Walker H24D User Manual

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Operator’s Manual

Safety, Assembly, Operating, and Maintenance Instructions

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For Safety, Read All Safety and Operation Instructions Prior to Operating Machine

Beginning S/N: 145723

P/N 2000-25

Foreword

Thank you. . .for purchasing a Walker mower. Every effort has been made to provide you with the

most reliable mower on the market, and we are sure you will be among our many satised custom ers.

If for any reason this product does not perform to your expectations, please contact your local dealer. Every customer is important to us. Your satisfaction is our goal.

Please. . .read this manual thoroughly! This manual is to be used in conjunction with the engine

manufacturer’s manual for the specic 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 clarication before operating or servicing this mower.

This manual covers Model H24d with the Kohler KDW1003 (23.7 HP) diesel 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.

Specications 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 specications listed.

Walker Mfg. Co. is continually striving to improve the design and performance of its products. We

reserve the right to make changes in specications and design without thereby incurring any obli-

gation relative to previously manufactured products.

Sincerely, WALKER MANUFACTURING COMPANY

Bob Walker, President

Table of Contents

General Information ________________ 1

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 DIMENSIONS (Tractor and Mower) __________ 4 DRIVE BELTS ___________________________ 5 SEAT __________________________________ 5 FRAME/BODY CONSTRUCTION ____________ 5 DECK CHART ___________________________ 5

Component Identication ___________ 6

Safety Instructions __________________ 9

BEFORE OPERATING ____________________ 9 OPERATING ___________________________ 11 MAINTENANCE ________________________ 13 SAFETY, CONTROL, AND INSTRUCTION DECALS _________________ 14

Assembly Instructions ______________ 19

SETUP INSTRUCTIONS __________________ 19

Battery Service _______________________ 19

Wet Battery Service __________________ 19 Dry Battery Service ___________________ 19 Battery Charging _____________________ 20 Battery Installation ___________________ 20

Mower Deck Assembly _________________ 20

Deck Caster Wheels Installation _________ 20 Deck Discharge Deector Shield Installation (DS60) ___________________ 21

PTO Shaft Guard Installation ___________ 21

Tilt-Up Roller Wheel Installation _________ 21

Mower Deck Installation on Tractor _______ 21

Deck Installation _____________________ 21 Deck Leveling _______________________ 23

Measuring Deck Levelness ____________ 23 Deck Leveling Procedure _____________ 24

PREOPERATING CHECKLIST _____________ 25

Operating Instructions _____________ 28

CONTROL IDENTIFICATION, LOCATION, AND FUNCTION _____________ 28

Ignition Switch _______________________ 28 Engine Throttle _______________________ 29 Body Latch __________________________ 29 Forward Speed Control (FSC) ___________ 29 Fuel Pump Priming ____________________ 29 Steering Levers_______________________ 30 Blade Clutch (PTO) ____________________ 30 Parking Brake ________________________ 30 Circuit Breakers ______________________ 31 Glow Plug Activation Light _____________ 31 Battery/Charge Malfunction Light ________ 31 Oil Pressure Warning Light/Horn ________ 31 Water Temperature Warning Light/Horn ___ 31 Transaxle Lockout Arms _______________ 32 Hourmeter ___________________________ 32 Roll-Over Protection System (ROPS) _____ 33 Suspension Seat______________________ 34

STARTING THE ENGINE _________________ 37 ADJUSTING GROUND SPEED AND STEERING __________________ 37

ENGAGING THE BLADE DRIVE ___________ 39

STOPPING THE MACHINE _______________ 40 FUEL TANK SELECTOR VALVE ___________ 41 ADJUSTABLE FOOT RESTS ______________ 41 ADJUSTING CUTTING HEIGHT ____________ 41 Transport Position ____________________ 42 TRANSAXLE LOCKOUT _________________ 42 RECOMMENDATIONS FOR MOWING ______ 43 RECOMMENDATIONS FOR TILT-UP DECK OPERATION/TRANSPORT _______________ 45

Table of Contents

Maintenance Instructions __________ 46

MAINTENANCE SCHEDULE CHART _______ 46 IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE _______________________ 47

Fuel System _________________________ 47 Starting/Stopping _____________________ 47 Cooling System ______________________ 47 Air Cleaner System ____________________ 47 Oil__________________________________ 47

LUBRICATION _________________________ 48

Engine Oil ___________________________ 48

Engine Break-In Oil ___________________ 48 Checking Engine Crankcase Oil Level ____ 48 Changing Engine Crankcase Oil/Oil Filter __ 48

Mower Deck Spindle Lubrication ________ 50 DR52, DS60 or DR64 Mower Deck Lubrication __________________________ 50 Transaxle Fluid Level __________________ 50 Transaxle Oil and Filter Change _________ 50 Grease Fitting and Oil Point Lubrication __ 51

CLEANING ____________________________ 54

Engine Air Cleaner System _____________ 54

Turbine Precleaner ___________________ 54 Enginaire™ VLR Air Cleaner ___________ 54

Engine Cooling System ________________ 56

Radiator Screen and Cooling Fins _______ 56 Flushing Radiator and Changing Coolant __ 57

Grass Buildup in Mower Deck Housing ___ 57 Transaxle Housing ____________________ 58

CHECKING/SERVICING __________________ 60

Engine Cooling System ________________ 60

Coolant Level _______________________ 60

Security of Air Cleaner System __________ 60 Battery ______________________________ 60

Electrolyte Level _____________________ 60 Cleaning the Terminals ________________ 61 Charging the Battery __________________ 61

Tire Pressure _________________________ 61 Wheel Nut Torque _____________________ 61 Sharpen Mower Blades ________________ 61 Drive Belts ___________________________ 62 Fuel Lines and Clamps _________________ 62 Radiator Hoses and Clamps ____________ 62 PTO U-Joints ________________________ 63 Blade Brake Action ____________________ 63 Safety Switch System__________________ 63 Forward Speed Control Friction Lock _____ 63 Transmission Control Setting ___________ 64

Neutral-Park ________________________ 64

Straight Ground Tracking ______________ 64

REPLACING/REPAIRING _________________ 65 Drive Belts ____________________________ 65

PTO Belt ___________________________ 66

Ground Drive Belt ____________________ 67

Deck Drive Belt ______________________ 68

Fuel Filter ___________________________ 69 Mower Blades ________________________ 69

ADJUSTMENTS ________________________ 71

Transmission Control__________________ 71

Steering Lever Position Adjustment ______ 71 Steering Handles Adjustment ___________ 71 Neutral Function Adjustment ____________ 72 Full Forward Speed Adjustment _________ 73 Straight Tracking Adjustment ___________ 74 FSC Neutral Switch Adjustment _________ 74 Forward Speed Control Friction Adjustment __________________ 75

Blade Clutch (PTO) ____________________ 76

Clutch Engagement/Belt Tension ________ 76 Clutch Disengagement/Brake Action _____ 77

Idler Pulley Maximum Travel Adjustment __ 77 Blade Brake Band Adjustment __________ 78

Warranty _____________________ 79

General Information

HIGHLIGHTED INFORMATION

Walker Manufacturing recommends that any ser vice 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 oper ation or maintenance of a Walker Mower are caused by

disregarding basic safety precautions or specic

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 fol-

lowing terms and their denitions 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, blade spindles, and cutter blades.

● SIDE DISCHARGE (SD) discharges mowed material from the right side of the mower deck.

● STEERING LEVERS steer the tractor by con- trolling the two transaxles.

● TRACTOR is the prime mover, including the 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 afxed to the trac-

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

mower deck serial number plate is afxed alongside

the spindle cover 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.

● FORWARD SPEED CONTROL (FSC) controls the maximum forward speed of the tractor; functioning as a cruise control.

● GROUND DRIVE refers to the dual transaxles which drive the main wheels.

● LEFT HAND (LH) refers to the left-hand side of the tractor when the operator is seated facing forward in the tractor seat.

● POWER TAKE-OFF (PTO) transmits engine power to run the cutter blades.

● REAR DISCHARGE (RD) discharges mowed material from the back of the mower deck.

● RIGHT HAND (RH) refers to the right-hand side of the tractor when the operator is seated facing forward in the tractor seat.

● ROLL-OVER PROTECTION SYSTEM (ROPS)

offers enhanced operator protection in the event of a roll-over type accident.

Tractor Model No. ______________________

Tractor Serial No. ______________________

Deck Serial No. ______________________

Engine Model No. ______________________

Engine Serial No. ______________________

Date of Purchase ______________________

Fill In By Purchaser

General Information

Serial Number

Tractor Serial Number Location

Serial Number

SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS

The detailed servicing and repair of the engine and transaxle 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

nd a local, authorized servicing agent of the com-

ponent manufacturer. Any unauthorized work done on these components during the warranty period may void the warranty. If you have any dif-

culty nding an authorized outlet or obtaining warranty service, please contact our Service Depart ment for assistance:

Walker Manufacturing Company

5925 E. Harmony Road

Fort Collins, CO 80528

1-970-221-5614

www.walker.com

Mower Deck Serial Number Location

ENGINE SERIAL NUMBER LOCATION

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

Serial Number

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

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

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

Engine Serial Number Location

Specications

MODEL H24d

ENGINE

Manufacturer/Model Kohler KDW1003, 3 Cyl., Diesel (Liquid Cooled)

Displacement cu. in. (cc) 62.7 (1028)

Max. Power HP (kW) 23.7 (17.7) @ 3600 RPM

Governed RPM 3600

Max. Torque lb·ft (N·m)

Idle RPM 1400

Crankcase Capacity qt (L) 2.5 (2.4)

Crankcase Lubricant API CF or Higher Grade Oil Only with 15W-40 Viscosity Above 5º F

Oil Filter Kohler P/N 2175-283-S

Fuel Tank Capacity gal (L) 9.4 (35.6), Two Independent 4.7 Gallon Tanks with Selector Valve

Fuel Diesel Fuel 2-D

Cooling System Capacity qt (L) 5.4 (5.1)

Cooling Fan Electric Radiator Cooling Fan with Reversible Self-Cleaning Action

Coolant 50/50 Pre-Mix Antifreeze/Water

Air Cleaner Remote Mounted Enginaire™ VLR Air Cleaner

36.8 (50.0) @ 2600 RPM

(-15º C), 20W-60 Viscosity Above 104º F (40º C), or 5W-30 Viscosity Below 32º F (0º C). (See Kohler manual for additional oil recommendations.)

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

ELECTRICAL SYSTEM

Battery 12 Volt, 340 CCA, (Interstate U1-SP40)

Charging System Flywheel Alternator

Charging Output 30 Amp DC (Regulated)

System Polarity Negative Ground

Ignition Diesel with Glow Plugs

Starter 12 Volt Electric Ring-Gear Type, Solenoid Shift

Interlock Switches Ignition Lockout by Seat Switch, Transmission Neutral and

Blade Clutch

Circuit Breaker(s) Auto Reset (One 40A, Two 30A)

Manual Reset (One 10A, One 7A)

TRANSMISSION

Manufacturer/Model Dual Hydrostatic Hydro-Gear® ZT3400 Integrated Transaxles

Steering Hand Lever Control / Individual Drive Wheel

Forward Speed Control Precision Friction Lock Lever, Cruise Control, with Neutral-Park

Position

Service Brake Dynamic Braking through Transaxles

Parking Brake Internal Mechanical Cog Lock for each Transaxle

(Single Lever Control)

Neutral Transmission Release by Manual Dump Valve

Final Drive Transaxle Direct to Drive Wheel

Specications

MODEL H24d

TRANSMISSION (continued)

Transmission Fluid

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

Transmission Oil Capacity  oz (L) 77 (2.3)

Transmission Cooling Cooling Fan Mounted on Drive Pulley

Oil Filter Hydro-Gear® P/N 52114 (Walker P/N 2026-6)

Ground Travel Speed

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

BLADE DRIVE

PTO Shaft Sliding Spline Shaft with Two (2) High-Speed U-Joints

Blade Drive Clutch and Brake Manual Belt Tightener Clutch and Band Brake

TIRE SIZE

Deck Caster Wheel 13 x 5.00-6 Pneumatic (4-Ply)

Drive 22 x 10.50-12 (4-Ply Low-Prole)

Tailwheel 13 x 5.00-6 (4-Ply)

0-10 (0-16) Innitely Variable 0-5 (0-8) Innitely Variable

(Quick Disconnect)

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

TIRE PRESSURE PSI (KPA)

Deck Caster Wheel 20 (137)

Drive 15 (103)

Tailwheel 20 (137)

DIMENSIONS (Tractor and Mower)

Length in. (cm)

Tractor Only 69 (175)

Tractor Wheel Base 45 (115)

Tractor with Tilted Deck (DR64-3)

Tractor with 64" Rear Discharge Deck (DR64-3)

Width in. (cm)

Tractor Only (Outside Tire) 46.5 (118)

Tractor with 64" Rear Discharge Deck (DR64-3)

Tread Width 36.5 (93)

Height in. (cm)

Tractor Only 46.5 (118)

With ROPS 66.25 (168)

With ROPS Lowered 51.25 (130)

87.75 (223)

107.75 (274)

66 (168)

Specications

MODEL H24d

DIMENSIONS (continued)

Weight (No Fuel) lb (kg)

Tractor Only 997 (452)

Tractor with 64" Rear Discharge Deck (DR64-3)

DRIVE BELTS

Engine PTO Walker P/N 2230 (Matched Set of 3)

Ground Drive Walker P/N 2248-1

SEAT Full Spring Suspension with Dampening and Adjustments for

FRAME/BODY CONSTRUCTION

Frame All Welded Unitized Steel Chassis

Body 14 Gauge Steel

Deck 11 Gauge Steel

1434 (650)

Back Angle, Lumbar Support, and Operator Weight. Includes Adjustable/Retractable Armrests

DECK DR52 DR64 DS60

Type Belt Driven,

Rear Discharge

Cutting Width in. (cm) 52 (132) 64 (163) 60 (152)

Cutting Height in. (cm) 1 to 5 (2.5 to 13)

Height Adjustment in. (cm) 1/4 (1) Increments, 17 Positions

Blade Length in. (cm) 18.4 (47) 22.2 (56) 20.5 (52)

Number of Blades 3

Direction of Rotation (Viewed from top of deck)

Deck Suspension Torsion-Flex Frame with Caster Wheels and Counterweight Springs

Maximum Blade RPM 3840 3200 3330

Maximum Blade Tip Speed

ft/min (m/min)

18500 (5640) 18500 (5640) 17870 (5460)

Belt Driven, Rear Discharge

Clockwise

Belt Driven, Side Discharge

NOTE: The manufacturer reserves the right to make changes in specications shown herein at any time without notice or obligation. The specications listed are for a standard conguration tractor, and may

change with the addition of optional equipment.

Component Identication

Body Tilt-Up

Latch

Forward Speed

Control (FSC)

Friction

Adjustment

NOTE: Control Identication

shown in Operating Instructions section.

Roll-Over Protection

System (ROPS)

Tilt-Up

Latch

Counterweight Springs and

Protective Covers

Deck Support

Arm

Adjustable

Footrests

Deck Tilt-Up

Bar

Deck Support Arm

(Not Visible)

Cutting Height Release Lever

(Cutting Height Adjustment)

(Raises Deck)

Deck Lift

Foot Pedal

Front View and Right Side View

Deck Height

Lift Chain

Tilt-Up

Hook

Deck Tilt-Up

Socket

Deck

Caster Wheels

Component Identication

Adjustable

Footrest

Left Hand

Drive Wheel

Fuel Tank

and Cap

Fuel Pickup

Line

Fuel Gauge

Tailpipe

Recovery Tank

Mufer

Coolant

Utility Bed

(Hinged for Dumping)

Radiator Fan

Guard

Spread Axle (Tail Wheel)

Rear View and Left Side View

Component Identication

LH Transaxle

Lockout Arm

Parking Brake

Lever

Battery

Fuel Tank Cap

Oil Fill

Fuel Tank

LH Transmission

Control Rod

Steering Lever

Spring/Dampeners

RH Transmission

Control Rod

RH Transaxle

Lockout Arm

PTO Clutch

Lever

Clutch

Linkage

Transaxle Oil

Expansion

Reservoir

Fuel Gauge

(Not Visible)

Fuel Return Line

Fuel Pickup Line

Mufer

Mufer Heat

Shield

Coolant

Recovery Tank

Oil Filter

(Not Visible)

Overow

Hose

Radiator Cap

Radiator

Fan

Top View (Body Raised)

Air Filter

Restriction Gauge

Air Filter

Cover

Fuel Tank Selector

Valve (Not Visible)

Dipstick

Enginaire™

Air Cleaner

Fuel Pump

(With Primer)

Radiator

NOTE: ROPS Top Bar Removed for Clarity

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 dened as follows:

DANGER

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

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: Identies 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 light weight footwear. Wear substantial pro-

tective footwear.

Safety Instructions - Before Operating

6. Do not wear loose tting 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.

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

spe cically instructed to do so.

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

WARNING

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

NOTE: There is a 1/2 second time delay func-

tion on the seat switch to avoid engine power interruption when driving over bumps.

10. Handle diesel with care:

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 ames, or sparks away from the fuel

tanks and fuel container.

d. Always ll the fuel tank(s) outdoors using

care. Fill to about one inch from the top of the tank. Use a funnel or spout to prevent spilling.

e. Replace the machine fuel cap(s) and con-

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

Safety Instructions - Operating

WARNING

● Always keep the ROPS roll bar in the up-

right and locked position when operating.

● Always use the seat belt when the roll bar

is upright.

● Only lower the roll bar when absolutely

necessary for overhead clearance.

● Never use the seat belt when the roll bar

is lowered.

1. Operate the mower only in daylight or in good articial 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 conguration, the back of the tractor swings to

the outside during turns.

5. In case the transmission drive belt breaks during operation, and if the machine is on a slope, the machine will freewheel down the slope. To maintain control, immediately (1) Release the steering levers and simultaneously (2) Move the FSC to the NEUTRAL-PARK position. When the machine is stopped or moving slowly, engage the parking brake.

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).

7. Do not operate machine if the operator pres- ence 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 after a 1/2 second delay.

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.

DANGER

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

4. Remember, for an emergency stop, the forward motion of the tractor can always be stopped by pulling the Forward Speed Control (FSC) into the NEUTRAL-PARK position.

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

11. Avoid sudden starts or stops. Before back- ing the machine up, look to the rear to be sure no one is behind the machine. Watch carefully for trafc when crossing or working near roadways.

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

Safety Instructions - Operating

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.

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 ma-

chine 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 ve (5) seconds of dis engaging the PTO clutch.

16. For side discharge mower decks, do not oper-

ate with the grass deector shield removed.

Keep the deector in the low est possible position.

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

lowing:

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

a. Disengage the blade clutch (PTO), engage

the parking brake, and turn the engine off before leaving the seat.

b. LOOK to make sure blade drive shaft

move ment has stopped before trying to unclog the system.

c. Never place hands under the deck - use a

stick or similar tool to remove clogged ma terial.

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

immediately disengage the blade clutch (PTO), stop the engine, and wait for all moving parts to stop. Thoroughly inspect the

mower and repair any damage before restarting the engine and operating the mower. Make sure cutter blades are in good condition and blade nuts are torqued to 60 lb·ft (81 N·m) for gear driven decks, and blade bolts torqued to 70 lb·ft (95 N·m) for belt driven decks.

20. Do not touch the engine or mufer while the engine is running or immediately after stopping the engine. These areas may be hot enough to cause serious burns.

21. Never remove the radiator pressure cap when the engine is hot (hot water may spray and cause burns).

22. Do not use ether or any starting uid to assist starting the engine in cold weather.

23. When leaving the machine unattended, disen-

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

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

position.

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

position.

Safety Instructions - Maintenance

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

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 bolts frequently, mak ing sure they are tight.

4. Perform only maintenance instructions de- scribed in this manual. Unauthorized mainte-

nance operations or machine modications

may result in unsafe operating conditions.

5. If the engine must be running to perform a maintenance adjustment, keep hands, feet, and clothing away from moving parts. Do not wear

jewelry or loose clothing.

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

Unauthorized maintenance operations or

modications to the engine may result in unsafe

operating conditions.

12. 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, ames, and smoking ma-

teri als away from the battery at all times. To avoid sparks, use care when removing bat tery cables from posts.

d. Disconnect both battery cables before

unplugging 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. The fuel oil injection system operates under high pressure and can penetrate the skin and

result in serious injury. Unqualied persons

should not remove or attempt to adjust the fuel injector pump, nozzle, or any part of the fuel injection system.

8. 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.

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

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

11. Use genuine factory replacement parts. 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 deector in place and in

the lowest position.

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

● Keep all body parts away from rotating mow-

er blades.

• Do not step on end of deck.

8600-12

Location: Engine Brace Part Number: 8600-12

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

● CO emitted by a running engine can be

deadly.

● Do not operate indoors or in other enclosed

areas.

Location: Deck Carrier Frame Part Number: 8600-15

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

8600-14

Location: Deck Carrier Frame Part Number: 8600-14

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 back to engage step to unlock

transaxle and allow machine to freewheel.

8746-2

Location: PTO Guard on Deck Part Number: 8746-2

1. Grease PTO shaft joints every 8 hours.

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.

DR64 BELT P/N 2731-5

1. 2.

BELT TWIST

2749-7

Location: Deck Housing Under Footrest Part Number: 2749-7 (DR64)

1. Deck drive belt routing.

Location: Deck Discharge Shield (DS60) Part Number: 5848-3

1. Warning – thrown object hazard.

● Always keep the discharge shield in the low-

est position when operating.

● Do not remove the discharge shield.

4.3.

Location: Front of Body on Right Side Part Number: 2807-9

1. Glow plugs activation indicator light.

5848-2

2. Battery charging system malfunction indicator

light.

3. Low engine oil pressure warning light.

4. High engine coolant temperature warning light.

2010-17

Location: Adjacent to Right Fuel Tank Part Number: 2010-17

1. Fuel tank selector/fuel shut-off valve.

Location: Underside of Panel Behind Operator Seat Part Number: 2107-5

1. Ground drive belt routing.

2. PTO clutch belt routing.

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: Top of Deck Housing Part Number: 8653-1

1. Warning – secure deck with straps and engage parking brake before transporting or trailering with deck tilted up.

4.75

4.25

3.75

3.25

2.75

2.25

1.75

5.0 127

121

4.5 114

108

4.0

102

3.5

3.0

2.5

2.0 51

1.5381.0

1.25 32

inch

2748-1

Location: Deck Height Adjuster Part Number: 2748-1

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: Radiator Part Number: 2427-9

1. Move pin to desired height of cut.

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: Right Fender Part Number: 2802-4

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. Body Tilt Latch

● Tilt utility bed back.

● Raise lever to release.

● Lift at back of body to raise.

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.

5685-3

Location: ROPS Roll Bar Part Number: 5685-3

1. Warning – roll-over/crushing hazard.

● Do not operate the machine on steep slopes

or near drop-offs.

● Avoid quick and/or sharp turns when operat-

ing on slopes.

2. During normal operation always keep the ROPS locked fully upright and use the seat belt.

3. Never use the seat belt if the ROPS is not locked fully upright.

4. Do not operate the machine on slopes if the ROPS is not locked fully upright.

5. Do not remove the ROPS.

Safety Instructions

SAFETY, CONTROL, AND INSTRUCTION DECALS

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

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

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

1. 2.

<15°

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 – read Operator ’s Manual before servicing or performing maintenance.

● Engage parking brake.

● Remove ignition key.

5. Warning – roll-over hazard.

● Do not operate on slopes greater than 15

degrees.

6. Warning – thrown object hazard.

● Keep bystanders away from the machine

when operating.

7. Warning – entanglement hazard.

● Keep all guards in place while engine is run-

ning.

8. Parking brake

● Move lever forward to engage Parking

Brake; back to disengage.

Location: Left Fender Part Number: 2802-5

2802-5

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.

Battery Service

Raise the utility bed and mower body up for battery access. 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 specic 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.

RH Drive Tire (Ref)

Battery

Dry Battery Service

DANGER

Activating a battery can be dangerous. The battery should be taken to a reliable service station, battery store, or power equipment dealer where a trained technician can activate the battery safely. DO NOT attempt to activate the battery unless you are experienced in battery service work. The following activation and charging instructions are provided for use by a trained battery technician.

DANGER

Battery electrolyte is a poisonous and corrosive sulfuric acid solution.

● Avoid spillage and contact with skin,

eyes, and clothing - causes severe burns.

Battery Location

IMPORTANT: Make sure battery is securely

mounted in the frame. A loose battery may cause damage to the case resulting in acid leakage and se vere damage to the machine. A hazard may be cre ated by damage to critical working parts and safety systems.

IMPORTANT: Never disconnect battery while engine is running.

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.

● To prevent accidents, wear safety gog-

gles and rubber gloves when working with electrolyte.

● Neutralize acid spills with baking soda

and water solution.

To ll (activate) battery with electrolyte (if battery has

been shipped dry):

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

IMPORTANT: Battery must be removed from

the mower before lling with electrolyte.

IMPORTANT: Obtain and use only battery grade sulfuric acid electrolyte with a 1.265 specic gravity to activate the battery. DO NOT use water or any other liquid during initial activation.

2. Remove the ller caps and carefully ll each cell

until the electrolyte is just above the plates.

3. After the battery is lled with electrolyte, replace the ller caps and charge the battery. Refer to

Battery Charging.

Assembly Instructions

Battery Charging

DANGER

BATTERIES PRODUCE EXPLOSIVE GASES

● Charge the battery in a well-ventilated

area, so that gases produced while charging can dissipate.

WARNING

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

● Keep sparks, ames, and smoking mate

rials away from the battery at all times.

● 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.

1. Charge the battery at 15 amps for 10 minutes. DO NOT exceed 20 amps maximum recom-

mended charging rate. Charge until specic

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 overll the battery. Electrolyte will overow through the vented

caps onto parts of the machine and WILL result in severe corrosion.

Battery Clamp Secured

by Wing Nut(s)

(+) Battery Cable

Connection

Battery Installation

(Viewed from RH Side)

Mower Deck Assembly

Deck Caster Wheels Installation

1. Remove the bolts and washers from each deck caster wheel.

2. Install wheel on fork using bolts and washers.

3. Tighten the bolts and washers.

3. Install battery.

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 (+) rst 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.

Deck Caster Wheel Installation

Assembly Instructions

Deck Discharge Deector Shield Installation (DS60)

Attach the side discharge deector 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 t

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

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 axle spacer tube, 3/8-16 x 3 in. bolt and 3/8-16 Whiz locknut. Tighten the bolt until the wheel rolls freely, but is not loose.

Roller

Wheel

Roller Wheel Installation (Typical DS60 Shown)

Mower Deck Installation on Tractor

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

Deck Installation

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

tractor. Refer to Mower Deck Installation photo for location of deck support arm.

Deck Support

Arms

Rubber Debris

Guard

Mower Deck Installation

2. First, engage the LH deck carrier frame tube

socket on the LH tractor support arm and then the RH arm into the RH tube socket. Slide the deck onto the support arms and install lynch pins to secure deck. Two (2) lynch pins are included in Owner’s Packet of materials.

Assembly Instructions

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 PTO Coupler Installation Tool photo.

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

4. Unhook lower edge of rubber debris guard and raise for access to the tractor PTO shaft. Refer to Mower Deck Installation photo for location of debris guard.

Coupler

Installation Tool

PTO Coupler

Tube

Retract Spring-Loaded Quick Disconnect Ring

PTO Coupler Installation Tool

Coupler

Installation Tool

Align

Arrows

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

Coupler Installation Tool Removal

(Shown with Debris Guard Removed for Clarity)

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 Discon- nect Ring “Locked” Position illustration). After installation, pull on the PTO coupler to check for security.

Coupler Ring in

Released Position

PTO Drive

Shaft

Tractor

PTO Shaft

PTO Shaft Connection

(Shown with Debris Guard Removed for Clarity)

5. 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. Refer to the PTO Shaft Connection photo.

PTO Coupler

U-Joint

Quick Disconnect Ring “Released” Position

Assembly Instructions

Internal Balls

Locked on Shaft

PTO Coupler

U-Joint

Quick Disconnect Ring “Locked” Position

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

8. With the counterweight springs connected, the weight on the deck caster wheels should be 190 to 230 Ib (86.2 to 104 kg); this adjustment is preset at the factory.

Coupler Ring in

Locked Position

Counterweight Springs

Clip Onto Body With

PTO Drive

Shaft

Body Tilted Up

Deck Leveling

The mower deck and support frame are jig welded and the deck support linkage is factory adjusted. Within normal tolerances, very little, if any, adjustment should be required to level the deck. Tire size and pressure will affect the levelness of the deck.

Assure that all tires (tractor and deck caster

wheels) are properly inated prior to checking

deck levelness or performing the deck leveling procedure.

Measuring Deck Levelness

1. Position the mower on a smooth, level surface, and set the deck height to the most common cutting position. Refer to ADJUSTING CUT- TING HEIGHT in Operating Instructions.

2. See the Deck Leveling illustration for side-toside and front-to-back deck level measurement points. Side-to-side measurements should not vary more than 1/8 in. (3 mm). Front-to-rear measurements should have the rear 1/4 in. (6 mm) to 3/8 in. (10 mm) higher than the front. If either set of measurements are not within tolerance, perform the Deck Leveling Procedure.

Lynch Pins Lock Deck on Support Arms

(Not Visible)

Deck Counterweight Spring Installation

Assembly Instructions

Deck Leveling Procedure

1. Position the mower on a smooth, level surface, and set the deck height to the most common cutting position. Refer to ADJUSTING CUT- TING HEIGHT in Operating Instructions.

WARNING

The machine must be shut off during this procedure.

2. Place a block of sufcient height under the left

rear corner of the deck housing to remove tension from the left rear deck support chain. Detach the left rear deck support chain by removing the upper bolt from the height adjuster arm. Remove the block and let the deck hang from the remaining three support chains.

3. Measure the side-to-side level of the deck by measuring from the ground to the top of the deck housing at the front corners of the deck as shown in the Deck Leveling illustration. The side-to-side measurements should not vary by more than 1/8 in. (3 mm). If necessary, raise or lower the left and/or right front support chain clevises to level the deck.

4. Measure the front-to-rear level of the deck using a straight edge as shown in the Deck Leveling illustration. The rear measurement should be 1/4 in. (6 mm) to 3/8 in. (10 mm) higher than the front measurement. If necessary, adjust the right side height adjustment rod by lengthening it to lower the back of the deck, or shortening it to raise the back of the deck.

5. With the side-to-side and front-to-rear deck level correct, reattach the left rear support chain that was removed in step 2. Adjust the left side height adjustment rod to equalize the left rear and right rear support chain tension.

6. Assure that all fasteners are tight and replace any guards removed during the leveling procedure.

Right Side

Measurement

Point

Ground

Right Support

Chain Clevis

Right Height

Adjustment Rod

Left Rear Deck Support

Chain (Remove Upper

Bolt for Leveling)

Left Height

Adjustment Rod

Left Support

Chain Clevis

Front

Measurement Point

Approx. 36 in. (914 mm)

Long Straight Edge

Rear

Measurement

Point

Left Side

Measurement Point

Deck Leveling

Assembly Instructions

PREOPERATING CHECKLIST

Before operating the mower for the rst 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 TANKS

Fill the fuel tanks with clean, fresh fuel. Clean diesel fuel is particularly important since contaminated fuel will damage the fuel injectors and injection pump.

NOTE: It may be necessary to use the fuel pump primer to bleed (purge out air bubbles) the diesel fuel

injector system when initially lling an empty tank.

Refer to Fuel Pump Priming instructions in the Op-

erating Instructions.

DANGER

Handle diesel fuel with care. Use safe refueling procedures:

● DO NOT ll fuel tanks with the engine

running.

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 lter 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 lter

every 100 hours). For detailed procedures, refer to CLEANING the Engine Air Cleaner System in Maintenance Instructions.

CHECK ENGINE COOLING SYSTEM

● Check the radiator air intake screen to make sure the screen is clean and free of obstruction.

Also, the radiator cooling ns should be in-

spected and cleaned if there is any buildup of dirt or debris. (Remove the intake screen assembly to inspect and clean.)

● Check the coolant levels in the radiator and

overow tank. If additional coolant is needed,

refer to CHECKING/SERVICING the Engine Cooling System in Maintenance Instructions.

● If the engine is hot, allow to cool before

refueling.

● Use an approved fuel container.

● Fuel the mower outdoors.

● DO NOT smoke while refueling.

● Avoid spilling fuel; use a funnel or

spout.

● DO NOT overll the fuel tanks; 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 tanks. Wipe dirt from around

the ller cap(s) before removing. Use a clean fuel

storage container and funnel.

WARNING

DO NOT remove the radiator pressure cap when engine is hot.

CHECK HYDROSTATIC TRANSAXLE OIL

LEVEL

Refer to LUBRICATION for Transaxle Fluid Level in Maintenance Instructions.

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).

Assembly Instructions

2802-5

<15°

1. 2.

INSPECT FIVE (5) DRIVE BELTS

Engine/PTO (3), Ground Drive (1) and Deck Drive (1).

CHECK TIRE PRESSURE

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

CHECK FUNCTIONS OF WARNING LIGHTS

AND WARNING HORN

Turn the ignition key to the ON (RUN) position. Glow Plug Activation Light, Low Engine Oil Pressure Warning Light, Battery Charging System Malfunction Indicator Light, and Warning Horn should all operate, indicating normal function.

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 mower blades engaged.

CHECK AND CLEAN GRASS BUILDUP

UNDERNEATH MOWER DECK

Refer to CLEANING the Grass Buildup in Mower Deck Housing in Maintenance Instructions for deck tilt-up and deck cleaning information.

Tilt Bar

Unlock Deck Arms for Deck Tilt-Up

3. Fit tilt bar into the socket on front of deck housing and secure with hitch pin.

4. Remove footrest or, if equipped with adjustable footrests, move the footrest to the full forward locking position.

5. Raise deck to tilt-up position using tilt bar and secure in position by inserting the deck hook in the tilt-up latch on the tractor body as shown in the Deck Secured in TILT-UP Position photo.

Before operating the mower, make sure to re-

engage the locking arms into the LOCKED position after lowering the deck to the normal operating position.

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 using the following procedure:

1. Remove the tilt bar from the stowed position on the carrier frame.

2. Use the tilt bar to release the two (2) deck locking arms as shown in the Unlock Deck Arms for Deck Tilt-Up illustration.

CAUTION

Do not operate mower with deck tilt-up pivot joint UNLOCKED. Make sure locking arms are in the LOCKED position and the tilt-up joint is rigid (locked).

DANGER

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

Assembly Instructions

Hitch Pin

CHECK MOWER BLADE CONDITION,

SHARPNESS, AND SECURITY OF MOUNTING

Tilt-Up Hook and

Latch Connected

Tilt-Up

Latch

Deck Secured in TILT-UP Position

Tilt-Up

Hook

Tilt Bar

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

Sharpen Mower Blades in Maintenance Instruc- tions.

ADJUST MOWER CUTTING HEIGHT, IF

REQUIRED

Refer to ADJUSTING CUTTING HEIGHT in Oper-

ating Instructions.

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 opera

tion 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 that activates the glow plugs for preheat and the position the key returns to after starting and “S” is the START position. When starting the engine, (1) turn the key to ON (RUN) and observe the glow plug activation light (this light may not come on if the engine is hot) and (2) as soon as the glow plug light goes off, immediately 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.

NOTE: The duration of glow plug activation (preheat) is automatic and varies with engine temperature. The longest duration will be with a cold engine and the warmer the engine, the shorter the time for the glow plugs to cycle on and off. If the glow plugs do not activate with a cold engine or the activation light stays on, the engine needs to be serviced by contacting your authorized Kohler engine dealer.

OFF

ON (RUN)

START

Forward Speed

Control (FSC)

Body

Latch

Blade Clutch

(PTO)

Ignition Switch

Circuit

Breaker(s)

Hourmeter

Ignition Switch

Parking

Brake

Parking

Brake

LH Side View

Throttle

Steering

Levers

Warning

Lights (4)

Warning Horn

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

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, rst tilt the

utility bed back, then pull back and up on body latch and lift the body from behind the seat.

portional 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 foward 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.

Fuel Pump Priming

The Kohler diesel engine is equipped with a mechanical fuel pump and in certain situations (running out of fuel, changing the fuel lter, or other fuel system maintenance) the fuel system may need to be primed by removing air trapped in the system. Fuel pump priming should be used if the engine does not start after a couple of 10 second cranking attempts.

NOTE: DO NOT use prolonged cranking to prime the fuel system as this may damage the starter and shorten battery life.

Use the following procedure to prime the fuel pump and purge air out of the fuel system:

1. Loosen the bolt on the fuel injection pump return

hose where it attaches to the fuel lter housing

as shown.

Body

Latch

Body Latch

Forward Speed Control (FSC)

Forward Speed Control (FSC) has two functions: One is to set forward travel speed, and the other is to establish the NEUTRAL-PARK position. When the FSC lever is moved into the FORWARD position, a friction lock holds any forward speed setting from 0 to 10 mph (0 to 16 km/h). The ground speed is pro-

Fuel Injection Pump

Fuel

Filter

Air Bleed Bolt Location

2. Turn ignition key to ON to open the electric fuel shutoff valve (do not crank or run engine).

3. Repeatedly stroke the Fuel Pump Primer lever

until fuel is owing out of the return hose tting.

(continued on next page)

Return Hose

Loosen Bolt to Bleed

Air From Fuel System

Operating Instructions

Fuel Pump

Primer Lever

Fuel Pump Primer Lever

4. After bleeding the system, tighten the return

hose tting bolt securely.

Steering Levers

IMPORTANT: Stop the tractor completely before

engaging the parking brake. The parking brake uses a positive mechanical lock similar to the PARK posi tion 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.

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 rst 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.

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.

Engaged

Position

Parking Brake Engaged

Disengaged

Position

Parking Brake

The parking brake functions by locking a detent arm to a cog in the hydraulic motor rotor. Moving the lever FOR WARD engages the parking brake; moving the lever BACKWARD releases the brake.

Parking Brake Disengaged

Operating Instructions

Circuit Breakers

Two manual reset circuit breakers are located on the front body. Each has a button that pops out if the circuit breaker trips. The 10 amp circuit breaker protects the safety and ignition circuits. The 7 amp protects the indicator lamps and hourmeter.

Glow Plug Activation Light

The glow plug activation light indicates the glow plugs are operating (preheating).

Battery/Charge Malfunction Light

The charge light indicates the electric system is not being charged.

Oil Pressure Warning Light/Horn

The oil pressure warning light and horn signal indicate that engine oil pressure is below the safe oper-

ating level [below 7 PSI (48 kPa)]. This light (and warning horn) will come on when the ignition is

turned ON, but should go off after the engine is start- ed. If the light fails to come on when the ignition switch is turned ON, it could indicate a burned out bulb, or the inline 7 amp circuit breaker could also be tripped. If the light comes on 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 an illuminated oil pressure warning light MAY cause severe engine damage (if a low oil pressure condition exists).

Water Temperature Warning Light/Horn

The water temperature warning light and horn signal indicate that engine coolant temperature is above the safe operating limit and the engine is overheat- ing. If this light comes on, there may be a problem with:

● Radiator cooling air ow (material packed into

radiator cooling ns, clogged air intake screen)

● Electric Radiator Fan not operating properly

● Low coolant quantity in cooling system

● Thermostat function

● Coolant pump

Stop the engine and correct the source of the problem before further operation.

IMPORTANT: Continued operation of the engine with an illuminated water temperature warning light MAY result in severe engine damage.

Glow Plug

Activation Light

Circuit

Breakers

Warning

Horn

Circuit Breakers, Glow Plug Activation Light and Engine Warning Lights/Horn

Battery/Charge

Malfunction Light

Water Temperature

Warning Light

Oil Pressure

Warning Light

Operating Instructions

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 LOCKOUT 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.

Procedure Interval* Reminder

Oil Change

(Break-In)**

Lubricate and Check Levels

Oil Change 49-51 Hours***

4-6 Hours

24-26 Hours

C H G

OIL

LUBE

OIL

* These intervals reect the actual time that the

reminder will ash (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.

Transaxle Lockout

Arms

Transaxle Lockout Arm Location

Hourmeter

The hourmeter, which is located on the right front of the body, displays operating time accumulated while the ignition switch is in the ON (RUN) position.

The hourmeter provides maintenance reminders after certain hours of operation. The hourmeter screen

will start ashing 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

Roll-Over Protection System (ROPS)

WARNING

The ROPS may offer enhanced operator protection in the event of a roll-over type accident, but only if used correctly. Failure to comply with the following ROPS instructions can result in serious injury or death if a roll-over occurs. Read and understand the following ROPS instructions before operating the machine.

● Keep the ROPS roll bar in the upright and locked

position when operating the machine.

o Always use the seat belt when the ROPS roll

bar is in the upright position.

o Make sure that the seat belt can be released

quickly in the event of an emergency.

o Make sure that the mower body hold-down

latch is engaged.

● Lower the ROPS roll bar only when absolutely

necessary for overhead clearance reasons.

To Lower the ROPS Roll Bar:

1. Loosen the two (2) tension knobs.

2. Remove the two (2) hitch pins.

3. Remove the two (2) locking pins.

4. Lower the roll bar.

5. Replace the locking pins and secure them with the hitch pins.

To Raise and Lock the ROPS Roll Bar:

1. Remove the two (2) hitch pins.

2. Remove the two (2) locking pins.

3. Raise the roll bar to the upright position.

4. Install the two (2) locking pins and secure them with the two (2) hitch pins.

5. Tighten the two (2) tension knobs to prevent the roll bar from rattling.

Locking

o Never use the seat belt if the ROPS roll bar is

not in the fully upright and locked position.

o Never lower the ROPS roll bar when operat-

ing in areas where there are slopes, drop offs, or other roll-over hazards.

o Be aware there is no roll-over protection

when the roll bar is lowered.

o Raise and lock the ROPS roll bar as soon as

overhead clearance permits.

● Check for overhead clearance (i.e. branches, doorways, electrical wires) before driving under any objects and be careful to avoid contact.

Locking

Hitch

Pins

Tension

Knobs

Roll-Over Protection System (ROPS)

Operating Instructions

Suspension Seat

A fully adjustable suspension seat is standard on Model H24d. This seat is adjustable for back pitch, weight, lumbar support and armrest inclination. Proper adjustment for each operator is essential to safe operation and operator comfort.

Read operating instructions in full before you use the seat.

NOTE: Driver seats that have been adjusted incorrectly have little or no vertical travel with the operator in the seat. To prevent damage to the driver’s back and to the seat, the seat must be adjusted for the driver’s weight before use and before every

change of driver. To prevent injury, no objects should be placed within the moving area of the

driver seat.

CAUTION

To eliminate any risk of accident, the seat settings must be checked to ensure they are correctly engaged before the mower is driven.

Adjustments must not be made while driving.

If you make any changes to the suspension seat

(for example tting parts which are not original

GRAMMER parts) it may no longer meet the safety standards to which it is tested. Functions may be

impaired, threatening your safety. For this reason, any change in design of the seat must be ap- proved by GRAMMER (Seat Manufacturer).

CAUTION: Before the tractor is used, the safety

switch must be checked for proper function. The operation of the switch is checked by having the operator lift off the seat with the tractor moving forward and/or the blades engaged -- this action should cause the machine to stop. If a malfunction is detected the tractor must not be driven, the safety switch system should be repaired or replaced before operating the mower.

CAUTION

Except for the driver’s weight during normal use, no loads must be placed on seats with a built-in switch detecting seat occupation, as the vehicle may otherwise start to move by itself.

For armrest inclination adjustment, the inclina-

tion of the armrests can be modied by turning the

adjustment knob. Refer to Figure 1.

Turning the knob to the right lifts the armrest in front, turning it to the left, lowers it in front.

For weight adjustment, the weight of the respective driver must be set while sitting on the seat. Fold out the weight adjustment handle completely, hold it at the front and move it upwards or downwards (10 movements from minimum to maximum).

Before every new movement, bring the handle back

to the starting position (audible locking sound). The driver’s weight has been set correctly, when the arrow is in the middle of the viewing window. Refer to

Figure 2.

IMPORTANT: Fasteners must be checked regularly for tightness. If the seat wobbles there may

be loose bolts or other faults.

If you note that the seat does not function correctly (for example a defective seat suspension; improper curving of the lumbar support or damaged bellows), contact your Walker dealer immediately to arrange for repairs to be carried out. If you fail to do so, your health may be affected and the risk of ac-

cident increased.

IMPORTANT: To prevent injury to the operator and/ or damage to the seat, the setting for the driver’s weight must be checked and adjusted as necessary before the mower is driven.

When the minimum/maximum weight adjustment has been reached, you will notice an empty movement in the handle.

When you have set the weight, fold the handle completely into the locking position.

Operating Instructions

For Backrest adjustment, moving the adjustment handle upwards loosens the notching of the backrest adjustment. Refer to Figure 3.

After the adjustment, the handle must lock in the desired position. It should not be possible to move the backrest into another position when it is locked.

For Armrest height adjustment, the armrests can be folded back if required and the height individually adjusted.

For adjusting the height of the armrest, pry out the round cap (arrow) of the cover and loosen the hexagon nut (size 13 mm) situated behind it. Set the armrests in the desired position (5 steps) and tighten the hexagon nut. Replace the cap onto the nut. Refer to Figure 4.

For Lumbar Support adjustment, turning the knob upwards sets the curve in the upper part of the back upholstery. Turning the knob downwards sets the curve in the lower part of the upholstery. Refer to

Figure 5.

IMPORTANT: Dirt can impair the function of the

seat, so make sure you keep your seat clean!

For cleaning, use a standard commercially available upholstery or plastics cleaning agent. Test rst for compatibility on a small, concealed area.

Figure 1

Figure 2

Figure 5

Remove

Cover

Figure 4

Figure 3

Operating Instructions

The Forward Speed Control also Establishes the Neutral-Park Position of the Steering Levers

LEFT WHEEL

STEERING LEVER

Forward Position

(No Control Change)

Neutral-Park

Position

Reverse Drive Wheel Motion

Position

Fast

Throttle

Position

Idle

Position

RIGHT WHEEL

STEERING LEVER

1. 2.

<15°

FORWARD SPEED

CONTROL LEVER (FSC)

Full Forward

Ground Speed

Position

Intermediate

Ground Speed

Position

Neutral-Park

Position

Engaged

Position

Disengaged

Position

THROTTLE

PARKING BRAKE

2802-5

Engaged

2802-4

Position

BLADE CLUTCH

(PTO)

Disengaged

Position

Operating Controls (Top View from Drivers Point of View)

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 DISEN-

GAGED.

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 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 adjust ed before operating the mower. DO NOT disconnect safety switches; they are for the operator’s protection.

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 Kohler dealer for additional help.

TROUBLESHOOTING NOTE: If the engine cranks but does not start, check the following:

● Engine is equipped with a mechanical fuel pump and the fuel system may need to be primed in certain conditions (after running out of fuel or after fuel system maintenance). See instruction for Fuel Pump Priming in this section.

● Is the fuel valve solenoid operating? Look at the exhaust pipe when cranking the engine - no smoke indicates no fuel is reaching the cylinder. If the solenoid is not operating, contact your authorized Kohler engine dealer.

● Are the glow plugs operating? Look at the exhaust pipe when cranking the engine - white smoke indicates improper glow plug operation and inadequate preheat. If the glow plugs are not operating, contact your authorized Kohler engine dealer.

4. After the engine starts, make sure the oil pressure light goes off. If not, stop the engine imme-

diately and nd the cause of the problem. Make

sure the oil pressure light is off prior to engaging the mower blades and beginning operation.

ADJUSTING GROUND SPEED AND STEERING

CAUTION

2. Move the throttle 1/4 to 1/2 open (toward FAST).

3. Turn the ignition key to the ON (RUN) position and observe the glow plug activation light (this light may not come on if the engine is hot). As soon as the glow plug activation light goes off, immediately turn the key clockwise to the “S” position to start the engine. Release the key when the engine starts, and it will return to the ON (RUN) 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 an-

other starting attempt.

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

If the operator has not operated a machine with LEVER STEERING OR DUAL TRAN SAXLES, steering and ground operation should be learned and practiced until the operator is completely comfortable han dling the machine BEFORE ATTEMPTING TO MOW.

Operating Instructions

DANGER

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

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).

WARNING

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 le ver controlling the inside wheel into reverse for a smooth “rolling” turn (one wheel roll ing forward while the other rolls backward).

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

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

In case the transmission drive belt breaks during operation, and if the machine is on a slope, the machine will freewheel down the slope. To maintain control, immediately (1) Release the steering levers and simultaneously (2) Move the FSC to the NEUTRAL-PARK position. When the machine is stopped or moving slowly, en gage the parking brake.

NOTE: This is exactly the same procedure used

to normally stop and park the machine.

NOTE: If the FSC lever will not stay in the selected position, the friction lock needs to be adjusted. Refer to ADJUSTMENTS for Step 7 - Forward Speed Control Friction Adjustment in the Maintenance Instructions.

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 op erator raising off the seat with the tractor moving forward (allow 1/2 second “off the seat” for the time delay function); the engine should stop. If the safety sys tem is not working, it should be repaired or replaced before operating the mower. DO NOT disconnect the safety switches; they are for the operator’s protection.

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.

Operating Instructions

Pull Steering

Levers with

Left Hand

Footrest when

Keep Feet on

Moving

5. Stop ground travel by pulling both steering levers backward to the NEUTRAL position (tractor not moving) and then moving the FSC lever to the NEUTRAL-PARK position.

NOTE: If the tractor creeps forward or back ward with the FSC lever in the NEUTRAL-PARK posi- tion, the transmission control needs to be adjusted. Refer to ADJUSTMENTS for Step 3 - Neutral Function Adjustment in the Maintenance

Instructions.

ENGAGING THE BLADE DRIVE

Forward Speed Control

(FSC)

Correct Operator Hand Position

on the Controls

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

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

WARNING

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

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

1. Set the engine throttle at about 1/3 speed. Do

not attempt to engage the blade clutch at high engine speeds. This will drastically short-

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

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

SLOWLY.

CAUTION

An operator presence switch (seat switch) will cause the engine to stop if the blade clutch is engaged and the operator is not in the seat. The function of this switch should be checked by the op erator 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).

Operating Instructions

Engaged

Position

Blade Clutch Engaged

STOPPING THE MACHINE

1. Pull the steering levers to the NEUTRAL posi- tion and then move the FSC lever backward to the NEUTRAL-PARK position.

2. Slow the engine to idle; put the throttle in the IDLE position.

3. Disengage the blade clutch.

IMPORTANT: DO NOT disengage the blade clutch with high engine speed (above 1/2 throttle) since the brake action on the blade drive will cause increased wear of the brake band.

WARNING

A brake stops the cutter blades from free-

wheeling within ve (5) seconds after dis

engaging 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.

Disengaged

Position

Blade Clutch Disengaged

CAUTION

If the cutting blades strike a stationary object while mowing, stop mower immediately, look to make sure all moving parts have stopped, then lift the deck, and inspect the deck and blades thoroughly for damage. Also, make sure the blade retaining bolts are torqued to 70 lb·ft (95 N·m).

4. Turn the ignition switch OFF.

WARNING

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

5. Engage the parking brake by moving the lever forward. Also, engaging the parking brake is recommended when stopping or parking the

machine in a conned 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 trans-

mission uid is warm.

Operating Instructions

WARNING

NOTE: The emergency stop procedure is ex-

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

Adjustable Footrest

ADJUSTING CUTTING HEIGHT

FUEL TANK SELECTOR VALVE

The tractor is equipped with dual fuel tanks. A fuel selector valve regulates which tank is being utilized. The valve is located on the right hand side of the engine. The valve switches between the LH and RH fuel tanks. DO NOT run tank dry before switching tanks. The fuel selector valve also has an OFF position to shut-off fuel supply.

Fuel Tank

Selector Valve

Fuel Tank Selector Valve

(RH Side View)

ADJUSTABLE FOOT RESTS

Some carrier frames are outtted with adjustable

foot rests. To adjust, rotate the footrests upward and slide to the desired position. Rotate the footrest down and insert the edge of the footrest into the nearest notch to lock in position.

WARNING

Never adjust cutting height while the mower is moving. Before adjusting cutting height or servicing, move the Forward Speed Control (FSC) into the NEUTRAL-PARK position, engage the parking brake, and disengage the blade clutch (PTO). Tractor should not be moving while adjusting cutting height.

Cutting height is adjusted from operator’s seat using the deck lift pedal to assist in raising the deck while adjusting the cutting height hitch pin.

1. Disengage PTO and stop tractor.

2. Push down on deck lift pedal until it latches in the full up (transport) position.

3. Select the desired cutting height by moving the hitch pin to the location shown on the cutting height decal.

4. Push down on the lift pedal and lift up on the cutting height release lever. Slowly release the pedal while lifting the lever until the deck is in the selected cutting height position.

Operating Instructions

Hitch Pin

Height

Adjustment Decal

Cutting Height Adjustment

Cutting Height Release Lever

Deck Lift Pedal

Push Deck

Lift Pedal

Raise Release

Lever

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

Transaxle Lockout Arm

Transaxle Lockout Arm - Freewheel Position

4. After moving the mower, release the arms, placing them down in the normal OPERATING posi- tion. The lockout arm ends should be com pletely retracted against the chassis, otherwise operation of the transaxle may be erratic.

Transaxle Lockout Arm

Lowering Deck to Selected Cutting Height

Transport Position

1. Disengage the PTO.

2. Push down on deck lift pedal until it latches in the full up (transport) position.

TRANSAXLE LOCKOUT

IMPORTANT: DO NOT TOW this mower faster than

2 mph (3.2 km/h) with the transaxle lockout 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 back to engage the step that holds the arm in the UP (unlocked) position.

Transaxle 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, operate the engine at full throttle for the best cutting action. Mowing with a lower engine RPM causes the mowing blade to not cut clean and tear the grass. The engine is designed to be

operated at full speed.

● When mowing in adverse conditions (tall and/or wet grass), mow the grass twice. Raise the mower

to the highest setting - 5 in. (127 mm) - for the rst

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

Avoid Low Hanging Branches

IMPORTANT: Operate the engine at full throttle

when mowing, to allow the engine to produce full

horsepower and to increase efciency 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.)

● Using the DS60 deck, or other side discharge

decks, the side discharge deector shield must not be removed and must be kept in the lowest possi-

ble position to deect 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.

Operating Instructions

Discharge

Shield

Side Discharge Deector Shield in

Lowest Position

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

sharp turns or sudden changes in direction. The

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

Operating Instructions

Maximum

Recommended Slope -

Do Not Operate

on Steep Slopes

15°

16 in.

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 conguration 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.

52 in.

Maximum Recommended Slope

DANGER

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

● 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 (caus ing breakage). This will also prevent the deck from unhooking from the tractor and falling, potentially causing deck or tractor damage. Damage to other items parked in front of the deck may also occur.

5 FT

MINIMUM

No Driving Zone

Maintenance Instructions

CAUTION

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

MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL H24d

Service Item

Check Engine Crankcase Oil Level x 48 Check Coolant Level in Radiator

and Overow Tank Clean Radiator Screen and Cooling Fins* x 56

Check Security of Air Cleaner System x 60 Check Air Filter Restriction Gauge x 54 Clean Grass Buildup Under Deck x 57 Check Transaxle Cooling Fan Condition x 58 Service Mower Blades x 61 Check Function of Warning Lights and Horn x 26 Lubricate Grease Fittings and Oil Points* x 51 Check Battery Electrolyte Level x 60 Check Transaxle Oil Level (in Reservoir) x 50 Check Tire Pressure x 61

Check Drive Belts (Engine PTO, Ground Drive, Blade Drive)

Check Operation of Safety Interlock Switches x 63

Check Operation of Turbine Precleaner Fan* x 54 Check Air Filter Element** x 55 Change Engine Crankcase Oil*** x 48 Check Blade Brake Action x 63

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

Check FSC Friction Lock x 63 Check/Adjust Blade Clutch x 76 Clean Transaxle Housing x 58 Change Engine Oil Filter x 48 Check Radiator Hoses and Clamps x 62 Change Transaxle Oil and Filter xΔΔ 50 Replace Fuel Filter x 69 Replace Air Filter Element** x 55 Check Fuel Lines and Clamps x 60 Flush Radiator and Change Coolant x 57 Service Battery x 60 Check PTO U-Joints for Wear/Looseness x 63 Adjust Engine Intake/Exhaust Valve Clearance x Replace Radiator Hoses and Clamps x 62 Replace Fuel Lines and Clamps x 62 Lap Engine Intake/Exhaust Valve

Seats (if required)

Replace Timing Belt (Every 4 Years)

* More often in extremely dusty or dirty conditions (Refer to notes about air cleaner element in IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE)

** Air cleaner is remote mounted Enginaire™ unit, replace lter(s) every year or when worn or damaged *** Change engine oil and lter after rst 35 hours of operation of a new engine (break-in period)

Δ See Authorized Kohler Engine Dealer for this service

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

Daily

x 60

Hours

x 62

100

Hours

x 61

200

Hours

400

Hours Yearly

Every

2 Years

Ref.

Page

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. Fuel contamination will greatly shorten the life of the fuel injector pump and injectors.

● Use of (B5) Bio-Diesel fuel is approved when pur- chased from recognized and authorized diesel fuel supplier.

Priming in Operating Instructions.

● DO NOT crank the engine to prime the fuel sys-

tem as this may damage the starter from prolonged cranking.

● Use only Kohler Fuel Filter as specied.

Starting/Stopping

● DO NOT use ether or any starting uid in the

air intake. This will damage the engine.

● To aid starting in cold weather [below 40° F (4°

C)], release the hydrostatic transmission drive belt to

reduce the engine starter cranking load. Reinstall belt after the engine has been warmed up.

● Start the engine with the throttle advanced off idle to a mid-point (1/4 to 1/2) throttle setting. This will aid starting, especially in cold weather.

● Keep the battery fully charged.

● Match crankcase oil viscosity to the ambient tem- perature, allowing the engine to crank faster and start easier.

● For maximum engine life, allow the engine to run at idle and cool down for one or two minutes before stopping the engine.

Cooling System

● Fill the cooling system with a pre-mixed solution of 50/50 antifreeze (ethylene glycol) and distilled water.

IMPORTANT: Solution must be pre-mixed before putting it in the engine (adding pure antifreeze into the radiator may cause damage to the engine by causing overheating).

● Never mix different types/colors of coolants.

● Maintain proper uid levels in the radiator and

overow tank.

Air Cleaner System

● Use only Enginaire™ air cleaner elements. Af-

termarket elements may not seal in the air cleaner housing, allowing dirt to enter the engine. Also, after-

market lters often skimp on the ltration media and

require more frequent cleaning and replacement (see following instructions).

● Use the air lter restriction gauge to indicate the

need to service the air lter.

● DO NOT overservice or frequently “disturb”

the air lter. A dirty air lter actually cleans better than a new one. Changing and cleaning the air lter too often can actually reduce lter efciency and in-

crease the opportunity for traces of dust to enter the engine. Wait until the element really needs servicing as indicated by the air lter restriction gauge.

● Do frequently 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.

● When the air lter element is removed or re- placed, make sure all dust is cleaned out of the air cleaner housing and hose. Use a damp cloth and wipe the interior of the canister and hose clean (a little dirt left here will be sucked into the engine and

reduce engine life). When the lter is reinstalled,

make sure the element is held tight and straight in the canister for proper seating and sealing.

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

Oil

● Use any top quality oil with an API classication of CF or greater. DO NOT use oil that is rated for gasoline engines only (API SJ) as this will cause problems with a diesel engine.

● Single viscosity or multi-viscosity oils may be

used as specied by the Kohler Operation Manual,

using the viscosity recommended to match ambient temperature range for the engine operation. This will aid starting in cold weather and assure proper lubrication in hot weather.

● Use only Kohler oil lters. Aftermarket lters may not seal properly and/or have the incorrect pressure relief valve for proper lubrication.

Maintenance Instructions 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.

Engine Oil

Engine Break-In Oil

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

in period of 35 hours. Thereafter, change oil after every 100 hours of operation.

Checking Engine Crankcase Oil Level

IMPORTANT: DO NOT operate engine without

sufcient oil supply in the crankcase. DO NOT operate with oil level below the LOW mark or above the FULL mark on the dipstick.

Full Mark

Operating

Range

Low Mark

Check the engine crankcase oil level before use and

after each 8 hours of continuous operation.

IMPORTANT: The importance of checking and

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

EACH USE.

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

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

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

2. Before removing the dipstick, clean the area

around the dipstick to keep any dirt or debris out of the engine.

3. Remove the dipstick, wipe off with a clean rag, then reinsert the dipstick into the tube and press all the way down.

4. Remove the dipstick again and check the oil level on the dipstick. The oil level should be within the “Operating Range” on the dipstick (between the LOW mark and the FULL mark).

Dipstick Operating Range

5. If additional oil is needed, refer to Specications for proper crankcase lubricant. Fill up to, but

not above the FULL mark on the dipstick.

IMPORTANT: DO NOT overll crankcase (oil

above FULL mark) as this CAN result in engine overheating, loss of power, and possi ble engine damage.

Changing Engine Crankcase Oil/Oil Filter

Change the engine crankcase oil after every 100 hours of operation and replace the oil lter after every 200 hours of operation as follows:

1. Park the mower on a level surface with the engine stopped. The engine oil should be

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

2. Before removing the dipstick, and oil ll cap,

clean the area around them to keep any dirt or debris out of the engine.

Maintenance Instructions LUBRICATION

3. Remove the dipstick, oil ll cap, and oil drain plug, and drain the oil into a suitable container. Be sure to allow ample time for complete drainage.

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

the engine.

5. Remove the old oil lter and wipe off the lter

mounting surface on the engine.

Oil

Dipstick

Oil Fill

Oil Fill and Oil Dipstick

(View from Above Left Side of Tractor)

7. Install the new oil lter on the engine. Turn the lter clockwise until the rubber gasket con tacts the sealing surface, then tighten the lter an ad-

ditional 3/4 turn.

8. Reinstall the drain plug. Make sure it is tightened to 10 lb·ft (14 N·m).

9. Remove the ll cap on the engine valve cover, and ll the crankcase with new, clean oil. Use

only crankcase lubricants recommended by the engine manufacturer. Refer to Specications in this manual or the engine owner’s manual. Use the recommended oil viscosity for the expected ambient temperature. Oil with the correct viscosity will aid starting in cold weather and assure proper lubrication in hot weather. Fill up to, but not above, the FULL mark on the dipstick; crankcase capacity is 2.5 quarts (2.4 liters)

when changing oil and lter.

IMPORTANT: Check the dipstick reading before adding the last 1/2 pint of oil and ll only to the FULL mark. The oil level should never be above the FULL mark on the dipstick; overlling can result in engine overheating, loss of power, and possible engine damage.

10. Start the engine and check for oil leaks around the oil lter. Stop the engine, recheck the oil level, and add oil if necessary. (When the en-

gine is rst operated with a new oil lter, the oil level will drop slightly as the lter is lled with

oil.)

Oil Drain

Plug

Oil Drain Plug Location

(View from the Rear of Tractor)

6. Apply a thin coating of new oil to the rubber gas-

ket on the replacement oil lter.

IMPORTANT: Use ONLY oil lters from the engine manufacturer (Kohler P/N 2175-283-S).

Aftermarket oil lters may not seal properly and/

or may not have the cor rect pressure relief valve for proper lubrication.

Oil

Filter

Oil Filter Location

Maintenance Instructions LUBRICATION

Mower Deck Spindle Lubrication

Lubricate each deck spindle grease tting every 25 hours. Use SAE general purpose lithium or

molybdenum base grease for grease ttings.

DR52, DS60 or DR64 Mower Deck Lubrication

Lubricate the U-Joint in the drive shaft every 25 hours with SAE general purpose lithium or molyb-

denum base grease.

Transaxle Fluid Level

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

Service Class SL or higher) engine oil.

● Inspect both transaxle cases and hoses after

every 25 hours of operation for visible leaks.

● The uid level for the transaxles can be checked

visually by looking at the uid level in the expansion reservoir. When the transaxles are cold, the uid

level in the expansion reservoir should be between 1/4 and 1/2 in. (0.64 cm and 1.27 cm).

Transaxle Oil and Filter Change

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

1. Thoroughly clean the exterior of the 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 lter guard, remove and replace the oil lter using an oil lter wrench. Tighten lter by turning lter 3/4 to 1 turn after gasket contacts the lter base surface. Reinstall the oil lter guard. (Refer to Transaxle Oil Drain Plug,

Filter, and Guard Location illustration.)

Oil Filter

Hot Level

Cold Level

Expansion Reservoir Location

Reservoir Cap

Hose

Oil Filter

Guard

Transaxle Oil Drain Plug, Filter, and

Guard Location

(Shown with Deck Support Arms

Removed for Clarity)

3. Reinstall drain plug.

4. Remove the oil reservoir hose attached to the elbow on top of the transaxle. Remove the el-

bow to access the oil ll opening.

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

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

Oil Drain

Plug

Maintenance Instructions LUBRICATION

Grease Fitting and Oil Point Lubrication

Elbow

Screw Locking

Nut Down

Lubricate the grease ttings and oil points after every 25 hours of operation. Lubricate more often

when operating in dusty or dirty conditions. Use SAE general purpose lithium or molybdenum base

grease for grease ttings and light machine oil (SAE

10) to lubricate oil points. Lubricate the locations

shown in the Chassis and Deck Lubrication Points illustration.

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

tor) require routine lubrication after every 25 hours of running time. Remove tractor PTO quick discon-

nect tube assembly for easy access to grease t-

tings.

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 1/4-1/2 in. (6-13 mm) using 20W-50 (API Service Class SL or higher) oil.

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

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

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

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

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

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

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

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 Front Deck Lift Pivot Grease 2 4 Rear Deck Lift Pivot Grease 2 5 Pivot Assembly, Tilt-Up DeckΔ Grease 2 6 Deck Support Arm Socket Grease 2 7 Steering Lever Pivot Grease 2 8 Deck Support Arm Pivot Grease 2 9 Deck-to-PTO Coupling Grease 1 (Grease Spline Slide Area)

10 Universal Joint Tube Assembly Grease* 1

11 FSC Lever Pivot Grease 1 12 Hydro Idler Arm Pivot Grease 1 13 Body Latch Pivot Oil 2 14 PTO Clutch Lever Pivot Grease 1 15 Clutch Arm Pivot Grease 1 16 Transaxle Oil Reservoir Oil 1 17 Throttle Control Cable Ends Oil 2 18 Engine Dipstick Oil** 1 19 Tail Wheel Caster Fork Pivot Grease 2 20 Rear Axle Pivot Grease 1 21 Rear Wheel Bearing Grease 2

Ident Lubrication No. No. Location Type Places

22 Engine / Oil Filler Oil** 1 23 PTO Belt Tightener Pivot Grease 1 24 Clutch Actuator Push Rod Grease 1 25 Brake Band Pivot Pins (Clevis) Oil 2 26 Parking Brake Pivot Grease 1 27 Parking Brake Clevis Oil 3 28 Throttle Control Pivot Oil 1 29 Universal Joint Shaft Assembly Grease* 1 30 Blade SpindleΔ Grease 3

* Greaseeverytwenty-ve(25)hours.

** Refer to Engine Oil locatedonpage48.

Fitting located underside, access with deck in tilt-up posi-

tion.

NOTE:DR64Tilt-UpDeckisshownforreference.Forother

Deck Lubrication Points, refer to Deck and Carrier Frame Illustrated Parts Manual.

Maintenance Instructions LUBRICATION

5 6 7 8

17 & 28

7 8

26 13

16 17

Chassis and Deck Lubrication Points

Maintenance Instructions CLEANING

CLEANING

CAUTION

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

Engine Air Cleaner System

Turbine Precleaner

The engine air cleaner system includes a turbine

precleaner; a spinning fan driven by intake airow

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™ VLR 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 lter restric- tion gauge on the air cleaner outlet to indicate when

the air lter needs servicing -- a yellow indicator will show when the lter is overly restricting airow into

the engine.

Primary Filter

Element

Enginaire™

Air Cleaner Cover

Air Cleaner

Safety

Filter

Turbine

Precleaner

Band

Enginaire™ VLR

Air Cleaner

Air Intake

Hose

Clamp

Hose

Air Filter

Restriction Gauge

Hose

Clamp

Engine

Engine Air Cleaner System Components

Maintenance Instructions CLEANING

IMPORTANT: Use only Enginaire™ air lter elements for replacement (Walker 5090-4 and 5090-5). After-

market lters may not seal properly or lter efciently.

Canister

Primary Filter

Element

Air Cleaner Components

(Shown with Cover Removed)

IMPORTANT: The Enginaire™ air cleaner uses a dry

paper-type air lter element. NEVER apply oil to the paper element.

Push Button to Reset

Indicator After Service

2. Remove the primary lter element by pulling it out

of the canister. There will be some initial resis-

tance as the lter seal breaks loose and slides off

of the outlet tube. Gently move the end of the

lter 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 lter is removed.

3. Discard the lter element if excessive air ow restriction has been indicated by the air lter

restriction gauge and proceed to Step 6. Clean

the lter 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 lter element. The lter 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 recom- mended. Do not try to clean the element with

compressed air. Remember replacing a lter is

less expensive than replacing a dusted engine.

4. Use a bright light inside the primary lter 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.

Air Filter

Restriction Gauge

Air Filter Restriction Gauge Location

Inspect the primary lter element after every 100 hours of service and replace the element and safety

lter yearly (or when dirty or damaged). More fre- quent replacement may be required when operating in extremely dusty conditions as indicated by the air

lter 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.

5. Check the condition and resilience of the radial sealing surface (inside of the open end) of the

primary lter element. Replace the lter if any

cracks, tears, or other damage to the sealing surface are noted.

6. Without removing, visually inspect the condition

of the safety lter for damage or holes. The safety lter should only be removed for replace-

ment YEARLY (or when dirty or damaged).

IMPORTANT: Prior to removing the safety lter,

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 lter, use a clean,

damp cloth and wipe the interior of the air cleaner canister clean. Use special care to clean both the inside and outside surfaces of the outlet tube.

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

Maintenance Instructions CLEANING

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

Safety FilterCanister

Primary

Outlet

Tube

Air Filter Element Replacement

9. Insert and seat the safety lter and primary lter

el ement carefully into the canister, applying

pres sure at the outer rim of the lter; not at the exible center. Make sure the lter element is

completely in place before installing the cover.

Radial Sealing

Surface

Filter

Element

Engine Cooling System

Radiator Screen and Cooling Fins

To prevent the engine from overheating and possible engine damage, clean grass clippings, chaff, and dirt from the ne mesh radiator intake screen daily. In certain mowing conditions (dry grass, leaves, tree “cotton”, etc.), it may be necessary to check and clean the screen several times during use to prevent engine overheating.

1. With utility bed raised, lift to remove the screen. To clean the screen, wash with soapy water or blow out with compressed air.

NOTE: DO NOT use petroleum based lubri cants

on the sealing surfaces of the lter elements; use

tal cum powder or dry silicone lubricants if re-

quired for lter installation.

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

Cover

Latch

Cover Latch

Proper Orientation of Air Cleaner Cover

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

12. Reset the air lter restriction gauge (press button

on the end of the indicator).

Radiator Screen

2. Inspect the radiator cooling ns for material

lodged in this area which would restrict cooling

airow. Use pressurized air or water to clean.

DO NOT use any tool, like a screwdriver or knife, to clean material out of the ns as this may

damage the cooling ns. DO NOT use cold water on a hot radiator.

NOTE: Directing pressurized air or water from the fan side of the radiator outward is recommended to dislodge material packed on the outside of the cooling ns. DO NOT use cold water on a hot radiator.

WARNING

Radiator and engine parts can become extremely hot during operation. Wear gloves and avoid touching hot parts while cleaning the radiator screen and cleaning debris away from the engine and cooling system.

Maintenance Instructions CLEANING

2802-5

<15°

1. 2.

Flushing Radiator and Changing Coolant

Change engine coolant every year. Drain the coolant from the engine and radiator:

1. Remove the radiator cap.

2. Open the drain plug on the bottom right corner of the radiator. Also, drain the coolant recovery tank.

3. Remove drain plug on RH side of the engine block (below intake manifold). Also see Kohler Owner’s Manual for location of the drain.

4. If there is any indication of deposits or scaling inside the radiator, use a commercial scale remover and ush the cooling system thorough- ly before adding fresh coolant.

Use a pre-mixed 50/50 solution of antifreeze (ethylene glycol) and distilled water to rell the cooling system.

IMPORTANT: The solution of antifreeze and water must be thoroughly pre-mixed before putting it in the engine. Adding pure antifreeze into the radiator may cause damage to the engine from overheating.

Tilt Bar

Unlock Deck Arms for Deck Tilt-Up

3. Fit tilt bar into the socket on front of deck housing and secure with hitch pin.

IMPORTANT: Maintain proper coolant level in the radiator and coolant recovery tank. The coolant level should be maintained between FULL and LOW marks on the coolant recovery tank. Recheck the

coolant level after the rst time the engine has been operated after lling the coolant system (it would be

normal to add a little coolant after initial operation).

Grass Buildup in Mower Deck Housing

DANGER

Before raising or removing the mower deck for cleaning, stop the engine, remove the ignition key, and disconnect the electrical plug on the fuel shut-off solenoid.

1. Remove the tilt bar from the stowed position on the carrier frame.

2. Use the tilt bar to release the two (2) deck locking arms as shown in the Unlock Deck Arms for Deck Tilt-Up illustration.

Use Hitch Pin to

Secure Tilt Bar.

Tilt Bar Installed

4. Remove footrest or, if equipped with adjustable footrests, move the footrest to the full forward locking position.

Maintenance Instructions CLEANING

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

8746-2

in the mower deck housing can be tolerated, a

point is nally reached where cutting quality deteriorates and clogging begins to occur

because of too much buildup on the bafing and

housing.

Full Forward/

Locked Position

Adjustable Footrest in Full Forward/Locked

Position for Deck Tilt-Up

5. Raise deck to tilt-up position using tilt bar and secure in position by inserting the deck hook in the tilt-up latch on the tractor body as shown in the Deck Secured in TILT-UP Position photo.

Hitch Pin

Tilt-Up Hook and Latch Connected

Tilt Bar

DANGER

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

7. Lower the deck to the normal operating position and rotate locking arms downward.

CAUTION

Do not operate mower with deck tilt-up pivot joint UNLOCKED. Make sure locking arms are in the LOCKED position and the tilt-up joint is rigid (locked).

8. Remove tilt bar and stow on carrier frame.

9. Replace footrests to desired position.

Transaxle Housing

Tilt-Up

Latch

Deck Secured in TILT-UP Position

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

Tilt-Up

Hook

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

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

Maintenance Instructions CLEANING

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 ns with oily dirt. If this condi- tion 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

DANGER

To prevent accidental starting of the engine when servicing or adjusting the machine, remove the key from the ignition switch and disconnect the electrical plug on the fuel shut-off solenoid.

Engine Cooling System

Coolant Level

WARNING

NEVER remove the radiator pressure cap when the engine is hot — hot water could spray and cause a burn if the cap is taken off too soon.

IMPORTANT: The coolant solution of antifreeze and

distilled water must be thoroughly pre-mixed before putting it in the engine (adding pure antifreeze into the radiator may cause damage to the engine by causing overheating).

Security of Air Cleaner System

NOTE: The following inspection is only an external inspection and should be done without “disturbing” the ltration 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 latches are secure–do not run the engine without the air cleaner cover in place and secure.

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

3. Check to make sure the air lter restriction gauge is in place and securely mounted on the air cleaner housing.

Recovery Tank

Recovery (Overow) Tank

Check the coolant level in the coolant recovery tank and maintain the coolant level between the FULL and LOW marks on the recovery tank. When the engine is cold, the coolant level should be at or slightly above the LOW mark on the recovery tank.

If the coolant level is low, remove the radiator cap and

ll to the overow port level and then ll the recovery

tank above the LOW mark. Use a pre-mixed 50/50 solution of antifreeze (ethylene glycol) and distilled

water to ll the cooling system.

Battery

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

IMPORTANT: Make sure battery is securely mount-

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

Electrolyte Level

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

1. Remove battery cell ller caps.

2. Check the electrolyte level. If the level is below

the bottom of the vent well, ll 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 ller caps.

IMPORTANT: DO NOT overll the battery. Electrolyte will overow 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.

Wheel Nuts Torque

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

75 to 85 lb·ft (102 to 115 N·m).

Sharpen Mower Blades

Check mower blade(s) for straightness, 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.

1. Stop the engine, remove ignition key, and disconnect the electrical plug on the fuel shut-off solenoid before raising the mower deck to service blades.

2. Raise the deck and secure it in the TILT-UP posi tion (refer to Deck Secured in TILT-UP Po-

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

Check the battery charge by measuring the specic gravity of electrolyte; if specic gravity is less than

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

1. Charge the battery at 15 amps for 10 minutes. DO NOT exceed 20 amps maximum recom-

mended charging rate. Charge until specic

gravity is at least 1.250. Total charging time should not exceed one (1) hour.

2. After charging the battery, use distilled water to adjust the electrolyte level to the bottom of the vent wells [1/4 to 1/2 in. (6 to 13 mm) above the

plates].

Tire Pressure

Inate tires to pressures shown below:

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

DANGER

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

NOTE: PTO shaft must be disconnected

before checking blades for straightness.

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

(3 mm), the blade is bent and should be re- placed.

Maintenance Instructions CHECKING/SERVICING

WARNING

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

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 bolt and washer that mounts the blade.

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

NOTE: Blades can be sharpened with an electric blade sharpener, conventional electric

grinder, or a hand le.

CAUTION

7. Mount the blade with wing tips pointing up into

Drive Belts

Blade Balancer

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 (95 N·m).

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 main tained 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 four (4) drive belts after every 25 hours of operation– engine/PTO drive (3), ground drive (1). Also, remove the belt cover on the mower deck and check the blade drive belt. If the belts show signs of

cracking or deteriorating, the belts should be re- placed. Refer to REPLACING/REPAIR ING the Drive Belts in this section.

Fuel Lines and Clamps

Every year, inspect the fuel lines from the tanks to

engine for deterioration or damage. Also, inspect the fuel line clamps for tightness. Good preventive maintenance calls for complete replacement of fuel lines and clamps every two (2) years.

NOTE: This procedure is of special importance for the diesel engine due to poor performance when air is injected with the fuel.

Radiator Hoses and Clamps

Inspect the radiator hoses every 200 hours for deterioration or damage. Also check the tightness of the hose clamps. Good preventive maintenance calls for complete replacement of the radiator hoses and clamps every two (2) years.

Maintenance Instructions CHECKING/SERVICING

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.

Blade Brake Action

WARNING

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

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

ve (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 78.

Safety Switch System

WARNING

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

● With an operator in the seat, the engine starts but dies soon after the Forward Speed Control (FSC) or PTO is engaged.

● Without an operator on the seat, the engine continues to run with the Forward Speed Control (FSC) and/or PTO engaged.

● With an operator in the seat, the Forward Speed Control (FSC) and PTO disengaged and warning horn sounding, but the starter will not engage.

Forward Speed Control Friction Lock

The FSC friction lock is designed to hold the selected forward travel speed when the steering le-

vers are moved and yet the friction is not too heavy to make moving the FSC control difcult (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.

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

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

NOTE: There is a 1/2 second time delay function on the seat switch to avoid engine power interruption when driving over bumps.

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.

Maintenance Instructions CHECKING/SERVICING

Transmission Control Setting

On a yearly interval or when an out-of-adjustment condition is observed, check the transmission control for proper function as follows:

Neutral-Park

With the mower parked on level ground, start and run the engine, rst at idle and then normal operat- ing speeds. With the FSC in the NEUTRAL-PARK position, there should be no movement of either drive tire. If the tire(s) are “creeping” forward or reverse, refer to ADJUSTMENTS for the Neutral Func-

tion Adjustment - Step 3 in this section.

Straight Ground Tracking

Check for straight ground track by driving on a smooth, level surface with hands off the steering levers. Set the FSC at different speeds and observe if the mower moves in a straight line (use a cement joint or other line on the ground for reference). If the machine is drifting to the right or left, refer to

ADJUSTMENTS for Straight Tracking Adjust- ment - Step 5 in this section.

Maintenance Instructions REPLACING/REPAIRING

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 electrical plug on the fuel shut-off solenoid.

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 ve (5) individual drive belts on the ma- chine:

● Engine/PTO Belt (Matched Set of 3)

● Ground Drive Belt

● Mower Blade Drive

The belts may be removed and replaced using the

procedures described on the following pages.

Ground

Drive Belt

Engine/PTO Belts

(Matched Set of 3)

Belt Locations (Engine Hidden for Clarity)

Maintenance Instructions REPLACING/REPAIRING

Engine/PTO Belt

1. To remove the Engine/PTO belt:

a. Remove Upper LH Belt Guard and RH Belt

Guard by removing two (2) wing nuts.

Wing Nut

Upper LH

Guard

Fixed Idler

Pulley

Lower LH

Guard

Wire Lock Pin

PTO

Pulley

Clutch

Idler Pulley

PTO Guard

b. Remove two (2) wire lock pins and open

Lower LH Belt Guard and PTO Belt Guard.

c. Roll the belt off the pulley(s) and remove

the belt.

Wire Lock Pin

Right Hand

Guard

Wing Nut

PTO Belt(s)

(Matched Set)

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

2. To replace the Engine/PTO belt:

a. Reverse the removal procedure to replace

the engine PTO belt.

Upper LH

Guard

Secure Wing

Nut

Lower LH

Guard

Wire Lock

Front View

Secure Wire Above Tab

b. Secure wire on lock pin above tab on lower

PTO guard.

Right Hand

Guard

Secure Wing

Nut

PTO Guard

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

Maintenance Instructions REPLACING/REPAIRING

Ground Drive Belt

1. To remove the ground drive belt:

a. Remove belt tension by raising the spring-

loaded idler pulley with the deck tilt bar.

Deck Tilt

Bar

LH Transaxle

Ground Drive

Belt

Belt Tightener

Idler Pulley

Ground Drive Belt Assembly (Disengaged)

b. Slide belt off pulleys, then release the idler

pulley.

RH Transaxle

Transmission Belt

Tensioner Arm

Drive Pulley

Raise Idler Pulley to

Relax Belt

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

Deck Tilt

Bar

LH Transaxle

Ground Drive

Belt

Idler Pulley

Ground Drive Belt Assembly (Engaged)

RH Transaxle

Transmission Belt

Tensioner Arm

Drive Pulley

Maintenance Instructions REPLACING/REPAIRING

Deck Drive Belt

1. To remove the deck drive belt:

a. Remove deck footrest and two (2) covers

over the RH and LH blade spindles.

b. Loosen belt tensioner stop bolt and turn in-

ward until retracted 1 in. (2.5 cm) from the operating position.

c. Lock drive pulley so that it can not rotate.

* If deck is installed on tractor, the PTO

blade brake will prevent the drive pulley from rotating.

* If deck is detached from tractor, use pry

bar or large screwdriver positioned through the drive shaft U-joint to hold shaft and prevent rotation.

d. From a position on the LH side of the deck,

grasp belt midsection and pull to compress the belt tensioner springs and move the tensioning pulley inward. The belt will then slip off the LH spindle pulley and can be completely removed.

2. Install the deck drive belt by reversing the removal procedure:

a. Route the belt as shown on the belt routing

decal (located on the deck housing). Leave the belt loose at the LH spindle and then install the belt by compressing the belt tensioner as noted above.

b. After the belt is in place, reset the belt ten-

sioner stop bolt by turning outward until contacting the pulley bracket and then making one (1) additional turn.

c. Reinstall spindle covers and footrest.

Spindle

Cover

Pulley Moves Inward to

Allow Belt to Slip Off

LH Blade Spindle

Belt Routing

Decal

2749-6

BELT TWIST

DR64 BELT P/N 2731-5

BELT TWIST

BELT ROUTING

Belt Tensioner

Stop Bolt

Footrest

8746-2

Spindle

Cover

Use Pry Bar or

Screwdriver Through

U-Joint to

Prevent Rotation

Grasp Belt Here and

Pull from LH Side to

Compress Springs on

Belt Tensioner

8600-28

Deck Drive Belt Replacement

Maintenance Instructions REPLACING/REPAIRING

Fuel Filter

Fuel

Filter

Fuel Filter Location

IMPORTANT: Replace the fuel lter only in a clean

area where the connection surface will not be contaminated by dust and dirt.

The Kohler engine has a spin-on type fuel lter that

should be replaced every year using the following procedure:

1. Turn the fuel tank selector valve to the OFF position.

2. Before removing the fuel lter, clean the area around the lter to keep dirt and debris out of

the engine fuel system.

3. Remove the fuel lter and wipe off the lter

mounting surface on the engine.

4. Install the new fuel lter. Turn the lter until the

rubber gasket contacts the sealing surface,

then tighten the lter an additional 1/2 to 3/4 turn. Turn fuel tank selector valve ON to one of

the fuel tanks.

5. Before starting the engine, use the Fuel Pump Priming procedure instruction in the Operating

Instructions to purge air out of the fuel system.

6. Start the engine and check for fuel leaks around

the lter/fuel hose connection used for priming.

Mower Blades

Mower blades are removed and remounted as described in the Sharpen Mower Blades instructions (refer to CHECKING/SERVICING to Sharpen Mow- er Blades in this section). During the course of sharpening and inspecting mower blades, if there are any of the following conditions of wear or dam age, blades should be replaced for reasons of safe ty 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 at 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 ma terial can wear metal away in this area, the blade should be replaced when metal thickness

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

DANGER

When blades are operated over sandy soil, and if blades are allowed to wear, a “slot” may be worn into the wing tip of blade. Eventually a piece of the blade may break off creating a serious potential for injury or damage.

● Check the blades for straightness by marking blade tip position inside the deck housing and then ro tating the opposite end of the blade to the same po sition and comparing. If the difference in blade tip track is more than 1/8 in. (3 mm), the blade is bent and should be replaced.

● Inspect the blade surface, especially in formed areas, for cracks. Replace the blade if any cracks are found.

WARNING

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

Maintenance Instructions REPLACING/REPAIRING

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

CAUTION

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

Maintenance Instructions ADJUSTMENTS

ADJUSTMENTS

Transmission Control

IMPORTANT: The proper adjustment of the tran-

saxle control stops is essential for efcient operation and life of the transaxle. These stops are properly ad justed 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

tran saxles). To ne 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.)

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

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

Step 2 - Steering Handles Adjustment

1. An adjustment range of approximately 3 in. (76.2 mm) is available on the steering handles the handles can be adjusted forward or aft depending on the arm length of the operator. The handles can be adjusted by loosening the locknut at the pivot point and the locknut holding the handle in position in the adjustment slide. Adjust the handles into the most comfortable position and tighten both locknuts.

Lever Alignment

Locknut

(Position)

Adjustment

Slide

Locknut

(Pivot Point)

Steering Handles Adjustment

Maintenance Instructions ADJUSTMENTS

Step 3 - Neutral Function 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

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

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

Control Rods

Control Arm

Tracking Adjustment Nuts

Transmission Control Rod and Arm Location

(Front Body Hidden for Clarity)

Tracking Adjustment Nut

(Adjusts Length of

Control Rod)

Maximum Speed

Adjustment Set Screw

Adjust Length of

Rod to Position

FSC Lever

FSC Lever Position Adjustment

Control Rod

Jam Nut

Ball Joint

Transmission

Control Arm

Tracking Adjustment Components

FWD

REV

Locating/Limit

Stud

Maintenance Instructions ADJUSTMENTS

Step 4 - Full Forward Speed Adjustment

WARNING

1. Move the FSC to the full FORWARD speed po-

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

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

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

5. Lift the body to access the steering adjustment components.

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.

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

sition.

2. Raise the body. The set screws in the left and right Transmission Control Arms should not be contacting the locating stud in the transaxle. If they are, back the set screws out until they do not touch.

T-Handle

Hex Wrench

Transmission

Control Arm

Maximum Speed Tracking Adjustment

(Shown with Parts Removed for Clarity)

Maximum

Speed Tracking

Adjustment

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

Maintenance Instructions ADJUSTMENTS

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 position check for movement of either drive wheel (if either wheel moves backward or forward, refer to the Step 3-Neutral Function Ad- justment and readjust).

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

3. If travel is not straight, shorten the control rod on the slow side by turning the tracking adjustment nut clockwise. If straight tracking and neutral can not be achieved, turn the tracking adjustment nut counterclockwise until neutral is restored.

4. Lengthen the control rod of the faster side by turning the tracking adjustment nut counterclockwise to match the slower side while maintaining the neutral position.

Step 6 - FSC Switch - Neutral Adjustment

1. Place the FSC lever in the NEUTRAL-PARK position. Loosen mounting screws and adjust the neutral switch up or down accordingly.

FSC Switch

FSC Neutral Switch Location

Switch Closed

in Neutral

FSC Switch

Actuator Arm

IMPORTANT: After tracking adjustments are

complete, conrm that there is at least one (1)

thread visible on both control rods past the tracking adjustment nuts.

5. If the forward travel is straight throughout the speed range, except at maximum speed - place the FSC in full FORWARD, turn the set screw in the Transmission Control Arm, of the faster side, in until it contacts the limit stud. (Turning the set screw in slows the wheel.) Turn the set screw in an additional 1/8 turn. Recheck for equal full for ward speed. Adjust this set screw until equal full forward speed is achieved. Tighten the jam nut.

Deck Support

Arm (Ref)

Loosen Screws

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

FSC Switch Adjustment

(Side View Through Chassis)

CAUTION

Before testing the FSC Neutral Switch, disconnect the electrical plug on the fuel shut-off solenoid and engage the parking brake to prevent accidental starting and inadvertent machine movement.

Maintenance Instructions ADJUSTMENTS

2. Check operation of the FSC Neutral Switch by placing the FSC lever in the full FORWARD position. While holding the ignition switch in the START position, slowly move the FSC lever back towards the NEUTRAL-PARK position until the starter motor engages. Stop moving the lever and note the position of the FSC lever where it passes through the slot in the body. The FSC lever should be within 1/8 in. (3 mm) of the NEUTRAL-PARK position. If this dis- tance is greater than 1/8 in. (3 mm), the FSC Neutral Switch needs to be adjusted downward for quicker activation.

Step 7 - Forward Speed Control Friction Adjustment

FSC Friction

Adjustment Nut

FSC Friction Adjustment Nut

FSC Friction Adjustment Test

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

reased.

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 de-

creased.

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.

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 disassem-

bled, rst 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

Ball Joint

1/4 in. to 5/16 in.

(6.35 mm to 7.94 mm)

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

Blade Clutch

Idler Pulley

Clutch Arm

Front of Mower

PTO Clutch Engaged

Maintenance Instructions ADJUSTMENTS

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

Step 1 - Idler Pulley Maximum Travel Adjustment

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

6-1/4 in.*

(158.75 mm)

Clutch Actuator

Link

6 in.*

(152.4 mm)

Clutch Spring Assembly (Spring Uncompressed)

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

Knuckle Joint

2-1/8 in.*

(53.98 mm)

(refer to Blade Brake Band Adjustment illustration).

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

2. Adjust the pivot stop bolt to give 1-5/8 in. to 1-3/4 in. (41 mm to 44 mm) pulley travel from “clutch engaged” to “clutch disengaged”.

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

1-5/8 in. to 1-3/4 in.

(41 mm to 44 mm)

CLUTCH DISENGAGED CLUTCH ENGAGED

PTO Clutch Disengaged

Clutch Disengagement/Brake Action

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 ve (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:

Blade Brake

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.

Band

CLUTCH DISENGAGED CLUTCH ENGAGED

5/8 in. to 3/4 in.

(16 mm to 19 mm)

Clutch Idler Pulley Travel Adjustment

Blade Brake

Band Adjustment Nut

Blade Brake Band Adjustment

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 ve (5) seconds,

check the following:

a. Make sure clutch and brake linkage are

working freely (no binding).

b. Check the brake band lining for wear.

c. Check the brake drum on the pulley. If ex-

cessive wear is present, it will be necessary to replace worn parts.

Chassis Mount

(Ref)

LIMITED WARRANTY

FOR

WALKER MODEL H24d

RIDER MOWER

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

Walker Manufacturing company will, at its option, repair or replace, without charge, any part covered by this warranty which

is found to be defective in material and/or workmanship within one (1) year* after date of sale to the original retail purchaser

unless the product is used for rental purposes, in which case this warranty is limited to ninety (90) days. At Walker’s request, customer will make the defective part available for inspection by Walker and/or return the defective part to Walker, 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 Hydro-Gear Transaxles

Battery

Tires

The available warranties covering these items are furnished with each mower. Walker does not assume any warranty obli-

gation, liability or modication for these items, which are covered exclusively by the stated warranty of the respective man-

ufacturers noted above.

* Extended warranties are offered for the following powertrain components:

• A three (3) year or 3000 hour (whichever comes rst) warranty is offered for Hydro-Gear ZT3400 Hydrostatic transaxle;

covers full cost of replacement up to 1000 hours of use, and after 1000 hours warranty coverage is prorated against 3000 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 specic 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 H24D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual