Walker H27I User Manual

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Page 1

Operator’s Manual

Safety, Assembly, Operating, and Maintenance Instructions

Please Read and Save These Instructions

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

Beginning S/N: 125122

Eective Date: 10.21.13

P/N 2000-10

Page 2

Foreword

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

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

This manual covers Model H27i with the Kohler Command Pro ECH749 (26.5 HP) Electronic Fuel Injection (EFI) gasoline engine.

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

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

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

Sincerely, WALKER MANUFACTURING COMPANY

Bob Walker, President

Page 3

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 ______________ 18

SETUP INSTRUCTIONS __________________ 18

Battery Service _______________________ 18

Wet Battery Service __________________ 18 Dry Battery Service ___________________ 19 Battery Charging _____________________ 19 Battery Installation ___________________ 20

Mower Deck Assembly _________________ 20

Deck Caster Wheels Installation _________ 20 Deck Discharge Deector Shield Installation ____________________ 20 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 Steering Levers_______________________ 29 Blade Clutch (PTO) ____________________ 29 Parking Brake ________________________ 30 Oil Pressure Warning Light/Horn ________ 31 Engine Service Light __________________ 31 Over Temperature Warning Light/Horn ____ 31 Transaxle Lockout Arms _______________ 32 Circuit Breaker _______________________ 32 Hourmeter ___________________________ 32

STARTING THE ENGINE _________________ 34 ADJUSTING GROUND SPEED AND STEERING __________________ 34 ENGAGING THE BLADE DRIVE ___________ 36 STOPPING THE MACHINE _______________ 37 FUEL TANK SELECTOR VALVE ___________ 38 ADJUSTABLE FOOT RESTS ______________ 38 ADJUSTING CUTTING HEIGHT ____________ 38

Transport Position ____________________ 39 TRANSAXLE LOCKOUT _________________ 39 RECOMMENDATIONS FOR MOWING ______ 39 RECOMMENDATIONS FOR TILT-UP DECK OPERATION/TRANSPORT _______________ 41

Maintenance Instructions __________ 42

MAINTENANCE SCHEDULE CHART _______ 42 IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE _______________________ 43

Fuel System _________________________ 43

Starting/Stopping _____________________ 43

Cooling System ______________________ 43

Air Cleaner System ____________________ 43

Oil__________________________________ 43 LUBRICATION _________________________ 44

Engine Oil ___________________________ 44

Engine Break-In Oil ___________________ 44 Checking Engine Crankcase Oil Level ____ 44 Changing Engine Crankcase Oil/Oil Filter __ 44

Mower Deck Spindle Lubrication ________ 46

DR52, DS60 or DR64 Mower Deck

Lubrication __________________________ 46

Transaxle Fluid Level __________________ 46

Transaxle Oil and Filter Change _________ 46

Grease Fitting and Oil Point Lubrication __ 47

Page 4

Table of Contents

CLEANING ____________________________ 50

Engine Air Cleaner System _____________ 50

Turbine Precleaner ___________________ 50 Cummins/Fleetguard OptiAir™ Air Cleaner _________________________ 50

Engine Cooling System ________________ 52

Cooling Air Intake Screen ______________ 52 Cylinder Head Cooling Fins ____________ 53

Grass Buildup in Mower Deck Housing ___ 54 Transaxle Housing ____________________ 55

CHECKING/SERVICING __________________ 56

Security of Air Cleaner System __________ 56 Battery ______________________________ 56

Electrolyte Level _____________________ 56 Cleaning the Terminals ________________ 57 Charging the Battery __________________ 57

Tire Pressure _________________________ 57 Wheel Nut Torque _____________________ 57 Sharpen Mower Blades ________________ 57 Drive Belts ___________________________ 58 Spark Plugs __________________________ 58 Ignition Wires ________________________ 58 Fuel Lines and Clamps _________________ 58 PTO U-Joints ________________________ 58 Engine Starter ________________________ 59 Blade Brake Action ____________________ 59 Safety Switch System__________________ 59 Forward Speed Control Friction Lock _____ 59

REPLACING/REPAIRING _________________ 60

Drive Belts ___________________________ 60

Engine/PTO Belt _____________________ 61 Ground Drive Belt ____________________ 62 Deck Drive Belt ______________________ 63

Fuel Filter ___________________________ 64 Mower Blades ________________________ 65

ADJUSTMENTS ________________________ 66

Transmission Control__________________ 66

Steering Lever Position Adjustment ______ 66 Steering Handles Adjustment ___________ 66 Neutral Position Adjustment ____________ 67 Full Forward Speed Adjustment _________ 68 Straight Tracking Adjustment ___________ 68 FSC Neutral Switch Adjustment _________ 68 Forward Speed Control Friction Adjustment ___________________ 69

Blade Clutch (PTO) ____________________ 70

Clutch Engagement/Belt Tension ________ 70 Clutch Disengagement/Brake Action _____ 71 Idler Pulley Maximum Travel Adjustment __ 71 Blade Brake Band Adjustment __________ 72

MAINTENANCE AND SERVICE RECORD SHEET _______________________ 73

Warranty _____________________ 75

Page 5

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 specific warnings. Such accidents, in most cases, can be prevented by being aware of the dangers present.

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

Instructions for the meanings of DANGER, WARN- ING, CAUTION, IMPORTANT, and NOTE.

GLOSSARY

There are many terms that are either unique to this equipment or that are used as acronyms. The following terms and their definitions will help while using this manual:

• DECK is the mowing attachment mounted on the

front of the tractor which includes the carrier frame, deck housing, blade spindles, and cutter blades.

• ELECTRONIC CONTROL UNIT (ECU) controls

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

• FORWARD SPEED CONTROL (FSC) controls

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

• STEERING LEVERS steer the tractor by con-

trolling the two transaxles.

• TRACTOR is the prime mover, including the

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

• TRANSAXLE transmits and controls power

from the ground drive belt to the main drive wheel.

• TRANSAXLE LOCKOUT ARMS release the

transaxles to permit freewheeling the tractor.

IDENTIFYING NUMBER LOCATIONS

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

Tractor Model No. ______________________

Tractor Serial No. ______________________

Deck Serial No. ______________________

Engine Model No. ______________________

Engine Serial No. ______________________

• 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.

• SIDE DISCHARGE (SD) discharges mowed

material from the right side of the mower deck.

Date of Purchase ______________________

Fill In By Purchaser

Page 6

General Information

Serial Number

Tractor Serial Number Location

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 find a local, authorized servicing agent of the component manufacturer. Any unauthorized work done on these components during the warranty period may void the warranty. If you have any dif- ficulty finding an authorized outlet or obtaining warranty service, please contact our Service Department for assistance:

Walker Manufacturing Company

5925 E. Harmony Road

Fort Collins, CO 80528

1-970-221-5614

www.walkermowers.com

Serial Number

Mower Deck Serial Number Location

ENGINE SERIAL NUMBER LOCATION

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

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

Serial Number

Engine Serial Number Location

Page 7

Specications

MODEL H27i

ENGINE

Manufacturer/Model Kohler Command Pro

Displacement cu. in. (cc) 45.6 (747)

Max Power HP (kW) 26.5 (19.8) @ 3600 RPM

Governed RPM 3600

Max. Torque lb

Idle RPM 1200

Spark Plug Type Champion

Spark Plug Gap in. (mm) .030 (0.76)

Crankcase Capacity qt (L) 2.0 (1.9)

Crankcase Lubricant Synthetic or API SJ or Higher Grade Oil Only with 10W-30

Oil Filter Kohler P/N 12 050 01-S

Fuel Tank Capacity gal (L) 9.4 (35.6)

Fuel Automotive Grade Unleaded Gasoline

Cooling System Air Cooled

Air Cleaner Remote mounted Cummins/Fleetguard OptiAir

·ft (N·m)

ECH749, 2 Cyl., OHV, Gasoline

(Air-Cooled), Electronic Fuel Injection (EFI)

40 (54)

RC12YC

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

Two Independent 4.7 Gallon Tanks with Selector Valve

(87 Octane Minimum, 10% Ethanol Maximum)

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

ELECTRICAL SYSTEM

Battery 12 Volt (340 CCA)

Charging System Flywheel Alternator

Charging Output 20 Amp DC (Regulated)

System Polarity Negative Ground

Ignition Electronic Capacitive Discharge

Starter 12 Volt Electric Ring-Gear Type, Solenoid Operated

Interlock Switches Ignition Lockout by Seat Switch, Transmission Neutral and Blade

Clutch

Circuit Breaker Manual Reset (20A), Auto Reset (30A)

TRANSMISSION

Manufacturer/Model Dual, Independent Hydro-Gear

ZT3400 Integrated Transaxles

Steering Hand Lever Control / Individual Wheel

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

Position

Service Brake Dynamic Braking through Transaxles

Parking Brake Internal Mechanical Cog Lock for each Transaxle

(Single Lever Control)

Neutral Transmission Release by Manual Dump Valve

Final Drive Direct Drive Axle from Transaxle

Page 8

Specications

MODEL H27i

TRANSMISSION (continued)

Transmission Fluid

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

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

Transmission Cooling Cooling Fan Mounted on Drive Pulley

Oil Filter Hydro-Gear

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-Profile)

Tailwheel 13 x 5.00-6 (Pneumatic 4-Ply)

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

0-10 (0-16) Infinitely Variable 0-5 (0-8) Infinitely 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 68-7/8 (174)

Tractor Wheel Base 45-3/8 (114)

Tractor with Tilted Deck (Approximate)

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

Width in. (cm)

Tractor Only (Outside Tire) 46-1/2 (118)

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

Tread Width 36-5/8 (91)

Height in. (cm)

Tractor 46-1/2 (118)

With ROPS (Optional) 66-3/8 (169)

With ROPS (Optional) Lowered 51-1/4 (130)

87-3/4 (223)

107 (272)

66 (168)

Page 9

Specications

MODEL H27i

DIMENSIONS (continued)

Weight lb (kg)

Tractor Only 753 (342)

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

DRIVE BELTS

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

Ground Drive Walker P/N 2248-1

SEAT Contour-Molded, with Nylon Backed Vinyl Cover and

FRAME/BODY CONSTRUCTION

Frame All Welded Unitized Steel Chassis

Body 14 Gauge Steel

Deck 11 Gauge Steel

1190 (540)

Integral Foam Cushion (Suspension)

DECK DR52 DS60 DR64

Type Belt Driven,

Rear Discharge

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

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

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

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

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 3330 3200

Maximum Blade Tip Speed ft/min (m/min)

18500 (5640) 17870 (5460) 18500 (5639)

Belt Driven, Side Discharge

Clockwise

Belt Driven, Rear Discharge

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

Page 10

Component Identication

NOTE: Control Identification

shown in Operating Instructions section.

Deck Support Arm

(Not Visible)

Body Tilt-Up

Latch

Body Lift

Handle

Forward Speed

Control (FSC)

Friction

Adjustment

Cutting Height Release

Lever (Cutting Height

Adjustment)

Tilt-Up Latch

Counterweight Springs and

Protective Covers

Deck Support Arm

(Not Visible)

Adjustable

Footrests

Deck

Tilt-Up Bar

Deck Tilt-Up

Socket

Deck Lift Foot Pedal

(Raises Deck)

Deck Height

Lift Chain

Front View and Right Side View

Tilt-Up

Hook

Deck

Caster Wheels

Page 11

Component Identication

Adjustable

Footrest

Fuel Gauge

Oil Fill

Dipstick

Tailpipe

Left Hand

Drive Wheel

Fuel Tank

and Cap

Fuel Pickup

Line

Cylinder Head

Cooling Fins

Spread Axle (Tail Wheel)

Muffler

Rear View and Left Side View

Page 12

Component Identication

LH Transaxle

Lockout Arm

Parking Brake

Linkage

Parking Brake

Lever

Battery

Cummins/Fleetguard OptiAir™ Air Cleaner

Air Filter

Cover

Fuel Tank Cap

Turbine Precleaner

Fuel Tank

Selector Valve

EVAP Line

Fuel Tank

LH Transmission

Control Rod

Steering Lever

Spring/Dampeners

RH Transmission

Control Rod

RH Transaxle

Lockout Arm

Clutch

Linkage

PTO Clutch

Lever

Air Filter

Restriction Gauge

(Not Visible)

Transaxle Oil

Expansion Reservoirs

Fuel Gauge

Fuel Filter

(Not Visible)

Roll Over Valve

Fuel Pump

(Low Pressure)

Fuel Pickup Line

Oil Fill

Dipstick

Muffler Heat

Shield

Rubber Bumpers

(Body Support)

Top View (Body Raised)

Air Intake Hose

Oil

Cooler

Oxygen

Sensor

Page 13

Safety Instructions - Before Operating

Pay particular attention to any information labeled DANGER, WARNING, CAUTION, IMPORTANT, and NOTE in this manual.

When you see the Safety Alert Symbol ( ), read, understand, and follow the instructions. Fail ure to comply with safety instructions may result in personal injury.

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

DANGER

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

WARNING

A POTENTIAL hazard that COULD result in severe personal injury or DEATH, if warn ing is ignored and proper safety precau tions are not taken.

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 Op-

erator’s Manual before starting and operating the machine. Become thoroughly familiar

with all machine controls and how to stop the machine and disengage the controls quickly. Replacement Operator’s Manuals are available by sending the Model and Serial Number to:

Walker Manufacturing Company

5925 East Harmony Road

Fort Collins, CO 80528

CAUTION

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

IMPORTANT: Identifies mechanical information

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

NOTE: Identifies information worthy of special attention.

2. Never allow children to operate rider mower.

Do not allow adults to operate without proper instruction.

3. Clear the area to be mowed of any foreign

objects which may be picked up and thrown by cutter blades. Pick up all sticks, stones, wire, and any other debris.

4. Keep everyone, especially children and pets, a

safe distance away from the area being mowed.

Do not mow with bystanders in the area.

5. Do not operate the machine barefoot or wearing

sandals, sneakers, tennis shoes, or similar lightweight footwear. Wear substantial protective

footwear.

Page 14

Safety Instructions - Before Operating

6. Do not wear loose fitting clothing that could get caught in moving parts. Do not operate this machine while wearing shorts; always wear ade- quate protective clothing, including long pants. Wearing safety glasses, safety shoes, and a helmet is advisable and required by some local ordinances and insurance regulations.

7. Prolonged exposure to loud noise can cause impairment or loss of hearing. Operator hear ing protection is recommended. Wear a suitable hearing protective device, such as ear muffs 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 miss ing, 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 cifically 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

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

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

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

10. Handle gasoline with care. Gasoline is highly flammable and its vapors are explosive:

a. Use an approved fuel container.

b. Never add fuel to a running engine or hot

engine (allow hot engine to cool several minutes).

c. Keep matches, cigarettes, cigars, pipes,

open flames, or sparks away from the fuel tanks and fuel container.

d. Always fill the fuel tank(s) outdoors using

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

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

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

Page 15

Safety Instructions - Operating

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

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

the tractor without a deck or imple ment installed.

3. For a beginning operator, learn to steer (maneuver) the tractor with a slow engine speed before attempting any mowing oper ation. Be

aware that, with the front mounted mower configuration, the back of the tractor swings to the outside during turns.

DANGER

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

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

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

8. Do not run the engine in a conned area with- out adequate ventilation. Exhaust fumes are hazardous and can be deadly.

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

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

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

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

5. 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 main- tain 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).

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

13. Disengage the blade drive when transporting the machine across drives, sidewalks, etc. Never

raise the mower deck while blades are rotating.

DANGER

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

Page 16

Safety Instructions - Operating

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

operating the machine on a slope, reduce speed and use caution to start, stop, and maneuver. To prevent tipping or loss of control of the machine, avoid sharp turns or sudden changes in direction.

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

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

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

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

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

ate with the grass deector shield removed.

Keep the deflector in the low est possible position.

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

lowing:

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

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

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

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

21. When leaving the machine unattended, disen-

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

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

position.

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

position.

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

a. Disengage the blade clutch (PTO), engage

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

b. LOOK to make sure blade drive shaft move-

ment has stopped before trying to unclog the system.

c. Disconnect the spark plug wires.

d. Never place hands under the deck - use a

stick or similar tool to remove clogged material.

Page 17

Safety Instructions - Maintenance

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

2. To reduce re hazards, keep the engine free of grass, leaves, excessive grease, and dirt.

3. Keep all nuts, bolts, and screws tight to ensure the machine is in a safe, working condition. Check the blade mounting bolts frequently, making sure they are tight.

4. Perform only maintenance instructions de- scribed in this manual. Unauthorized maintenance operations or machine modifications may result in unsafe operating conditions.

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

elry or loose clothing.

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

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

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, flames, and smoking materi 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. Do not attempt to service the engine fuel injection system, which contains high pressure fuel and may cause injury if mishandled. For service of the pressurized fuel system, including the fuel pump, fuel lines, and fuel injectors, contact your Walker dealer or authorized Kohler service dealer.

8. Altering the equipment or engine in any manner which adversely affects its operation, performance, durability, or use will VOID the warranty and may cause hazardous conditions.

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

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

11. Use genuine factory replacement parts. Substitute parts may result in product malfunction and possible injury to the operator and/or others.

Page 18

Safety Instructions

SAFETY, CONTROL, AND INSTRUCTION DECALS

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

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

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

8600-28

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

1. Warning – thrown object hazard.

• Keep bystanders away from the machine when operating.

• Clear lawn of debris before operating.

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

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

• Keep all body parts away from rotating mower blades.

• Do not step on end of deck.

8600-12

Location: Engine Part Number: 8600-12

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

• CO emitted by a running engine can be deadly.

• Do not operate indoors or in other enclosed areas.

Location: 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 into slot 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.

8600-5

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

1. Warning – hot surface, do not touch.

Page 19

Safety Instructions

SAFETY, CONTROL, AND INSTRUCTION DECALS

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

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

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

BELT ROUTING

BELT TWIST

DR52 DR64

BELT TWIST

DS60

DR52 BE LT P/N 27 31-2 DS60 BELT P/N 2731- 3 DR64 BELT P/N 2731-4

BELT TWIST

2749-4

Location: Deck Housing Under Footrest Part Number: 2749-4

1. Deck drive belt routing.

5848-2

Location: Deck Discharge Shield (DS60) Part Number: 5848-2

1. Warning – thrown object hazard.

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

• Do not remove the discharge shield.

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: Adjacent to Left Fuel Tank Part Number: 2010-16

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

Location: Deck Height Adjuster Part Number: 2748-1

1. Move pin to desired height of cut.

Location: Engine Shroud Part Number: 5855

Page 20

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.

8600-2

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: Underside of Rear Body Part Number: 2107-5

1. Ground drive belt routing.

2. PTO clutch belt routing.

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

• 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.

Page 21

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 running.

8. Parking brake

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

2802-5

Location: Left Fender Part Number: 2802-5

Location: Rear Body, One on Each Side Part Number: 5082-5

1. 2. 3.

CYL HEAD TEMP SERVICE ENGINEOIL PRESSURE

Location: Front Body Adjacent to RH Steering Lever Part Number: 2807-7

1. Low Engine Oil Pressure Warning Light.

2. High Oil/Cylinder Head Temperature Light.

3. Service Engine Soon Light.

Page 22

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

CAUTION

Important Battery Service, Installation, and Charging Tips for Electronic Fuel Injection Engines:

Battery

Battery Location

• Do not allow the battery cables to touch

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

positive (+) battery terminal rst, followed

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

• Never start the engine when the cables

are loose or poorly connected to the battery terminals.

• Never disconnect battery while engine is

running.

• Never use a quick battery charger to start

the engine.

• Never “jump start” the engine using an-

other source. Electricity uctuations can

damage the ECU (Electronic Control Unit).

• Always disconnect negative (-) battery

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

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.

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.

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

Page 23

Assembly Instructions

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 techni cian can activate the battery safely. DO NOT attempt to activate the battery unless you are experienced in battery service work. The following activation and charg ing instructions are provided for use by a trained battery technician.

DANGER

Battery electrolyte is a poisonous and corrosive sulfuric acid solution.

• Avoid spillage and contact with skin,

eyes, and clothing - causes severe burns.

• To prevent accidents, wear safety gog-

gles and rubber gloves when working with electrolyte.

• Neutralize acid spills with baking soda

and water solution.

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

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

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

Battery Charging

DANGER

BATTERIES PRODUCE EXPLOSIVE GASES

• Charge the battery in a well-ventilated

area, so that gases produced while charging can dissipate.

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

rials away from the battery at all times.

• 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.

IMPORTANT: Always disconnect the negative (-)

battery terminal before charging. Failure to do so can result in damage to the ECU.

 Charge the battery at 15 amps for 10 minutes.

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

2. After charging the battery, adjust the electrolyte

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

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

3. Install battery.

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

 Remove the filler caps and carefully fill each cell

until the electrolyte is just above the plates.

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

Page 24

Assembly Instructions

Battery Installation

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

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

WARNING

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

Battery Clamp

Secured by

Wing Nut(s)

Mower Deck Assembly

Deck Caster Wheels Installation

 Remove the bolts and washers from each deck

1. caster wheel.

2. Install wheel on fork using bolts and washers.

3. Tighten the bolts and washers.

Deck Caster Wheel Installation

Deck Discharge Deector Shield Installation (DS60)

Attach the side discharge deflector shield using two (2) 3/8-16 x 1-1/4 in. bolts, 3/8-16 ESNA nuts, and 3/8 in. wave spring washers. The wave washers fit between the two hinging surfaces. Tighten the nuts until the shield moves freely but is not loose.

(+) Battery Cable

Connection

Battery Installation

WARNING

DO NOT operate the machine without the

grass deector shield attached and in the

lowest possible position.

Attach Shield

Deck Discharge Shield Installation

Page 25

Assembly Instructions

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 Socket

Attach Guard

PTO Shaft Guard Installation

Tilt-Up Roller Wheel Installation

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

Roller

Wheel

Mower Deck Installation on Tractor

Deck Installation

1. Lightly grease each deck support arm (2) on the tractor. Refer to Mower Deck Installation photo for location of deck support arm.

Deck Support

Arms

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.

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

Roller Wheel Installation

NOTE: The Coupler Installation Tool is provided

for convenience, but is not required for installation.

Page 26

Assembly Instructions

Coupler

Installation Tool

PTO Coupler

Tube

Retract Spring-Loaded Quick Disconnect Ring

PTO Coupler Installation Tool

Coupler

Installation Tool

PTO Shaft Connection

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

Align

Arrows

Coupler Installation Tool Removal

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 Coupler

U-Joint

PTO Drive

Shaft

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

Quick Disconnect Ring “Released” Position

Page 27

Assembly Instructions

Internal Balls

Locked on Shaft

PTO Coupler

U-Joint

Quick Disconnect Ring “Locked” Position

6. 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.)

7. With the counterweight springs connected, the weight on the deck caster wheels should be 190 to 230 Ib (86.2 to 104.3 kg); this adjustment is preset at the factory.

Coupler Ring in

Locked Position

PTO Drive

Shaft

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 CUTTING HEIGHT in Operating Instructions.

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

Counterweight Springs

Clip Onto Body

With Body Tilted Up

Lynch Pins Lock Deck on Support Arms

(Not Visible)

Deck Counterweight Spring Installation

Page 28

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 CUTTING HEIGHT in Operating Instructions.

WARNING

The machine must be shut off during this procedure.

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

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-toside 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

Page 29

Assembly Instructions

PREOPERATING CHECKLIST

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

For proper fuel and lubricants refer to Specications.

FILL FUEL TANKS

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

DANGER

Handle gasoline with care. Gasoline is high-

ly ammable and its vapors are explosive.

Use safe refueling procedures:

• DO NOT ll fuel tank(s) with the engine

running.

• If the engine is hot, allow to cool before

refueling.

• Use an approved fuel container.

• Fuel the mower outdoors.

CHECK ENGINE CRANKCASE OIL LEVEL

Check the engine crankcase oil level before use and

after each 8 hours of continuous operation. Refer to LUBRICATION for Checking Engine Crankcase Oil

Level in Maintenance Instructions.

CHECK AND SERVICE ENGINE AIR CLEAN-

ER SYSTEM

• Check air filter restriction gauge to make sure the

yellow indicator disk is in the safe operating (green) range.

• Check condition, cleanliness, and security of the

complete air cleaner system (inspect air filter every 100 hours). For detailed procedures, refer

to CLEANING the Engine Air Cleaner System in Maintenance Instructions.

CHECK ENGINE COOLING SYSTEM

Check that the engine cooling air intake screen is free of obstruction by grass clippings or debris and clean if required. Also, cylinder head cooling fins should be inspected and cleaned if any build-up of debris is noted [remove two (2) cylinder head ac cess panels to inspect and clean]. Refer to CLEANING the Cyl- inder Head Cooling Fins in Maintenance Instructions.

Check performance of the cooling system by starting the engine, holding a hand adjacent to the cylinder heads, and feeling the cooling airflow.

• DO NOT smoke while refueling.

• Avoid spilling fuel; use a funnel or spout.

• DO NOT overll the fuel tank(s); 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 filler cap(s) before removing. Use a clean fuel storage container and funnel.

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

DANGER

Make sure to keep hands clear of exhaust

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

CHECK SECURITY OF DRIVE TIRE MOUNT-

ING NUTS

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

INSPECT FIVE (5) DRIVE BELTS

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

·ft (102 to 115 N·m).

Page 30

Assembly Instructions

CHECK HYDROSTATIC TRANSAXLE OIL

LEVEL

Refer to LUBRICATION for Transaxle Fluid Level in Maintenance Instructions.

CHECK TIRE PRESSURE

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

CHECK FUNCTIONS OF WARNING LIGHTS

AND WARNING HORN

Turn the ignition key to the ON (RUN) position. Oil Pressure Warning Light, Engine Service Light, and Warning Horn should all operate, indicating normal function.

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.

DANGER

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

Tilt Bar

Unlock Deck Arms for Deck Tilt-Up

3. Fit tilt bar into the socket on front of deck housing and secure with lynch 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 reengage the locking arms into the LOCKED position after lowering the deck to the normal operating position.

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).

The tilt-up deck is 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.

DANGER

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

Page 31

Assembly Instructions

Tilt-Up Hook and

Latch Connected

Tilt-Up

Latch

Tilt-Up

Hook

Tilt Bar

CHECK MOWER BLADE CONDITION,

SHARPNESS, AND SECURITY OF MOUNTING

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

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.

Deck Secured in TILT-UP Position

Page 32

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 the key returns to after starting, and “S” is the START position. When start- ing the engine, turn the key clockwise to the “S” position. Do not hold the key in the “S” position longer than 10 seconds.

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

OFF

Ignition Switch

START

Body Lift

Handle

Blade Clutch

(PTO)

Body

Latch

Forward Speed

Control (FSC)

Ignition

Switch

Circuit

Breaker

Parking

Brake

Throttle

Steering

Levers

Hourmeter

Warning Lights (3)

Warning Horn

Operating Controls

Page 33

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 tractor body hinges forward for maintenance access and is latched down in the OPERATING posi- tion. To raise the body, pull back and up on body latch and lift body using the lift handle on the right hand side of body.

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 proportional to the lever position; the further the lever is advanced forward, the faster the tractor moves. It is not necessary to hold the FSC in position since the friction lock maintains the selected lever position. Pulling back on the steering levers overrides the FSC setting and slows or stops forward travel. Releasing the steering levers allows the tractor to resume forward travel at the speed set by the FSC lever. To stop and park the machine, the FSC lever is moved backward to the NEUTRAL-PARK position.

Steering Levers

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

Latch

Body Latch

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.

Page 34

Operating Instructions

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.

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.

Disengaged

Position

Engaged

Position

Parking Brake Engaged

Parking Brake Disengaged

Page 35

Operating Instructions

Oil Pressure Warning Light/Horn

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

Engine Service Light

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

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

Over Temperature Warning Light/Horn

The over temperature warning light and horn indicate that the engine cylinder head temperature is above the safe operating limit (450° F or 232° C) and the engine is overheating. If this light comes on, there may be a problem with the engine cooling system (material packed into cylinder head cooling fins, clogged air intake screen, etc.). Stop the engine and correct the source of the problem before further operation:

IMPORTANT: Continued operation of the engine with an illuminated over temperature warning light MAY cause severe engine damage if a high cylinder head temperature condition exists.

Oil Pressure

Warning Light

Over Temperature

Warning Light

Engine Service

Light

Warning Horn

Engine Warning Lights/Horn

Page 36

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.

Transaxle

Lockout Arms

Transaxle Lockout Arm Location

Circuit Breaker

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

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 flashing the reminder one hour prior to the recommended interval and will continue until one hour after the recommended interval (two hours). The hourmeter does not have a manual reset

function.

Procedure Interval* 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 reflect the actual time that the

reminder will flash (one hour prior to and one hour after the recommended interval).

** This reminder is only used one time.

*** In normal operating conditions, oil changes in

100-hour intervals are acceptable. Walker and the engine manufacturers recommend engine oil changes every 50 hours in extremely dirty or dusty conditions or for units with less than 100 hours annual use.

NOTE: The blinking hour glass on the display means that the meter is operating properly.

Hourmeter

Page 37

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

8600-5

2802-4

Position

Disengaged

BLADE CLUTCH

Position

(PTO)

Operating Controls (Top View from Drivers Point of View)

Page 38

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.

IMPORTANT: DO NOT crank the engine con-

tinuously for more than 10 seconds at a time. If the engine does not start, turn the key to the OFF position and allow a 60 second cool-down period between starting attempts. Failure to fol low these guidelines can damage the starter motor and shorten battery life. Contact your Walker dealer or authorized Kohler dealer for additional help.

ADJUSTING GROUND SPEED AND STEERING

CAUTION

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

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

NOTE: Release parking brake to prevent extra

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

CAUTION

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

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

DANGER

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

Page 39

Operating Instructions

Beginning Recommendations are:

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

structions. Learn operation on at ground

BEFORE operating on slopes.

1. Move the FSC out of NEUTRAL-PARK position to the desired forward speed. DO NOT hold forward on steering levers. It is not necessary to hold the FSC lever in position since a friction lock maintains the selected lever position (and forward travel speed).

♦ 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 TRALPARK position.

WARNING

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

Page 40

Operating Instructions

Pull Steering

Levers with

Left Hand

Keep Feet on

Footrest when

Moving

Forward Speed Control

(FSC)

Correct Operator Hand Position on the Controls

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

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

5. Stop ground travel by pulling both steering levers backward to the NEUTRAL-PARK 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

Position Adjustment in the Maintenance Instruc- tions.

ENGAGING THE BLADE DRIVE

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

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

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

SLOWLY.

CAUTION

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.

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).

Page 41

Operating Instructions

Engaged

Position

Blade Clutch Engaged

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.

4. Turn the ignition switch OFF.

WARNING

Disengaged

Position

Blade Clutch Disengaged

CAUTION

If the cutting blades strike a stationary object while mowing, stop the mower immediately, disconnect the spark plug wires, lift the deck, and inspect the deck and blades thoroughly for damage. Also, make sure the blade retaining bolts are torqued to 70 lb·ft (95 N·m).

STOPPING THE MACHINE

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

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

5. Engage the parking brake by moving the lever forward. Also, engaging the parking brake is recommended when stopping or parking the machine in a confined space with little tolerance for movement.

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

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

3. Disengage the blade clutch.

Page 42

Operating Instructions

WARNING

NOTE: The emergency stop procedure is ex-

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

FUEL TANK SELECTOR VALVE

ADJUSTABLE FOOT RESTS

Some carrier frames are outfitted with adjustable foot rests. To adjust, rotate the footrests upward and slide to the desired position. Rotate the footrest down and insert the edge of the footrest into the nearest notch to lock in position.

The tractor is equipped with dual fuel tanks. A fuel selector valve regulates which tank is being utilized. The valve is located on the left hand side of the engine. The valve switches between the LH and RH gas tanks. DO NOT run tank dry before switching tanks.

Fuel Tank

Selector Valve

Fuel Tank Selector Valve

Adjustable Footrest

ADJUSTING CUTTING HEIGHT

WARNING

Never adjust cutting height while the mower is moving. Before adjusting cutting height or servicing, move the Forward Speed Control (FSC) into the NEUTRALPARK 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.

Page 43

Operating Instructions

Hitch Pin

Height

Adjustment Decal

Cutting Height Adjustment

Cutting Height Release Lever

Deck Lift Pedal

Push Deck

Lift Pedal

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.

Hydro Lockout Arm

Hydro 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.

Raise Release

Lever

Lowering Deck to Selected Cutting Height

Transport Position

1. Disengage the PTO.

2. Push down on deck lift pedal until it latches in the full up 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 toward the center of the machine to engage the step that holds the arm in the UP (unlocked) position.

Hydro Lockout Arm

Hydro Lockout Arm - Normal Operating Position

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.

Page 44

Operating Instructions

• Use a slow setting on the FSC for trimming op-

erations.

• Make sure the mower is leveled properly for a

smooth cut. Refer to Deck Leveling in Assembly In-

structions.

• Use an alternating stripe mowing pattern for

best appearance and vary the direction of the stripe

each time the grass is mowed to avoid wear patterns in the grass.

• Avoid damage to the grass by slipping and skid-

ding of the drive tires. Use smooth control movements of the steering levers since the transaxles are

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

Avoid Low Hanging Branches

IMPORTANT: Operate the engine at full throttle

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

• Keep the mower deck and discharge shield clean.

• Mow with sharp blades. A dull blade tears the

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

• It is preferable to cut grass when it is dry and not

too tall. Mow frequently and do not cut grass too

short. (For best appearance, cut off 1/3 or less of existing grass height.)

• When mowing, operate the engine at full throttle

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

operated at full speed.

• When mowing in adverse conditions (tall and/or

wet grass), mow the grass twice. Raise the mower to the highest setting - 5 in. (127 mm) - for the first pass and then make a second pass cutting to the desired height.

• Using the DS60 deck, or other side discharge

decks, the side discharge deflector shield must not be removed and must be kept in the lowest possible

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

Discharge

Shield

Side Discharge Deector Shield in

Lowest Position

• 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.

Page 45

Operating Instructions

5 FT

MINIMUM

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 configuration should only be used when the tractor is parked.

• The tractor body should never be tilted for ward

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

60 in.

Maximum Recommended Slope

DANGER

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

• 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.

No Driving Zone

Page 46

Maintenance Instructions

CAUTION

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

MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL H27i

Service Item

Check Engine Crankcase Oil Level x 44

Check/Clean Engine Air Cooling System* x 52

Check Air Filter Restriction Gauge x 51

Clean Grass Buildup Under Deck x 54

Service Mower Blades x 57

Check Security of Air Cleaner System x 56

Check Function of Warning Lights and Horn x 26

Lubricate Grease Fittings and Oil Points* x 47

Check Tire Pressure x 57 Check Drive Belts

(Engine/PTO, Ground Drive, Blade Drive) Check Operation of Safety Interlock Switches x 59

Check Battery Electrolyte Level x 56

Check Transaxle Oil Level (in Reservoir) x 46

Change Engine Crankcase Oil**

Check Air Filter Element*** x 51

Clean Engine Cooling Fins x 53 Check Security of Drive Tire

Mounting Nuts (75 to 85 Check Blade Brake Action x x 59

Check FSC Friction Lock x 59

Check Operation of Turbine Precleaner Fan* x 50

Check/Adjust Blade Clutch x 70

Clean Transaxle Housing x 55

Change Engine Oil Filter x 44

Check/Regap Spark Plugs x 58

Replace Fuel Filter x 64

Change Transaxle Oil and Filter

Check Fuel Lines and Clamps x 58 Replace Air Filter Element

and Dust Ejection Valve*** Service Battery x 56

Service Solenoid Shift Starter x

Check PTO U-Joints for Wear/Looseness x 58

Replace Fuel Lines and Clamps x 58

Replace Ignition Wires x 58

lb·ft)

Daily

Hours

x 58

100

Hours

x 57

200

Hours

400

Hours Yearly

ΔΔ

x 51

Every

2 Years

Ref.

Page

ΔΔΔ

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

∗∗ Change engine oil and lter after rst 5 hours of operation of a new engine (break-in period) ∗∗∗ Air cleaner is remote mounted Cummins/Fleetguard OptiAir™ unit, replace lters every year, and

adjust dust ejection valve every year or when worn or damaged

Δ Change oil every 50 hours when operating in dry, dirty conditions

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

ΔΔΔ See your Walker dealer for this service or refer to the Walker Service Manual

Page 47

Maintenance Instructions KOHLER TIPS

IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE

Fuel System

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

ganic material.

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

tamination is suspected or found in the fuel.

• The fuel injection pump module is a sealed unit

and is not serviceable; opening the fuel pump module will void the warranty. Additionally, the fuel pump module and the fuel lines between it and the injectors are pressurized. For service of the pressurized fuel system including the fuel pump module, fuel lines, and fuel injectors contact your Walker dealer or authorized Kohler service dealer.

Starting/Stopping

• Start engine with the throttle advanced off idle

to a mid-point (1/4 to 1/2) throttle setting. This will aid starting, especially in cold weather.

• Keep the battery fully charged.

• Match crankcase oil viscosity to the ambient tem-

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

• Allow engine to run at idle for a few seconds before

stopping engine to avoid run-on or backfiring.

Cooling System

CAUTION

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

Make sure to keep hands clear of exhaust

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

• Operate the engine at full speed when mowing.

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

Air Cleaner System

• Use only Cummins/Fleetguard air cleaner

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

• Use the air filter restriction gauge to indicate the

need to service the air filter.

• Do frequently check the Turbine Precleaner for

free movement of the internal fan.

• DO NOT overservice or frequently “disturb” the

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

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

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

interior of the canister and hose clean (a lit tle dirt left here will be sucked into the engine and reduce engine life). When the filter is reinstalled, make sure the element is held tight and straight in the canister for proper seating and sealing.

DANGER

• Keep engine air intake screen and cylinder head

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

• Periodically remove two access panels in the en-

gine shroud to inspect and clean cylinder head cooling fins.

• Check performance of the cooling system by start-

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

• Periodically check the air intake hose for cuts,

nicks, etc., and the hose clamps for tightness.

Oil

• Use only multi-viscosity oils as specified with the

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

• Use only Kohler oil filters. Aftermarket lters

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

Page 48

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 SJ oil from the factory. Change the oil after the initial engine

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

Checking Engine Crankcase Oil Level

Check the engine crankcase oil level before use and

after each 8 hours of continuous operation.

IMPORTANT: DO NOT operate engine without

a sufficient oil supply in the crankcase. DO NOT operate with oil level below the “L” mark or above the “F” mark on the dipstick.

Full

Mark

Operating

Range

{

Low

Mark

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 “L“ mark and the “F” 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 “F” mark on the dipstick.

IMPORTANT: DO NOT overfill the crankcase (oil

above “F” mark) as this CAN result in engine overheating, loss of power, and 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 filter after every 200 hours of operation as follows:

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

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

2. Before removing the dipstick and oil fill cap, clean the area around them to keep any dirt or debris out of the engine.

Page 49

Maintenance Instructions LUBRICATION

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

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

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

Dipstick

Oil Fill

Oil Drain

Dipstick, Oil Fill and Oil Drain Locations

(View from Above Left Side of Tractor)

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

3/4 turn to 1 turn.

8. Close the oil drain valve and tighten until snug. Do not overtighten.

9. Fill the crankcase with new, clean oil. Use only crankcase lubricants recommended by the engine manufacturer. Refer to 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 “F” mark on the dipstick. Crankcase capacity is 2.0 quarts (1.9 liters) when changing oil and filter.

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

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

Oil Filter

Oil Filter Location

(View from Above Right Side of Tractor)

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

IMPORTANT: Use ONLY oil filters from the engine manufacturer (Kohler P/N 12-050-01). Aftermarket oil filters may not seal properly and/or may not have the cor rect pressure relief valve for proper lubrication.

Page 50

Maintenance Instructions LUBRICATION

Mower Deck Spindle Lubrication

Lubricate each deck spindle grease fitting every 25 hours. Use SAE general purpose lithium or molyb-

denum base grease for grease fittings.

DR52, DS60 or DR64 Mower Deck Lubrication

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

num 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 after every 25 hours

of operation for visible leaks.

• The fluid levels for each transaxle can be checked

visually by looking at the fluid levels in each expansion reservoir. When the transaxles are cold, the fluid level in the expansion reservoirs 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 filter guard, remove and replace the oil filter using an oil filter wrench. Tighten filter by turning filter 3/4 to 1 turn after gasket contacts the filter base surface. Reinstall the oil filter guard. (Refer to Transaxle Oil Drain Plug, Filter, and Guard Location illustration.)

Oil Filter

Reservoir Cap

Hot Level

Cold Level

Expansion Reservoir Location

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 elbow to access the oil fill opening.

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

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

Oil Drain

Plug

Page 51

Maintenance Instructions LUBRICATION

Grease Fitting and Oil Point Lubrication

Elbow

Reinstall Transaxle Elbows

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

Screw Locking

Nut Down

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

in the Chassis and Deck Lubrication Points illustration.

NOTE: PTO universal joints (on the deck and tractor)

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

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

er Deck Installation on Tractor in the Assem bly In- structions.

8. Fill both reservoirs 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 the 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.

Page 52

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-to-PTO Coupling Grease 1 (Grease Spline Slide Area) 9 Deck Support Arm Pivot Grease 2

10 Universal Joint Tube Assembly Grease* 1 11 FSC Lever Pivot Grease 1 12 Body Latch Pivot Oil 2 13 PTO Clutch Lever Pivot Grease 1 14 Clutch Arm Pivot Grease 1 15 Hydro Idler Arm Pivot Grease 1 16 Transaxle Oil Reservoir Oil 2 17 Throttle Control Cable Ends Oil 2 18 Engine Dipstick Oil** 1

Ident Lubrication No. No. Location Type Places

19 Tail Wheel Caster Fork Pivot Grease 2 20 Rear Axle Pivot Grease 1 21 Rear Wheel Bearing Grease 2 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 25 hours.

** Refer to Engine Oil located on page 44.

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

tion.

NOTE: DR52 Tilt-Up Deck is shown for reference. For other

Deck Lubrication Points, refer to Deck and Carri-

er Frame Illustrated Parts Manual.

Page 53

Maintenance Instructions LUBRICATION

17 & 28

Chassis and Deck Lubrication Points

Page 54

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

There are two main components in the engine air cleaner system: a turbine precleaner and a Cummins/Fleetguard OptiAir™ air cleaner. Each component is checked, cleaned and maintained on a different schedule based on the filtering action required. Each component is serviced as follows:

Turbine Precleaner

The turbine precleaner is mounted on the Cummins/ Fleetguard air cleaner. A spinning fan driven by the intake airflow separates dust from the air, giving the initial stage of air clean ing. Dust particles are exhausted through a single small vent in the side of the housing. Since no dust is trapped, the precleaner operates without clean ing.

The only maintenance required is to check the operation of the internal fan every 100 hours. Verify operation:

1. Look into the exhaust vent while shining a light into the intake.

2. Start the engine and watch the fan begin to spin as the throttle is advanced.

If the fan is not spinning, service or replace the precleaner as required.

Cummins/Fleetguard OptiAir™ Air Cleaner

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

Precleaner

Hose

Clamp

Cummins/Fleetguard

Air Cleaner

Air Filter

Restriction Gauge

Hose

Clamp

Air Intake

Hose

Air Cleaner

Band

Safety

Filter

Primary Filter

Element

Hose

Clamp

Engine

8600-12

Cummins/Fleetguard

Air Cleaner Cover

Dust Ejection

Valve

Engine Air Cleaner System Components

Page 55

Maintenance Instructions CLEANING

IMPORTANT: Use only Cummins/Fleetguard air filter elements for replacement (Walker 2090-1 and 2090-3). Aftermarket filters may not seal properly or filter efficiently.

Canister

Primary

Filter Element

Air Cleaner Components

(Shown with Cover Removed)

IMPORTANT: The Cummins/Fleetguard air cleaner

uses a dry paper-type air filter element. NEVER apply oil to the paper element.

Air Filter

Restriction Gauge

Push Button to Reset

Indicator After Service

Air Filter Restriction Gauge Location

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

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

1. Lift Mono Latch Twist Lock™ and twist the OptiAir™ cover to the left into the “open” position to remove the air cleaner cover. Wash the cover and dust ejection valve. Check that these components are in good condition. The dust ejection valve is subject to wear and deterioration and should be replaced yearly or when damaged. The lips of the valve should close and fit together; any cracks, deformation, or wear in the valve is cause for replacement.

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

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

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

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

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

6. Without removing, visually inspect the condition of the safety filter for damage or holes. The safety filter should only be removed for replace- ment yearly (or when dirty or damaged).

Page 56

Maintenance Instructions CLEANING

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

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

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

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

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

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

Mono Latch

Twist Lock™

DOWN

Orient to Bottom

of Canister

Dust Ejection

Valve

Proper Orientation of Air Cleaner Cover

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

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

Engine Cooling System

Canister

Safety Filter

Radial Sealing

Primary

Filter Element

Surface

Air Filter Element Replacement

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

Cooling Air Intake Screen

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

CAUTION

Operating the engine with a blocked air intake screen, dirty or plugged cooling

ns, and/or cooling shrouds removed will

cause engine damage from overheating.

Page 57

Maintenance Instructions CLEANING

Every 100 hours, inspect and clean the cooling fins (more often when operating in extremely dusty, dirty conditions). Remove the two (2) cooling fin access

Rotating Engine Cooling

Air Intake Screen

Keep Rotating Engine Cooling

Air Intake Screen Clean

Cylinder Head Cooling Fins

It is essential for performance and longevity of the air-cooled engine to keep the cylinder head cooling fins clean and free of obstruction. After every 8 hours of operation, check the performance of the cooling system by starting the engine, holding a hand adjacent to the cylinder head(s), and feeling the cooling airflow. If there is little or no airflow, clean the cooling fins as follows:

panels in the engine shroud and clean the cooling fins and external surfaces using compressed air. Make sure to reinstall the access panels before oper ating the engine.

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

Engine Cooling

Fin Access Panels

Kohler Engine

Shroud

DANGER

Make sure to keep hands clear of exhaust

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

Check Airflow

with Hand

Check Cooling System Airow

Rotating Engine Cooling

Air Intake Screen

Rotating Engine Cooling Air Intake Screen

and Cooling Fin Access Panels

Page 58

Maintenance Instructions CLEANING

Grass Buildup in Mower Deck Housing

DANGER

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

8746-2

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.

Tilt Bar

Unlock Deck Arms for Deck Tilt-Up

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

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.

Tilt-Up Hook and

Latch Connected

Tilt Bar

Use lynch 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.

Tilt-Up

Latch

Tilt-Up

Hook

Deck Secured in TILT-UP Position

Page 59

Maintenance Instructions CLEANING

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

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

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

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

Cooling

Fins

Transaxle Housing and Cooling Fins

IMPORTANT: In case an oil leak develops on the

input shaft, the cooling fan blowing dusty air and oil on the transmission will quickly cover the housing and pack the cooling fins with oily dirt. If this condition occurs, contact your dealer immediately to avoid overheating and dam aging the transaxle.

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

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 store on carrier frame.

9. Replace footrests to desired position.

Transaxle Housing

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

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

Cooling

Fans

Transaxle Cooling Fans

Page 60

Maintenance Instructions CHECKING/SERVICING

CHECKING/SERVICING

CAUTION

DANGER

Important Battery Service, Installation, and

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

Security of Air Cleaner System

NOTE: The following inspection is only an external inspection and should be done without “disturbing” the filtration components.

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

Charging Tips for Electronic Fuel Injected Engines:

• Do not allow the battery cables to touch

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

positive (+) battery terminal rst, followed

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

• Never start the engine when the cables

are loose or poorly connected to the battery terminals.

• Never disconnect battery while engine is

running.

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

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

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

Battery

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

IMPORTANT: Make sure battery is securely mount-

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

• Never use a quick battery charger to start

the engine.

• Never “jump start” the engine using an-

other source. Electricity uctuations can

damage the ECU (Electronic Control Unit).

• Always disconnect negative (-) battery

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

Electrolyte Level

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

level:

1. Remove battery cell filler caps.

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

3. Replace filler caps.

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

Page 61

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 Nut Torque

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

75 to 85 lb

Sharpen Mower Blades

Check mower blade(s) for straightness, sharpness, condition of the cutting edge, and balance every 10 hours of operation (or more often when

mowing abrasive type grass or operating on sandy soils). Replace blades if worn, bent, cracked, or

otherwise damaged (refer to REPLACING/REPAIRING the Mower Blades in this section). Use the

following procedure to check and sharpen blades:

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

1. Stop the engine, remove ignition key, and dis-

2. Raise the deck and secure it in the TILT-UP

·ft (102 to 115 N·m).

connect the spark plug wires before raising the mower deck to service blades.

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 specific gravity of electrolyte; if specific gravity is less than

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

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

result in damage to the ECU.

1. Charge the battery at 15 amps for 10 minutes. DO NOT exceed 20 amps maximum recommended charging rate. Charge until specific gravity is at least 1.250. Total charging time should not exceed one (1) hour.

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

Tire Pressure

Inflate tires to pressures shown below:

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

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 replac ed.

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.

Page 62

Maintenance Instructions CHECKING/SERVICING

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

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

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

CAUTION

ALWAYS wear eye protection and gloves when sharpening a blade.

Sharpen at Original

30° Angle

30°

Do Not Grind or

Sharpen on Underside

Mower Blade Prole for Sharpening

6. Check blade balance by positioning the blade horizontally on a blade balancer or use a nail or shaft through the center hole. If either end of the blade rotates downward, grind (remove) metal on that end until the blade will balance. The blade is properly balanced when neither end drops. Balance of a blade is generally maintained by removing an equal amount of material from each end of the blade when sharpening.

Intersection

Wear Area

Wing Tip

7. Mount the blade with wing tips pointing up into the housing. For gear driven decks reinstall the blade, washer, lock washer, and nut. Tighten

the nut to 60 lb·ft (81 N·m). For belt driven decks reinstall the spacer (if applicable), blade, washer, and bolt. Tighten the bolt to 70 lb·ft (95 N·m).

Drive Belts

Raise the body and inspect the condition of the four (4) drive belts after every 25 hours of operation -engine/PTO drive (3) and ground drive (1). Also 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 replaced. Re- fer to REPLACING/REPAIR ING the Drive Belts in this section.

Spark Plugs

Every 200 hours, remove the spark plugs, inspect,

clean, and reset the gap (or replace with a new plug). Clean spark plug with a wire brush. If the electrodes are burned short or pitted, replace the plug (refer to Specications for the proper type of replacement plug). Check the spark plug gap with a wire-type feeler gauge and set the gap to 0.030 in. (0.76 mm). Reinstall and tighten to 20 lb plugs should be replaced yearly.

Ignition Wires

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

Fuel Lines and Clamps

NOTE: After the fuel injection pump module, the fuel

system is pressurized and should only be serviced by a Walker dealer or authorized Kohler service dealer.

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

·ft (27 N·m). Both spark

Blade Balancer

Blade Balanced on Magnetic

Wall-Mounted Balancer

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.

Page 63

Maintenance Instructions CHECKING/SERVICING

Engine Starter

Yearly or every 500 hours disassemble and clean

the solenoid shift starter. Refer to the Kohler Service Manual for this procedure or contact an authorized Kohler engine dealer to perform this service.

Blade Brake Action

WARNING

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

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

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

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

Disengagement/Brake Action, Step 2 - Blade Brake Band Adjustment, on page 72.

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 engine

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

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

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

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

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

• With an operator in the seat, the Forward Speed

Control (FSC) and PTO disengaged and warning horn sounding, but the starter is not engaging.

Forward Speed Control Friction Lock

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

are moved and yet the friction is not too heavy to make moving the FSC control difficult (too much friction). The procedure for checking the FSC friction lock is as follows:

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

creased.

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 de-

creased.

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

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

Page 64

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 spark plug wires.

IMPORTANT: ALWAYS use genuine factory re-

placement parts. Substitute parts CAN result in product malfunction and possible injury to the operator and/or others.

Drive Belts

There are 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)

Page 65

Maintenance Instructions REPLACING/REPAIRING

Engine/PTO Belt

1. To remove an engine/PTO belt:

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

guards.

Upper LH

Guard

Fixed Idler

Pulley

Lower LH

Guard

Wire Lock Pin

Clutch

Idler Pulley

PTO

Pulley

b. Roll the belt off the pulley and remove the

belt.

Wire Lock Pins

Right Hand

Guard

Wire Lock Pin

PTO Belts

(Matched Set)

PTO Guard

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

2. To replace an engine/PTO belt:

a. Reverse the removal procedure to replace

an engine/PTO belt.

Upper LH

Guard

Lower LH

Guard

Front View

Secure Wire Above Tab

b. Secure wire on lock pin above tab on lower

PTO guard and right hand guard.

Right Hand

Guard

Secure Wire in

Front of Tab

PTO Guard

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

Page 66

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)

2. a. Reverse the procedure to install the ground drive belt. Remove deck tilt bar.

b. Slide belt off pulleys.

RH Transaxle

Transmission Belt

Tensioner Arm

Drive Pulley

Raise Idler Pulley to

Relax Belt

LH Transaxle

Ground Drive

Belt

Deck Tilt

Bar

RH Transaxle

Transmission Belt

Tensioner Arm

Drive Pulley

Idler Pulley

Ground Drive Belt Assembly (Engaged)

Page 67

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

2749-4

BELT TWIST

DR64 BELT P/N 2 731-4 DS60 BELT P/N 2731-3 DR52 BELT P/N 2731-2

DR64 DR52 BELT TWIST

DS60 BELT TWIST

BELT ROUTI NG

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

Page 68

Maintenance Instructions REPLACING/REPAIRING

Fuel Filter

Model H27i is equipped with a 10 micron in-line fuel filter between the fuel tank and the fuel pump (low pressure pump). Replacement of this filter is recommended every 200 hours of operation or when contamination is suspected or found in the fuel.

Fuel

Pump

In-Line

Fuel Filter

Fuel Filter Location

IMPORTANT: Replace the fuel filter only in a clean

area where the fuel line and connections will not be contaminated by any dust and dirt.

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

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

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

DANGER

Gasoline is extremely ammable and can

be highly explosive. To minimize danger:

• Use only an approved fuel container for

gasoline.

• DO NOT allow open ames or sparks

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

• Wipe up spilled gasoline immediately

and completely.

Page 69

Maintenance Instructions REPLACING/REPAIRING

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 flat section of the blade turns up to form the “wing tip” (refer to Mower Blade Pro-

le for Sharpening illustration in Sharpen Mower Blades instructions). Since sand and abrasive 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.

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

Reinstall the blades following procedure from 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.

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

WARNING

CAUTION

DANGER

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

• Check the blades for straightness by marking

blade tip position inside the deck housing and then 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.

Page 70

Maintenance Instructions ADJUSTMENTS

ADJUSTMENTS

Transmission Control

IMPORTANT: The proper adjustment of the tran-

saxle control stops is essential for efficient 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 fine tune tracking, refer to Step 5 - Straight Tracking Adjustment in this section.

Step 1 - Steering Lever Position Adjustment

NOTE: For proper operation, the steering levers

should be adjusted to sit evenly using the following procedure.

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

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.

Locknut

(Position)

Adjustment

Slide

Locknut

(Pivot Point)

Lever Alignment

Steering Handles Adjustment

Page 71

Maintenance Instructions ADJUSTMENTS

Step 3 - Neutral Position Adjustment

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

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

Control Rods

Tracking Adjustment Nuts

Transmission Control Rod and Arm Location

(Front Body Hidden for Clarity)

Tracking Adjustment Nut

(Adjusts Length of

Control Rod)

Adjustment Set Screw

Control Arm

Maximum Speed

Correct FSC Lever Neutral-Park Position

Adjust Length of

Rod to Position

FSC Lever

FSC Lever Position Adjustment

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.

FWD

REV

Locating/Limit

Control Rod

Jam Nut

Ball Joint

Tracking Adjustment Components

Transmission

Control Arm

Stud

WARNING

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

Page 72

Maintenance Instructions ADJUSTMENTS

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.

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

Step 4 - Full Forward Speed Adjustment

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

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.

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 for ward, refer to Step 3 - Neutral Position Adjust- ment 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 adjuster nut clockwise. If straight tracking and neutral can not be achieved, turn the adjuster 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.

IMPORTANT: After tracking adjustments are complete, confirm that there is at least one (1) thread visible on both control rods past the track-

ing 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.

Step 6 - FSC Neutral Switch Adjustment

Maximum

Speed Tracking

Adjustment

T-Handle

Hex Wrench

Transmission

Control Arm

Maximum Speed Tracking Adjustment

(Shown with Parts Removed for Clarity)

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

Page 73

Maintenance Instructions ADJUSTMENTS

Step 7 - Forward Speed Control Friction Adjustment

FSC Switch

FSC Neutral Switch Location

Switch Closed

in Neutral

Loosen Screws

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

FSC Neutral Switch Adjustment

(Side View Through Chassis)

FSC Switch

Actuator Arm

Deck Support

Arm (Ref)

CAUTION

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

FSC Friction Adjustment Test

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

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

FSC Friction

Adjustment Nut

2. Check operation of the FSC Neutral Switch by placing the FSC lever in the full FORWARD posi- tion. While holding the ignition switch in the START position, slowly move the FSC lever back towards the NEUTRAL-PARK position un- til 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 distance is greater than 1/8 in. (3 mm), the FSC Neutral Switch needs to be adjusted downward for quicker activation.

FSC Friction Adjustment Nut

Page 74

Maintenance Instructions ADJUSTMENTS

Blade Clutch (PTO)

Clutch Engagement/Belt Tension

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

Clutch Actuator

Link

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

Page 75

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

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

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 five (5) seconds after disengaging the clutch.

Idler Pulley

Clutch Pivot

Stop Bolt

Brake Engagement

Arm

Clutch Idler Pulley Travel

Clutch Pivot

Stop Arm

Page 76

Maintenance Instructions ADJUSTMENTS

Step 2 - Blade Brake Band Adjustment

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

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

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

Blade Brake

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 five (5) seconds, check the following:

a. Make sure clutch and brake linkage are

working freely (no binding).

b. Check the brake band lining for wear.

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

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

Chassis Mount

(Ref)

Page 77

MAINTENANCE AND SERVICE RECORD SHEET

DATE SERVICE ENGINE ITEM HOURS

______________________________________________________________________________________________________________

Page 78

MAINTENANCE AND SERVICE RECORD SHEET

DATE SERVICE ENGINE ITEM HOURS

______________________________________________________________________________________________________________

Page 79

LIMITED WARRANTY

FOR

WALKER MODEL H27i

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 Battery

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

* A three (3) year or 3000 hour (whichever comes first) warranty is offered for Hydro-Gear ZT3400 hydrostatic transmissions; covers full cost of replacement up to 1000 hours of use, and after 1000 hours warranty coverage is prorated against 3000 hours.

2. WHAT THIS WARRANTY DOES NOT COVER:

A. This warranty does not cover defects caused by depreciation or damage caused by normal wear, accidents, improper

maintenance, improper use or abuse of the product, alterations, or failure to follow the instructions contained in the Operator’s Manual for operation and maintenance.

B. The customer shall pay any charges for making service calls and/or for transporting the mower to and from the place

where the inspection and/or warranty work is performed.

3. HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:

Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Walker Manufacturing Company, 5925 East Harmony Road, Ft. Collins, CO 80528. Proof of the date of purchase may be required to verify warranty coverage.

4. WARRANTY LIMITATION:

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

INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY LIMITED TO THE DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts, so the

above limitations may not apply to you.

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

EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply to you.

C. Only the warranty expressed in this limited warranty shall apply and no dealer, distributor, or individual is authorized to

amend, modify, or extend this warranty in any way. Accordingly, additional statements such as dealer advertising or presentations, whether oral or written, do not constitute warranties by Walker, and should not be relied upon.

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

Page 80

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

Walker H27I User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Foreword

Table of Contents

General Information ________________ 1

Safety Instructions __________________ 9

Assembly Instructions ______________ 18

Operating Instructions _____________ 28

Maintenance Instructions __________ 42

Warranty _____________________ 75

General Information

HIGHLIGHTED INFORMATION

GLOSSARY

IDENTIFYING NUMBER LOCATIONS

Fill In By Purchaser

Tractor Serial Number Location

SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS

Mower Deck Serial Number Location

ENGINE SERIAL NUMBER LOCATION

Engine Serial Number Location

ENGINE

ELECTRICAL SYSTEM

TRANSMISSION

BLADE DRIVE

TIRE SIZE

TIRE PRESSURE PSI (KPA)

DIMENSIONS (Tractor and Mower)

DRIVE BELTS

SEAT Contour-Molded, with Nylon Backed Vinyl Cover and

FRAME/BODY CONSTRUCTION

Front View and Right Side View

Rear View and Left Side View

Top View (Body Raised)

BEFORE OPERATING

SAFETY, CONTROL, AND INSTRUCTION DECALS

SAFETY, CONTROL, AND INSTRUCTION DECALS

SAFETY, CONTROL, AND INSTRUCTION DECALS

SAFETY, CONTROL, AND INSTRUCTION DECALS

Assembly Instructions

SETUP INSTRUCTIONS

Battery Service

Battery Location

Wet Battery Service

Dry Battery Service

Battery Charging

Battery Installation

Mower Deck Assembly

Deck Caster Wheels Installation

Deck Caster Wheel Installation

Battery Installation

Deck Discharge Shield Installation

PTO Shaft Guard Installation

PTO Shaft Guard Installation

Tilt-Up Roller Wheel Installation

Mower Deck Installation on Tractor

Deck Installation

Mower Deck Installation

Roller Wheel Installation

PTO Coupler Installation Tool

PTO Shaft Connection

Coupler Installation Tool Removal

Quick Disconnect Ring “Released” Position

Quick Disconnect Ring “Locked” Position

Deck Leveling

Measuring Deck Levelness

Deck Counterweight Spring Installation

Deck Leveling Procedure

Deck Leveling

PREOPERATING CHECKLIST

Unlock Deck Arms for Deck Tilt-Up

Deck Secured in TILT-UP Position

Operating Instructions

CONTROL IDENTIFICATION, LOCATION, AND FUNCTION

Ignition Switch

Ignition Switch

Operating Controls

Engine Throttle

Throttle Location