OWNER’S MANUAL
Safety, Assembly, Operating, and Maintenance Instructions
Model MC (18 HP)
(Covers Serial Numb er s 03 -6 1 06 1 and on )
™
Please Read and Save These Instructions Effective Date: 04-15-03
For Safety, Read All Safety and Operation P/N 6000-8
Instructions Prior to Operating Machine Price $5.00
Foreword
Thank you. . .for purchasing a Walker mower. Every effort has been made to provide you with the
most reliable mower on the market, and we are sure you will be among our many satisfied customers. If for any reason this product does not perform to your expectations, please contact us at (970)
221-5614. Every customer is important to us. Your satisfaction is our goal.
Please. . .rea d this manual thoroughl y! This manual is to be used in conjuncti on 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 call our service department, at (970) 221-5614,
for clarification before operating or servicing this mower.
This manual covers Model MC with the Kohler Command CH18 (18.0 HP) gasoline engine.
All shields and guards must be in place for the proper and safe operation of this machine.
Where they are shown removed in this manual, it is for illustration purposes only. Do not operate
this machine unless all shields and guards are in place.
Specifications given are based on the latest in format ion available at the time this manual was produced.
Walker Mfg. Co. is continually s tr iv ing to improve the desi gn and per for ma nc e of its prod uc ts. We
reserve the righ t to m ake c hanges i n sp ecifi catio ns and de sign wi thout th ereby incu rring any obligation relative to previously manufactured products.
Sincerely,
WALKER MANUFACTURING COMPANY
Bob Walker, President
Table of Contents
General Information________________ 1
HIGHLIGHTED INFORMATION _____________ 1
GLOSSARY ____________________________ 1
IDENTIFYING NUMBER LOCATIONS________ 1
ENGINE SERIAL NUMBER LOCATION ______ 2
SERVICING OF ENGINE AND DRIVETRAIN
COMPONENTS__________________________ 2
Specifications________________________ 3
ENGINE________________________________ 3
ELECTRICAL SYSTEM ___________________ 3
TRANSMISSION_________________________ 3
BLADE DRIVE __________________________ 4
TIRE SIZE______________________________ 4
TIRE PRESSURE ________________________ 4
DIMENSIONS (Tractor and Mower) _________ 4
MOWER DECK__________________________ 5
CURB WEIGHT__________________________ 5
DRIVE BELTS___________________________ 5
GHS SYSTEM (Optional)__________________ 6
SEAT__________________________________ 6
FRAME/BODY CONSTRUCTION ___________ 6
Component Identification___________ 7
Safety Instructions _________________ 10
BEFORE OPERATING___________________ 10
OPERATING___________________________ 11
MAINTENANCE ________________________ 12
SAFETY, CONTROL,
AND INSTRUCTION DECALS _____________ 14
Assembly Instructions _____________ 16
SETUP INSTRUCTIONS _________________ 16
Tire Installation (Tractor)_______________ 16
Battery Service_______________________ 16
Wet Battery Service __________________ 16
Dry Battery Service __________________ 16
Battery Charging ____________________ 17
Battery Installation ___________________ 17
Mower Deck Assembly ________________ 17
Deck Caster Wheels Installation ________ 17
Deck Discharge Chute Installation ______ 18
Deck Discharge Shield Installation ______ 18
PTO Shaft Guard Installation __________ 18
Tilt-Up Roller Wheel Installation ________ 18
Mower Deck lnstallation on Tractor ______ 19
Deck Installation ____________________ 19
Deck Leveling ______________________ 21
PREOPERATING CHECKLIST ____________ 22
Operating Instructions_____________ 24
CONTROL IDENTIFICATION,
LOCATION, AND FUNCTION _____________ 24
Ignition Switch_______________________ 24
Engine Choke________________________ 25
Engine Throttle ______________________ 25
Forward Speed Control (FSC) __________ 25
Steering Levers ______________________ 25
Blade Clutch (PTO) ___________________ 25
Parking Brake _______________________ 26
Transmission Lockout Levers __________ 26
Hourmeter __________________________ 26
Oil Pressure Warning Light ____________ 26
Circuit Breaker (5 Amp) _______________ 26
Light Switch (For Optional Lights)_______ 26
STARTING THE ENGINE_________________ 28
ADJUSTING GROUND
SPEED AND STEERING _________________ 28
ENGAGING THE MOWER________________ 30
STOPPING THE MACHINE _______________ 31
ADJUSTING CUTTING HEIGHT ___________ 31
TRANSMISSION LOCKOUT ______________ 32
RECOMMENDATIONS FOR MOWING ______ 33
RECOMMENDATIONS FOR TILT-UP DECK
OPERATION/TRANSPORT_______________ 34
GRASS HANDLING SYSTEM (GHS) _______ 35
General Information __________________ 36
Clogging Checklist ___________________ 37
Using the Tilt-Up Deck ________________ 38
Using the GHS Catcher________________ 38
Powerfil ® _________________________ 38
“Full” Signal Horn ___________________ 38
Cleaning the GHS Exhaust Screen ______ 38
Dumping the Catcher _________________ 39
Tailgate Dumping ___________________ 39
Using the Dump Bag _________________ 39
Table of Contents
Maintenance Instructions__________ 41
MAINTENACE SCHEDULE CHART ________ 41
IMPORTANT TIPS FOR CARE
OF THE KOHLER ENGINE _______________ 42
Fuel System _________________________ 42
Starting/Stopping_____________________ 42
Cooling System ______________________ 42
Air Cleaner System ___________________ 42
Oil _________________________________ 42
LUBRICATION _________________________ 43
Engine Oil ___________________________ 43
Engine Break-In Oil __________________ 43
Checking Engine Crankcase Oil Level ___ 43
Changing Engine Crankcase Oil/Oil Filter _43
Grease Fitting and Oil Point Lubrication__ 44
Mower Deck Gearbox Lubrication _______ 44
DSD52 Mower Deck Lubrication_________ 45
Tractor PTO Gearbox Lubrication _______ 46
Checking Gearbox Oil Level ___________ 46
Changing Gearbox Oil ________________ 46
Gear Axle Lubrication _________________ 46
Hydrostatic Transmission Fluid_________ 46
Checking Hydrostatic
Transmission Fluid Level ______________ 46
Changing Hydrostatic Transmission Fluid _47
CLEANING ____________________________ 50
Engine Air Cleaner System_____________ 50
Turbine Precleaner __________________ 50
Donaldson Radialseal™ Air Cleaner _____ 51
Engine Cooling System________________ 52
Air Intake System ___________________ 52
Cylinder Head Cooling Fins ____________ 53
Grass Buildup in Mower Housing________ 53
GHS Blower _________________________ 54
GHS Exhaust Screen__________________ 55
Hydrostatic Transmission Cooling Fins __ 55
CHECKING/SERVICING _________________ 55
Security of Air Filtration Components____ 55
Battery______________________________ 55
Electrolyte Level ____________________ 55
Cleaning the Terminals _______________ 56
Chargin g the Battery _________________ 56
Tire Pressure ________________________ 56
Sharpen Mower Blades ________________ 56
Drive Belts __________________________ 57
Mower Deck Gearbox Oil Seals _________ 58
Spark Plugs _________________________ 58
Fuel Lines and Clamps ________________ 58
Engine Starter________________________ 58
Engine Valve Clearance________________ 58
Blade Brake Action ___________________ 58
REPLACING/REPAIRING ________________ 59
Drive Belts __________________________ 59
Engine PTO Drive Belt _______________ 61
Jackshaft Drive Belt _________________ 62
GHS Blower Drive Belt _______________ 63
Hydrostatic Ground Drive Belt _________ 64
Fuel Filter ___________________________ 65
Blade Overload Shear Bolts ____________ 65
PTO Shear Pin _______________________ 66
Mower Blades _______________________ 66
Mower Deck Gearbox Replacement______ 67
GHS Blower Assembly ________________ 68
GHS Blower Assembly Removal _______ 68
Blower Wheel Removal ______________ 68
Blower Wheel Installation _____________ 69
GHS Blower Assembly Installation ______ 69
ADJUSTMENTS________________________ 70
Safety Switches ______________________ 70
Steering Levers ______________________ 70
Blade Clutch (PTO) ___________________ 71
Clutch Engagement/B elt Tens io n _______ 71
Clutch Disengagement/B ra ke Action ____ 72
Stop Block Eccentric Adjustment _______ 73
Clutch Idler Pulley Travel Adjustment ___ 73
Blade Brake Band Adjustment _________ 73
Transmission Control _________________ 74
Set Forward Travel Limit (Stop) ________ 74
Steering Lever End Play Adjustment ____ 75
Neutral Function Adjustment __________ 75
Straight Ground Travel Adjustment _____ 76
Forward Speed Control Friction Lock ____ 76
Tilt-Up Deck Adjustable Stop ___________ 77
Carburetor __________________________ 77
Engine Idle Adjustment _______________ 77
GHS “Full” Signal Horn
with Grass-Pak® Switch _______________ 78
Troubleshooting
(When Horn Fails to Operate) __________ 78
ELECTRICAL SYSTEM__________________ 79
Circuit Breakers______________________ 79
Wiring Diagram - Model MC ____________ 80
Operator’s Notes___________________ 81
Warranty___________________________ 83
General Information
HIGHLIGHTED INFORMATION
Walker Manufacturing recommends that any service
requiring special tr aining or tools be performed by
an authorized Walker Mower Dealer. There are several general pract ices to be aware of in the area o f
safety. Most accidents associated with the operation or maintenance o f a Walker Mower ar e cau se d
by disregarding ba si c safety precautions or s peci fic
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 man ual. Refer to Safety
Instructions for the mean ing s of DANGE R, WARNING, CAUTION, IMPORTANT, and NOTE.
GLOSSARY
There are many ter ms th at are either unique to th is
equipment or that ar e 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 drive gearboxes,
and cutter blades.
• FORW ARD SPEED CONTROL (FSC) cont r ol s
the maximum forward speed of the tractor;
functioning as a cruise control.
• GRASS HANDLING SYSTEM (GHS
mowed material and deposits it in the catcher.
) collects
• POWER TAKE-OFF (PTO) transmits engine
power to run the cutter blades and GHS blower.
• POWERFIL
throughout the interior of the gr ass catcher by
an oscillating delivery spo ut.
spreads the mowed material
• 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) mows but does not
collect the mowed material.
• STEERING LEVERS steer the tractor by con-
trolling the dual hydrostatic transmissions.
• TRACTOR is the prime mo ver, including t he en-
gine, drive train, operator seat, and contr ols to
operate the mower.
• TRANSMISSION LOCKOUT releases the hy-
drostatic transmissions 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 i ron framing on the RH side of
the RH mower blade drive. Model and ser ial numbers are helpful when obtaining repl acement parts
and maintenance assistance. For ready refer ence,
please record these numbers in the space provided.
• GRASS-PAK
grass delivery s pout (in the catcher) and act ivates the “full” signal horn when the grass
catcher is full.
SWITCH is mounted on the
• GROUND DRIVE refers to the dual h yd rostatic
transmissions which drive the main wheels.
• HYDROSTATIC TRANSMISSION transmits
and controls power from the ground drive belt to
the main drive wheel.
• LEFT HAND (LH) refers to the left-hand side of
the tractor when the opera tor is seated facing
forward in the tractor seat.
Tractor Model No. _______________________
Tractor Serial No. _______________________
Deck Serial No. _______________________
Engine Model No. _______________________
Engine Serial No. _______________________
Date of Purchase _______________________
Fill In By Purchaser
1
General Information
Serial Number
Tractor Serial Number Location
Serial Number
SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS
The detailed servicing and repair of the engine,
hydrostatic transmission, and gearboxes are not covered in this manual. Only routine maintenance and
general service instructions are provided. F or 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 don e on these components during the warranty period may void the warranty. If
you have any difficulty finding an authorized outlet or
obtaining warranty service, please contact our Service Department for assistance:
Walker Manufacturing Company
5925 E. Harmony Road
Fort Collins, CO 80528
1-970-221-5614
Service manuals are available for each of these
components from their respective manufacturers as
follows:
Mower Deck Serial Number Location
ENGINE SERIAL NUMBER LOCATION
Refer to the engine manu al that accompanies this
manual for the location of the engine serial number.
For the mower model covered by this manual,
an e ngine manual is availa ble coveri ng the Kohl er
Command CH18 gasoline engine.
Serial Number
Kohler Engines Kohler Company
Kohler, WI 53044
Hydrostatic Eaton Corporation
Transmissions 15151 Highway 5
Eden Prairie, MN 55344
Gearboxes (Deck) Tecumseh Products Co.
900 North Street
Grafton, Wl 53024
Engine Serial Number Location
2
Specifications
MODEL MC
ENGINE
Manufacturer/Model Kohler Command CH18, 2 Cyl., Gasoline (Air-Cooled)
Displacement 38.0 cu. in. (624 cc)
HP (@ 3600 RPM) 18.0
Max. RPM (No Load) 3750
Governed RPM 3600
Max. To rq ue [ft-lb (N
Idle RPM 1200 ± 75
Spark Plug Type Champion
Spark Plug Gap .030 in. (.76 mm)
Crankcase Capacity 2 qts (1.9 liters)
Crankcase Lubricant API SG or SH Grade Oil Only with 10W-30 Viscosity above 0° F
Fuel Tank Capacity 3 Gallons (11.4 liters)
Fuel Regular Grade Unleaded Gasoline (87 Octane)
Cooling System Capacity Air Cooled
ELECTRICAL SYSTEM
Battery 12 Volt, 35 AH, 295 CCA
Charging System Flywheel Alternator
Charging Output 15 Amp DC (Regulated)
System Polarity Negative Ground
Ignition Electronic Capacitive Discharge
⋅m) @ RPM] 30 (41) @ 2500
®
RC12YC
(-18° C), or 5W-20 or 5W-30 Viscosity below 32° F (0° C)
Starter 12 Volt Electric Ring-Gear Type, Solenoid Shift
Interlock Switch Ignition Lockout by Seat Switch, Transmission Neutral and Blade Clutch
Circuit Breaker Auto Reset (30A)
TRANSMISSION
Manufacturer/Model Dual Hydrostatic, Eaton Model 7, Each Wheel Independently Driven
Steering Hand Lever Control / Individual Wheel
Forward Speed Control Precision Friction Lock Lever, Cruise Control, with Neutral-Park
Position
Service Brake Dynamic Braking through Hydrostatic Transmission
Parking Brake Mechanical Pin Lock in Transmission Gear
Neutral Transmission Release by Manual Dump Valve
Final Drive Gear Drive Axle
3
Specifications
MODEL MC
TRANSMISSION (continued)
Transmission Fluid
Factory Service Mobil 1 Synthetic Motor Oil (15W-50)
Alternate Transmission Fluid SAE 30W Straight Viscosity Motor Oil
Transmission Fluid Capacity 1 qt (1 liter)
Transmission Cooling Cooling Fan Mounted on Drive Pulley
Ground Travel Speed
Forward m.p.h. (km/h)
Reverse m.p.h. (km/h)
BLADE DRIVE
PTO Shaft Quick Disconnect Spline Shaft with Two High-Speed U-Joints
Blade Spindle Each Blade (2) Mounts Direct on Peerless Right Angle
Blade Drive Clutch and Brake Manual Belt Tightener Clutch and Band Brake
0-5 (0-8) Infinitely Variable
0-5 (0-8) Infinitely Variable
Gearbox with Tee Gearbox in Center Connected to PTO Shaft
(Complete Geared Drive, Peerless Model 1000 Gearboxes)
(Stops Blades within Five (5) Seconds of Disengagement)
Max. Blade Speed
[22 in. (56 cm) Blade] @ 3600
RPM Engine
TIRE SIZE
Deck Caster Wheel 2.80/2.50-4 Pneumatic (4-Ply)
Deck Caster Wheel (Optional) 8.25 x 2.75 Semi-Pneumatic
Drive 18 x 8.50-8 (4-Ply)
Drive (Optional Narrow Tire) 18 x 6.50-8 (4-Ply)
Rear 13 x 6.50-6 (4-Ply)
TIRE PRESSURE
Deck Caster Wheel 20 PSI (137 kPa)
Drive 15 PSI (103 kPa)
Rear
DIMENSIONS (Tractor and Mower)
Length
36 in. (91 cm) GHS Model 87 in. (221 cm)
42 in. (107 cm) GHS Model 89 in. (226 cm)
Width
36 in. (91 cm) SD Model
(with Deflector)
42 in. (107 cm) SD Model
(with Deflector)
36 in. (91 cm) GHS Model 37 in. (94 cm)
42 in. (107 cm) GHS Model 43 in. (109 cm)
2900 RPM
[16700 FPM (5090 m/min)]
20 PSI (137 kPa)
41-3/4 in. (106 cm)
47-3/4 in. (121 cm)
4
Specifications
MODEL MC
DIMENSIONS (continued)
Height
SD Model 37-1/2 in. (95 cm)
GHS Model 44-1/2 in. (112 cm)
Wheel Base (Tractor) 42-1/4 in. (107 cm)
Tread Width (Tractor)
Standard Ti res 28-1/4 in. (72 cm)
Optional Tires 29-3/4 in. (76 cm)
MOWER DECK
Width of Cut SD/GHS 36 or 42 in. (91 or 107 cm)
Cutting Height 1 to 4 in. (3 to 10 cm)
Height Adjustment 7 Positions - 1/2 in. (1 cm) Increment Hitch Pins Installed in
Blade Size
Multi-Position Deck Support
36 in. (91 cm) SD Model 20 in. (51 cm) Two (2) Clockwise-Rotating Blades with a 4 in.
(10 cm) Center Overlap
36 in. (91 cm) GHS Model 20 in. (51 cm) Two (2) Counter-Rotating Blades with a 4 in.
(10 cm) Center Overlap
42 in. (107 cm) SD Model 22 in. (56 cm) Two (2) Clockwise-Rotating Blades with a 2 in.
(5 cm) Center Overlap
42 in. (107 cm) GHS Model 22 in. (56 cm) Two (2) Counter-Rotating Blades with a 2 in.
(5 cm) Center Overlap
Deck Suspension Torsion-Flex Frame with Caster Wheels and
Counterweight Springs
CURB WEIGHT (Approximate)
SD Tractor Only 645 lb (293 kg)
GHS Tractor Only 735 lb (334 kg)
SD Tractor and 36 in. SD Deck 775 lb (352 kg)
SD Tractor and 42 in. SD Deck 810 lb (368 kg)
GHS Tractor and 36 in. GHS Deck 860 lb (390 kg)
GHS Tractor and 42 in. GHS Deck 895 lb (406 kg)
DRIVE BELTS
Engine PTO Walker P/N 8230
Jackshaft Drive Gates 3VX395 (or Walker P/N 6251)
Ground Drive, Micro-V Walker P/N 7248
Blower (GHS Model) Walker P/N 7234-1
5
Specifications
MODEL MC
GHS SYSTEM (Optional)
Blower 4 x 10 x 1/4 in. (10 x 25 x 1 cm) Three-Blade Paddle Wheel
Blower Brake Band Brake (Works in Combination with PTO Clutch, Stops
Max. Blower Speed 3600 RPM
Grass Catcher Capacity 63 Gallons (238 liters)/6.7 Bushels
Optional Grass Catcher Capacity* 89 Gallons (335 liters)/9.5 Bushels
Full Signal Oscillating Vane Switch Mounted on Grass Delivery Spout Triggers
Powerfil
®
(Driven by Mower Engine)
Blower within Five (5) Seconds of PTO Disengagement)
Horn Signal
Oscillating Delivery Spout Driven by 12 Volt Electric Gearmotor
Spreads Material throughout Interior of Catcher @ 25 Cycles/Minute
SEAT
FRAME/BODY CONSTRUCTION
Frame All Welded Unitized Steel Chassis
Body 14 Gauge Steel
Deck 11 Gauge Steel
GHS Catcher and Chutes Molded Cross-Linked Polyethylene (UV Stabilized)
Contour-Molded, with Nylon Backed Vinyl Cover and Integral
Foam Cushion
*Optional (9.5 Bushel) Grass Catcher adds approx. 5 lb (2 kg) and 5 in. (13 cm) in Height
NOTE: The manufacturer reserves the right to make changes in specifications shown herein at any time
without notice or obligation.
6
Component Identification
NOTE: Control Identification
shown in Operating
Instructions section.
Catcher Door
Safety Latch
Anti-Scuff
Roller
Catcher Lift /
Dump Handle
Turbine
Precleaner
Grass Handling System
9.5 Bushel Catcher
Tilt-Up
Latch
Spring Clip
Counterweight Spring
and Protective Cover
Transmission Control Rod
Adjustment Nut (LH)
Deck Support Pins
and Height Adjustment
Hitch Pins
Fuel Tank and Cap
Transmission Control
Rod Adjustment Nut
(RH)
Deck Support Arms
(Cutting Height Adjustment)
Deck Lift Handle
Tilt-Up Hook
(Not Visible)
Front View and Right Side View
Tilt-Up
Deck Handle
Footrests
Deck
Caster Wheels
7
Component Identification
Catcher Door
Catcher Door
Gas Spring
Protective Cover
Catcher Lift /
Dump Handle
Gas Spring
Removable Grass
Catcher Screen
(Not Visible)
Catcher Exhaust
Deflector
Left Hand
Drive Wheel
Muffler
Tailpipe
Oil
Filter
Catcher
Door
Catcher
Door Handle
Anti-Scuff
Roller
Oil Drain
Plug
Tailwheel Fork
and Wheel
Rear View and Left Side View
8
Component Identification
Air Restriction
Indicator
Rubber Bumper
(Body Support)
(Not Visible)
Donaldson
Air Cleaner
Air Cleaner
Cover
Rubber Bumper
(Body Support)
Fuel Pump
Air Intake
Hose
Precleaner
Tube
Fuel Tank Cap
Jackshaft
PTO Gearbox
Dipstick
Turbine
Precleaner
RH Transmission
Lockout Lever
PTO
Clutch Lever
30 Amp
Circuit Breaker
Muffler
Throttle and
Choke Linkage
Muffler Heat Shield
Oil Fill/
Dipstick
GHS Blower
RH Hydrostatic
Transmission
Neutral Safety
Switch
LH Hydrostatic
Transmission
Positive (+)
Battery Cable
Negative (-)
Battery Cable
Battery
Top View (Engine Compartment)
LH Transmission
Lockout Lever
9
Safety Instructions
Pay particular attentio n 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 instr uctions. Failure to comply with safety instructions may result in
personal injury.
The seriousness or degree of imp ortance of each
type of information is defined as follows:
DANGER
An IMMEDIATE hazard that WILL result in
severe personal injury or DEATH, if warning is ignored and proper safety precautions are not taken.
WARNING
A POTENTIAL hazard that COULD result in
severe personal injury or DEATH, if warning is ignored and proper safety precautions are not taken.
Walker Manufacturing cannot predict every potentially dangerous situation. Therefore, items labeled
as such in this manual do not cover all conceivable
situations. Any person using procedur es, 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 persona l 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
Owner’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 Owner’s Manuals are available
by sending the Model and Serial Number to:
Possible hazards or unsafe practices that
MAY result in MODERATE personal injury
or property damage, or machine damage, if
warning is ignored and proper sa fety precautions are not taken.
IMPORTANT: Identifies mechanical information de-
manding special attention, sinc e it deals wit h the possibility of damaging a part or parts of the machine.
NOTE: Identifies information worthy of special
attention.
CAUTION
Walker Manufacturing Company
5925 East Harmony Road
Fort Collins, CO 80528
2. Never al low chi ldre n to op erate rider mower.
Do not allow adults to operate without proper
instruction.
3. Clear the area to be mowed of any fo reign
objects which may be picked up and thrown by
cutter blades. Pick up all sticks, stones, wire,
and any other debris.
4. Keep everyone, es peci all y child re n an d 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.
10
Safety Instructions
6. Do not wear loose fitting clothing that could get
caught in moving parts. Do not operate this
machine while wearing shorts; always wear
adequate protective clothing, including long
pants. Wearing safety glasses, safety shoes,
and a helmet is advisable and required by some
local ordinances and insurance regulations.
7. Prolonged exposure to loud noise can cause
impairment or loss of he ar ing . Operator hear-
ing protection is recommended; particularly
for continuous operation of the GHS Model due
to blower noise level. Wear a suitabl e hearing
protective device, such as earmuffs or earplugs.
8. Keep all protective shields and safety de-
vices in place. If a protective shield, safety
device, or decal is damaged, unusable, or missing, repair or replace it before operating the machine.
9. Be sure interlock switches are functioning
correctly, so th e engine cannot be starte d 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 li fts off the seat
with the PTO clutch in the ENGAGED position.
10. Handle gasoline with care. Gasoline is highly
flammable and its vapors are explosive :
a. Use an approved fuel container.
b. Never add fuel to a running engine or hot
engine (allow hot engine to cool several
minutes).
c. Keep matches, cigarettes, cigars, pipes,
open flames, or sparks away from the fuel
tank and fuel container.
d. Always fill the fuel tank outdoors using care.
Fill to about one inch from the top of the tank.
Use a funnel or spout to prevent spilling.
12. The elec trical system battery contains sulfuric
acid. Avoid any contact with skin, eyes, and
clothing. Keep the battery and acid out of reach
of children.
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.
3. For a beginn ing operator, learn to steer (ma-
neuver) the tractor with a slow engine speed
before attempting any mowing operation.
Be aware that, with the front mou nted mower
configuration, the bac k of the tractor swings to
the outside during turns.
4. Remember, for an emergency stop, the forward
motion of th e tractor can always be stopped by
pulling the Forwar d Speed Control (F SC) into
the NEUTRAL-PARK position.
5. In case either of the transmission drive belts
break during operation, and if the machine is on
a slope, the machine will f reewheel 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 sto pped or moving
slowly, engage the parking brake.
NOTE: This is exactl y the s ame pr ocedu re us ed 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 th e machine if these controls ar e in the OPERATING position).
e. Replace the machine fuel cap and container
cap securely a nd clean up any s pilled fuel
before starting the engine.
11. Never attempt to make any adjustments
while the engine is running, except where
specifically instructed to do so.
7. Do not run the engine in a confined area
without adequate ventilation. Exhaust fumes
are hazardous and can be deadly.
8. Do not carry passengers - maximum seating
capacity is one (1) person.
11
Safety Instructions
9. Watch for holes, rocks, and roots in the terrain
and for other hidde n hazards. When mowing
tall grass, mow hig her than desired to e xpose
any hidden obstacles. Then, clean the area and
mow to the desired height.
10. Avoid sudden start s or stops. Bef ore backing
the machine up, look to th e rear to b e sure n o
one is behind the machine. Watch carefully for
traffic when crossing or working near roadways.
11. Disengage the blade drive when transporting
the machine across drives, si de wa lks , e tc. Ne-
ver raise the mower deck while blades are
rotating.
12. The maximum recommended side slope operating angle is 20 degrees or 33% grade.
When operating the machine on a slope, reduce
speed and use ca ution to start, stop, and m aneuver. To prevent tippin g or loss of control of
the machine, avoid sharp turns or sudden
changes in direction.
13. Never adjust cutti ng height with the engine
running. Before adjusting cutting height or
servicing, disengage the blade clutch (PTO),
stop the engine, and remov e the ignition key.
Wait for all movement to stop before getting off
the seat.
NOTE: A blade/blower br ake should nor mally
stop drive line rotation within five (5) seconds of
disengaging the PTO clutch.
17. For GHS equipped models, use care when
closing the grass catcher door . Keep fingers
and hands away from the hinge and pinch
points when the door is being closed. Also,
keep fingers and hands clear of the door frame.
The door is held closed with springs and the
door may slam shut with considerable force.
18. In case of a clogged or plugged mower deck
or GHS catching system:
a. Disengage the blade clutch (PTO) and turn
the engine off before leaving the seat.
b. LOOK to make sure blade drive sh aft and
blower drive pulley movement has stopped
before trying to unclog the system.
c. Disconnect the spark plug wires.
d. Never place hands under the deck or in the
GHS blower - us e a stick or similar tool to
remove clogged material.
19. If the cutting bl ades strike a solid object o r the
machine begins to vibrate abnormally, immedi-
ately disengage the blade clutch (PTO), stop
the engine, and wait for all moving parts to
stop. T o prevent accidental starting, disconnect
the spark plug wires. Thoroughl y 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 ft-lb (81.3 N
⋅m).
12
14. For side discharge mower decks, do not oper-
ate with the grass deflector chut e removed .
Keep the deflec tor in th e lowest possible position.
15. For tractors equipped with tilt-up deck, observe
the following recommendations:
a. Do not move tractor with dec k in tilt-up po-
sition.
b. Never tilt body f orward with deck in tilt-up
position.
16. For GHS equipped models, do not operate the
machine with the grass catcher in the DUMP
position or with the back door OPEN. Dan-
gerous projectiles may be thrown out of the discharge chute or the back of the grass catcher.
20. Do not touch the engine or muffler while the
engine is running or immediately after stopping
the engine. These areas may be hot enough to
cause serious burns.
21. When leaving the machine unattended, dis-
enga ge t he b lade clu tch (PTO), stop t he e n gine, and remove the key.
MAINTENANCE
1. To prevent accidental starting of the engine
when servicing or adjusting the machine, remove the key fro m the ignition sw itch and disconnect the spark plug wires.
Safety Instructions
2. T o reduce fire haz ards, keep the engine free of
grass, leaves, excessive grease, and dirt.
3. Keep all nuts, bolts, and sc rews tig ht to e n su re
the machine is in a safe, working condition.
Check the blade mounting nuts frequently , making sure they are tight.
4. Perform only maintenance instructions de-
scribed in this manual. Unauthorized maintenance operations or machine modifications
may result in unsafe operating conditions.
5. If the engine must be running to perform a maintenance adjustment, keep hands, feet, and
clothing away from moving parts. Do not wear
jewelry or loose clothing.
6. Always use the proper engine service manual when working on the engine. Unautho-
rized maintenance o perations or modifications
to the engine may result in unsafe operating
conditions.
7. Altering the equipment or engine in any manner
which adversely affects its operation, performance, durability, or use will VOID the warran-
ty and may cause hazardous conditions.
c. Ke ep sparks, fla mes, a nd smo king mater i-
als away from the ba ttery at all times. To
avoid sparks, use care when removing battery cables from posts.
d. Disconnect both battery cables before
unplugging any wiri ng connectors or mak ing repairs on the electrical system.
IMPORTANT: Keep all applicable manuals
immediately accessible to anyone who may
operate or service this machine.
8. Never attempt to discon nect an y safe ty de vices
or defeat the purpose of these safety devices.
9. Do not change the engine g ove rnor se ttings or
overspeed the engine. The governor has been
factory-set for m axim um- s afe engi ne ope rating
speed.
10. Use genuine factory replacement parts.
Substitute parts may resu lt in produ ct malfunc tion and possible inj ury to the operator and/or
others.
11. Use care when charging the batter y or per-
forming maintenance on the battery and electrical system:
a. Make sure the battery charger is unplugged
before connecting or disconn ecting cables
to the battery.
b. Charge the battery in a well-ventilated
space, so gases pro duced while charging
can dissipate. Make sure the battery vents
in the caps are open.
13
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
Each End of Mower Deck (5808)
SD Deck Discharge Shield (5848)
Adjacent to Blower Discharge Chute
Front Body Adjacent to
RH Steering Lever (6807)
Engine Shroud (5855)
through Body (5804)
Hydrostat Oil
Reservoir (5810-2)
14
Underside of Body (5861)
Gear Axle (5810-1)
Rear of Grass Catcher Exhaust Screen (5869)
Catcher Safety Latch,
RH Side (5874)
LH Side of Body,
Above Muffler (5805)
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 list ed below and in the Parts Manual.
Top of Blower Housing (5819)
Jackshaft Support Adjacent
to Dipstick (7827)
Deck Gearbox Cover (5807-3)
Deck Carrier Frame (5865)
Deck Carrier Frame (8653)
Fender, LH Side (5802-2)
On Engine (6810)
Right Side, Below Operator Seat (7809)
Catcher Door Hinge Bar, LH and RH Sides (5868)
Rear Bumper (5815)
Deck Carrier Frame (8647)
Fender, RH Side (7802)
15
Assembly Instructions
SETUP INSTRUCTIONS
Walker Mowers are shipped partially assembled.
After uncrating the tractor and mower deck, initial
setup is required.
NOTE: During the process of unpacking, any damaged or missing parts should be noted and reported
to the delivering ca rrier immediately (put in wri ting
within 15 days). The carr ier will provide directions
for proceeding with a claim to receive compensation
for damage.
Tire Installation (Tractor)
• Install the drive ti res usin g the eig ht (8) lug bo lts
that are supplied with the o wner’s packet of materials. Drive tires are 18 x 8.50-8, 4-pl y; rear tire is
13 x 6.50-6, 4-ply.
• Check and adjust the inflation of the tires. The
tire inflation recommendations are:
Drive = 15 PSI (103 kPa)
Rear = 20 PSI (137 kPa)
Battery Service
Tilt mower body up (lift on rear of body ) for battery
access. Check the battery for electrolyte level and
charge. The electrolyte lev el 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.
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 cr itical work ing parts and sa fety
systems.
Wet Battery Service
Dry Battery Servic e
DANGER
Activating a battery can be dangerous.
The battery should be taken to a reliable
service station, battery store, or power
equipment dealer where a trained technician can activate the b attery safely. DO
NOT attempt to activate the battery unless
you are experienced in battery service
work. The following activation and charging instructions are provided for use by a
trained battery technician.
DANGER
Battery electrolyte is a poisonous and corrosive sulfuric acid solution.
• Avoid spillage and contact with skin,
eyes, and clothing - causes severe burns.
• To prevent accidents, wear safety gog-
gles and rubber gloves when working with
electrolyte.
• Neutralize acid spills with baking soda
and water solution.
T o fill (activate) battery with electrolyte (if battery has
been shipped dry):
1. Remove the battery ho ld dow n bar, disconnect
the battery cables and li ft the battery ou t of the
tray.
IMPORTANT: Battery must be removed from
the mower before filling with electrolyte.
16
If the battery has been shipped wet, but the electrolyte level is low or the batte ry needs to be charge d
then:
1. Fill each battery cell with drin king water to the
bottom of the vent wells.
2. Charge battery. Refer to Battery Charging in
this section.
IMPORTANT: Obtain and use only battery
grade sulfuric acid electrolyte with a 1.265 specific gravity to activate the battery. DO NOT use
water or any other liquid during initial activation.
2. Remove the filler caps and carefully fill each cell
until the electrolyte is just above the plates.
Assembly Instructions
3. After the battery is filled with electrolyte, replace
the filler caps and c harge the ba ttery. Refer to
Battery Charging.
Battery Charging
DANGER
BATTERIES PRODUCE EXPLOSIVE GASES
• Charge the battery in a well-ventilated
area, so that gases produced while charging can dissipate.
• Keep sparks, flames, and smoking mate-
rials away from the battery at all times.
• Make sure the battery cap vents are open
after the battery is filled with acid (check
manifold vent on each cap).
• Make sure the battery charger is unplug-
ged before connecting or disconnecting
cables to the battery.
1. Charge the battery at 15 amps for 10 minutes .
DO NOT exceed 20 amps maximum recommended charging rate. Charge until specific
gravity is at least 1.250. Total charging time
should not exceed one (1) hour.
Install the battery in the mower as shown in Battery
Installation photo. Connect the pos itive and n egative cables to the proper battery terminal (red cable
and boot connects to the Positive (+) te rminal).
Slide the rubber boot up and over the battery post,
making sure it co vers the post completely to pre-
vent 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)
(+) Battery Cable
Connection
Battery Installation
Mower Deck Assembly
2. After charging the battery , adjust the electrolyte
level to the bottom of the vent wells [1/4 to 1/2 in.
(6 to 13 mm) above the plates].
IMPORTANT: DO NOT overfill the battery.
Electrolyte will overflow through the vented caps
onto parts of the machine and WILL result in
severe corrosion.
3. Install battery.
Battery Installation
IMPORTANT: Make sure battery is securely
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 cr itical work ing parts and sa fety
systems.
Deck Caster Wheels Installation
1. Remove the bolt, nut, axle spacer tube, and
spacer washers from each deck caster wheel
fork.
NOTE: Spacer washers are used only when
the optional semi-pneumatic deck wheels (8.25
x 2.75) are installed.
2. Fit the axle spacer tube through the wheel hub,
position the spacer wa sh er on ea ch si de of the
hub (if used), and fit the assembly into the wheel
fork.
3. Insert the 3/8-16 x 4-1/2 in. bolt through the
wheel fork with the bolt head to the outside and
install the 3/8-16 in. Keps nut.
4. Tighten the bolt and nut until the axle spacer
tube bottoms against the inside of the wheel
fork (will not turn) while the wheel and spacer
washers (if used) spin freely without binding.
17
Assembly Instructions
Grease Fitting
Locations
Spacer Washer
Axle Spacer Tube
Deck Caster Wheel Installation
NOTE: If semi-pneumatic wheels are installed,
make sure the spacer washers fit over the spacer
tube and are not caught between the fork and the
end of the tube. The washers should move freely
on the axle spacer tube.
5. Grease the caster wheel bearings and caster
pivot bearings - one grease fitting for each wheel
and each pivot.
Deck Discharge Shield Installation (Side Discharge Models Only)
Attach the deck side discharge shield by positioning
the shield hinge lug i n fr ont of the deck mou nt and
fastening with two 3/8-16 x 1-1/4 in. bolts, 3/8-16
ESNA nuts, and 3/8 in. wave sp ring washers. Th e
wave washers fit between the two hinging surfaces.
Tighten the nuts until the shield moves freel y but is
not loose.
WARNING
DO NOT operate the machine without the
grass deflector chute a ttached and in the
lowest possible position.
Attach Shield
Deck Discharge Chute Installation (GHS Rear Discharge Models Only)
Mount the discharge chute hinge on top of the deck
discharge openin g using the 1/4-20 x 1/2 i n. s oc ket
button head bolt and 1/4-20 ESNA nut. Position the
bolt with the head inside of the chute and the nut on
the outside.
Carrier Frame
Tube Sockets
Attach Guard
Nut on Top
Discharge Chute and PTO Shaft Guard
Installation on Rear Discharge Deck
Attach
Chute
Discharge Shield Installation
on Side Discharge Deck
PTO Shaft Guard Installation
Position the shaft guard as shown and moun t with
two 1/4-20 x 1/2 in. bolts.
Tilt-Up Roller Wheel Installation
Mount the two (2) tilt-up roller whee ls on the brac kets on the rear skirt of the deck housing using the
P/N 8490 axle b olt , 3 /8 in. wa ve s pr in g washer and
3/8-16 in. Whiz loc knut. Tighten the axle bolt until
the wheel rolls freely, but is not loose.
18
Assembly Instructions
Attach Spring
Tilt-Up Spring and Roller Wheel
Installation on Rear Discharge Deck
Roller Wheels
5. Connect the mower deck PTO drive shaft
assembly to the tractor with the splined quick
disconnect coupler. This coupler simplifies
shaft alignment and installation.
a. Use the arrows on the shaft and tube to
align and slide the PTO quick coupler onto
the deck splined shaft.
b. Reaching under the tractor, pull the ring
back on the coupler, slide onto the spline
shaft on the tractor, and release the ring.
IMPORTANT: To prevent damage to the mower,
make sure the PTO shaft assembly is securely locked
on the tractor, with the locking balls fully seated in the
groove and the ring in the full forward position (refer
to the Coupler Ring “Locked” Position photo). After installation, pull on the shaft to check for security .
Mower Deck lnstallation on Tractor
Deck Installation
1. Lightly grease each deck support arm (2) on the
tractor. Refer to Mower Deck In stallat ion photo on next page for location of deck support arm.
2. Engage the deck carrier frame tube sockets on
the tractor support arms (refer to Discharge
Chute and PTO Shaf t Guard Installation photo
for socket location). Slide the deck onto the support arms: all the way if SD equipped model,
approximately 3 in. (76 mm) if G HS equipped
model.
NOTE: When installing the DSD52 Mower
deck, make sure to retract the dolly wheel after
mounting the deck on the tractor .
3. If the deck is rear discharge (GHS equipped
model), the rear discharge chute will need to be
aligned and connected to th e blower inlet during the last 2 in. ( 51 mm) of sl ide acti on on th e
support arms.
Pull Back Spring-Loaded
Coupler Ring
Installing PTO Quick Coupler
Spring-Loaded Coupler Ring
In Fully Forward Position
NOTE: Raising the mower body may be helpful in fitting and guiding the deck chute into the
blower.
4. Install the hitch pin through the hole on the end
of each suppo rt arm to lock the deck in place
(refer to Deck Counterweight Spring Installa-
tion p hoto). Two (2) hitch pins are inc luded in
the owner’s packet of materials.
Coupler Ring “Locked” Position
19
Assembly Instructions
6. Raise the mower body (instead of lifting the
front of deck) and clip the counterweight springs
to the receptacle on fro nt of body. Lower the
body to tension the springs. (Refer to Deck
Counterweight Spring Installation Photo.)
Arrows on Shaft and Tube
(used to align when sliding together)
PTO
Connection
Spring Tension Adjustment
Nut Located Under Lower
Spring Hook (Not Visible)
Grease Deck
Support Arms
Mower Deck Installation (PTO Shaft Connection)
7. With the counterweight springs c onnected, the
weight on the deck caster wheels should be
15 to 25 Ib (6.8 to 11.3 kg). Check this weight
by lifting on the front of the deck carrier frame. If
required, the spring tension can be adjusted by
tightening or loosening the elastic stop nuts
located underneath the lower spring hook.
Refer to Deck Counterweight Spring Installa-
tion photo.
Counterweight S prings
Clip Onto Body
With Body Tilted Up
Deck Counterweight Spring Installation
Hitch Pins
Lock Deck On
Support Arms
20
Assembly Instructions
Deck Leveling
1. Position mower on a smoo th, leve l surfac e. Set
the cutting height to th e highest position - 4 in.
(102 mm) - for easy acce ss under the deck to
measure blade hei ght. Refer to ADJUSTING
CUTTING HEIGHT in Operating Instructions.
NOTE: A block of wood cut 4 in. (102 mm) high
is a convenient gauge to measure blade height
above ground during the leveling process.
WARNING
The machine must be shut off during this
procedure.
2. Check the side-to-side level. Rotate each blade
sideways and measure the distance from blade
tip to ground on each side. If measurements
vary more than 1/8 in. (3 mm), ad d a washer
shim under the deck support pins on the low side
to level the deck.
3. Check the front-to-rear level. Rot ate the blades
to point forward. Me asure the distance from
blade tip to ground on t he front and rear. The
rear of the blade should be 1/8 to 1/4 in. (3 to 6
mm) higher than the front of the blade; shim the
rear (or front) deck support pins equally to
achieve at least 1/8 in. (3 mm) difference.
NOTE: The mower deck and support frame are
jig welded; within normal tolerances, very little, if
any, shimming should be required to level the
deck. Tire pressure will influence the levelness
of the deck. Check the tire pressure as a possible cause of the deck not being level.
4 in. (102 mm)
Wood Block
Should not vary more
than 1/8 in. (3 mm)
side-to-side
Should be 1/8 in. (3 mm)
to 1/4 in. (6 mm) higher
at the rear of the blade
4 in. (102 mm)
Wood Block
Deck Leveling
21
Assembly Instructions
PREOPERATING CHECKLIST
Before operating the mower for the first time, and as
a routine before da ily 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 fuels and lubricants refer to Specifica-
tions.
FILL FUEL TANK
Fill the fuel tank using clean, fresh automotive grade
unleaded gasoline (87 octane rating minimum).
DANGER
Handle gasoline with care. Gasoline is
highly flammable and its vapors are explosive. Use safe refueling procedures:
IMPORTANT: DO NOT mix oil with gasoline. Al -
ways use fresh, automotive grade gasoline. DO
NOT use premium, white, or high-test gasoline. DO
NOT use additives, such as carburetor cleaners, de-
icers, or moisture removing agents. DO NOT use
gasoline blended with methyl alcohol.
CHECK ENGINE CRANKCASE OIL LEVEL
Check the en gine cran kcase oi l level bef ore use an d
after each 5 hours of continuous operation. Refe r
to LUBRICATION for Checki ng Engine Cra nkcase
Oil Level in Maintenance Instructions.
CHECK AND SERVICE ENGINE AIR CLEAN-
ER SYSTEM
• Check air restriction gauge to make sure there is
no red indication showing.
• Check condition, cleanliness, and security of the
complete air cleaner system (clean air filter
every 100 hours). For detailed procedures,
refer to CLEANING the Engine Air Cleaner
System in Maintenance Instructions.
• DO NOT fill fuel tank with the engine run-
ning.
• If the engine is hot, allow to cool before
refueling.
• Use an approved fuel container.
• Fuel the mower outdoors.
• DO NOT smoke while refueling.
• Avoid spilling fuel; use a funnel or spout.
• DO NOT overfill the fuel tank; fill up to
about 1 in. (25 mm) below the top of tank.
IMPORTANT: DO NOT permit dirt or other foreign
matter to enter the fuel tank. Wipe dirt from around
the filler cap before removing. Use a clean fuel storage container and funnel.
ADJUST CARBURETOR (Initial Start-up Only)
Refer to ADJUSTMENTS of Carburetor in Mainte-
nance Instructions.
CHECK ENGINE COOLING SYSTEM
Check that the engin e cooling air intake screen is
free of obstruction by grass clipping s or debris and
clean if required. Also, cylinder head cooling fins
should be inspected and cl eaned if any build-up of
debris is noted [remov e two (2) cylinder head access panels to inspect and clean].
Check performance of the c ooling system by s tarting the engine, holding a hand adjacent to the cylinder heads, and feeling the cooling airflow.
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
22
Assembly Instructions
CHECK GEAR AXLE OIL LEVEL
Refer to Gear Axle Lubrication in Maintenance In-
structions.
INSPECT FOUR (4) DRIVE BELTS
Engine PTO Drive, Jackshaft Drive, Hydrostatic
Ground Drive, and GHS Blower Drive (if equipped).
Tilt-Up Lift Handle
Tilt-Up Latch
Tilt-Up Latch
CHECK HYDROSTATIC TRANSMISSION OIL
LEVEL
Refer to LUBRICATION for Checking Hydrostatic
Transmission Fluid Level in Maintenance Instructions.
CHECK BATTERY ELECTROLYTE LEVEL
Refer to CHECKING/SERVICING the Battery in
Maintenance Instructions.
CHECK FUNCTION OF OIL PRESSURE
WARNING LIGHT
Turn ignition key to the RUN position. The oil pressure light should operate, indicating normal function.
CHECK TIRE PRESSURE
Deck Caster Wheel = 20 PSI (137 kPa)
Drive = 15 PSI (103 kPa)
Rear = 20 PSI (137 kPa)
CHECK AND CLEAN GRASS BUILDUP UN-
DERNEATH MOWER DECK (and insid e GHS
blower, if equipped)
Refer to CLEANING the GHS Blower in Mainte-
nance Instructions for blower cleaning information.
DANGER
Tilt-Up Hook
on Deck
Deck Lock Lever
Deck Secured in TILT-UP Position
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
DANGER
Do not operate the mower with deck in tiltup position. Do not move t he tra ctor with
the deck in the tilt-up position.
CHECK MOWER BLADE CONDITION, SHARP-
NESS, AND SECURITY OF MOUNTING
The blade mounting nut should be tightened to
60 ft-lb (81.3 N
refer to CHECKING/SERVICING for Sharpen
Mower Blades in Maintenance Instructions.
⋅m). If blade sharpening is required,
Never operate cutter b lades with deck in
raised position because it is hazardous.
The tilt-up deck can be secured in the raised position
by unlocking the deck lock levers on each side of the
carrier frame and inserting the deck hook into the tiltup latch on the tractor body. Before operating th e
tractor, make sure to re-engage the deck lock levers
after lowering the deck to the normal operating position.
ADJUST MOWER CUTTING HEIGHT, IF RE-
QUIRED
Position the hitch pins in the four deck support pins.
Refer to the “Cutting Heigh t Adjustment” decal on
the deck gearbox cover.
PERFORM ANY ADDITIONAL PROCEDURES
called for on the MAINTENANCE SCHEDULE
CHART in Maintenance Instructions.
23
Operating Instructions
CONTROL IDENTIFICATION, LOCATION, AND FUNCTION
CAUTION
Before operating the mower, become familiar with the location and function of
all operator controls. Knowing the location, function, and operation of these
controls is important for safe and efficient operation of the mower.
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 po sitions: “ O” is the OFF positi on,
RUN is the position the key returns to after starting,
and “S” is the START position. When starting the
engine, turn the key clo ckwise 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. Pr olonged cranking can
damage the starter motor and shorten battery life.
Release the key when the engine starts, a nd it will
return to the RUN position. To stop the engine, rotate
the key counterclockwise to the “O” position.
Forward Speed Control (FSC)
Steering Levers
24
Parking
Brake
Blade Clutch
Ignition Switch
Hourmeter
Oil Pressure
Warning Light
(PTO)
Light Switch
(Optional, Not Shown)
5 Amp
Circuit Breaker
Operating Controls
Operating Instructions
OFF
ON
START
Ignition Switch
Engine Choke
The choke control lever (black kno b) is located on
the left side of the seat. T o start a cold engine, move
the choke control forward to the ON positi on. A fter
engine starts, move the choke control toward the
OFF position, keeping enough choke to allow the
engine to run smoothly as it warms up. As soon as
possible, move th e choke to the OFF position . A
warm engine requires little or no choke for starting.
IMPORTANT: Make sure the choke is in the OFF
position during normal engine operation; running
with the choke in the ON position CAN damage the
engine.
Engine Throttle
Forward Speed Control (FSC)
Forward Speed Control (FSC) has two functions:
One is to set forw ard tra vel spe ed, and the ot her is
to establish the NEUTRAL-PARK position. When
the FSC lever is moved into the FORWARD posi -
tion, a friction lock holds any forward s peed setting
from 0 to 5 mph (0 to 8 km/h). The ground speed is
proportional to the lever positio n; the further th e lever is advanced forward, the faster the tractor
moves. It is not nece ss ary to hol d th e F SC in position since the friction lock maintains the selected lever position. Pulling back on the steering levers
overrides the FSC s etting 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 inde pendent steering lever, for both steering function and
FORWARD/REVERSE motion. The FSC lever sets
the maximum forward speed , and als o sets the for ward 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 releas ed to the FORWARD position for “straight-
ahead” ground travel.
The throttle control lever (red knob) is located on the
left side of the sea t and is used to control engin e
speed. Moving the leve r forward toward the FAST
position increases engine speed ; moving it back-
ward toward the IDLE position decreases engine
speed.
Throttle
Choke and Throttle Location
Choke
NOTE: Pushing forward on the steering levers will
not cause any change in tractor moti on - there will
be no steering lev er reaction and there will be no
machine damage.
Blade Clutch (PTO)
The blade clutch lever has two positions. Pulling the
lever UP engages the PTO that dr ives the mower
blades. Pushing th e lever DOWN disengages the
PTO and engages the blade brake.
NOTE: On GHS equipp ed models, the Powerfil
motor and Grass-Pak® full signal switch are activated by engaging the blade clutch. Refer to Using the
GHS Catcher in this se ction for a complet e descri ption of GHS operation.
®
25
Operating Instructions
Parking Brake
The parking brake functions by locking a pin into the
hydrostatic transmis sion pinion gear teeth. Mov ing
the lever FORWARD 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 m echanical lock s imilar to the PARK position on an automo tive automatic transm ission. If
the tractor is moving wh en the brake is engage d, it
will result in su dde n s to ppage a nd pos s ible internal
damage to the axle drive.
NOTE: If pressure on the parking brake p in (e.g.,
parked on a hill) ma kes it imp ossibl e to re leas e the
parking br ake with t he parki ng brake le ver , move t he
mower gently forward or backward to release the
pin.
Transmission Lockout Levers
The transmission loc kout levers disengag e the hydrostatic transmissons. By lifting the lever on top of
the transmission a nd locking it into place with th e
lockout cam, the hydrostatic tr ansmissions are released to permit freewheeling. By releasing the cam
and lowering the lever, the transmissions are en-
gaged for normal operation. The transmission lever
in the LOCKOUT position is used to enable moving
the machine without the engine running (e.g., for service). Refer to TRANSMISSION LOCKOUT in this
section for operating instructions.
NOTE: The transmission plunger on the side of the
transmission case (activated by the LOCKOUT LE-
VER) must be completely released during operation
of the mower, otherwise operation of the tran smission will be erratic.
Hourmeter
The hourmeter, which is located on the left front of
the body, displays operating time accumulated
while the ignition switch is in the ON position.
Oil Pressure Warning Light
The oil pressure warni ng ligh t indic ates t hat engine
oil pressure is below the safe operating range [below
3 to 5 PSI (21 to 34 kPa)]. This light 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 turne d ON, it could indicate a
burned out bulb. If the light comes on during engine
operation, stop the engi ne immedi ately and c orrect
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 d amage (if a low oi l pressure
condition exists).
Circuit Breaker (5 Amp)
A 5-amp, manual-reset circuit breaker is located below the ignition switch. The button pops up if the circuit breaker trips. This circ uit breaker protects the
circuits to the safety switch rel ays, time delay mod ule, and GHS.
26
Transmission
Plunger
Lockout Lever Location
Lockout
Levers
Light Switch (For Optional Lights)
Operates headlights (when installed).
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)
RIGHT WHEEL
STEERING LEVER
FORWARD SPEED
CONTROL LEVER (FSC)
Full Forward
Ground Speed
Position
Neutral-Park
Position
Reverse Drive
Wheel Motion
Position
Fast
Throttle
Position
PARKING
BRAKE
Disengaged
Position
Intermediate
Ground Speed
Position
Neutral-Park
Position
Engaged
Position
Disengaged
Position
THROTTLE
ON Position
OFF Position
Idle
Position
Engaged
Position
BLADE CLUTCH (PTO)
Pull Up to Engage
CHOKE
Operating Controls (Top View from Drivers Point of View)
27
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
DISENGAGED.
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 or the blade
clutch (PTO) out of neutral. If the engine
cranks otherwise, the safety system is not
working and should be repaired or adjusted before operating the mower. DO
NOT disconnect safety switches; they are
for the operator’s protection.
2. Move the choke lever to the ON position and
move the throttle 1/4 to 1/2 open (toward
FAST) . Turn the ignition s witc h to the START
position to start the engine. Release the key to
RUN position as soon as the engine starts.
NOTE: The c hoke may not be required if the
engine is warm.
IMPORTANT: If the engine fails to start after
approximately 10 seconds of cranking, the
engine should be checked before further cranking. Turn the key to the OFF position and allow
a 60 second cool-down period between starting
attempts. Failure to fo llow the se guideline s can
damage the starter motor and shorten battery
life.
3. After the engine starts, make sure th e oil pres sure light goes off. If not, stop the engine immediately and find the cause of the problem. Make
sure the oil pressure light is off prior to engaging
the mower blades and beginning operation.
4. Gradually move th e ch oke t o the OFF position,
keeping enough choke o n to allow the engine
to run smoothly as it warms up. As soon as
possible, move the choke to the OFF position.
IMPORTANT: Make sure the choke is in the
OFF position during normal engine operation;
running with the choke in the ON position CAN
damage the engine.
ADJUSTING GROUND SPEED AND STEERING
IMPORTANT: If the DSD52 Mower deck is in-
stalled on the tractor, make sure the dolly wheel is
retracted BEFORE moving.
CAUTION
Learn to START, STOP, and MANEUVER
the mower in a large, open area.
If the operator has not operated a machine with LEVER STEERING OR DUAL
HYDROSTATIC TRANSMISSIONS, steering and ground operation should be
learned and practiced until the operator is
completely comfortable handling the machine BEFORE ATTEMPTING TO MOW.
DANGER
Keep feet on footrests at all times when
the machine is moving.
28
Operating Instructions
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 lev er in position since a friction
lock maintains the selected lever position (and
forward travel speed).
WARNING
In case either of the transmission drive
belts break during operation, and if the
machine is on a slope, the machine will
freewheel down the slope. To maintain
control, immediately (1) Release the
steering levers and simultaneously (2)
Move the FSC to the NEUTRAL-PARK
position. When the machine is stopped
or moving slowly, engage the parking
brake.
Beginning Recommendations are:
♦ Learn operation of the mower in an open
area away from buildings, fences, and obstructions. Learn operation on flat ground
BEFORE operating on slopes.
♦ St art maneuvering the mower with SL OW
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.
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 of Forward
Speed Control Friction Lock in Maintenance
Instructions.
2. Steer by pulling the lever on the side of desired
direction of turn, e.g., pull the LH lever to turn
left. To mini mize the p ossibil ity of ov ercontro l,
use only one hand on both steering levers.
♦ Learn to operate the steering levers with
smooth action. Jerky movements are hard
on the transmission and lawn. For sharp
turns, do not allow th e insid e whee l to stop
and twist on the grass . Pull the steer ing lever controlling the inside wheel into reverse
for a smooth “rolling” turn (one wheel rolling forward while the other rolls backward).
♦ Practice maneuvering the mower until
you can make it go exactly wh ere you are
aiming.
♦ Remember, for an emergency stop, or in
case of loss of control, mach ine movement
can always be stopped quickly by pulling
the Forward Speed Control into the NEUTRAL-PARK position.
29
Operating Instructions
Pull Steering
Levers With
Left Hand
ENGAGING THE MOWER
1. Set the engine throt tle at ab out 1/3 s peed. 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. Pull the blade clutch leve r SLOWLY up to en-
gage the mower blades.
CAUTION
Forward Speed Control
(FSC)
Keep Feet On Footrest
When Moving
Correct Operator Hand Position
on the Controls
3. Reverse directio n of the m ower by pu lling both
levers backward.
NOTE: Smooth action on the steering levers
will produce smooth mower operation. Remember to keep the engine and ground speed slow
until learning the control response.
4. The FSC may be adjusted forward for faster
ground speed and bac kw ard for s lower ground
speed. When mowing, ground speed should be
adjusted to match the load on the cutter blades,
i.e., as the eng ine pull s down i n heavy cutting ,
pull back on the FSC lever to reduce ground
speed. Adjusting ground speed helps maintain
a balance between engine power and blade
speed for high-quality cutting action.
5. Stop ground travel by pulling both steeri ng levers backward to th e NEUTRAL po si tion (tra ctor not moving) and then moving the FSC lever
to the NEUTRAL-PARK position.
NOTE: If the tractor creeps forward or backward with the FS C lever in the NEUTRAL-PARK
position, the transmission control needs to be
adjusted. Refer to ADJUSTMENTS of Trans-
mission Control in Maintenance Instruc tions.
A safety interlock 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 operato r 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 t he mower across drives, sidewalks, loose materials, etc. DO NOT engage the
blade clutch with the PTO shaft disconnected
(the mower deck removed from tractor).
CAUTION
If the cutting blades strike a stationary object while mowing, stop the mower immediately, disconnect the spark plug wires,
lift the deck, and inspect the deck and
blades thoroughly for damage. Make sure
that the blade timing has not been disturbed (the blades should be at 90 degrees
to each other). Refer to REPLACING/REPAIRING the Blade Overload Shear Bolts
in Maintenanc e Instructions if blades are out
of time. Also, make sure t he bl ade re t ai ning nuts are torqued to 60 ft-lb (81.3 N
⋅m).
30
Operating Instructions
Engaged
Position
WARNING
A brake stops the cutter blades (and
blower on GHS equipped models) from
freewheeling within five (5) seconds after
disengaging the clutch. If the brake system malfunctions and the blades do not
stop within five (5) seconds, the brake
should be adjusted or repaired before operating the mower. Refer to ADJUSTMENTS of Blade Clutch (PTO) in
Maintenance Instructions.
Blade Clutch Engaged
Disengaged
Position
Blade Clutch Disengaged
STOPPING THE MACHINE
1. Slow the engine to a fast idle; put the throttle in
the 1/2 throttle position.
2. Pull the steering lever s to the NEUTRAL position and then move the FSC le ver bac kward to
the NEUTRAL-PARK position.
3. Disengage the blade clutch.
IMPORTANT: DO NOT disengage the blade
clutch with high engine speed (above 1/2 throttle) since the brake action on the blade drive will
cause premature wear of the brake band.
4. Slow the engine to idle, put throttle in IDLE position; and turn the ignition switch OFF.
WARNING
Remove the key from th e ignition switch
when leaving the mower unattended. This
will prevent children and inexperienced
operators from starting the engine.
5. Engage the parking brake.
IMPORTANT: The hydrostatic transmissions
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 hydrostatic tr ansmissions, especially
when transmission fluid is warm.
ADJUSTING CUTTING HEIGHT
WARNING
The engine must be stopped before adjusting cutting height. Disengage the
blade clutch (PTO), stop the engine, and
remove the ignition key. W ait for all movement to stop before getting off the seat.
31
Operating Instructions
Cutting height is adjusted by positioning the four retainer hitch pins in a series of seven vertical holes on
the deck support pins. Lift handles have been provided on each end of the deck to assist in raising the
deck while positioning the hitch pins. Cutting
heights range from 1 in. (25 mm) [top holes] to 4 in.
(102 mm) [bottom ho les] in 1/2 in. (13 mm) increments.
Lift Handle
Lockout Lever
Plunger
Depressed
Cam in
LOCKOUT
Position
Deck Support
Pin
Hitch Pin
Cutting Height Adjustment
TRANSMISSION LOCKOUT
IMPORTANT: DO NOT TOW this mower with the
transmission lockout engaged. Towing can produce
excessive interna l pressure an d damage th e transmission.
To mo ve the mower with the engine NOT running
(dead battery, maintenance, etc.), the hydrostatic
transmissions are unlocked (released).
1. Raise the body.
2. Lift the transmissi on lockout lever on both th e
RH and LH transmissions and secure into place
with the locking cam.
3. The mower will “freewheel” with the levers in the
LOCKOUT position. The levers must be in the
highest position to completely unlock the transmissions.
Lockout Lever - Freewheel Position
4. After moving the mower, release the locking
cam, placing the lever DOWN in the normal OP-
ERATING position. Make sure the transmission
lockout plunger on the side of the tran smission
case (activated by the lockout lever) is com-
pletely released, otherwise the transmission
operation will be erratic.
Lockout Lever
Cam in
Plunger
Released
Lockout Lever - Normal Operating Position
UNLOCKED
Position
32
Operating Instructions
RECOMMENDATIONS FOR MOWING
IMPORTANT: Operate the engine at full speed
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 chute clean.
• Mow with shar p blades. A dull blade tea rs 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 appearanc e, cut off 1/3 or less of
existing grass height.)
• When mowing, operate the engine at or near full
throttle for the best cutting action and performance
of the grass handling system (GHS). Mowing with a
lower engine RPM caus es the mow ing bla de to not
cut clean and tear the grass. The engine is designed
to be operated at full speed.
• Whe n mowing in adverse condition s (tall and/or
wet grass), mo w the grass twi ce. Raise the mo wer to
the highest setting - 4 in. (102 mm) - for the first pass
and then make a second pass cutting to the desired
height.
• When using a side discharge mower deck, the
side discharge shield must not be removed and
must be kept in the lowest possible position to
deflect grass clippings and thrown objects downward. Orient the side discharge away from sidewalks or streets to minimize cleanup of clippings.
When mowing close to obstacles, orient the side discharge away from obstacles to reduce the chance of
damage to property by thrown objects.
Side Discharge Shield in Lowest Position
• When op erating on a slope, reduce speed and
use caution to start, stop, and maneuver. Avoid
sharp turns or sudden changes in direction. The
maximum recommended side slope operating
angle is 20 degrees or 33% grade.
• Use a slow setting on the FSC for trimming
operations.
• Make sure the mower is leveled properly for a
smooth cut. Refer to Deck Leveling in Assembly
Instructions.
• Use an alternating stripe mowing pattern for
best appearance and vary the direction of the stripe
each time the grass is mowed to avoid wear patterns
in the grass.
• Avoid damage to the grass by slipping and skid-
ding of the drive tires . Use sm oot h co ntrol mov ements of the steering levers since the hydrostatic
transmissions 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).
Maximum Recommended
Side Slope - Do Not Operate
on Steep Slopes
Maximum Recommended Side Slope
33
Operating Instructions
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) an d the GHS di scharge c hute 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 posit ion. This can
cause the deck to unhook from the tractor and fall
with considerable force , poten tiall y caus ing dec k or
tractor damage and/or bodily injury.
• Whe n transporting a tr actor with the d eck in the
tilt-up position (on a truck or trailer), the deck
should be secured to the vehicle with a strap or
rope (stop vertical movement). This will prevent the
deck from bouncing on the rear roller wheels (causing breakage). This wi ll al so prev ent t he d ec k from
unhooking from the tractor and falling, potentially
causing deck or tracto r damage. Damage to other
items parked in front of the deck may also occur.
34
Operating Instructions
GRASS HANDLING SYSTEM (GHS)
GHS Model Only
PTO and Blade
Gear Drive
Shear
Bolt
Shear Pin
PTO
Clutch
Powerfil
Drive Motor
Actuator
Rod
“Full” Signal
Horn
Delivery
Chute
Grass-Pak
Vane Switch
®
Catcher Door
Safety Latch
®
Exhaust Screen
(Removable)
Dump Handle
Powerfil
Delivery Spout
®
Exhaust
Deflector
Catcher
Door
Catcher
Door Spring
Grass Catcher
Rear Discharge
Mower Deck
Body Chute
Assembly
Blower
Deck
Discharge Chute
GHS Flow and Components
35
Operating Instructions
General Information
The Grass Handling System (GHS) consists of a
rear discharge mower deck connected to a 10 in.
(25 cm) blower an d a rear mounted grass ca tcher
with 6.7 bushel (238 lite rs) capacity or optional 9. 5
bushel (335 liters) capacity. The GHS blower operates any time the mower blade clutch is eng aged
and moves grass thr ough the rear discharge de ck
chute into the grass ca tcher. Blower airflow is exhausted out the back of the grass catcher, through a
filtering screen. When the grass catche r is full and
needs to be emptied, a “full” signal horn alerts
the operator. When the “full” signal horn sounds, it
is important to stop mowing to prevent overfilling
and clogging of the blower system.
IMPORTANT: Normally, the GHS blower operates
with no maintenance or cleaning required. However, under certain operating conditions, the insid e
of the blower housing may accumulate a deposit of
dirt, causing wear and binding of the blower wheel.
Normally, dirt buildup occurs when mowing a com-
bination of dirty and damp grass, especiall y in
the springtime. When operating in these conditions, check the blower wheel frequently for
binding and clean the blower hous ing as requir ed.
Refer to CLEANING the GHS Blower in Mainte-
nance Instructions.
NOTE: In Autumn, when using the GH S mo wer to
vacuum leaves, it is recommended to raise the
front of the mower deck 2 to 3 n otches [1 to 1-1/2
in. (25 to 38 mm)] higher than the rear. This will
avoid “bulldozing” leaves, particularly when the
leaves are piled in a thick layer. To make this adjustment, the hitch pins in the two (2) front deck
support pins are repositi oned 2 to 3 no tches high er
while leaving the rear pins in their original position.
DANGER
NEVER operate the GHS catcher with the
back door open. Objects may be thrown
out the back of the catcher with sufficient
force to cause serious injury to bystanders or property damage.
NOTE: When a side discharge or mulching mow-
er deck is installed on the GHS model, a blower
intake cover should be installed in the blower intake
tube. This cover “unloads” the blower and seals
the intake to effectively eliminate power loss and
blower noise when the blower is not being used.
Blower
Intake Cover
Blower Intake Cover
DANGER
ROTATING BLOWER BLADES
NEVER operate the GHS blower with the
blower discharge chute un covered (gr ass
catcher in the dump position) since dan gerous projectiles may be thrown. NEVER
put hands into the blower discharge chute
for any reason. Use a stick or similar instrument to remove any material if clogging has occurred.
CAUTION
NEVER leave grass clippings in the grass
catcher after mowing. Damp clippings
generate heat as they decompose. This
MAY cause spontaneous combustion.
36
Operating Instructions
Clogging Checklist In case of clogging, there will be a distinct change
in the sound of the blower, i.e., the blower soun d
will stop. Also, the mower deck will begin to leave a
trail of grass clippi ngs. When th is occurs, sto p the
engine, disconnect th e spark plug wir es, and make
sure all movement has stopped before attempting to unclog.
DANGER
NEVER place hands under the mower deck
or in the GHS blower discharge chute. Use
a stick or similar tool to remove any
clogged material.
Normally, any clogging will first dev el op at the ba ck
of the mower deck in the discharge opening into the
blower chute. Clogging at this point does not indi-
cate a particular problem in this part of the
system, but is a symptom of something restricting the flow of material throughout the entire
system. The following list of items should be
checked if a pattern of clogg ing begins to deve lop.
All of these items are capable of causing clogging at
the back of the deck.
• Check to see if the RH and LH mower blades are
installed for the correct rotation - install blades so
the cutting edges move toward each other.
• Check the amount of flat section re maining at
blade tip. This is the are a that is g round aw ay (removed) when the blades are sharpened. If too much
of the flat section is removed, the “air lift” performance
or “shovel” effect of the blade deteriorates to the point
that discharge of grass clippings into the blower
chute is marginal. Replace cutter blades if less than
3/4 in. (19 mm) flat section remains at the blade tip.
• Check th at the interior of the dec k housing and
baffling is reasonably clean and free of grass and
dirt buildup. While some degree of material buildup
can be tolerated, a point is finally reached where the
flow of air and grass clippings is restricted.
NOTE: One condition that quickly causes a
buildup of material in the deck housing is mowi ng
grass and/or weeds whic h ar e “jui cy.” The material
collects under the deck with sticky, green juice. Clover and weeds are especially a problem. The
mower deck will need to be cleaned frequently when
operating in these conditions.
• Check the deck cutting height setting. When
working in thick, tall grass, lower deck settings
[1 to 2 in. (25 to 51 mm) cutting heights] tend to
restrict airflow from moving into and under the
deck. Raising the deck cutting height will significantly increase airflow and reduce clogging when
working in thick, tall grass.
• Check the interior of the chute connecting the
mower deck to the blower for smoothness and
freedom from obstruction.
Blades Must Operate at
Right Angles (90 Degrees)
Torque = 60 ft-lb
Rear Discharge
Chute
Blade Rotation for GHS Mower Deck
(view from underneath)
FORWARD
Mounting Nut
(81.3 N
⋅m)
• Check the blower wheel for bent blades and
excessive clearance between the blade tip and the
blower housing. A clearance greater than 1/8 in.
(3 mm) will cause a significant loss of blower
performance.
• Check the bl ower disc harge chu te into the gr ass
catcher for smoothness and freedom from obstruction.
• Check the elbow inside the grass catcher for a
buildup of material in the radius of the elbow. In
certain conditions (damp/dirty grass) a considerable
“clump” of material can accumulate at this point,
greatly restricting material and airflow.
• Check that the openings in the removable air
exhaust screen in the grass catcher are not
plugged. If the screen is clogged, refer to Cleaning
the GHS Exhaust Screen in this section.
37
Operating Instructions
Remember, anything that restricts airflow or material
flow along the entire path from the mower deck to
the grass catcher can cause clogging.
Using the Tilt-Up Deck Refer to CLEANING of Grass Build up in Mower
Housing in Maintenance Instructions.
Using the GHS Catcher
Powerfil
The GHS catcher has an oscillating grass delivery
spout (POWERFIL
®
®
) which is designed to spread
grass clippings thr oughout the interior of the grass
catcher (even when mowing wet, heavy grass). The
oscillating action may be checked by turning the
ignition switch to the ON position and movi ng the
blade clutch to the ENGAGED position. The spout
should oscillate approximately 25 cycles per
minute.
NOTE: If the grass spout fails to oscillate, the clutch
switch should be che cked for function (the switch
closure is adjustable).
“Full” Signal Horn
The GHS catcher has a “full” signal horn to alert
the operator to dump the catcher when it is full (to
prevent overfilling an d clogging). The “full” signal
horn is activated by a vane switch (Grass-Pak
switch) mounted on the grass delivery spout. Oscillating action of the spout triggers the vane switch as
grass begins to fill in around the spout when the
catcher is almost full.
The “full” signal horn is designed to operate (sound)
when the grass catcher is almost full. The timing of
the signal is adjus table by chang ing the pos ition of
the vane on the Grass-Pak
®
switch. If the s ignal i s
coming on too soon (catcher not completely full) or
too late (grass cl ogging in cat cher spout a nd delivery chute), refer to ADJUSTMENTS of GHS “Full”
Signal Horn in Maintenance Instructions.
NOTE: The horn signal should be adjusted to
sound BEFORE the catcher is co mpletely full to
give the operator time to react and stop mowing. An
indication the horn s ig nal is c omi ng on to o l ate (d e layed too much) is if grass clippings are falling out of
the grass catcher delivery chute when the catcher is
dumped.
Cleaning the GHS Exhaust Screen
To remove the grass catcher screen f or cleaning,
open the catcher doo r, push forward and pul l down
on the grass catcher screen knobs (on either side of
the screen), and slide the screen ou t. Use a high
pressure washer or water spray and brush to clean
the screen.
Keeping the catcher exhaust screen clean and open
is essential to good performance of the catching
system. In some mowing condition s, e.g., wet and
dirty, it will be necessary to clean the screen frequently to avoid cl ogging the mower deck, blower,
and chutes due to airflow restriction.
®
Grass Catcher
Screen
38
The “full” signal function may be checked by turning
the ignition switch ON, engaging the blade clutch
(engine not running), opening the catcher back door,
and triggering the Grass-Pak
®
vane by hand as it
oscillates. The hor n should s ound as the sw itch is
moved in both directions.
WARNING
DO NOT test the Grass-Pak® switch with
the engine running. Projectiles may be
thrown out of the grass delivery spout,
and COULD cause serious injury.
Removal
Knobs
Grass Catcher Screen Removal for Cleaning
Operating Instructions
Dumping the Catcher
For dumping, th e cat ch er e ither tailg ate du mps int o
a disposal area or dumps into the optional dump
bag. The dump bag i s a reusable nylon fabric bag
desi gn ed to conv eniently move grass cl ippings from
the catcher to a remote disposal area or container.
Tailgate Dumping
1. Open the back door by lifting on the door handle.
NOTE: To prevent accidental door closure, a
safety latch locks the door open in the fully
opened position while the catcher is being
dumped.
2. Tilt the catcher back to dump by lifting on the
catcher lift handle on the lower front corner of
the catcher.
3. Lower the catcher smoothly down to the normal
operating position. DO NOT allow the catcher
to drop down.
4. Close the door by holding the door handle
with the left hand and releasing the safety
latch on the door hinge mechanism with the
right hand. The safety latch is released by
pressing in on the top of the latch. Then,
smoothly close the d oor, working against the
spring pressure that holds the door closed.
DO NOT let the door slam shut by releasing
the door before i t is c l os ed.
Using the Dump Bag
1. Open the back door by lift ing on the do or handle.
NOTE: To prevent accidental door closure,
a safety latch locks the door open in the
fully opened position while the catcher is being dumped.
2. Orient the dump bag with one of the handle
straps on the bag opening facing up.
Tailgate Door
Handle
Hook Bag
on Bumper
Safety
Latch
Catcher Door Safety Latch
Positioning Dump Bag on Catcher
39
Operating Instructions
3. Hook the bottom of the bag over the rear
bumper while lifting on the handle strap.
4. Tilt the catcher back to dump into the bag by lift-
ing on the catcher lift handle on the lower
front corner of the c atcher with the one hand
while continuing to hold up on the bag strap
with the other hand. Refer to photos for positioning the bag and dumping.
Catcher Lift /
Dump Handle
40
Dumping Catcher into Dump Bag
5. Lower the catcher smoothly down to the normal
operating position. DO NOT allow the catcher
to drop down.
6. Close the door by holding the door handle with
the left hand and releasing th e s afet y latc h on
the door hinge mechanism with the right hand.
The safety latch is releas ed by press ing in on
the top of the latch. Then, smo othly close the
door, working against the spring pressure that
holds the door closed. DO NOT let the door
slam shut by releas ing the door before it is
closed.
Maintenance Instructions
CAUTION
Maintenance procedures requiring special training or
tools should be performed by a trained technician.
MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL MC
Service Item
Check Engine Crankcase Oil Level x 43
Check/Clean Engine Air Cooling System* x 52
Check Security of Air Filtration Components x 55
Check Air Filter Restriction Gauge x 51
Clean Grass Buildup Under Deck x 53
Clean GHS Exhaust Screen* x 38
Clean GHS Blower* x 54
Service Mower Blades x 56
Check Function of Oil Pressure Warning Light x 23
Lubricate Grease Fittings and Oil Points* x 44
Check PTO Gearbox Oil Level** x 46
Check Battery Electrolyte Level x 55
Check Hydrostatic Transmission Fluid x 46
Check Tire Pressure x 56
Check Drive Belts (Jackshaft, Engine PTO,
GHS Blower, Ground Drive)
Check Gearbox Oil Seals x 58
Check Turbine Precleaner* x 50
Check/Clean Air Filter Element
Change Engine Crankcase Oil
Check/Adjust Blade Clutch (PTO)/
Brake Action
Check Oil Level in Gear Axle x 46
Clean Hydrostatic Transmission Cooling Fins x 55
Clean Engine Cooling Fins x 52
Check/Regap Spark Plugs x 58
Change Engine Oil Filter x 43
Check Fuel Lines and Clamps x 58
Replace Air Filter Element
and Vacuator™ Valve
Replace Fuel Filter x65
Service Battery x55
Check/Adjust FSC Friction Lock x 76
Service Solenoid Shift Starter x 58
Check Engine Valve Clearance x 58
Change Gear Axle Oil
Change Hydrostatic Transmission Fluid
Replace Fuel Lines and Clamps x58
∆
∆∆∆
∆
∆∆
∆∆∆
Daily
25
Hours
x57
100
Hours
x51
x43
x71
200
Hours Yearly
x51
Every
2Years
x46
x47
Ref.
Page
∗ More often in extremely dusty or dirty conditions
(refer to notes about air clean er element in
IMPORTANT TIPS FOR CARE OF KOHLER ENGINE)
∗∗ Change PTO gearbox oil and filter after first
100 hours of operation (break-in period)
∆ Air cleaner is remote mounted Donaldson Radialseal™
unit, replace filter every year or after 6 cleanings
∆∆ Change engine oil and filter after first 5 hours of
operation of a new engine (break-in period)
∆∆∆ Change every 2 years or 1000 hours
CAUTION
When performing maintenance with the
mower body raised, a safety prop should
be installed from back of body to chassis
frame (fail-safe prot ection in case of f ailure of body lift support). For GHS Model,
empty grass catcher before raising body.
41
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.
• Chang e fuel filter on a regular basis and when
contamination is suspected or found in the fuel.
Starting/Stopping
• Start engine with the throttle advanced off idle (1/
4 to 1/2 throttle). This will aid starting, especially in
cold weather.
• Keep the battery fully charged.
• Match crankcase oil viscos ity to the am bient tem -
perature, allowing the engine to crank faster and
start easier.
• Allow eng ine to ru n at idle for a few se conds be-
fore stopping engine to avoid run-on or backfiring.
Cooling System
• Keep eng in e ai r intake sc r een and cy li nd er hea d
fins free of grass clippings , chaff, and dirt . Inspect
intake screen and cooling fins for cleanliness and no
damage.
Air Cleaner System
• Use only Donaldson air cleaner elements. After-
market elements may not seal in the air cleaner
housing, allowing dirt to en ter the engine . Als o, aftermarket filters often ski mp on the filtration media
and require more frequent cleaning and replacement (see following instructions).
• Use the a ir flow restri ction gauge to indicate the
need to service the air filter.
• Do frequ ently c heck the Turbine Precleaner for
free movement of the internal fan.
• DO NOT over service or freq uently “disturb ” the
air filter. A dirty air filter actually cleans better than
a new one. Changing and cle ani ng th e air f ilt er too
often can actually reduce filter efficiency and increase the opportunity for traces of dust to enter the
engine. Wait until the element really needs servicing
as indicated by the air flow 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 little dirt left here will be sucked int o the engine and
reduce engine li fe). When the filter is reinstalled,
make sure the element is held tight and straight in
the canister for proper seating and sealing.
• Periodically remove two access panels in the en-
gine shroud to inspect and clean cylinder head cooling fins.
• Check performance of the cooling system by
starting the engine, holding a hand adja cent to the
cylinder head, and feeling the cooling airflow.
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
• Opera te the engine at full speed when mow ing.
This allows the engine to produce full horsepower
and move more cooling air through the engine cooling fins.
• 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 condit ions. This will a id starting in
cold weather and assure proper lubrication in hot
weather.
• Use only Kohler oil filters. Aftermarket filters
may not seal properly and/or have the incorrect
pressure relief valve for proper lubrication.
42
Maintenance Instructions LUBRICATION
LUBRICATION
WARNING
DO NOT attempt to lubricate the machin e
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 SG oil from the
factory. Change the oil after the initial engine break-
in period of 5 hours. Thereafter, change oil after
every 100 hours of operation.
4. Remove the dipstick again and check the oil level on the dipstick. The oil level should be within
the “Operating Range” on the dipstick (between
the “L” mark and the “F” mark).
IMPORTANT: DO NOT operate engine without
a sufficient oil supply in the crankcase. DO NOT
operate with the oil level below the “L” mark or
above the “F” mark on the dipstick.
5. If additional oil is needed, refer to Specifications
for proper crankcase lubricant. Fill up to, but
not above, the “F” mark on the dipstick.
IMPORTANT: DO NOT overfill the crankcase
(oil above “F” mark) as this CAN result in engine
overheating, loss of power, and possible engine damage.
Checking Engine Crankcase Oil Level
Check the engine crankcase oil level before use and
after each 8 hours of continuous operation.
IMPORTANT: The importance of checking and
maintaining the proper crankcase oil level cannot be
overemphasized. Check the oil level BEFORE
EACH USE.
1. Park the mower on a level surface with the engine stopped. Also, make sure the eng ine is
cool and oil has had time to drain into the sump
[allow at least fiv e (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 o ff with a clean r ag,
then reinsert the dipstick into the tube and press
all the way down.
Full Mark
Low Mark
Dipstick Operating Range
Changing Engine Crankcase Oil/Oil Filter
Change the engine crankcase oil after every 100
hours of operation and replace the oil filter every
other oil change (every 200 hours of operation).
43
Maintenance Instructions LUBRICATION
1. Park the mower on a level surface with the engine stopped. The engine oil should be warm
before draining. If not warm from operation,
start the engine and run a few minutes to warm
the oil.
2. Before removing the dipstick, clean the area
around it to keep any dirt or debris out of the engine.
3. Remove the dipstick and oil drain plug and drain
the oil into a suitable container. Be sure to allow
ample time for complete drainage.
Oil Filter
Drain Plug
9. Fill the crankcase with new, clean oil. Use only
crankcase lubricants recom mended by the engine manufacturer. Refer to
this manual or the engine owner’s manual. Use
the recommended oil viscosity for the expected
ambient temperature. Oil with the correct viscosity will aid starting in cold weather and assure
proper lubrication in hot weather. Fill up to, but
not above, the “F” mark on the dipstick.
Crankcase capacity is 1.85 quarts (1.75 liter s)
plus 1/2 pint (.24 liters) for the new oil filter.
IMPORTANT: Check the dipstick reading before adding the last 1/2 pint of o il and fill on ly to
the “F” mark. DO NOT overfill the crankcase
(oil above “F” mark) as t h is CAN result in engine overheating, loss of power, and possible
engine damage.
10. Start the engine and check for oil le aks aro und
the oil filter. Stop the engine, recheck the oil level, and add oil if nec essar y. (When the engine
is first operated with a new oil filter, the oil level
drops slightly as the filter is filled with oil.)
Grease Fitting and Oil Point Lubrication
Specifications in
Oil Drain/Oil Filter Location
4. Before removing the oil filter, clean the area
around the filter to keep dir t and debris out of
the engine.
5. Remove the old oil filter and wipe off the filter
mounting surface on the engine.
6. Apply a thin coati ng of clean oil to the rubber
gasket on the replacement oil filter.
IMPORTANT: Use ONLY oil filters from the engine manufacturer (Kohler 12-050-01). Aftermarket oil filters may not seal properly and/or
may not have the correct pressure relief valve
for proper lubrication.
7. Install the new oil filter on the engine. Turn the
filter clockwise unt il the r ubber gasket c ontacts
the sealing surface, then tighten an additional
1/2 turn.
8. Reinstall the drain plug. Make sure it is tightened to 10 ft-lb (13.6 N
·m).
Lubricate the grease fi ttin gs and oil points after ev-
ery 25 hours of opera tion. Lubricate more often
when operating in dusty or dirty conditions. Use
SAE general purpos e lithium or mol ybdenum 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 joi nts (on the deck and trac-
tor) require routine lubrication after eve ry 8 hours of
running time.
Mower Deck Gearbox Lubrication
NOTE: These instructions apply to all mower
decks with gear-driven blades. Refer to DSD52
Mower Deck Lubrication in this section for the
DSD52 deck with belt-driven blades.
44
Maintenance Instructions LUBRICATION
The mower deck gearboxes (tee gearbox and blade
drive gearboxes) are connected as a unitized assembly, and oil flows freely between them. The gearboxes
are permanently lubricated (oil filled) and sealed requiring no scheduled lubrication. However, the gearbox oil seals should be checked every 25 hours for
indication of an oil leak; particularly the lower seals
on the blade drive gear boxes sho uld be inspec ted,
since they operate in a dirty environment. If an oil leak
is noted, replace the oil seal and relubricate the gearbox assembly as follows:
1. Remove gearbox cover (footrest). Deck orientation should be the normal operating position.
Blade Drive
Gearboxes
IMPORTANT: DO N OT overfill the deck gearboxes. The gearbox assembly is not vented,
and overfilling with oil will cause excessive pressure and result in oil leaks.
5. Check condition of the cover gasket and replace
if worn or damaged. Reinstall ge arbox cover
plates; torque screws to 24 in-lb (2.7 N
DSD52 Mower Deck Lubrication
There are several sp ecial lubrication requiremen ts
for the DSD52 mower deck in addition to the requirements detailed in the C hassis and Deck Lubrica-
tion illustration. Lubricate the locations shown in the
Blade Spindle Lubrication and Gearbox, Dolly
Wheel, and U-Joint Lubrication photos and check
and maintain oil in the belt drive gearbox.
1. Lubricate the blade spindles every 25 hours
with two (2) shots of SAE general purpose lithium or molybdenum base grease.
Blade
Spindles
⋅m).
Tee
Gearbox
Mower Deck Gearboxes
(shown with gearbox cover removed for clarity)
2. Clean the area around the indivi dual gearbox
cover plates to prevent contaminants from entering the gearcase.
3. Remove the screws securing the cover plates
on the blade drive gearboxes.
4. Check the level of lubricant in the gearboxes. If
the lubricant is low, add SAE E.P. (Extreme
Pressure) 90W oil until the oil level is up to (submerges) the horizontal shaft in the gearbox
(shaft parallel to cover plate).
NOTE: In case the gearboxes are completely
drained of oil, approximately 5 fl. oz. (15 cl) of oil
per gearbox is required to refill the gear drive
assembly.
NOTE: Since the gearboxes are connected as
a unit by connector tubes, it is n ecessary to add
oil slowly. Allow a few minutes after adding oil
for the oil to flow throughout the assembly and
the oil level to stabilize before reassembly.
Blade Spindle Lubrication
2. Check the oil level in the belt drive gearbox every 100 hours (or sooner if a visible oil leak has
developed). With the deck in the norm al operating position, remove the level plug in the side
of the gearcase. Add SAE E.P. (Extreme Pressure) 90W oil to maintain the oi l level to the plug.
If the oil level is low, check the gearbox for an y
indication of an oi l leak. If an oil leak is noted,
the gearbox will need to be removed and rebuilt.
3. Lubricate the dolly wheel pivot every 25 hours
with general purpose grease.
45
Maintenance Instructions LUBRICATION
4. Lubricate the U-Joint in the drive shaft every
8 hours with SAE general purpose lithium or
molybdenum base grease.
Belt Drive
Gearbox
Dolly Wheel
Pivot
U-Joint
Gearbox, Dolly Wheel, and U-Joint Lubrication
Tractor PTO Gearbox Lubrication
Checking Gearbox Oil Level
Check the gearbo x oil le vel every 25 hours, an d if
necessary, add oil [SAE E.P. (Extreme Pressure)
90W gear lube] to maintain oil level to the FULL
mark on the dipstick.
IMPORTANT: DO NOT overfill the PTO gearbox to
avoid oil leakage out of the dipstick standpipe.
Level Plug
Changing Gearbox Oil
The tractor PTO gearbox is oil filled and vented. No
scheduled oil change is required. However, changing the oil after the first 100 hour break-in period
will extend gearbox life and is recommend ed.
1. Remove the drain plug in the bottom of the
gearcase, drain the oil, and reinstall the plug.
2. Refill the gearbox through the dipstick standpipe using 7 to 8 fl. oz. (21 to 24 cl) of SAE E.P.
(Extreme Pressure) 90W gear lube.
3. Check that the oil level is at the FULL mark on
the dipstick. DO NOT overfill.
Gear Axle Lubrication
• The gear axle oil lubrication is SAE 80W-90 (API
GL-5) gear lube.
• Check the axle oil level after every 100 hours of
operation by removing the oil level plug. If additional
oil is needed, remove the breather vent on top of axle and fill until oil is at the level plug.
• Change axle oil every 1000 hours or two (2)
years.
Hydrostatic Transmission Fluid
46
If the oil level is low, check the gearbox for any indication of an oil leak. If an oil leak is noted, the gearbox will need to be removed and rebuilt.
Jackshaft
Dipstick
PTO
Gearbox
Dipstick Location, Tractor PTO Gearbox
Checking Hydrostatic Transmission Fluid Level
Hydrostatic transmission fluid level should be
checked every 25 hours of machine operation. It is
preferable to check the flu id level when fluid is
cold. Check fluid le vel as follows:
1. Park the mower on a le vel surface. St op th e
engine and wipe dirt and contaminants from
around the reservoir cap and air bleed plug.
IMPORTANT: Before removing the reservoir
cap, clean any dirt from around it. Any di rt or contaminants entering the transmission will accelerate wear and eventually cause loss of power to
the drive wheels.
2. Remove the reservoir cap and check the level
of the fluid. The reservoir has a fluid level COLD
mark and HOT mark. The reservoir oil level
should ALWAYS be at or above the COLD
mark and NEVER above the HOT mark.
Maintenance Instructions LUBRICATION
IMPORTANT: The transmission reservoir has a fine
Reservoir Cap
Hot Level
Cold Level
Air Bleed Plug
Transmission Reservoir
and Air Bleed Plug Location
3. If the fluid is below the COLD mark (or the transmission is not performing properly), loosen the
air bleed plug (located on the top of transmission case next to the plastic reservoir).
a. If a small amount of fluid leaks from around
the air bleed plug:
* The transmission is full of fluid.
* Tighten the plug and fill the reservoir t o
the COLD level mark.
b. If no fluid leaks from around the air bleed
plug:
* Slowly add fluid into the reserv oir until
fluid starts to leak from around the plug.
(Transmissions are serviced from the
factory with Mo bil 1 (15W 50) Synth et-
ic Oil). When it is necessary to add fluid, refer to Specifications for the proper
fluid.
mesh screen in the bottom to trap dirt and foreign
particles from entering the t ransmissio n. When fill ing the reservoir, fluid will flow quite slowly through
this screen; so it is essential that there is fluid at the
bleed plug before the transmission is considered full.
IMPORTANT: Any attempt to remove or in any way
alter the filtering screen in the transmission reservoir
could cause damage to the transmission and will
VOID any transmission warranty.
Changing Hydrostatic Transmission Fluid
The hydrostatic fluid should be changed every 1000
hours or two (2) years. Also, the fluid should be
changed if the natural color of the fluid has become black or milky (indicating possible overheating or water contamination of fluid). The trans mission is refilled using the factory service fluid
noted in TRANSMISSION Specifications. The fluid is
changed as follows:
1. Park the mower on a level surface and stop the
engine.
2. Remove the lower drain plug and the air bleed
plug. Allow the fluid to drain out.
IMPORTANT: Clean any dirt from around the
plugs and reservoir cap before removing them.
3. Reinstall the lower drain plug, making sure the
rubber O-ring on the plug is in place and in
good condition.
4. Refill the transmission through the air bleed
plug hole until it is as full as possible.
IMPORTANT: Avoid fluid contamination when filling the reservoir. Use clean container , spout, funnel, etc. when pouring the f luid into the reservoir .
* As soon as there is fluid leaking from
around the air bleed plug, tighten the
plug and fill the reserv oir to the COLD
level mark. Wipe any excess oil off of
the transmission housing.
IMPORTANT: DO NOT overfill the transmission
reservoir. This will result in oil leaking out of the reservoir cap vent when the transmission warms up. It
is preferable to add fluid to the transmission when it
is cold and make sure the oil is not above or be-
low the COLD level mark.
5. Rotate the transmission input shaft about five (5)
revolutions to allow any trapped air to escape.
6. Before installing the air bleed plug, fill the reservoir with fluid allowi ng a small amount to leak
out of the air bleed plug hole.
7. Install the air bleed plug and fill the reservoir to
the COLD level line.
47
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 Tee Gearbox, Deck Oil
4 Blade Drive Gearbox Oil
5 PTO Shaft Guard Hinge Oil 1
6 Universal Joint Shaft Assembly Grease
7 Pivot Assembly, Tilt-Up Deck Grease 4
8 Deck Support Arm Socket Grease 2
9 Body Hinge Point Oil 2
10 FSC Actuator Rod Pivot Pins Oil 2
11 FSC Lever Pivot Grease 1
12 FSC Lever Fork Grease 1
(Grease Slide Area)
13 (FSC) Friction Body Pivot Grease 1
14 Steering Lever Pivot Grease 4
15 Deck Roller Wheel Oil 2
16 Deck Support Arm Pivot Grease 2
17 Deck-to-PTO Coupling Grease 1
(Grease Slide Area)
18 Universal Joint Tube Assembly Grease
19 Universal Joint Quick Connect Grease 1
Spline (Grease Slide Area)
20 Parking Brake Lever Grease 1
21 Gear Axle Oil
22 Belt Tightener Pivot, Grease 1
Jackshaft Drive
23 Clutch Actuator Push Rod Grease 2
24 PTO Clutch Lever Pivot Grease 1
25 Belt Tightener Pivot, Grease 1
PTO Clutch
* 1
* 2
** 1
** 1
*** 2
Ident Lubrication No.
No. Location Type Places
26 Brake Actuator Rod and Brake Oil 3
Band Pivot Pins (Clevis)
27 Brake Actuator Pivot Grease 1
28 Anti-Scuff Roller Wheel Oil 2
29 Catcher Hinge Point Oil 2
30 Choke Control Cable Ends Oil 2
31 Throttle Control Cable Ends Oil 2
32 Engine Oil Oil
33 Belt Tightener Pivot, Grease 1
Blower Drive (GHS Model Only)
34 Belt Tightener Pivot, Grease 1
Ground Drive
35 PTO Gearbox Dipstick Oil
36 Hydrostatic Drive Oil
37 Choke Control Pivot Oil 1
38 Throttle Control Pivot Oil 1
39 Discharge Chute Hinge Oil 1
40 Tilt-Up Latch Assembly Oil 1
41 Steering Lever Support Oil 1
*** 1
*** 1
*** 2
* Gearboxes are permanently lubricated and
sealed requiring no scheduled lubrication.
Oil level should be chec ked onl y when an oil
leak is noted. Refer to Mower Deck Gear-
box Lubrication in this section.
** Grease every eight (8) hours.
*** Refer to Gear Axle Lubrication, Engine
Oil, Tractor PTO Gearbox Lubrication, and
Hydrostatic T ransmission Fluid in this se c-
tion.
48
NOTE: DGHS42 Tilt-Up Deck is shown for reference.
For other Deck Lubrication Points, Refer to
Deck and Carrier Frame Illustrated Parts
Manual.
Maintenance Instructions LUBRICATION
2
4
7
8
7
41
40
9
14
39
15
16
21
31 & 38
11
2
3
4
5
6
7
8
7
9
10
13
14
15
16
17
18
19
11
12
32 & 37
36
35
34
33
32
31
30
20
21
22
24
23
23
27
26
25
29 29
28 28
Chassis and Deck Lubrication Points
49
Maintenance Instructions CLEANING
Turbine Precleaner
CLEANING
Engine Air Cleaner System
There are two main com ponents in the engine air
cleaner system: a turbine precleaner and a Donaldson Radialseal™ air clea ner. Ea ch component is
checked, cleaned and maintained on a different
schedule based on the filtering action required.
Each component is serviced as follows:
The turbine precleaner is mounted on a remote air
intake tube connected to the Donaldson air cleaner.
A spinning fan driven by the intake airflow separates
dust from the air, giving the initial stage of air cleaning. Dust particles are exhaus ted through a single
small vent in the side of the housing. Since no dust
is trapped, the preclean er operates without cleaning. The only maintenance r equ ir ed is to ch eck the
operation of the internal fan every 100 hours. Verify
operation:
1. Look into the exhau st vent while shi nin g a li ght
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.
Precleaner Tube
Turbine Precleaner
Engine
Air Intake
Hose
Restriction
Hose
Clamp
Brass
Elbow
Air
Gauge
Donaldson
Air Cleaner
Donaldson Air
Cleaner Cover
Safety
Filter
Air Cleaner
Cartridge
Vacuator™
Valve
50
Engine Air Cleaner System Components
Maintenance Instructions CLEANING
Donaldson Radialseal™ Air Cleaner
A remote mounted Donaldson Radialseal™ air
cleaner provides the air filtering function. The paper
filter element slides over an outlet tube inside the air
cleaner canister with radial sealing action, eliminating the possibility of dust leaks due to improper filter
installation. Intake design, interna l baffling, and a
Vacuator™ valve provide dust separation and automatic precleaning action. Daily or frequent servicing
of the air cleaner is not required. Use the air restriction gauge o n the air cleaner outlet to indicat e
when the air filter needs serv icing -- a red flag will
appear when the filter is overly restricting airflow into
the engine.
IMPORTANT: Use only Donaldson air filter elements for replacement (Donaldson P822686 or
Walker 5090-1). Aftermarket filters may not seal
properly or filter efficiently.
Cover
Canister
Air Restriction Gauge Location
Clean and insp ect the paper element after every
100 hours of service and replace the element yearly or after six (6) cleanings (or when dirt y or dam-
aged). More frequent cleaning may be required
when operating in extremely dusty conditions as indicated by the air restriction gauge. Se rvice t h e air
cleaner as follows:
Push Button to Reset
Indicator After Service
Air Restriction
Gauge
Cover
Latch
Radialseal™
Vacuator™
Valve
Air Cleaner Components
(shown with cover being removed)
IMPORTANT: The Donaldson air cleaner uses a dry
paper-type air filter element. NEVER apply oil to the
paper element.
Filter Element
1. Release the top and bottom c over latches and
remove the ai r clean er cover. Wash the co ver
and Vacuator™ valve. Check that these components are in good condition. The Vacuator™
valve is subject to wear and deterioration and
should be replaced yearly or when da maged.
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 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. Clean the filter element using low pressure
compressed air [les s than 100 PSI (68 9 kPa)].
Blow out the filter from the interior of the element while turning the element.
NOTE: Washing the element in water or cleaning solution is not recommended. Replace the
element if it does not clean up with compressed
air.
51
Maintenance Instructions CLEANING
4. Use a bright light inside the element to inspect
for damage. Check the e lement very ca refully
for pin holes or other damage that will allow
dirt to leak through the paper me dia. Replace
element if necessary.
5. Check the condition and resilience of the radial
sealing surfac e (inside o f the open end) of th e
filter. Replace the filter if any cracks, tears, or
other damage to the sealing surface are noted.
6. 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.
7. Check the outside surface of the outlet tube for
smoothness and cleann ess (this is the seal ing
surface).
8. Insert and seat the filte r element carefully into
the canister, applying pressure at the o ute r rim
of the filter; not at the flexible center. Make sure
the filter element is completely in place befor e
installing the cover.
IMPORTANT: DO NOT use the cover latches
to force the filter into the canister -- the cover
should fit on with no extra force.
9. Install the cover with the word “TOP” properly
oriented to the top of the canister. Give the cover a slight twist as it reaches the canister to
make sure the tab inside the cover goe s into a
slot, otherwise the cover will not fit properly.
Make sure both the top and bottom cover latches are securing the cover in place.
Cover Latch
Vacuator™
Valve
Proper Orientation of Air Cleaner Cover
10. Che ck the air intake hose for cuts, nicks, etc.,
and the hose clamps for tightness.
11. Res et the air restrict ion indicator (p ress button
on bottom).
Engine Cooling System
Air Intake System
Orient to Top
of Canister
Cover Latch
52
NOTE: DO NOT use petroleum based lubricants on the sealing surfaces of the filter; use talcum powder or dry silicone lubricants if required
for filter installation.
Outlet Tube
Canister
Radial Sealing
Surface
Air Filter Element Replacement
Radialseal™
Filter Element
To pr ev ent en gin e ov erhea ting and possible engine
damage, clean grass c lippings, cha ff, and dirt from
the rotating engine air intake screen after every 8
hours of operation. In certain mowing conditions
(dry grass, leaves, tree “cotton”, etc.), it may be necessary to check and clean the screen several times
each day to prevent engine overheating.
CAUTION
Operating the engine with a blocked air
intake screen, dirty or plugged cooling
fins, and/or cooling shrouds removed will
cause engine damage from overheating.
Maintenance Instructions CLEANING
Cylinder Head Cooling Fins
It is essentia l for performance and longevity of th e
air-cooled engi ne to keep the cylinder h ead c ool in g
fins clean and free of obstruction. After every 8
hours of operation, check the perf ormance of the
cooling system by starting the engine, holding a
hand adjacent to the c ylinder hea d, and feeling th e
cooling airf low . If there is littl e or no airflow , clea n the
cooling fins as described below.
Cylinder
Head
Check Airflow
with Hand
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
Every 100 hours, inspect and clean the cooling fins
(more often when operating in extremely dusty, dirty
conditions). R emo ve the two (2 ) co o ling fin access
panels in the engine shr oud and clean the coolin g
fins and external surfaces using compressed air.
Make sure to reinstall the a cces s panels befo re operating the engine.
Engine Cooling
Fin Access Panels
Kohler Engine
Shroud
Cooling System Airflow
Grass Buildup in Mower Housing
DANGER
Before raising or removing the mower
deck for cleaning, stop the engine, remove the ignition key , and disconnect the
spark plug wires.
1. Raise the dec k lock lever handle on e ach side
of the carrier frame and pull out to release carrier frame for tilting action.
2. Using the carrier frame lift handle, raise deck to
the TILT-UP posi tion and inser t the deck hook
into the tilt-up latch on the tractor body.
Tilt-Up Lift Handle
Engine Air
Intake Screen
Engine Air Intake Screen
and Cooling Fin Access Panels
Tilt-Up Latch
Tilt-Up Latch
Tilt-Up Hook
on Deck
Deck Lock Lever
Deck Secured in TILT-UP Position
53
Maintenance Instructions CLEANING
1. Remove the GHS blowe r dr iv e belt by unhook-
DANGER
Do not operate the mower with deck in tiltup position. Do not move the tractor with
the deck in the tilt-up position.
3. Clean grass buildup underneath the deck using
a pressure washer (and scraper if required).
NOTE: While some degree of material buildup
in the mower deck housing can be tolerated, a
point is finally reached where cutting quality
deteriorates and clogging begins to occur
because of too much buildup on the b affling and
housing.
4. Lower the deck to the normal operating position
and re-engage the deck lock levers.
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
ing the belt tension spring from the hook on the
chassis frame (located above the blower pulley). Lift the belt tightener idler pulley up and roll
the belt off of the blower pulley. The belt should
be clear of the blower pulley, allowing free
movement of the blower wheel.
IMPORTANT: With the belt removed, the blow-
er wheel must spin freely. Any binding or drag-
ging of the wheel is an indication of dirt
buildup. This buildup must be cleaned to
avoid abrasive wear of the blower blades, excessive power loss and eventual loss of blower
performance (clogging).
2. Use a pressure washer or water spray, and direct the spray inside the blower housing against
the blower blades. Water pressure will cause
the blower wheel to begin to spin and the combination of spinning ac tio n and water will effectively wash th e inside of the housi ng. Spra y may
be directed against the blower blades vertically
and horizontally to cause rotation in both directions for thorough washing action. W ash blow-
er until the blower wheel spins freely in both
directions.
GHS Blower
Normally, the GHS blower operates with no maintenance or cleanin g. However, when mowing grass
that is dirty and damp (especially spri ngtime mo wing), a deposit of dirt may accumulate inside the
blower housing, causing wear and binding of the
blower wheel. W hen op erati ng in thes e co ndi tio ns ,
inspect the blower frequently for dirt buildup.
NOTE: A visual clue of binding of the blower wheel
is the blower blade tips are polished from rubbing
on dirt.
When a dirt deposit is found, use a high pressure
washer or water spray to clean the inside of the
housing as follows:
DANGER
Before attempting to wash the blower,
stop the engine, remove the ignition key,
and disconnect the spark plug wires.
3. Reinstall the GHS blower drive belt by reversing
the removal procedure.
Blower
Blower
Drive Pulley
GHS Blower
Drive Belt
Belt Tightener
Collapse Blower Belt Tightener
to Remove GHS Blower Drive Belt
Pulley
Idler Pulley
54
Maintenance Instructions
CLEANING/
CHECKING/SERVICING
GHS Exhaust Screen
Refer to Cleaning the GHS Exhaust Screen in Operating Instructions.
Hydrostatic Transmission Cooling Fins
Keeping the cooling fins on the hydrostatic transmissions clean and free of obstruction is essential to
avoid overheating the transmission fluid and shortening transmission life. The cooling fins should be
checked every 100 hours; and cleaned if necessary.
T o clean the fins, use compressed air and/or a pressure washer. The cooling fins extend all th e way
around the housing -- the fins underneath need to be
clean as well as the more vi sible fins ab ove. Also,
pay close attention to the are a under the drive pu lley.
IMPORTANT: In case an oil leak dev elops on the
input shaft, the cooling fan blowing du sty ai r and oil
on the transmission will quickly pack the cooling
fins with oily dirt. If this cond ition occurs, repl ace
the seal immediately to avoid overheating and damaging the transm ission. The in put shaft assembly
and seal are easily re placed without removing the
transmission from the machi ne.
An additional procedure in maintaining transmission
cooling is to inspect t he cooling fans. Replac e the
fan(s) if blades are missing or damaged.
CHECKING/SERVICING
DANGER
To prevent accidental starting of the engine when servicing or adjusting th e machine, remove the key from the ignition
switch and disconnect the spark plug
wires.
Security of Air Filtration Components
NOTE: The foll owing inspection is only an exter -
nal inspection and should be done without “dis-
turbing” the filtration components.
On a daily basis, visually inspect the external condition of the complete air cleaner system. The following items should be inspected:
1. Check the Donald son Radialse al™ air c leaner
canister for damage. Make sure the cover is in
place and the cover latches are secure - do not
run the engine with out the air clean er cover in
place and secure.
2. Inspect the air intake hose for cracks, nicks,
cuts, etc., and check the hose clamps for tightness.
Cooling Fan
Cooling Fins
Hydrostatic Transmission Cooling Fins
Battery
NOTE: For initi al batte ry servic e during setup, re -
fer to Battery Service in Assembly Instruction s.
IMPORTANT: Make sure battery is securely mo unt-
ed in the frame. A loose battery may cause damage
to the case resulting in acid leakage and severe damage to the machine. A hazard may be created by
damage to critical working parts and safety systems.
Electrolyte Level
The battery electrolyt e level shoul d be checked after every 25 hours of ope ra tio n. To check electro-
lyte level:
1. Remove battery cell filler caps.
2. Check the electrolyte level. If the level is below
the bottom of the vent well, fill with drinking 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.
55
Maintenance Instructions
CHECKING/SERVICING
IMPORTANT: DO NOT overfill the battery. Electro-
lyte will overflow through the vented caps onto parts
of the machin e and WILL result in severe co rrosion.
Cleaning the Terminals
If battery terminal s are corroded, remove battery
from the mower. Using a wire brush, remove corrosion with a solution of one part baking soda and
four parts wat er. Rinse with clean water. Coat the
terminals with p etroleum jelly or ter minal protector
spray to retard further corrosion.
Charging the Battery
Check the battery charge by measuring the specific
gravity of elec trolyte; if specif ic gravity is l ess than
1.225, the battery will need to be charged as follows:
1. Charge the battery at 15 amps for 10 minutes .
DO NOT exceed 20 amps maximum recommended charging rate. Charge until specific
gravity is at least 1.250. Total charging time
should not exceed one (1) hour.
2. After charging the battery, use drinking water to
adjust the electr olyte lev el 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)
Rear = 20 PSI (137 kPa)
Sharpen Mower Blades Check mower blade(s) for straightness, sharp-
ness, condition of the cutting edge, and balance
every 10 hours of operation ( or more often when
mowing abrasive typ e grass or operat ing on sandy
soils). Replace blades if worn, bent, cracked, o r
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 yiel ds a p oor mowin g job b ut slo ws
the cutting speed of the mower and causes extra
wear on the engine and blade drive by pulling hard.
1. Stop the engine, remove ig nition key, and disconnect the spark plug wires before raising the
mower deck to service blades.
DANGER
BATTERIES PRODUCE EXPLOSIVE
GASES
• Charge the battery in a well-v entilated
area, so that gases produced while charging can dissipate.
• Keep sparks, flames, 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.
2. Raise the deck and secure it in either the UP position using the dec k li ft rod (n on-ti lt dec k) o r in
the TILT-UP position. Refer to CLEANING the
Grass Buildup in Mower Housing in this section for deck raising instructions.
DANGER
NEVER operate cutter blades with the
deck in the raised position.
3. Check the blades for straightness by m arking
the blade tip position ins ide the deck housing,
and then rotating the opposite end of the blade
to the same position and comparing . If the difference in blade tip track is more than 1/8 in.
(3 mm), the blade is bent and should be replaced.
56
Maintenance Instructions
WARNING
DO NOT try to straigh ten a blade that is
bent. NEVER weld a broken or cr acked
blade. ALWAYS replace with a new blade
to assure safety.
4. If the blade cutting edge is dull or nicked, it
should be sharpened. Remove blades for
sharpening by grasping the end of the blade using a rag or a thick, padded glove, while loosening and removing the nut, lock washer, and flat
washer that mounts the blade.
5. Grind cutting edge at the same bevel as the
original. Sharpen only the top of the cutting
edge to maintain sharpness.
NOTE: Blades can be sharpened with an electric blade sharpener , conventional electric grinder, or a hand file.
CHECKING/SERVICING
6. Check blade balanc e by positioning the bl ade
horizontally on a blade balancer or use a nail or
shaft through the center hole. If either end of the
blade rotates downward, grin d (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.
Blade Balancer
CAUTION
ALWAYS wear eye protection and gloves
when sharpening a blade.
Sharpen at
Original 30° Angle
30°
Sharpen on Underside
Mower Blade Profile For Sharpening
Intersection
Wear Area
Wing
Do Not Grind or
Tip
Blade Balanced on Magnetic
Wall-Mounted Balancer
7. Mount the blade with wing ti ps pointing up into
the housing. Reins tall the blade, was her, lock
washer, and nut. Tighten the nut to 60 ft-lb
(81.3 N
NOTE: When reinstalling blades on GHS models,
remember, the blades turn toward each other
(counter-rotate) and the RH and LH blade cannot be
switched. Check for proper blade rotation before installing blades on the d eck. Refer to Blade Rota-
tion for GHS Mower Deck illustration shown in
Clogging Checklist in Operating Instructions for
correct blade rotation.
Drive Belts
Raise the body and inspect the condition of the
four (4) belts (3 belts on SD models) every 25 hours
of operation - engine PTO drive, jackshaft drive, hydrostatic ground drive, and GHS blower drive. If the
belts show signs of cracking or deteriorating, the
belts should be replaced. Refer to REPLACING/
REPAIRING the Drive Belts in this section.
⋅m).
57
Maintenance Instructions CHECKING/SERVICING
Mower Deck Gearbox Oil Seals
The mower deck gearbox seals should be inspected
every 25 hours for evidence of oil leaking; particularly the lower oil seal on the blad e drive gearbox. This seal is protected by the trash guard on the
blade hub and seal prot ector plate o n the ho using,
but is still vulnerable to se al damag e due to op er ating in an adverse envi ronment. The mower bl ade
must be removed for ins pection of the s eal, so it is
recommended to inspect the gearbox seals when
blades are removed for sharpening. If an oil leak
is noted, the seal should be repl aced and the gearbox assembly relubricated. Refer to Mower Deck
Gearbox Lubrication in this section.
Spark Plugs
Every 200 hours of operation, remove the spark
plugs, inspect, c lean, and r eset the g ap (or repl ace
with new plugs). Before removing the spark plugs,
clean the area around the base of the plugs to keep
dirt and debris out of the eng ine . Clea n spark pl ugs
with a wire brush. DO NOT use an abrasive grit type
cleaner. If the electrodes are burned short or pitted,
replace plugs with Champion
equivalent). Check s park plug gap wi th a wi re-t yp e
feeler gauge and s et the ga p a t 0. 030 in. (.76 mm).
Reinstall and tighten to between 18 and 22 ft-lb
(24.4 to 29.8 N
Fuel Lines and Clamps
Every year, inspect the fuel supply line from the tank
to engine for deterioration or damage. Also, inspect
the fuel line clamps for tightness. Good preventive
maintenance ca lls for comp lete replacement of fuel
lines and clamps every two (2) years.
⋅m).
type RC12YC (or
Engine Starter
Yearly or every 500 hours disassemble and clean
the solenoid shift starter. Refer to the Kohler Service
Manual for this proced ure or contact an authorized
Kohler engine dealer to perform this service.
Engine Valve Clearance
Yearly or every 500 hours, check and adjust the
Kohler engine valve cl earance. Ref er to the Kohler
Service Manual for s pecificati ons and proc edure to
check the valve clea rance or contact an author ized
Kohler engine dealer to perform this service.
Blade Brake Action
WARNING
It is important to check and maint ain blade
brake action for safe operation of the machine.
Check the function of the cutter blade br ake (and
blower brake on GHS models) by engaging the
blade clutch (PTO), operating the engine at full throttle, then disengaging the clutch and measuring how
quickly the blades s top. Watch the rotation of the
blade drive shaft and bl owe r pul le y a s a v isual i ndi cation that movement has s topped. If the brake is
working properly, all rotation will stop five (5)
seconds after disengagement of the clutch. If the
brake system malfunc tions - blades do not stop in
five (5) seconds - adjust or repair the brake before
operating the mower. Refer to ADJUSTME NTS of
Blade Clutch (PTO) in this section .
58
Maintenance Instructions
REPLACING/REPAIRING
DANGER
To prevent accidental starting of the engine when replacing parts or repa iring 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 four (4) individual belt s on GHS models
or three (3) belts on SD models:
REPLACING/REPAIRING
• Engine PTO Drive Belt (3 Groove Power Band)
• Jackshaft Drive Belt
• GHS Blower Drive Belt (GHS Model Only)
• Hydrostatic Ground Drive Belt
The belts may be removed and r eplaced using the
procedures described on the following pages.
59
Maintenance Instructions REPLACING/REPAIRING
Jackshaft
Drive Belt
Engine PTO
Belt
Hydrostatic Ground
Drive Belt
GHS Blower Belt
(GHS Model Only)
60
Belt Locations
Maintenance Instructions REPLACING/REPAIRING
Engine PTO Drive Belt (3 Groove Power Band)
1. To remove the engine PTO drive belt:
a. Remove the jackshaft drive belt from its
idler pulley (by pushi ng down on idler pulley) and let the belt drop down out of the
way.
NOTE: Step (a) is not essential to removing
the PTO belt, but it makes more room to work
with the PTO belt.
b. Push the clutch i dl er pu ll ey do wn (u n til th e
PTO belt tightener stop block contacts the
frame) and then shift the b elt off the idler
pulley (to the inside).
Pull UP to Engage
c. Raise the clutc h lever (e ngage pos ition ) to
lift the clutch idler away from the belt.
d. Next remove the belt from the engin e pul-
ley and then the PTO drive pulley.
2. Install the PTO drive belt by reversing th e removal procedure.
IMPORTANT: Make sure the belt is installed
inside the four (4) belt guide pins.
Refer to ADJUSTMENTS of Blade Clutch
(PTO) in this section to check and make the fol-
lowing adjustments:
a. Clutch engagement for proper belt tension
b. Clutch disengagement and brake action
Clutch
Linkage
PTO Belt Tightener
Stop Block
PTO Belt
Tightener Arm
Blade Clutch Lever
in the DOWN Position
Belt Guides
(Bottom Guide Not Visible)
Engine
PTO Belt
Belt
Guide
Engine
Pulley
Clutch Idler
Pulley
Belt
Guide
PTO Drive
Pulley
Micro-V
Pulley
Engine PTO Drive Belt Removal
61
Maintenance Instructions REPLACING/REPAIRING
Jackshaft Drive Belt
b. Relax the belt by depressing the spring-
1. To remove the jackshaft drive belt:
loaded idler arm.
a. Remove the engine PTO drive belt, as
described in previous section.
Push Idler Pulley
Jackshaft
Jackshaft
Drive Belt
Tension Spring
Jackshaft Drive Belt (Disengaged)
c. Roll the belt off the jackshaft pulley and
remove.
Idler Pulley
Engine
Pulley
2. Reverse the removal procedure to replace the
jackshaft drive belt.
Idler Arm
Jackshaft
Jackshaft
Drive Belt
Ten si on Spring
Jackshaft Drive Belt (Engaged)
Engine
Pulley
62
Maintenance Instructions REPLACING/REPAIRING
GHS Blower Drive Belt
1. Remove the GHS blower drive belt by unhooking the belt tension spring from the hook on the
chassis frame (located above the blower pulley). Lift the belt tightener idler pulley up and roll
belt off the pulleys.
Blower Drive
Pulley
GHS Blower
Drive Belt
Belt Tightener
Idler Pulley
(Disengaged)
GHS Blower Drive Belt Assembly (Disengaged)
Blower Drive Belt Spring Removal
2. Reverse the procedure to install the GHS blower drive belt and spring.
Blower
Pulley
Idler Pulley
(Engaged)
GHS Blower Drive Belt Assembly (Engaged)
63
Maintenance Instructions REPLACING/REPAIRING
Hydrostatic Ground Drive Belt
1. To remove the hydrostatic ground drive belt:
a. Raise the spring-loade d belt tighten er arm
and idler pulley to relax belt.
Belt Tightener Arm
Idler Pulley
Hydrostatic
Ground Drive Belt
b. Slide belt off pulleys, then release the idler.
Jackshaft
Transmission
Drive Pulley
Spring
Hydrostatic Ground Drive Belt Assembly (Disengaged)
2. Reverse the procedure to install the hydrostatic
ground drive belt.
Belt Tightener Arm
Idler Pulley
Hydrostatic
Ground Drive Belt
Spring
64
Hydrostatic Ground Drive Belt Assembly (Engaged)
Maintenance Instructions REPLACING/REPAIRING
Fuel Filter
Model MC is e quippe d with an i n-line fuel filter. Visually inspect the f ilter pe riodic ally, and replace the
filter yearly.
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.
DANGER
Blade Overload Shear Bolts The cutting blade i s key ed to th e b lade hub by two
(2) shear bolts (10-24 x 5/8 in. stainless steel ma-
chine screws). T hese bolts are des igned to shear
and protect the blade drive gearbox from damage if
the blade encounters a shock load.
Cutting Blade
Shear Bolts
Cutting Blade Shear Bolts
NOTE: Tightening the 5/8-18 blade mounting nut
to 60 ft-lb (81.3 N
shock load protection . It is important to not overtighten the mounting nut since thi s defeats (over-
rides) the function of the shear bolts.
⋅m) is also important for proper
Gasoline is extremely flammable and can
be highly explosive. To minimize danger:
• Use only an approved fuel container for
gasoline.
• DO NOT allow open flames or sparks
near the machine while perfo rming maintenance or refueling; DO NOT smoke
while working with fuel.
• Wipe up spilled gasoline immediately
and completely.
1. Expand and slide clam ps on either side of the
filter away from filter and pull fuel lines off filter.
2. Replace filter.
If these bolts shear, remove the blade and install new
bolts. Refer to CHECKING/SERVICING in this section for Sharpen Mower Blades which describes the
blade removal and installation procedure.
65
Maintenance Instructions REPLACING/REPAIRING
After reinstalling the blade, check blade timing by
moving blades through one (1) comple te revolu-
tion. Make sure blade tips pass clear of each other.
If timing is incorrect, refer to Mower Deck Gearbox
Replacement in this section. PTO Shear Pin
The PTO drive shaft connection to the deck gearbox
has a shear pin to pro vide shock l oad protecti on to
the mower deck drive. This system provides prima-
ry shock protection in case of blade impact and will
normally shear before the individual shear bolts on
the blade hub.
When the PTO pin has sh eared, use the followin g
procedure to replace it:
1. Loosen the two bolts securing the PTO shaft
guard on the deck; lift the guard off. (Holes in
guard are slotted for easy removal.)
2. Rotate U-joint on shaft to align the shear pin
hole with the hole (and s hear pin fragment) in
the shaft. Use a punch to drive the rem aining
portion of the old shear pin out.
3. Install new shear pin and secure with cotter pin.
Before operating the deck , inspect the blade overload shear bolts and also check blade timing (on
gear driven decks) by moving blades through one (1)
complete revolution. Ma ke sure blade tips pass
clear of each other. If timing is incorrect, refe r to
Mower Deck Gearbox Replacement in this section. Mower Blades
Mower blades are remov ed and remounted as described in Sharpen Mower Blades instructions.
During the course of sharpening and inspecting
mower blades, if there are any of the following con-
ditions of wear or damage, blades should be replaced for reasons of safety and performance of the
machine:
• An ex cessive amount of the flat secti on of the
blade has been ground away (remov ed) when the
blade is sharpene d. Replace the blade when l ess
than a 3/4 in. (19 mm) flat section remains at the
blade tip.
• Exam ine ends of the blade carefully, especiall y
the intersection where th e flat section of the bl ade
turns up to form the “wing tip” (refer to Mower Blade
Profile for Sharpening illustration in Sharpen
Mower Blades instru ctions). S ince sand an d abra-
sive material can wear me tal away in this area , the
blade should be replaced when metal thickness
has worn to 1/16 in. (1.6 mm) or less.
Shear Pin
Split Spring Pin
U-Joint
Tube Assembly
U-Joint
Shaft Assembly
Cotter Pin
PTO Shear Pin
IMPORTANT: Use only Walker P/N 8067-10
shear pins for replacement to provide proper
shock protection -- these pins are hardened to
shear under a specific amount of load.
4. Reinstall the PTO shaft guard.
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 se rious potential for
injury or damage.
• Check the blades for straightness by marking
blade tip position inside the deck ho using and t hen
rotating the opposite en d of the blade to the same
position and comparing. If the difference in blade tip
track is more than 1/8 in. (3 mm), the blade is bent
and should be replaced.
• Inspect the blade surface, especially in formed
areas, for cracks. Replace the b lade if any cracks
are found.
66
Maintenance Instructions REPLACING/REPAIRING
4. Remove the screws s ecuring the cover plates
WARNING
DO NOT try to straigh ten a blade that is
bent. NEVER weld a broken or cr acked
blade. ALWAYS replace with a new blade
to assure safety.
Reinstall the blades following procedure from Sharpen 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.
on the gearboxes and remove the covers. Remove all covers to be sure oil is completely
drained from all gearboxes.
NOTE: With oil flow throughout the unitized
gear drive assembly; if one gearbox has internal
damage or excessive wear, the remaining gearboxes and connector tubes should be completely disassembled and thoroughly flushed out with
solvent before reassembly.
5. Drain and properly dispose of oil.
6. Remove the four (4) bolts mounting the gearbox
to the connector tub e an d s lide the gearbox off
the splined drive shaft coupling.
CAUTION
ALW A YS use genuine factory replacement
part s. Substitute parts CAN result in product malfunction and possible injury to the
operator.
Mower Deck Gearbox Replacement
NOTE: Deck gearbox(es) may be changed with
the deck mounted on the tractor. However , the deck
may be removed from the tractor making the overall
job of removing the gearbox assembly easier. Refer
to Deck Install at ion in Assembly Instructions and reverse the procedure to remove the deck.
T o replace the mower deck gearbox(es), use the following procedure:
1. Remove mower blades. Refer to pr ocedure i n
Sharpen Mower Blade instructions.
2. Remove gearbox cover (two machine screws)
and PTO shaft guard (two 1/4-20 bolts).
3. Remove two (2) 3/8-16 mounting bolts from
each blade drive gearbox and lift the entire
gearbox assembly from the deck (including
PTO drive shaft).
7. Install the new gearbox on the spline coupli ng
of the drive shaft. Establish correct timing of
the blade drive gearboxes by setting flats on
the output shaft at 90 degrees when connecting
the gearbox(es) to the spline coupling. Make
sure the timing is correct before proceeding
with assembly.
8. Reinstall the four (4) bolts mounting the gearbox
to the connector tube but do not tighten them
at this time; leave con nector tube bolts fingertight.
9. Position the gear drive assembly on the deck
and install the 3/8-16 b olts mounting t he entire
assembly. Leave the mount bolts finger-tight.
10. Torque all the connector tube bol ts to 80 in-lb
⋅m); then tighten the deck mount bolts.
(9 N
NOTE: This fastener tightening sequence aligns
the gearbox as sembly with the deck housing and
eliminates the possibility of mounting the unitized
assembly in a bind.
1 1. Fill gearbox assembly with oil. Refer to Mower
Deck Gearbox Lubrication in this section for
instructions.
12. Reassemble remaining items onto deck to complete installation. Aft er in stall ing bl ade s, c hec k
that the blade timing is correct by moving the
blades through one (1 ) complete revolu tion.
Make sure blade tips pass clear of each other.
67
Maintenance Instructions REPLACING/REPAIRING
4. Remove the blower assem bly fr om th e ch as sis
Mower Deck
Gearboxes
Connector Tubes
Mower Deck Gearboxes
(Shown with Gearbox Cover Removed for Clarity)
GHS Blower Assembly (and/or Blower Wheel)
as follows:
a. Remove the blower skid bar by removing
front and rear mounting bolts from the skid
bar (underneath the blow er) and remo ving
the bolt connecti ng the blower housing to
the skid bar.
b. Remove the blower belt tightener idler arm
assembly by removing the pivot bolt.
c. Remove two (2) bolts mounting t he bl owe r
housing to the frame.
d. Lower the blower assembly straight down
out of the chassis frame and remove.
Blower Wheel Removal
GHS Blower Assembly Removal
1. Remove the mower deck. Refer to Deck I nstallation in Assembly Instructions and reverse the
procedure to remove the deck.
Skid Bar
Mounting Bolts
Blower Assembly
Remove Skid Bar for
GHS Blower Removal
2. Remove the blower facepl ate by removing six
(6) 1/4-20 nuts.
Skid Bar
When required, replace th e blower wheel using the
following procedure:
1. Loosen blower pulley s et screws and remove
the pulley using a wheel puller.
2. Remove the locking collar from the back bearing (closest to the p ulley) by lo osening the set
screw and rotating the col lar cou nterclo ckwis e
(use punch to drive).
3. Press blower wheel out of th e housing using a
wheel puller hooked to lugs on the bearing housing. The bearings have been secured in the
housing with a retaining compound - Loctite
RC/680, and considerable force will be required to break this bond. After the bearing s
have “broken loose” from the housing, only light
pressure should be required to remove the
wheel assembly out of the housing.
NOTE: It may or may not be possible to remove
the front bearing from the blower wheel without
damaging it. If the bearing is damaged, it will
need to be replaced along with the wheel.
®
68
3. Remove the GHS blower drive belt. Refer to
REPLACING/REPAIRING the Drive Belts in
this section for instructions.
Maintenance Instructions
REPLACING/REPAIRING
Blower Wheel Installation
1. T o install the blower wheel, reverse the removal procedures. The front bearing is mounted
on the blower wheel shaft, secured by a locking
collar. Drive the lo ck in g c oll ar cl oc k wis e wi th a
punch, and tighten the set screw.
Wheel Puller
Hooked to Lugs
on Bearing Housing
Pressing Blower Wheel Out of Housing
Bearing (3/4)
Bearing (3/4)
2. Press blower wheel a nd front bearing into the
blower housing. Use Loctite
compound on the outer bearing race and inside
the bearing housing.
3. Press the rear bearing into place, using Loctite
on both the outer bearing race and the housing.
4. Install the locking collar on the rear bearing and
install the blower pulley to co mpl ete the bl owe r
assembly. Torque the blower pulley set screws
to 250 in-lb (28.3 N
GHS Blower Assembly Installation
Reinstall the blow er asse mbly into t he m ower u sing
the reverse procedures of GHS Blower Assembly
Removal.
Blower Pulley
⋅m).
®
RC/680 retaining
5/16-18 x 5/8 SQH
Set Screw
5/16-18 x 3/4 SQH
Set Screw
®
Face Plate
Intake Tube
5/16-18 Whiz Locknut
Skid Bar
3/8-16 x 1 Hex Bolt
3/8-16 Keps Nut
3/16 x 3/16 x 1 Key
1/4-20 x 3/8
Set Screw
Housing
1/4-20 x 3/8
Set Screw
Blower Wheel
7/16-14 Hex Nut
7/16 Split Lock Washer
5/16-18 x 3/4 Hex Bolt
7/16-14 x 1-1/4 Hex Bolt
GHS Blower Components
69
Maintenance Instructions
ADJUSTMENTS
ADJUSTMENTS
DANGER
If the engine must be running to perform
a maintenance adjustment, keep hands,
feet, and clothing from moving parts. DO
NOT wear jewelry or loose clothing.
Safety Switches
There are three (3) safety inter lock swi tches on th e
tractor; Seat Switch, FSC Neutral - Park Switch, and
PTO Switch.
If any of the following condi tions o ccur du ring starting or operating, a s afety interlock switch may be
malfunctioning. Contact your Walker dealer for troubleshooting and/or replacement.
Slight adjustments c an be m ade by c arefully bending the leaf switch up or down as needed.
Steering Levers
An adjustment range of ap proximately 3 inches is
available on the steerin g levers - the lev ers can be
adjusted forward or aft depending on the arm length
of the operator. The levers can be adjusted by loosening the locknut at th e pivot point and the lock nut
holding the lever in position in the adjustment slide.
Adjust levers into most comfortable position and
tighten both locknuts.
Adjustment
Slide
Locknut
(Position)
• With 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 starts
and continues to run w ith the Forward Speed Control (FSC) and/or PTO engaged.
• With an o perato r in the se at, the F orward Speed
Control (FSC) and PTO disengaged and panel horn
works, but the starter is not engaging.
Locknut
(Pivot Point)
Steering Lever Adjustment
70
Maintenance Instructions ADJUSTMENTS
Blade Clutch (PTO)
Clutch Engagement/Belt Tension
The clutch engagement and PTO belt tension are adjusted using the clutch actuator rod. Initially, after installing a new PTO belt, after 10 hours and every
100 hours thereafter, check and adjust for the two dimensions in the clutch actuator rod as shown in the
PTO Clutch Engaged and PTO Clutch Disen-
gaged illustrations.
Clutch
Actuator Rod
Adjust the bolt head clearance [1/4 in. to 3/8 in.
(6.35 mm to 9.53 mm)] first (clutch en gaged), then
adjust uncompressed spring length (clutch disengaged). The spring must be adjus ted to an uncompressed overal l length of 2 in . (51 mm). If adjustments are needed more frequently than every
100 hours to maintain the linkage dimensions, it may
suggest problems with pulley wear or belt misalignment.
1/4 in. to 3/8 in.
(6.35 mm to 9.53 mm)
PTO Belt
Tightener Arm
Locknut
Spring
Compressed
Blade Clutch
Lever Engaged
PTO Clutch Engaged
71
Maintenance Instructions ADJUSTMENTS
Clutch Disengagement/Brake Action The declutched or disengaged position of the
blade clutch id ler pulley is adjustable and is set to
WARNING
It is important to check and maintain
blade brake action for safe operation of
the machine.
give belt releas e without excessive slack and to
apply the blade brake. The blade brake is activated
by the brake actuator rod linkag e to the clutch idler
pulley mechanism . The brake is designed to stop
the blades within five (5) seconds after disengaging
the clutch.
Adjustment
Blade Clutch
Idler Pulley
Nut
2 in.
(51 mm)
Spring Overall Length
Knuckle
Joint
Spring
Uncompressed
Blade Clutch
Lever Disengaged
72
PTO Clutch Disengaged
Maintenance Instructions ADJUSTMENTS
Use the following procedures to check and adjust
clutch disengagement and brake action:
Pulley
Travel
Stop Block Eccentric Adjustment - Step 1
Use the stop block attached to PTO belt tightener
arm to set the bottom position of the clutch idler pulley in the disengaged position. The stop block
should contact the chassis to stop the clutch idl er
pulley from movi ng further down in th e disengage d
position. If the stop block is not contacting the
chassis in the disengaged position, it will be necessary to loosen the brake band adjustment nut.
The stop block is an “eccentric” block that will allow
four adjustment positions from 5/16 in. (8 mm) to
11/16 in. (17 mm).
Stop
Block
Stop Block
Contacting Frame
Clutch Idler Pulley Travel Adjustment
Engage
Disengage
1 in. to 1-1/2 in.
(25 mm to 38 mm)
11/16 in.
(17 mm)
7/16 in.
(11 mm)
PTO Belt Tightener Stop Block Adjustments
Clutch Idler Pulley Travel Adjustment - Step 2
Adjust the stop bl ock to gi ve 1 in. ( 25 mm) to 1-1/ 2
in. (38 m m) pulley travel from “clutch engaged” to
“clutch disengaged”. To check and adjust the pulley
travel, first engage the clutch, then measure the distance the pulley moves down as the clutch is disengaged and the stop block contacts the frame.
9/16 in.
(14 mm)
5/16 in.
(8 mm)
Blade Brake Band Adjustment - Step 3
After the pulley travel is set, make the following adjustment as needed:
1. Adjust the blad e brake band , using th e adjustment nut until there is a gap of approximately
1/8 in. (3 mm) between the PTO belt tightener
stop block and chassis. If there are not enough
threads on the brake band for adjustment,
lengthen the brake actuator rod.
Blade Brake Band
Adjustment Nut
Brake Actuator
Rod
NOTE: The i mportance of this adjustmen t is if the
pulley travel is exces sive an d the belt d evelops to o
much slack, the belt will derail when disengaged.
Blade Brake Band Adjustment
73
Maintenance Instructions ADJUSTMENTS
Blade Clutch
Idler Pulley
Stop Block
PTO Belt Tightener
Chassis
Blade Brake Band Adjustment
NOTE: The l ength of the actuator rod is adjusted
by disconnecti ng the bottom clevis a nd shortening
or lengthening accordingly. The standard pre-set
length of the actuator rod is set at the factory at
8-1/4 in. (209 mm).
1/8 in.
(3 mm)
2. After adjustments are complete, check blade
brake action as described in CHECKING/SER-
VICING the Blade Brake Action in this section.
If blades do not stop within five (5) seconds,
check the following:
a. Recheck 1/8 in. (3 mm ) gap bet ween stop
block and chassis.
b. Make sure clutch and brake linkage are
working freely (no binding).
c. Check the brake band lining.
d. Check the brake drum on the pulley. If
excessive w ear is present, it wi ll be ne ce s-
sary to replace worn parts.
Transmission Control
IMPORTANT: The pr oper adjustment of the trans -
mission control stops is ess en tial for efficient operation and life of th e transmiss ion. These stops are
properly adjusted at the fac tory and should on ly re quire readjustment if the transmission or related
control linkage is removed or changed.
NOTE: It would not be unusual for a new machine,
after initial 5 or 10 hours of operation, to begin to not
travel straight (this is due to the break-in of the
transmissions). In this case, proceed to Straight
Ground Travel Adjustment - Step 4.
74
8-1/4 in.
(209 mm)
Brake Actuator Rod Adjustment
Locknuts
Bottom
Clevis
IMPORTANT: The following adjustment procedures
are sequential. Check and adjust each functio n in
the order given.
Set Forward Travel Limit (Stop) - Step 1
1. Move the Forward Speed Control (FSC) lever to
the most FORWARD position.
2. Check clearance of the RH and LH steer i ng le ver actuator arms with the frame and adjust for-
ward stop bolt so each lever clears the frame
by at least 1/16 in. (1.6 mm). Clearance of the
arm to the frame should be check ed while ap-
plying pressure back on the arm to remove
any slack in the linkage.
3. Tighten the jam nut on the forward travel st op
adjusting bolt.
Maintenance Instructions ADJUSTMENTS
Steering Lever
Actuator Arms
Forward Travel
Stop Bolt
Steering
Adjustment Nut
Forward Speed Control Stop
and Steering Lever Adjustment
Steering Lever End Play Adjustment - Step 2
1. Position the FSC lever to the most FORWARD
position.
2. Loosen the adjustment nut on each steering lever actuator until end play develops between
the lever actuator a nd the adj us tme nt n ut (s li ding on transmission control rod).
CAUTION
NEVER attempt to disconnect any sa fety
devices or defeat the purpose of these
safety devices.
FSC Actuator
Clevis
LH Steering Lever
(For Orientation)
Neutral Function Adjustment
3. Hold the actuator back as shown (against the
spring pressure) and tighten the nut to the point
where the end play is removed and then tight-
en two additional turns.
IMPORTANT: If the adjustment nut is too loose
(end play exists) excessive loads are placed on
transmission internal control stops. If the adjust-
ment nut is too tight (preferred condition), the maximum forward travel speed is reduced.
Neutral Function Adjustment - Step 3
1. Move the FSC lever to the NEUTRAL-PARK
position (rear travel limit).
2. Start the engine (operate first at idle and then
normal operating speeds) and check for move-
ment of the drive wheels.
NOTE: If the engine will not start, check and ad-
just the neutral safety switch (see item 4 below).
3. If drive wheels are moving, stop the engine and
adjust the FSC neutral stop by adjusti ng the
FSC actuat or clev is (see Neutral Function Ad-
justment photo for clevis location). If the drive
wheels are moving backward, remove the cotter
pin and clevis pin and screw the clevis forward.
If the drive wheels are movi ng forward, screw
the clevis backward. Restart the engine and
check for wheel movement (several “trial and error” adjustments may be required). At this point
it may not be possible to adjust both wheels
stationary since the differential adjustmen t has
not been made. (This is covered by the Straight
Ground Travel Adjustment - Step 4.) In this
case, the neutral adjustment should be made for
one wheel stationary and the other moving for-
ward slightly.
4. Check and adjust the neut ral safety switch
for closure and function with the FSC in neutral
(the engine will not start when the switch is
open). Use panel nuts on the switch body to
adjust switch position for closure in neutral. Refer to adjustment description for Safety Switch-
es in this section.
75
Maintenance Instructions ADJUSTMENTS
Straight Ground Travel Adjustment - Step 4
1. Sit in the seat, start the engine (opera te at normal speed), and with the FSC in the NEUTRAL-
PARK position check for forward movement of
either drive wheel (if either wheel moves back-
ward, refer back to Neutral Function Adjust-
ment - Step 3 and readjust). Tighten the
steering lever adjustment nut on the side of
the mower with the wheel moving forward
until wheel movement stops.
2. Check for straight grou nd trac k on a leve l sur-
face (with hands off the steering levers). Set
the FSC at several different speeds and observe if the mower moves in a straight line (use
cement joint or other l ine on the g ro und for r eference).
NOTE: The final tracking adjustment is made
with the mower moving, since the adjustment is
quite sensitive and is more easily “fine tuned”
when moving.
3. If travel is not straight, tighten the adjustment
nut that is on the same side of the mower as
the wheel that is moving too fast, e.g., the
mower tracks to the right, indicating the LH wheel
is moving too fast, tighten the LH adjustment nut.
Forward Speed Control Friction Lock The FSC friction lock is adjusted to hold the select-
ed forward speed when the steering levers are
moved and yet the fri ct ion is not too heavy to make
moving the control difficult (too much friction).
The procedure for checkin g and adjusting th e FSC
friction lock is as follows:
Friction Washer
Friction
Adjustment Nut
Forward Speed Control Friction Lock
1. Place the FSC in the full FORWARD position
and pull both ste ering leve rs bac k; the FSC lever should not move. If the FSC leve r moves
back when the steering leve rs are pu lled b ack,
the friction needs to be increased.
FSC Actuator
End Wrench on
Adjustment Nut
Straight Ground Travel Adjustment
2. With the steering levers held back, move the
FSC lever back from the FORWARD position.
With a proper amoun t 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.
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 conditions of both
steps 1 and 2 (above) are met.
76
Maintenance Instructions ADJUSTMENTS
Tilt-Up Deck Adjustable Stop
When the carrier frame hinge joint is properly adjusted, the deck lock levers should move in and out of the
engaged and disenga ged positions freely. All four
hitch pins used for height adjustment should sit flush
on the washers above the deck pin bus hing. On a
level surface, if any pin is sticking up (likely the front
pins), tighten the opposit e side or loosen the same
side to lower the pin. Adjustments are made by loosening the jam nut and tightening or loosening the set
screws on the Deck Mount Pivot Brackets. Retighten
the jam nut when the adjustment is complete.
Jam Nut
Set Screw
Tilt-Up Deck Adjustable Stop
NOTE: Due to the techn ical requirements of mod-
ern carburetors, re fer to th e Kohler Servic e Manu al
or contact an authorized Kohler engine dealer for
carburetor adjustments and service not described in
this section.
CAUTION
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.
Since the carburetor main jet is non -adjustable, for
operation above 5000 ft (1,524 m) above s ea l eve l,
it may be necessary to chan ge the ca rbur etor main
jet for best fuel economy and power. Contact an authorized Kohler dealer to change the carburetor
main jet.
Engine Idle Adjustment
IMPORTANT: Some emission certified engines
may not have an adjustable idle mixture needle
valve; it is fixed from the factor y and the ad justable
screw is "capped". In this case, only the idle speed
is adjustable and only Step 4 of the in str uc ti ons be low applies.
Carburetor
CAUTION
DO NOT change the engine governor settings or overspeed the engine. The governor has been factory set for ma ximum
safe engine operating speed.
The fixed main jet ca rbureto r is designed to deliver
the correct fuel-to-air mixture to the engine under all
operating conditions. The high idle is set at the factory and cannot be adjust ed. The low idle mixture
screw is also set at the fac tory and normally does
not need adjustment. The only adjustment normally
made to the carburetor is to set the idle speed.
However, if the engine exhibits any of the follo wing
symptoms, it may be necessary to adjust or service
the carburetor: black, sooty exhaust smoke; lack of
power; engine miss or backfir e; hard to start; roug h
running; stalls at low idle speed.
1. Gently close the i dle mixture needle valve by
turning it clockwise until it bottoms lightly.
IMPORTANT: The needle valve and carburetor
seat may be damaged by turning the adjustment screw too tight.
2. Preliminary Se tting : Turn the idle mixture nee dle valve out (counterclockwise) 1-1/2 turns
from the closed position. This initial adjust-
ment will allow the engine to be started and
warmed up prior to the final adjustment.
77
Maintenance Instructions ADJUSTMENTS
Low Idle Mixture
Needle Valve
(May be Non-Adjustable)
Idle Speed
Screw
Carburetor Adjustment
Fixed Main Jet Under
Shutdown Solenoid
DANGER
The engine must be running to adjust the
carburetor for engine idle. To guard
against injury, keep hands, feet, face, and
other part s of body away f rom the muffler/
exhaust pipe, other hot parts of the engine,
and moving or rotat ing parts of the engine.
3. Start the engine and allow it to warm up by running at 1/2 throttle for approximately five (5)
minutes. The engine must be warm before
making final settings.
GHS “Full” Signal Horn with Grass-Pak
If the GHS “full” signal horn is not sounding when the
catcher is full, the followi ng trou bl esh oot ing instructions apply:
T roubleshooting (When Horn Fails to Operate)
1. Check the horn.
a. Disconnect the two wires fr om the Grass-
b. Turn the ignition switch ON and move the
c. If the horn does not sound, the horn is bad
d. If the horn does sound, proceed to step 2.
2. Check the Grass-Pak
a. Reconnect the wires to the Grass-Pak
b. Turn the ignition switch ON and move the
c. Open the catcher back door and trigger the
®
switch electric connector plug and
Pak
make a jumper wire connection between
these wires (bypassing switch).
blade clutch to the ENGAGED position
(engine not running) to make the horn
sound.
and needs to be replaced.
®
switch.
switch electric connector pl ug.
blade clutch to the ENGAGED position
(engine not running).
Grass-Pak
®
vane by hand as it oscillates.
®
Switch
®
78
4. Move the throttle to the idle position. Adjust idle
speed for 1200 rpm (± 75 rpm) by adjusting the
idle speed screw. Check the idle speed using a
tachometer.
5. With the engine idling, adjust the idle mixture by
turning the idle mixture needle valve in (slowly)
from the preliminary s etting until en gine speed
decreases and then back out approximately 3/4
to 1 turn to obtain the best low speed performance.
6. Recheck idle spe ed after the final idle mixture
adjustment.
d. The horn should sound as the switch is
moved in both di rect ions. If the horn does
not sound, the switc h is bad and ne eds to
be replaced.
WARNING
DO NOT test the Grass-Pak® switch with
the engine running. Projectiles CAN be
thrown out of the grass delivery spout and
CAN cause serious injury to bystanders or
property damage.
Maintenance Instructions
ADJUSTMENTS/
ELECTRICAL SYSTEM
Grass-Pak
Vane Switch
Checking the Grass-Pak® Switch
ELECTRICAL SYSTEM
For troubleshooting, refer to Wiring Diagram.
IMPORTANT: Disconnect both battery cables be-
fore unplugging any wiring connectors or making repairs on the electrical system.
Circuit Breakers
A master circuit breaker is mounted on a bracket behind the battery. The circuit breaker may have either
the manual or automatic reset function -- both types
have been used. See Circuit Breaker Location
photo.
®
30 Amp
Circuit Breaker
Circuit Breaker
Mounting Bracket
Circuit Breaker Location
79
Maintenance Instructions ELECTRICAL SYSTEM
Wiring Diagram - Model MC
WALKER MODEL MC
Beginning S/N 2001-49399
IGNITION SWITCH CIRCUITS
TO MOTOR MOUNT
ORG
CASE GROUND
ORG
WHT
BLK
POWERFIL
MOTOR
BLK
-
HORN
+
YEL
PUR
WHT
GRN
R
GRASS PAK
SWITCH
BLK
WHT
RED
BLK
BLU
PUR
RECTIFIER/REGULATOR
WHT
GRN
OIL PRESSURE SWITCH
R
STARTER
STARTER SOLENOID
MAGNETO
OFF
START
RUN
S1 = START CIRCUIT
S2 = START/ACCESSORY CIRCUIT
M = MAGNETO GROUND CIRCUIT
B = BATTERY CIRCUIT
A = ACCESSORY CIRCUIT
G = GROUND CIRCUIT
OFF
START
PTO ON
ENGINE
G + M
B + A / S1 + S2
B + A
RELAY - A
IGNITION RELAY
30 + 87A
30 + 87A
OPEN
BLK
OFF
START
PTO ON
OFF
START
RUN
BLK
87A
30
RELAY - B
START RELAY
OPEN
30 + 87
OPEN
RELAY - C
DELAY RELAY
30 + 87A
OPEN
OPEN
RELAY - A
ORG
8685
ORG
OPTIONAL
LIGHT
BATTERY
BLK
BLK
30 AMP
CIRCUIT
BREAKER
RED RED
RED
BRN
YEL
BLU
YEL
RED
30
8586
87
RELAY - B
WHT
BRN
BRN
WHT
WHT
BRN/WHT
WHT
BRN/WHT
OPTIONAL
LIGHT
GRAGRA
FSC
NEUTRAL
INTERLOCK
SWITCH
RED
LIGHTS
B
M
WHT
S2
BLU
A
S1
G
PRESSURE
RED
YEL
BLK
BLK
OIL
LIGHT
PUR
ORG
BLK/WHT
BRN
PTO
INTERLOCK
SWITCH
GRA
SEAT
SWITCH
HOUR METER
RELAY - C
GRN
BLK
WHT
87A
8586
30
GRN
GRA GRA
TIME
DELAY
MODULE
BLK
RED RED
PUR
RED
PUR
RED
REDRED
GRN
PUR
RED
5 AMP
CIRCUIT
BREAKER
RED
OPTIONAL
BRN GRA
80
CHASSIS
GROUND
Operator’s Notes
81
Operator’s Notes
82
LIMITED W ARRANTY
FOR
WALKER
COMMERCIAL RIDER MOWER
1. WHAT THIS WARRANTY COVERS, AND FOR HOW LONG:
Walker Manufacturing company will, at its option, repair or replace, without charge, any p art 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
Kubota Engine
Kawasaki Engine
Eaton Hydraulic Transmission
Peerless Gearboxes
Battery
Tires
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.
* An extended three (3) year warranty is offered on the Walker P/N 6200-8 Gear Axle Assembly.
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
Owner’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 wa rranty sh all apply and no dealer, distributor, or individual is authorized
to amend, modify, or extend this warranty in any way. Accordingly, additional statements such as dea ler 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.
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Lwa
105
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OPERATOR
Sound - Model MC
Sound Test
Sound test conducted was in accordance
with 79/113/EEC and was performed on
28 January 98 under the conditions listed:
General Condition: Cloudy
o
Temperature: 32 (F)
Wind Speed: < 5 mph (< 8 kmh)
Humidity: 58%
Barometric Pressure: 25.0" HG (636 mm Hg)
0(C)o
Vibration - Model MC
Vibration Level
Vibration levels at the operators handles
were measured in the vertical, lateral, and
0.7g
longitudinal directions using calibrated
vibration test equipment.
Tests were performed on 28 January 98 under the
conditions listed:
General Condition: Cloudy
o
Temperature: 32 (F)
Wind Speed: < 5 mph (< 8 kmh)
Humidity: 58%
Barometric Pressure: 25.0" HG (636 mm Hg)
0(C)o
WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, C O 80528 • (970) 221-5614
FORM NO. 041503 PRINTED IN USA www.walkermowers.com ©2003 WALKER MFG. CO
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