Walker H27I User Manual

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

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

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

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

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

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

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

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)

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.

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

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

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

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.

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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

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