Rear Wheel Bearing Grease 2 26 Engine Dipstick Oil*** 1 27 Throttle Control Cable Ends Oil 2 28 Engine Oil Filler Oil*** 1 29 Brake Band Pivot Pins Oil 2 30 PTO Belt Tightener Pivot Grease 1 31 Parking Brake Clevis Oil 2 32 Parking Brake Lever Grease 1 33 Throttle Control Pivot Oil 1

* Gearboxes are permanently lubricated and sealed requiring

no scheduled lubrication. Oil level should be checked only when an oil leak is noted.

** Grease every 25 hours.

*** Refer to Engine Oil located on page 39.

Belt Driven Decks Only

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

For other Deck Lubrication Points, refer to Deck and Car-

rier Frame Illustrated Parts Manual.

4 895 7 6 5 4

212

Lubrication Points for Optional Belt Driven Decks (DS52 Shown)

Maintenance Instructions LUBRICATION

4 5 4

27 & 33

27 26

Chassis and Deck Lubrication Points (DS42 Shown)

Maintenance Instructions LUBRICATION

DS52 or DS62 Mower Deck Lubrication

There are several special lubrication requirements for the DS52 or DS62 mower deck in addition to the require ments detailed in the Chassis and Deck Lubrica tion 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 ev- ery 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 8 hours with SAE general purpose lithium or molybdenum base grease.

Transaxle Oil and Filter Change

Change the transaxle oil after the initial break-in period of 75-100 hours. Thereafter, change oil ev- ery 400 hours of operation as follows:

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

2. Remove the oil filter guard, remove and replace the oil filter using an oil filter wrench. Tighten filter by turning filter 3/4 to 1 turn after gasket contacts the filter base surface. Reinstall the oil filter guard. (Refer to Transaxle Oil Drain Plug, Filter, and Guard Location illustration.)

Oil Filter

Belt Drive

Gearbox

Dolly Wheel

Pivot

U-Joints

Gearbox, Dolly Wheel, and U-Joint Lubrication

Oil Filter

Guard

Transaxle Oil Drain Plug, Filter, and

Guard Location

(Shown with Deck Support Arms

Removed for Clarity)

3. Reinstall drain plugs.

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

5. Fill the transaxles with 20W-50 (API Service Class SL or higher) oil through the opening where the elbows were. Fill up to the opening.

6. Before reinstalling the elbows, screw the locking nut on the elbows down until they are snug (the o-ring on the elbow will be to the bottom of the o-ring groove).

Oil Drain

Plug

Maintenance Instructions LUBRICATION/CLEANING

Transaxle Lubrication

Elbow

Reinstall Transaxle Elbows

7. Reinstall the elbows. When the elbow begins to be snug, position the elbow as it was when removed and tighten the locknut. Reinstall reservoir hoses to elbows.

8. Fill reservoir to 1/4-1/2 in. (6-13 mm) with 20W-50 (API Service Class SL or higher) oil.

Screw Locking

Nut Down

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

Service Class SL or higher) engine oil.

• Inspect both transaxle cases and hoses after ev-

ery 25 hours of operation for visible leaks.

• The fluid level of each transaxle can be checked

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

Reservoir Cap

Cold Level

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

10. If the transaxle sounds noisy or has poor steering response, there may be air trapped in the transaxle. Follow purge instructions below.

11. If oil needs to be added refer back to steps 5-10.

12. To purge air from transaxle, raise unit and block with tires off the ground. With engine running, slowly move Forward Speed Control forward and backward 5 to 6 times. Turn off engine and check oil level and add if needed. Repeat procedure until transaxle operate at normal noise levels and move smoothly in forward and reverse.

Mower Deck Spindle Lubrication

For belt driven decks, lubricate each deck spindle grease fitting every 25 hours. Use SAE general purpose lithium or molybdenum base grease for grease fittings.

Expansion Reservoir Location

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

To prevent engine overheating and possible engine damage, clean grass clippings, chaff and dirt from the rotating engine air intake screen every 8 hours of operation. In certain mowing conditions (dry grass, leaves, tree “cotton”, etc.) it may be necessary to check and clean this area several times each day to prevent engine overheating. Also, visually check inside cylinder head shroud and between cylinder head fins for material packed in this area which would prevent cooling airflow; remove shroud and clean as required.

Maintenance Instructions CLEANING

Check Airflow

with Hand

Rotating Engine Cooling

Air Intake Screen

Keep Rotating Engine Cooling

Air Intake Screen Clean

CAUTION

Operating the engine with a blocked air in-

take screen, dirty or plugged cooling ns,

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

Cooling System Airow

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.

IMPORTANT: Yearly, it is good maintenance practice to remove the engine cooling shroud and clean the cylinder head cooling fins thoroughly to prevent overheating and extend engine life. Make sure cooling shroud is reinstalled properly. This procedure will require removing the engine from the chassis.

Engine Cooling

Fin Access Panels

Kohler Engine

Shroud

Make sure to keep hands clear of exhaust

pipe, mufer, and moving parts when checking airow.

Engine Air

Intake Screen

Engine Air Intake Screen

and Cooling Fin Access Panels

Maintenance Instructions CLEANING

Engine Air Cleaner System

Turbine Precleaner

The engine air cleaner system includes a turbine precleaner; a spinning fan driven by the intake airflow separates dust from the air, giving the initial stage of air cleaning. Every 100 hours check the Turbine Precleaner (located in the end cap of the air cleaner assembly) for free movement of the internal fan. Shine light into end cap to verify movement of fan with engine running.

Enginaire™ VLR Air Cleaner

A remote mounted Enginaire™ air cleaner provides the air filtering function. The paper filter element slides over an outlet tube inside the air cleaner canister with radial sealing action, eliminating the possibility of dust leaks due to improper filter installation. Intake design and internal baffling provide dust separation and automatic precleaning action. Daily or frequent servicing of the air cleaner is not required. Use the air filter restriction gauge on the air cleaner outlet to indicate when the air filter needs servicing -- a yellow indicator will show when the filter is overly restricting airflow into the engine.

IMPORTANT: Use only Enginaire™ air filter elements for replacement (S/N 133534 and on uses Walker 5090-4 and 5090-5). Aftermarket filters may not seal properly or filter efficiently.

IMPORTANT: The Enginaire™ VLR air cleaner uses a dry paper-type air filter element. NEVER apply oil to the paper element.

Air Filter

Restriction Gauge

Push Button to Reset

Indicator After Service

Air Filter Restriction Gauge Location

Hose

Clamp

EnginaireTM Air Cleaner

Air Filter

Restriction Gauge

Air Intake

Hose

Clamp

Engine

8600-12

Safety

Filter

EnginaireTM

Air Cleaner Cover

Turbine

Precleaner

Mounting

Band

Primary Filter

Element

Engine Air Cleaner System Components

Maintenance Instructions CLEANING

Inspect the paper element after every 100 hours of service and replace the element and safety filter ev- ery 400 hours (or when dirty or damaged). More frequent replacement may be required when operating in extremely dusty conditions as indicated by the air filter restriction gauge. Service the air cleaner as follows:

1. Unlatch and remove Enginaire™ air cleaner cover. Wash the cover. Check that the cover is in good condition.

2. Remove the filter element by pulling it out of the canister. There will be some initial resistance as the filter seal breaks loose and slides off of the outlet tube. Gently move the end of the filter up and down and side to side or twist to loosen the seal. Use gentle action to minimize the amount of dust dislodged as the filter is removed.

3. Discard the filter element if excessive air flow restriction has been indicated by the air filter restriction gauge and proceed to Step 6. Clean the filter element by gently tapping on a at, hard surface. If excessive restriction still exists after cleaning the element, it should be replaced.

NOTE: Use care when cleaning the filter element. The filter element and/or seal surface may be damaged by tapping too hard or hitting on an uneven surface or sharp edge. Washing the element in water or cleaning solution is not recommended. Do not try to clean the element with compressed air. Remember replacing a filter is less expensive than replacing a dusted engine.

4. Use a bright light inside the element to inspect for damage. Check the element very carefully for pin holes or other damage that will allow dirt to leak through the paper media. Replace element if necessary.

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

6. Without removing, visually inspect the condition of the safety filter for damage or holes. The safety filter should only be removed for replacement every 400 hours (or when dirty or damaged).

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

7. After removing the safety filter, use a clean, damp cloth and wipe the interior of the air cleaner canister clean. Use special care to clean both the inside and outside surfaces of the outlet tube.

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

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

9. Insert and seat the safety filter and primary element carefully into the canister, applying pressure at the outer rim of the filter; not at the flexible center. Make sure the filter element is completely in place before installing the cover.

NOTE: DO NOT use petroleum based lubricants on the sealing surfaces of the filter; use tal cum powder or dry silicone lubricants if required for filter installation.

Maintenance Instructions CLEANING

Grass Buildup in Mower Deck Housing

Canister

Outlet Tube

Primary

Filter Element

DANGER

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

Safety Filter

Air Filter Element Replacement

10. Install the Enginaire™ air cleaner cover. Latch the two (2) cover latches.

Cover

Latch

Cover

Latch

Proper Orientation of Air Cleaner Cover

Radial Sealing

Surface

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 Hook and

Latch Connected

Tilt-Up

Latch

Tilt-Up

Hook

Deck Secured in TILT-UP Position

Tilt Bar

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

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

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

DANGER

Maintenance Instructions CLEANING

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

NOTE: If the buildup is severe, it may be easier to clean the deck by removing the deck assembly from the tractor and standing the deck assembly on its “nose”.

NOTE: While some degree of material buildup in the mower deck housing can be tolerated, a point is finally reached where cutting quality deteriorates and clogging begins to occur because of too much buildup on the baffling and housing.

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

CAUTION

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

Transaxle Housing

Keeping the housing on the transaxles clean and free of obstruction is essential to avoid overheat- ing the transmission fluid and shortening transmission life. The housing should be checked every 100 hours; and cleaned if necessary.

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

Cooling

Fins

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 transmission 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

Maintenance Instructions CHECKING/SERVICING

CHECKING/SERVICING

CAUTION

DANGER

Important Battery Service, Installation, and

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 Cleaner System

NOTE: The following inspection is only an external 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 following items should be inspected:

1. Check the Enginaire™ 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 tightness.

Changing Tips for Electronic Fuel Injected Engines:

• Do not allow the battery cables to touch

opposing terminals. When connecting battery cables attach the positive (+) cable to

positive (+) battery terminal rst, followed

by negative (-) cable to negative (-) battery terminal.

• Never start the engine when the cables

are loose or poorly connected to the battery terminals.

• Never disconnect battery while engine

is running.

• Never use a quick battery charger to

start the engine.

• Never “jump start” the engine using an-

other source. Electricity uctuations can

damage the ECU (Electronic Control Unit).

• Always disconnect negative (-) battery

cable lead before charging battery, and also unplug harness from ECU before performing any welding on equipment.

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

Battery

NOTE: For initial battery service during setup, re fer to Battery Service in Assembly Instructions.

IMPORTANT: Make sure battery is securely mount-

ed in the frame. A loose battery may cause damage to the case resulting in acid leakage and severe dam age to the machine. A hazard may be created by damage to critical working parts and safety systems.

Electrolyte Level

The battery electrolyte level should be checked after every 25 hours of operation. To check electro-

lyte level:

1. Remove battery cell filler caps.

2. Check the electrolyte level. If the level is below the bottom of the vent well, fill with distilled water to the bottom of the vent wells [1/4 to 1/2 in. (6 to 13 mm) above the plates].

3. Replace filler caps.

IMPORTANT: DO NOT overfill the battery. Electrolyte will overflow through the vented caps onto parts of the machine and WILL result in severe corrosion.

Maintenance Instructions CHECKING/SERVICING

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 charging can dissipate.

• Keep sparks, ames, and smoking ma

terials away from the battery at all times.

• Make sure the battery cap vents are

open (check manifold vent on each cap).

• Make sure the battery charger is un-

plugged before connecting or disconnecting cables to the battery.

Tire Pressure

Inflate tires to pressures shown below:

Deck Caster Wheel = 20 PSI (137 kPa) Drive = 15 PSI (103 kPa) Tailwheel = 20 PSI (137 kPa)

Wheel Nut Torque

Check the eight (8) Drive Tire mounting nuts. Every 100 hours they should each be torqued to

75 to 85 lb

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/REPAIRING the Mower Blades in this section). Use

the following procedure to check and sharpen blades:

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

·ft (102 to 115 N·m).

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

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

IMPORTANT: Always disconnect the negative (-) battery terminal before charging. Failure to do so can result in damage to the ECU.

1. 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].

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 Deck Secured in TILT-UP

Position photo in CLEANING of Grass Buildup in Mower Deck Housing in this section).

DANGER

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

NOTE: PTO shaft must be disconnected be-

fore checking blades for straightness.

3. Check the blades for straightness by marking the blade tip position inside the deck housing, and then rotating the opposite end of the blade to the same position and comparing. If the difference in blade tip track is more than 1/8 in.

(3 mm), the blade is bent and should be replaced.

Maintenance Instructions CHECKING/SERVICING

WARNING

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

Blade Balancer

4. If the blade cutting edge is dull or nicked, it should be sharpened. Remove blades for sharpening by grasping the end of the blade using a rag or a thick, padded glove, while loosening and removing the nut, lock washer, and flat washer that mounts the blade.

7. Mount the blade with wing tips pointing up into

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

NOTE: Blades can be sharpened with an electric blade sharpener, conventional electric grinder, or a hand file.

Drive Belts

Blade Balanced on Magnetic

Wall-Mounted Balancer

the housing. For gear driven decks reinstall the blade, washer, lock washer, and nut. Tight-

en 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 (90 N·m).

CAUTION

ALWAYS wear eye protection and gloves when sharpening a blade.

Sharpen at

Original 30° Angle

30°

Do Not Grind or

Sharpen on Underside

Mower Blade Prole 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.

Intersection

Wear Area

Wing

Tip

Raise the body and inspect the condition of the three (3) drive belts after every 25 hours of operation -- engine/PTO drive and ground drive. If the belts show signs of cracking or deteriorating, the belts should be replaced. Refer to REPLACING/

REPAIRING the Drive Belts in this section.

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 operating in an adverse environment. The mower blade must be removed for inspection of the seal, so it is recommended to inspect the gearbox seals when blades are removed for sharpening. If an oil leak is noted, the seal should be replaced and the gearbox assembly relubricated. Refer to LUBRICATION for Mower Deck Gearbox Lubrication in this section.

Maintenance Instructions CHECKING/SERVICING

Spark Plugs

Every 100 hours, remove the spark plugs, inspect, clean, and reset the gap (or replace with a new plug). Clean spark plug with a wire brush. If the

electrodes are burned short or pitted, replace the plug (refer to Specications for the proper type of replacement plug). Check the spark plug gap with a wire-type feeler gauge and set the gap between

0.028 and 0.032 in. (0.7 and 0.8 mm). Reinstall and

tighten to 17 lb·ft (23.0 N·m). Both spark plugs should be replaced yearly.

Ignition Wires

Good preventive maintenance calls for complete replacement of spark plug wires every two (2) years.

Fuel Lines and Clamps

NOTE: The fuel system is pressurized and should

only be serviced by a Walker dealer or authorized Kohler service dealer.

Every year, inspect the fuel supply line from the tank to engine for deterioration or damage. Also, inspect the fuel line clamps for tightness. Good preventive maintenance calls for complete replace-

ment of fuel lines and clamps every two (2) years.

PTO U-Joints

The PTO U-joints should be inspected yearly for looseness and wear. If either is noticed, the respective shaft or tube should be replaced. A worn U-joint can cause vibration and extensive damage to the PTO and the whole machine.

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 three (3) safety interlock switches on the tractor; Seat Switch, FSC Neutral - Park Switch, and PTO Switch.

Blade Brake Action

WARNING

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

Check the function of the cutter blade brake by engaging the blade clutch (PTO), operating the engine at full throttle, then disengaging the clutch and measuring how quickly the blades stop. Watch the rotation of the blade drive shaft as a visual indication that movement has stopped. If the brake is working

properly, all rotation will stop ve (5) seconds

after disengagement of the clutch. If the brake system malfunctions - blades do not stop in five (5) seconds - adjust or repair the brake before operating the mower. Refer to ADJUSTMENTS for Clutch

Disengagement/Brake Action, Step 2 - Blade Brake Band Adjustment, on page 68.

If any of the following conditions occur during starting or operating, a safety interlock switch may be malfunctioning. Contact your Walker dealer for troubleshooting and/or replacement.

• With or without an operator in the seat, the engine

starts with the Forward Speed Control (FSC) and/or the PTO engaged.

• With an operator in the seat, the engine starts but

dies soon after the Forward Speed Control (FSC) or PTO is engaged.

• Without an operator in the seat, the engine con-

tinues to run with the Forward Speed Control (FSC) and/or PTO engaged.

• With an operator in the seat, the Forward Speed

Control (FSC) and PTO disengaged, and the Oil Pressure Warning Horn sounding, the starter will not engage.

Maintenance Instructions

CHECKING/SERVICING/

REPLACING/REPAIRING

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 friction lock is as follows:

1. With the engine off, place the FSC in the full FORWARD position and pull both steering levers back; the FSC lever should not move. If the FSC lever moves back when the steering levers are pulled back, the friction needs to be

increased.

2. With the steering levers held back, move the FSC lever back from the FORWARD position. With a proper amount of friction adjusted, the FSC lever should move back with a slight amount of resistance (friction). If the FSC lever movement is “stiff”, the friction needs to be

decreased.

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

ADJUSTMENTS for Step 7 - Forward Speed Control Friction Adjustment in this section.

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 operator and/or others.

Drive Belts

There are three (3) individual belts on the machine:

• Engine/PTO Belt (Matched Set of 2)

• Ground Drive Belt

The belts may be removed and replaced using the

procedures described on the following pages.

Ground

Drive Belt

Engine/PTO Belts

(Matched Set of 2)

Belt Locations

Maintenance Instructions REPLACING/REPAIRING

Engine/PTO Belt

1. To remove an engine/PTO belt:

a. Remove wire lock pins (4), open belt

guards.

Upper LH

Guard

Lower LH

Guard

Wire Lock Pins

PTO

Pulley

b. Relax belt by depressing idler arm.

c. Roll the belt off the pulley and remove the

belt.

Idler Arm

Wire Lock Pin

Right Hand

Guard

Engine/PTO Belt

(Matched Set)

PTO Guard

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

2. To replace an engine/PTO belt:

a. Reverse the removal procedure to replace

an engine/PTO belt.

Upper LH

Guard

Lower LH

Guard

Secure wire

above tab

b. Secure wire on lock pin above tab on lower

PTO guard.

Right Hand

Guard

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 to relax

belt.

LH Transaxle RH Transaxle

Drive Pulley

Ground Drive Belt Assembly (Disengaged)

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

Ground Drive

Belt

Idler Pulley

Depress Idler Pulley to

Relax Belt

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

LH Transaxle

Ground Drive Belt Assembly (Engaged)

Ground Drive

Belt

Drive Pulley Idler Pulley

RH Transaxle

Maintenance Instructions REPLACING/REPAIRING

Fuel Filter

DANGER

Gasoline is extremely ammable 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 ames 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 B23i is equipped with a 10 micron in-line fuel filter between the fuel tank and the fuel pump module. Replacement of this filter is recommended ev- ery 200 hours of operation or more frequently under extremely dusty or dirty conditions.

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

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

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.

Fuel Filter Location

In-Line

Fuel Filter

Maintenance Instructions REPLACING/REPAIRING

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 a blade hub by two (2) shear bolts (10-24 x 5/8 in. stainless steel machine screws). These bolts are designed to shear and protect the blade drive gearbox from damage if the blade encounters a shock load.

Cutting Blade

Shear Bolts

Cutting Blade Shear Bolts

NOTE: Tightening the 5/8-18 blade mounting nut to 60 lb·ft (81 N·m) is also important for proper shock load protection. It is important to not over- tighten the mounting nut since this defeats (over-

rides) the function of the shear bolts.

Shear Pin (If Equipped)

The PTO drive shaft connection to the deck gearbox has a shear pin to provide shock load protection to the mower deck drive. This system provides pri- mary shock protection in case of blade impact and will normally shear before the individual shear bolts on the blade hub.

When the PTO pin has sheared, use the following procedure to replace it:

1. Loosen the two bolts securing the PTO shaft guard on the deck; lift the guard off. (Holes in guard are slotted for easy removal.)

2. Rotate U-joint on shaft to align the shear pin hole with the hole (and shear pin fragment) in the shaft. Use a punch to drive the remaining portion of the old shear pin out.

3. Install new shear pin and secure with cotter pin.

Split Spring Pin

(Retains U-Joint on Shaft

with Broken Shear Pin)

Shear Pin

U-Joint

Tube Assembly

If these bolts shear, remove the blade and install new bolts. Refer to CHECKING/SERVICING in this section for Sharpen Mower Blades which describes the blade removal and installation procedure.

After reinstalling the blade, check blade timing (on gear driven decks) by moving blades through one (1) complete revolution. Make sure blade tips pass clear of each other. If timing is incorrect, contact your Walker dealer.

IMPORTANT: Use only Walker P/N 8067-13 shear pins for replacement to provide proper shock protection -- these pins are hardened to shear under a specific amount of load.

4. Reinstall the PTO shaft guard.

Before operating the deck, inspect the blade overload shear bolts and also check blade timing (on gear driven decks) by moving blades through one (1) complete revolution. Make sure blade tips pass clear of each other. If timing is incorrect, contact your Walker dealer.

Cotter Pin

PTO Shear Pin

U-Joint

Shaft Assembly

Maintenance Instructions REPLACING/REPAIRING

Mower Blades

Mower blades are removed and remounted as described in Sharpen Mower Blades instructions (refer to CHECKING/SERVICING in this section). During the course of sharpening and inspecting mower blades, if there are any of the following conditions of wear or damage, blades should be replaced for reasons of safety and performance of the machine:

• An excessive amount of the at 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) at 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 Mower Blade

Prole for Sharpening illustration in Sharpen Mower Blades instructions). Since sand and abra-

sive material can wear metal away in this area, the blade should be replaced when metal thickness

has worn to 1/16 in. (1.6 mm) or less.

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

Reinstall the blades following procedure from Sharpen Mower Blades instructions. If blades are replaced, always use Walker original equipment blades to ensure safety and optimum performance. The quality and performance of replacement blades offered by other manufacturers cannot be guaranteed, they could be dangerous.

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

WARNING

CAUTION

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.

Maintenance Instructions ADJUSTMENTS

ADJUSTMENTS

Transmission Control

IMPORTANT: The proper adjustment of the

transaxle 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 the initial 5 or 10 hours of operation, to begin to not travel straight (this is due to the break-in of the transaxles). To fine tune tracking, refer to Step 5 - Straight Tracking Adjustment in this section.

Step 1 - Steering Lever Position Adjustment

NOTE: For proper operation, the steering levers

should be adjusted to sit evenly using the following procedure.

1. Examine the steering levers to make sure they are parallel front to back in relation to one an- other. If they are not equal, adjust accordingly. (The handles may or may not be even at this point.)

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

NOTE: The LH steering lever is non-adjust-

able. This procedure will require adjustment of

the RH lever to make it even with the LH lever.

Levers should sit

parallel to each other

Lever Alignment

Maintenance Instructions ADJUSTMENTS

Step 2 - Steering Handles Adjustment

1. An adjustment range of approximately 3 in. (76.2 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 adjustment slide. Adjust the han dles into the most comfortable position and tighten both locknuts.

Adjustment

Slide

Locknut

(Position)

Step 3 - Neutral Position Adjustment

1. With the Forward Speed Control (FSC) in NEUTRAL-PARK, the lever should be straight up.

Adjust by loosening the jam nuts on the FSC Rod and turn the rod to attain the straight up position. Tighten the jam nuts.

Correct FSC Lever NEUTRAL-PARK Position

Locknut

(Pivot Point)

Steering Handles Adjustment

Adjust Length of

Rod to Position

FSC Lever

FSC Lever Position Adjustment

Maintenance Instructions ADJUSTMENTS

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

WARNING

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

(Components Hidden for Clarity)

Ball Joint

Jam Nut

Control Rod

Maximum Speed

Adjustment Set Screw

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

4. With the body lowered and the FSC in NEUTRAL-PARK, start the engine. With the engine

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

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.

5. Using a wrench on one tracking adjustment nut, rotate the control rod counterclockwise just until the wheel on that side begins to move for- ward. Then, counting the turns required, rotate the control rod clockwise just until the wheel stops and then begins to move in reverse. Rotate the control rod back counterclockwise half the number of turns required to make the wheel go from moving forward to reverse. The transmission is now centered in the neutral window. Tighten the jam nut on the ball joint and repeat the same procedure on the other transmission.

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

Locating Stud

Transmission

Control Arm

Tracking Adjustment Nut

(Adjusts Length of Control Rod)

Tracking Adjustment Components

Maintenance Instructions ADJUSTMENTS

Step 4 - Full Forward Speed Adjustment

1. Move the FSC to the full FORWARD speed position.

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

T-Handle

Hex Wrench

Transmission

Control Arm

Maximum

Speed Tracking

Adjustment

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

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

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

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

b. Recheck maximum speed tracking, and if

necessary continue adjusting the set screw in small increments until straight travel is achieved.

c. Tighten the jam nut.

Step 6 - FSC Neutral Switch Adjustment

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 Position 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 adjustment nut clockwise. If straight tracking and neutral are both achieved, proceed to the next step. If straight tracking and neutral cannot both be achieved, turn the tracking adjustment nut on the faster side counterclockwise until neutral is restored.

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 Fric- tion Adjustment later in this section for location of the FSC friction adjustment nut.

FSC Switch

FSC Neutral Switch Location

Maintenance Instructions ADJUSTMENTS

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

Switch Closed

in Neutral

Switch Adjustment

Bolt

Jam Nut

Front of Mower

FSC Neutral Switch Adjustment

(Side View Through Chassis)

FSC Switch

Actuator Arm

Friction Nut

CAUTION

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

Step 7 - Forward Speed Control Friction Adjustment

FSC Friction Adjustment Test

1. Place the FSC lever in the full FORWARD position, and pull both steering levers fully back; the FSC lever should not move. If the FSC lever moves back the friction needs to be increased.

2. With the steering levers held back, move the FSC lever back from the FORWARD position. With a proper amount of friction adjusted, the FSC le ver should move back with a slight amount of re sistance (friction). If the FSC lever movement is “stiff”, the friction needs to be

decreased.

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 toward the NEUTRAL-PARK position and stop when the starter motor engages. Note the position of the FSC lever where it passes through the slot in the body. The FSC lever should be within 1/8 in. (3 mm) of the NEUTRAL-PARK position. If this distance is greater than 1/8 in. (3 mm), turn the adjustment bolt down slightly and recheck switch operation. When finished adjusting, tighten the jam nut and reconnect the spark plug wire.

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

Maintenance Instructions ADJUSTMENTS

Blade Clutch (PTO)

Clutch Engagement/Belt Tension

The clutch engagement and PTO belt tension are adjusted using the clutch actuator link. After installing new PTO belts, after 10 hours and every 100 hours thereafter, check and adjust for the clutch spring assembly bolt head dimension as shown in the PTO Clutch Engaged illustration. If the clutch actuator link or clutch spring assembly have been disassembled, first reset them to their factory preset lengths (as shown in the PTO Clutch Disengaged illustration) and then proceed with adjustment as follows.

Clutch Actuator

Link

1/4 in. to 5/16 in.

(6.35 mm to 7.94 mm)

Ball Joint

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.

Blade Clutch

Engaged

Clutch Spring Assembly

(Spring Compressed)

Clutch Engagement

Arm

Safety

Switch

Clutch Arm

Blade Clutch

Idler Pulley

Front of Mower

PTO Clutch Engaged

Maintenance Instructions ADJUSTMENTS

CLUTCH DISENGAGED CLUTCH ENGAGED

Use the following procedures to check and adjust

Knuckle Joint

clutch disengagement and brake action:

Step 1 - Idler Pulley Maximum Travel Adjustment

6-1/2 in.*

(165.1 mm)

Clutch Actuator

Link

Clutch Spring Assembly (Spring Uncompressed)

*NOTE: Factory preset dimensions. Reset to these dimensions prior to adjustment if components have been disassembled.

PTO Clutch Disengaged

6 in.*

(152.4 mm)

2-1/8 in.*

(53.98 mm)

Loosen the brake band adjustment nut allowing stop arm and stop bolt to make contact (refer to Blade Brake Band Adjustment illustration).

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

2. Adjust the pivot stop bolt to give 1 in. to 1-1/8 in. (25 mm to 29 mm) pulley travel from “clutch engaged” to “clutch disengaged”.

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

1 in. to 1-1/8 in.

(25 mm to 29 mm)

Clutch Disengagement/Brake Action

WARNING

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

The declutched or disengaged position of the blade clutch idler pulley is adjustable and is set to give belt release without excessive slack and to apply the blade brake. The blade brake is activated by the brake band connected to the clutch engagement arm. The brake is designed to stop the blades within five (5) seconds after disengaging the clutch.

Idler Pulley

Clutch Pivot

Stop Bolt

Brake Engagement

Arm

Clutch Idler Pulley Travel

Clutch Pivot

Stop Arm

Maintenance Instructions ADJUSTMENTS

Step 2 - Blade Brake Band Adjustment

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

1. Adjust the blade brake band, using the adjustment nut until pulley travel is approximately 5/8 in. to 3/4 in. (16 mm to 19 mm) from engaged to disengaged.

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

CLUTCH DISENGAGED CLUTCH ENGAGED

5/8 in. to 3/4 in.

(16 mm to 19 mm)

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 exces-

sive 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 complete.

Clutch Idler Pulley Travel Adjustment

Blade Brake

Band

Blade Brake

Band Adjustment Nut

Chassis Mount

(Ref)

Blade Brake Band Adjustment

Jam Nut

Set Screw

Tilt-Up Deck Adjustable Stop

Operator’s Notes

LIMITED WARRANTY

FOR

WALKER MODEL B23i

RIDER MOWERS

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

Walker Manufacturing company will, at its option, repair or replace, without charge, any part covered by this warranty which is found to be defective in material and/or workmanship within one (1) year* after date of sale to the original retail purchaser unless the product is used for rental purposes, in which case this warranty is limited to ninety (90) days. At Walker’s request, customer will make the defective part available for inspection by Walker and/or return the defective part to Walker, transportation charges prepaid. All parts and components of the Walker Mower are covered by this warranty except the following components which are warranted separately by their respective manufacturers:

Kohler Engine Battery

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

* Extended warranties are offered for the following powertrain components:

• A two (2) year or 2000 hour (whichever comes first) warranty is offered for Hydro-Gear ZT3100 Hydrostatic transaxle;

covers full cost of replacement up to 1000 hours of use, and after 1000 hours warranty coverage is prorated against 2000 hours.

2. 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.

WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, CO 80528 • (970) 221-5614

Walker B23i Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual