Walker MC19 User Manual

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OPERATOR’S MANUAL

Safety, Assembly, Operating, and Maintenance Instructions

Model MC19

Please Read and Save These Instructions Beginning S/N: 125718

For Safety, Read All Safety and Operation Effective Date: 11-25-13 Instructions Prior to Operating Machine P/N 6000-16

Foreword

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

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

This manual covers Model MC19 with the Kohler Command Pro CH621 (19.0 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.

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

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

Sincerely, WALKER MANUFACTURING COMPANY

Bob Walker, President

Table of Contents

General Information ________________ 1

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

Specications ________________________ 3

ENGINE ________________________________ 3 ELECTRICAL SYSTEM ___________________ 3 TRANSMISSION _________________________ 3 BLADE DRIVE __________________________ 4 TIRE SIZE ______________________________ 4 TIRE PRESSURE ________________________ 4 DRIVE BELTS ___________________________ 4 SEAT __________________________________ 4 FRAME/BODY CONSTRUCTION ___________ 4 GHS SYSTEM ___________________________ 5 MOWER DECK __________________________ 5 DIMENSIONS (Tractor and Mower) _________ 5

Component Identication ___________ 6

Safety Instructions __________________ 9

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

Assembly Instructions ______________ 18

SETUP INSTRUCTIONS __________________ 18

Tire Installation (Tractor) _______________ 18 Battery Service _______________________ 18

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

Mower Deck Assembly _________________ 19

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

Mower Deck Installation on Tractor _______ 21

Deck Installation _____________________ 21 Deck Leveling _______________________ 23

PREOPERATING CHECKLIST _____________ 24

Operating Instructions _____________ 26

CONTROL IDENTIFICATION, LOCATION, AND FUNCTION _____________ 26

Ignition Switch _______________________ 26 Engine Choke ________________________ 26 Engine Throttle _______________________ 27 Forward Speed Control (FSC) ___________ 27 Steering Levers_______________________ 27 Blade Clutch (PTO) ____________________ 27 Parking Brake ________________________ 27 Front Body Latch Release ______________ 28 Transmission Lockout Levers ___________ 28 Hourmeter ___________________________ 29 Oil Pressure Warning Horn _____________ 29 Circuit Breaker (7 Amp) ________________ 29

Light Switch (For Optional Lights) _______ 29 STARTING THE ENGINE _________________ 31 ADJUSTING GROUND SPEED AND STEERING __________________ 31 ENGAGING THE BLADE DRIVE ___________ 33 STOPPING THE MACHINE _______________ 34 ADJUSTING CUTTING HEIGHT ____________ 35 TRANSMISSION LOCKOUT ______________ 35 RECOMMENDATIONS FOR MOWING ______ 36 RECOMMENDATIONS FOR TILT-UP DECK OPERATION/TRANSPORT _______________ 38 GRASS HANDLING SYSTEM (GHS) ________ 39

General Information ___________________ 40

Clogging Checklist ____________________ 41

Using the Tilt-Up Deck _________________ 42

Using the GHS Catcher ________________ 42

Powerl ® __________________________ 42 “Full” Signal Horn ____________________ 42

Cleaning the GHS Exhaust Screen _______ 42

Dumping the Catcher __________________ 43

Tailgate Dumping ____________________ 43 Using the Dump Bag __________________ 43

Table of Contents

Maintenance Instructions __________ 45

MAINTENANCE SCHEDULE CHART _______ 45 IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE ________________ 46

Fuel System _________________________ 46 Starting/Stopping _____________________ 46 Cooling System ______________________ 46 Air Cleaner System ____________________ 46 Oil__________________________________ 46

LUBRICATION _________________________ 47

Engine Oil ___________________________ 47

Engine Break-In Oil ___________________ 47 Checking Engine Crankcase Oil Level ____ 47 Changing Engine Crankcase Oil/Oil Filter __ 47

Mower Deck Gearbox Lubrication ________ 48 DS52 or DS62 Mower Deck Lubrication ___ 49 Mower Deck Spindle Lubrication ________ 49 Tractor PTO Gearbox Lubrication ________ 50

Checking Gearbox Oil Level ____________ 50 Changing Gearbox Oil ________________ 50

Gear Axle Lubrication _________________ 50 Hydrostatic Transmission Fluid _________ 50

Checking Hydrostatic Transmission Fluid Level ______________ 50

Grease Fitting and Oil Point Lubrication __ 51

CLEANING ____________________________ 54

Engine Air Cleaner System _____________ 54

Turbine Precleaner ___________________ 54 Enginaire™ Air Cleaner _______________ 54

Engine Cooling System ________________ 56

Cooling Air Intake System ______________ 56 Cylinder Head Cooling Fins ____________ 57

Grass Buildup in Mower Deck Housing ___ 57 GHS Blower __________________________ 58 GHS Exhaust Screen __________________ 59 Hydrostatic Transmission Cooling Fins ___ 59

CHECKING/SERVICING __________________ 59

Security of Air Filtration Components ____ 59

Battery ______________________________ 59

Electrolyte Level _____________________ 59 Cleaning the Terminals ________________ 60 Charging the Battery __________________ 60

Tire Pressure _________________________ 60

Wheel Bolt Torque ____________________ 60

Sharpen Mower Blades ________________ 60

Drive Belts ___________________________ 61

Mower Deck Gearbox Oil Seals __________ 62

Spark Plugs __________________________ 62

Fuel Lines and Clamps _________________ 62

Engine Starter ________________________ 62

Blade Brake Action ____________________ 62

Safety Switch System__________________ 62

Forward Speed Control Friction Lock _____ 63 REPLACING/REPAIRING _________________ 63

Drive Belts ___________________________ 63

Engine PTO Drive Belt ________________ 65 Jackshaft Drive Belt __________________ 66 GHS Blower Drive Belt ________________ 67 Hydrostatic Ground Drive Belt ___________ 68

Fuel Filter ___________________________ 69

Blade Overload Shear Bolts_____________ 69

PTO Shear Pin (If Equipped) ____________ 70

Mower Blades ________________________ 70 ADJUSTMENTS ________________________ 71

Steering Handles _____________________ 71

Tilt-Up Deck Adjustable Stop ____________ 71

GHS Signal Horn Adjustment

(When Horn Sounds at Wrong Time) ______ 71

Operator’s Notes _______________ 73

Warranty _____________________ 75

General Information

HIGHLIGHTED INFORMATION

Walker Manufacturing recommends that any service requiring special training or tools be performed by an authorized Walker Mower dealer. There are several general practices to be aware of in the area of safety. Most accidents associated with the operation or maintenance of a Walker Mower are caused by disregarding basic safety precautions or specic warnings. Such accidents, in most cases, can be prevented by being aware of the dangers present.

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

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

GLOSSARY

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

• DECK is the mowing attachment mounted on

the front of the tractor which includes the carrier frame, deck housing, belt or gear drive components, and cutter blades.

• FORWARD SPEED CONTROL (FSC) controls

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

• GRASS HANDLING SYSTEM (GHS

mowed material and deposits it in the catcher.

• GRASS-PAK

grass delivery spout (in the catcher) and activates the “full” signal horn when the grass catcher is full.

SWITCH is mounted on the

) collects

• GROUND DRIVE refers to the dual hydrostatic

transmissions which drive the main wheels.

• POWER TAKE-OFF (PTO) transmits engine

power to run the cutter blades and GHS blower.

• POWERFIL

throughout the interior of the grass catcher by an oscillating delivery spout.

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) discharges mowed

material from the right side of the mower deck.

• STEERING LEVERS steer the tractor by con-

trolling the dual hydrostatic transmissions.

• TRACTOR is the prime mover, including the en-

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

Tractor Model No. ______________________

Tractor Serial No. ______________________

Deck Serial No. ______________________

• 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 operator is seated facing forward in the tractor seat.

Engine Model No. ______________________

Engine Serial No. ______________________

Date of Purchase ______________________

Fill In By Purchaser

General Information

Serial Number

Tractor Serial Number Location

SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS

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

Serial Number

Mower Deck Serial Number Location

ENGINE SERIAL NUMBER LOCATION

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

Walker Manufacturing Company

5925 E. Harmony Road

Fort Collins, CO 80528

1-970-221-5614

walkermowers.com

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

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

Hydrostatic Eaton Fluid Power Group Transmissions Hydraulics Business USA 14615 Lone Oak Road Eden Prairie, MN 55344 USA 952-937-9800 www.eaton.com/hydraulics

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

Serial Number

Engine Serial Number Location

Specications

MODEL MC19

ENGINE

Manufacturer/Model Kohler Command Pro CH621, 2 Cyl., Gasoline (Air-Cooled)

Displacement cu. in. (cc) 38.1 (624)

Max. Power HP (kW) 19.0 (14.2) @ 3600 RPM

Governed RPM 3600

Max. Torque lb·ft (N·m) 32.2 (43.7)

Idle RPM 1200

Spark Plug Type

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

Crankcase Capacity qt (L) 2.0 (1.9)

Crankcase Lubricant

Oil Filter Kohler P/N 28-050-01

Champion

API SG, SH, SJ or higher Grade Oil Only with 10W-30 Viscosity above 0° F (-18° C), or 5W-20 or 5W-30 Viscosity below 32° F (0° C)

RC12YC

Fuel Tank Capacity gal (L) 2.8 (10.6)

Fuel

Cooling System Air Cooled

Air Cleaner

ELECTRICAL SYSTEM

Battery 12 Volt, 35 AH, 300 CCA

Charging System Flywheel Alternator

Charging Output 15 Amp DC (Regulated)

System Polarity Negative Ground

Ignition Electronic Capacitive Discharge

Starter 12 Volt Electric Ring-Gear Type, Solenoid Shift

Interlock Switches

Circuit Breaker Auto Reset (30A)

TRANSMISSION

Manufacturer/Model Dual Hydrostatic, Eaton Model 7, Each Wheel Independently Driven

Regular Grade Unleaded Gasoline (87 Octane or Greater, 10% Ethanol Maximum)

Remote mounted Enginaire™ VLR (Walker P/N 5090-1 Primary/5090-3 Safety Filter)

Ignition Lockout by Seat Switch, Transmission Neutral and Blade Clutch

Steering Hand Lever Control / Individual Wheel

Forward Speed Control

Service Brake Dynamic Braking through Hydrostatic Transmission

Parking Brake Mechanical Pin Lock in Transmission Gear

Precision Friction Lock Lever, Cruise Control, with Neutral-Park Position

Specications

MODEL MC19

TRANSMISSION (continued)

Neutral Transmission Release by Manual Dump Valve

Final Drive Gear Drive Axle

Transmission Fluid

Factory Service Mobil 1 Synthetic Motor Oil (15W-50)

Transmission Oil Capacity oz (L) 19 (0.56)

Transmission Cooling Cooling Fan Mounted on Drive Pulley

Ground Travel Speed

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

BLADE DRIVE

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

Blade Drive Clutch and Brake

0-7 (0-11.3) Innitely Variable 0-5 (0-8) Innitely Variable

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

TIRE SIZE

Deck Caster 8 x 3.00-4 (Pneumatic 4-Ply)

Drive 18 x 8.50-10 (Pneumatic 4-Ply, Low-Prole)

Rear Caster 13 x 6.50-6 (Pneumatic 4-Ply)

TIRE PRESSURE PSI (KPA)

Deck Caster Wheel 20 (137)

Drive 15 (103)

Rear 20 (137)

DRIVE BELTS

Engine PTO Walker P/N 8230

Jackshaft Drive Walker P/N 6250-1

Ground Drive, Micro-V Walker P/N 7248

Blower Walker P/N 7234-2

SEAT

FRAME/BODY CONSTRUCTION

Frame All Welded Unitized Steel Chassis

Contour-Molded, with Nylon Backed Vinyl Cover and Integral Foam Cushion

Body 14 Gauge Steel

Deck 11 Gauge Steel

GHS Catcher and Chutes Molded Cross-Linked Polyethylene (UV Stabilized)

Specications

MODEL MC19

GHS SYSTEM

Blower 10.5 in. Diameter, Three-Blade Paddle Wheel

Blower Brake

Max. Blower RPM 4000

Grass Catcher Capacity gal / bu / L

Full Signal (Grass-Pak

Powerl

MOWER DECK

Recommended Cut Width Collection

Side Discharge 36 to 62 in. (81 to 157 cm)

Switch)

Band Brake [Works in Combination with PTO Clutch, Stops Blower within Five (5) Seconds of PTO Disengagement]

65 / 7 / 246

Oscillating Vane Switch Mounted on Grass Delivery Spout Triggers Horn Signal

Oscillating Delivery Spout Driven by 12 Volt Electric Gearmotor Spreads Material throughout Interior of Catcher @ 25 Cycles/Minute

36 to 48 in. (81 to 122 cm)

Mulch 36 to 52 in. (81 to 132 cm)

Cutting Height

Deck Suspension

DIMENSIONS (Tractor and Mower)

Length in. (cm)

Tractor Only 64.5 (164)

Tractor Wheel Base 42.25 (107.5)

Tractor with Tilted Deck (Approximate)

Tractor with 42" Collection Deck (DC42-1)

Width in. (cm)

Tractor Only (Outside Tire) 37.75 (96)

Tractor with 42" Collection Deck (DC42-1)

Height in. (cm)

Tractor 47.5 (120.5)

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

Independent Torsion-Flex Frame with Caster Wheels and Counterweight Springs

77 (195.5)

89.25 (226.5)

43.25 (110)

Weight lb (kg)

Tractor Only 734 (333)

Tractor with 42" Collection Deck (DC42-1)

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

925 (419.5)

Component Identication

NOTE: Control Identication

shown in Operating Instructions section.

Grass Handling System

7.0 Bushel Catcher

Tilt-Up Latch

Spring Clip

Counterweight Spring

and Protective Cover

Anti-Scuff

Roller

Catcher Lift /

Dump Handle

Transmission Control

Rod Adjustment Nut

Fuel Tank and Cap

(RH)

Deck Support Arms

Deck Lift Handle

(Cutting Height Adjustment)

Tilt-Up

Hook

Transmission Control Rod

Adjustment Nut (LH)

Deck Support Pins

and Height Adjustment

Hitch Pins

Footrests

Tilt-Up

Deck Handle

Deck

Caster Wheels

Front View and Right Side View

Component Identication

Catcher Lift /

Dump Handle

Catcher Door

Gas Spring

(Not Visible)

Removable Grass

Catcher Screen

(Not Visible)

Catcher Door

Footrest

Left Hand

Drive Wheel

Mufer

Tailpipe

Oil

Filter

Anti-Scuff

Roller

Catcher

Door Handle

Oil Drain

Plug

Tailwheel Fork

and Wheel

Rear View and Left Side View

Component Identication

Air Cleaner

Cover

Air Intake

Hose

Fuel Tank Cap

Jackshaft

PTO Gearbox

Dipstick

Enginaire™

Air Cleaner

Air Filter

Restriction

Gauge

Fuel Pump

Mufer

Throttle and

Choke Linkage

Mufer Heat

Shield

Oil Fill/

Dipstick

Rubber Bumpers

(Catcher Support)

GHS Blower

RH Transmission

Lockout Lever

Positive (+)

Battery Cable

PTO

Clutch Lever

30 Amp

Circuit Breaker

(Not Visible)

Battery Cable

Negative (-)

Battery

Top View (Engine Compartment)

LH Hydrostatic

Transmission

RH Hydrostatic

Transmission

Neutral

Safety Switch

LH Transmission

Lockout Lever

Safety Instructions - Before Operating

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

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

The seriousness or degree of importance of each type of information is dened as follows:

DANGER

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

WARNING

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

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

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

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

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

BEFORE OPERATING

1. Read and understand the contents of this

Operator’s Manual before starting and operating the machine. Become thoroughly famil-

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

Walker Manufacturing Company

5925 East Harmony Road

Fort Collins, CO 80528

CAUTION

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

IMPORTANT: Identies mechanical information

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

NOTE: Identies information worthy of special attention.

2. Never allow children to operate rider mower.

Do not allow adults to operate without proper instruction.

3. Clear the area to be mowed of any foreign

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

4. Keep everyone, especially children and pets, a

safe distance away from the area being mowed.

Do not mow with bystanders in the area.

5. Do not operate the machine barefoot or wearing

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

tective footwear.

Safety Instructions - Before Operating

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

7. Prolonged exposure to loud noise can cause impairment or loss of hearing. Operator hear- ing protection is recommended; particularly for continuous operation of the GHS Model due to blower noise level. Wear a suitable hearing protective device, such as earmuffs or earplugs.

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

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

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

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

WARNING

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

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

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

10. Handle gasoline with care. Gasoline is highly

ammable 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 ames, or sparks away from the fuel tank and fuel container.

d. Always ll the fuel tank outdoors using care.

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

e. Replace the machine fuel cap and container

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

Safety Instructions - Operating

1. Operate the mower only in daylight or in

good articial light with good visibility of the area being mowed.

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

erate the tractor without a deck or implement installed.

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

Be aware that, with the front mounted mower conguration, the back of the tractor swings to the outside during turns.

DANGER

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

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

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

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

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

7. Do not operate machine if the operator pres- ence safety switch system is not working. Verify proper operation by having the operator lift off the seat with the engine running and moving two controls, one at a time; (1) Move the FSC lever out of the NEUTRAL-PARK position, and (2) Engage the PTO Clutch. Moving either control should stop the engine after a 1/2 second delay.

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

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

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

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

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

13. Disengage the blade drive when transporting the machine across drives, sidewalks, etc. Nev-

er raise the mower deck while blades are rotating.

DANGER

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

Safety Instructions - Operating

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

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

slope greater than 15 degrees.

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

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

NOTE: A blade/blower brake should normally stop drive line rotation within ve (5) seconds of disengaging the PTO clutch.

16. For side discharge mower decks, do not oper- ate with the grass deector shield removed. Keep the deector in the lowest possible position.

17. For tractors equipped with tilt-up deck, observe

the following recommendations:

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

position.

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

position.

18. Do not operate the machine with the grass

catcher in the DUMP position or with the back door OPEN. Dangerous projectiles may

be thrown out of the discharge chute or the back of the grass catcher.

19. Use care when closing the grass catcher door. Keep ngers and hands away from the hinge and pinch points when the door is being closed. Also, keep ngers and hands clear of the door frame. The door may slam shut with considerable force.

20. 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 shaft 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 - use a stick or similar tool to remove clogged material.

21. If the cutting blades strike a solid object or the

machine begins to vibrate abnormally,

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

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

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

23. When leaving the machine unattended, disen-

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

CAUTION

Use leg muscles and rm footing when lifting the catcher to dump; avoid bending at the waist and using back muscles in order to prevent back injury.

Safety Instructions - Maintenance

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

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

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

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

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

jewelry or loose clothing.

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

Unauthorized maintenance operations or modications to the engine may result in unsafe operating conditions.

11. Use care when charging the battery or per-

forming maintenance on the battery and electrical system:

a. Make sure the battery charger is unplugged

before connecting or disconnecting cables to the battery.

b. Charge the battery in a well-ventilated

space, so gases produced while charging can dissipate. Make sure the battery vents in the caps are open.

c. Keep sparks, ames, and smoking materi-

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

d. Disconnect both battery cables before un-

plugging any wiring connectors or making repairs on the electrical system.

IMPORTANT: Keep all applicable manuals immediately accessible to anyone who may operate or service this machine.

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

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

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

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

Safety Instructions

SAFETY, CONTROL, AND INSTRUCTION DECALS

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

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

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

8600-4

Location: Adjacent to Blower Discharge Chute through Body Part Number: 8600-4

1. Warning - rotating impeller is a cutting/dismemberment hazard to ngers and hands.

• Never reach down into the blower discharge chute.

2. Warning - thrown object hazard.

• Never engage the PTO with grass catcher raised.

8600-12

Location: Front Body, LH Side Above Mufer Part Number: 8600-12

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

• CO emitted by a running engine can be deadly.

• Do not operate indoors or in other enclosed areas.

Location: Front Body, RH Side Adjacent to Operator Seat Part Number: 8600-30

1. Parking brake Move lever forward to engage Parking Brake; back to disengage.

Location: Engine Shroud Part Number: 5855

8600-16

Location: Rear Cross Member of Front Body Part Number: 8600-16

1. Important - Lower front body before lowering catcher box.

Location: Rear of Grass Catcher Exhaust Screen Part Number: 5869

60 lb·f t (81 N·m)

8600-9

Location: Gearbox Cover (Gear Drive Decks Only) Part Number: 8600-9

1. Tighten blade nuts on gear driven decks to 60 lb·ft (81 N·m).

6807-1

Location: Front Body, Adjacent to Oil Pressure Warning Horn Part Number: 6807-1

Safety Instructions

SAFETY, CONTROL, AND INSTRUCTION DECALS

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

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

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

8600-28

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

1. Warning – thrown object hazard.

• Keep bystanders away from the machine when operating.

• Clear lawn of debris before operating.

• Keep any discharge deector in place and in the lowest position.

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

• Keep all body parts away from rotating mower blades.

• Do not step on end of deck.

8600-14

Location: Deck Carrier Frame Part Number: 8600-14

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

Location: Front Body, RH Side Part Number: 5082-5

5848-2

Location: Deck Discharge Shield (SD Decks Only) Part Number: 5848-2

1. Warning – thrown object hazard.

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

• Do not remove the discharge shield.

Location: Deck Carrier Frame Part Number: 8600-15

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

Location: Gear Axle Part Number: 5810-1

Location: Deck Gearbox Cover Part Number: 8600-7

1. Warning - stop engine and remove ignition key before adjusting deck cutting height.

Location: Jackshaft Support Adjacent to Dipstick Part Number: 7827

Safety Instructions

SAFETY, CONTROL, AND INSTRUCTION DECALS

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

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

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

8600-23

Location: Right Side, Behind Operator Seat Part Number: 8600-23

1. Warning – entanglement hazard.

• Remove ignition key before raising front body.

2. Body Tilt Latch

• Raise lever to release.

• Lift at back of body to raise.

Location: Catcher Door Hinge Bar, LH and RH Sides Part Number: 8600-10

1. 2.

1. Caution - Pinch point.

• Keep all body parts clear when closing grass catcher door.

Location: Bridge Assembly and LH Gear Axle Part Number: 5810-3

Location: RH Fender Part Number: 8600-33

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

• Engage parking brake.

• Remove ignition key.

2. Forward Speed Control

• Move lever forward to increase speed; back to stop.

3. Warning – do not operate the machine without a deck or other implement attached.

4. PTO Clutch Lever

• Move lever back to engage PTO clutch; forward to disengage.

5. Warning – do not engage PTO clutch with PTO shaft disconnected.

Safety Instructions

SAFETY, CONTROL, AND INSTRUCTION DECALS

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

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

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

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

Warning – wear eye and ear protection when op-

erating the machine.

2. Forward Speed Control

• Move lever forward to increase speed; back to stop.

3. Warning – roll-over hazard.

• Do not operate on slopes greater than 15 degrees.

4. Warning – thrown object hazard.

• Keep bystanders away from the machine when operating.

5. Warning – entanglement hazard.

• Keep all guards in place while engine is running.

6. Choke

Location: LH Fender Part Number: 8600-35

6.5.

Location: Hydrostat Oil Reservoir

Assembly Instructions

SETUP INSTRUCTIONS

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

Tire Installation (Tractor)

• Install the drive tires using the eight (8) lug bolts

that are supplied with the owner’s packet of materials. Bolts are torqued to 75 to 85 lb·ft (102 to 115 N·m). Drive tires are 18 x 8.50-10, 4-ply; rear tire is 13 x 6.50-6, 4-ply.

• Check and adjust the ination of the tires. The

tire ination recommendations are:

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

Battery Service

Raise front mower body up for battery access (refer to Front Body Latch Release in Operating Instruc- tions). Check the battery for electrolyte level and charge. The electrolyte level should be at the bottom of the vent wells [1/4 to 1/2 in. (6 to 13 mm) above plates]. If the specic gravity is less than

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

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

Dry Battery Service

DANGER

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

DANGER

Battery electrolyte is a poisonous and corrosive sulfuric acid solution.

• Avoid spillage and contact with skin,

eyes, and clothing - causes severe burns.

• To prevent accidents, wear safety gog-

gles and rubber gloves when working with electrolyte.

• Neutralize acid spills with baking soda

and water solution.

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

Wet Battery Service

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

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

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

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

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

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

2. Remove the ller caps and carefully ll each cell until the electrolyte is just above the plates.

Assembly Instructions

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

Battery Charging.

Battery Charging

DANGER

BATTERIES PRODUCE EXPLOSIVE GASES

• Charge the battery in a well-ventilated

area, so that gases produced while charging can dissipate.

• Keep sparks, ames, and smoking mate-

rials away from the battery at all times.

• Make sure the battery cap vents are open

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

• Make sure the battery charger is un-

plugged before connecting or disconnecting cables to the battery.

Install the battery in the mower as shown in Battery Installation photo. Connect the positive (+) rst and

then the negative (-) cable to the proper battery terminal [red cable and boot connects to the Posi- tive (+) terminal]. Slide the rubber boot up and over the battery post, making sure it covers the post completely to prevent an electrical short.

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)

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

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

IMPORTANT: DO NOT overll the battery. Electrolyte will overow through the vented caps onto parts of the machine and WILL result in severe corrosion.

3. Install battery.

Battery Installation

(+) Battery Cable

Connection

Battery Installation

Mower Deck Assembly

Deck Caster Wheels Installation

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

NOTE: Spacer washers are used only when the optional semi-pneumatic deck wheels (8.25 x 2.75) are installed.

2. Fit the axle spacer tube through the wheel hub, position the spacer washer on each side of the hub (if used), and t 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.

Assembly Instructions

Axle Spacer Tube

Spacer Washer

Axle Bolt

Deck Discharge Deector Shield Installation (Side Discharge Models Only)

Attach the side discharge deector shield using two (2) 3/8-16 x 1-1/4 in. bolts, 3/8-16 nylon insert locknuts, and 3/8 in. wave spring washers. The wave washers t between the two hinging surfaces. Tighten the nuts until the shield moves freely but is not loose.

WARNING

Deck Caster Wheel Installation

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

Deck Discharge Chute Installation (GHS Rear Discharge Models Only)

Mount the discharge chute hinge on top of the deck discharge opening using the 1/4-20 x 1/2 in. socket button head screw and 1/4-20 ESNA nut. Position the screw with the head inside of the chute and the nut on the outside. Attach spring for tilt-up action from chute to bracket on deck.

Carrier Frame

Attach Guard

Tube Sockets

Attach Chute

DO NOT operate the machine without the grass deector shield attached and in the lowest possible position.

Attach Shield

Discharge Shield Installation

on Side Discharge Deck

PTO Shaft Guard Installation

Position the shaft guard as shown and mount with two (2) 1/4-20 x 1/2 in. bolts.

Nut on Top

Discharge Chute and PTO Shaft Guard

Installation on Rear Discharge Deck

Tilt-Up Roller Wheel Installation

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

Assembly Instructions

Attach Spring

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

NOTE: When installing the DS52 or DS62 Mower deck, make sure to retract the dolly wheel after mounting the deck on the tractor.

Arrows on Shaft and Tube

(Used to Align When Sliding Together)

Roller

Wheels

Tilt-Up Spring and Roller Wheel

Installation on Rear Discharge Deck

Mower Deck Installation on Tractor

Deck Installation

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

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

2. Engage the deck carrier frame tube sockets on

the tractor support arms (refer to Discharge Chute and PTO Shaft Guard Installation photo for socket location), slide the deck onto the support arms approximately 3 in. (76 mm).

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

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

Coupler

Installation Tool

PTO

Connection

Grease Deck

Support Arms

Mower Deck Installation

(PTO Shaft Connection)

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

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

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

PTO Coupler

Tube

PTO Coupler Installation Tool

Retract Spring-Loaded Quick Disconnect Ring

Assembly Instructions

Coupler Ring in

Released Position

PTO Coupler

U-Joint

Quick Disconnect Ring “Released” Position

Internal Balls

Locked on Shaft

PTO Drive

Shaft

PTO Drive

Shaft

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

Spring Tension Adjustment

Nut Located Under Lower Spring Hook (Not Visible)

Counterweight Springs

Clip Onto Body With

Forward Body Tilted Up

Deck Counterweight Spring Installation

Hitch Pins

Lock Deck On

Support Arms

PTO Coupler

U-Joint

Quick Disconnect Ring “Locked” Position

6. Slide the deck the rest of the way on the deck arms. If the deck is rear discharge (GHS equipped model), the rear discharge chute will need to be aligned and connected to the blower inlet during the last 2 in. (51 mm) of slide action on the support arms.

NOTE: Raising the mower body may be helpful in tting and guiding the deck chute into the blower.

7. Install the hitch pin through the hole on the end of each support arm to lock the deck in place (refer to Deck Counterweight Spring Installa- tion photo). Two (2) hitch pins are included in the Owner’s Packet of materials.

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

Coupler Ring in

Locked Position

Assembly Instructions

Deck Leveling

1. Position mower on a smooth, level surface. Set the cutting height to the highest position - 4 in. (102 mm) - for easy access under the deck to measure blade height. Refer to ADJUSTING

CUTTING HEIGHT in Operating Instructions.

NOTE: A block of wood cut 4 in. (102 mm) high

is a convenient gauge to measure blade height above ground during the leveling process.

WARNING

The machine must be shut off during this procedure.

2. Check the side-to-side level. Rotate each blade sideways and measure the distance

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

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

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

NOTE: The mower deck and support frame are

jig welded; within normal tolerances, very little, if any, shimming should be required to level the deck. Tire pressure will inuence the levelness of the deck. Check the tire pressure as a possible cause of the deck not being level.

4 in. (102 mm)

Wood Block

Should not vary more

than 1/8 in. (3 mm)

side-to-side

NOTE: For DS52 and DS62 decks with three (3) blades, the front-to-rear level should be set using the middle blade pointing forward, and either outside blade pointing back.

Should be 1/8 in. (3 mm)

to 1/4 in. (6 mm) higher

at the rear of the blade

4 in. (102 mm)

Wood Block

Deck Leveling

Assembly Instructions

PREOPERATING CHECKLIST

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

For proper fuel and lubricants refer to Specications.

FILL FUEL TANK

Fill the fuel tank using clean, fresh automotive grade unleaded gasoline (87 octane rating minimum).

DANGER

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

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

ning.

• If the engine is hot, allow to cool before

refueling.

• Use an approved fuel container.

• Fuel the mower outdoors.

• DO NOT smoke while refueling.

• Avoid spilling fuel; use a funnel or spout.

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

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

IMPORTANT: DO NOT mix oil with gasoline. Al-

ways use fresh, automotive grade unleaded gasoline. DO NOT use premium, white, or high-test gasoline. DO NOT use additives, such as carburetor cleaners, deicers, or moisture removing agents. DO NOT use gasoline blended with methyl alcohol.

CHECK ENGINE CRANKCASE OIL LEVEL

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

CHECK AND SERVICE ENGINE AIR CLEAN-

ER SYSTEM

• Check air lter restriction gauge to make sure

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

• Check condition, cleanliness, and security of the

complete air cleaner system (inspect paper element every 100 hours). For detailed procedures, refer to CLEANING the Engine Air Cleaner System in Maintenance Instructions.

CHECK ENGINE COOLING SYSTEM

Check that the engine cooling air intake screen is free of obstruction by grass clippings or debris and clean if required. Also, cylinder head cooling ns should be inspected and cleaned if any build-up of debris is noted [remove two (2) cylinder head access panels to inspect and clean]. Refer to CLEAN-

ING the Cylinder Head Cooling Fins in the Mainte- nance Instructions for this procedure.

CHECK GEAR AXLE OIL LEVEL

Refer to LUBRICATION for Gear Axle Lubrication in Maintenance Instructions.

IMPORTANT: DO NOT permit dirt or other foreign matter to enter the fuel tank. Wipe dirt from around the ller cap before removing. Use a clean fuel storage container and funnel.

INSPECT FOUR (4) DRIVE BELTS

Engine PTO Drive, Jackshaft Drive, Hydrostatic Ground Drive, and GHS Blower Drive.

CHECK HYDROSTATIC TRANSMISSION OIL

LEVEL

Refer to LUBRICATION for Checking Hydrostatic

Transmission Fluid Level in Maintenance Instruc- tions.

Assembly Instructions

CHECK FUNCTION OF OIL PRESSURE

WARNING HORN

Turn ignition key to the RUN position. The oil pressure horn should signal, indicating normal function.

CHECK FUNCTION OF SAFETY INTERLOCK

SWITCHES

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

CHECK AND CLEAN GRASS BUILDUP UN-

DERNEATH MOWER DECK (and inside GHS blower)

Refer to CLEANING the GHS Blower in Mainte- nance Instructions for blower cleaning information.

DANGER

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

CAUTION

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

DANGER

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

CHECK MOWER BLADE CONDITION,

SHARPNESS, BALANCE, AND SECURITY OF MOUNTING

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

CHECKING/SERVICING for Sharpen Mower Blades in Maintenance Instructions.

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

Tilt-Up Hook and Latch Connected

Tilt-Up

Latch

Tilt-Up

Hook

Deck Lock Lever

ADJUST MOWER CUTTING HEIGHT, IF RE-

QUIRED

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

CHECK TIRE PRESSURE

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

CHECK SECURITY OF DRIVE WHEEL BOLTS

The eight (8) lug bolts mounting the drive tires should each be torqued to 75 to 85 lb·ft (102 to 115 N·m).

PERFORM ANY ADDITIONAL PROCEDURES

called for on the MAINTENANCE SCHEDULE

CHART in Maintenance Instructions.

Deck Secured in TILT-UP Position

Operating Instructions

CONTROL IDENTIFICATION, LOCATION, AND FUNCTION

CAUTION

Before operating the mower, become familiar with the location and function of all operator controls. Knowing the location, function, and operation of these controls is important for safe and efcient operation of the mower.

Ignition Switch

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

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

Engine Choke

The choke control lever (black knob) is located on the left side of the seat. To start a cold engine, move the choke control forward to the ON position. After 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 the 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.

Front Body Latch

Release (Not Visible)

Forward Speed

Control (FSC)

Parking

Brake

Blade Clutch

(PTO)

Light Switch

(Optional, Not Shown)

Steering

Levers

Choke

Throttle

OFF

Ignition Switch

Key Positions

Ignition Switch

(See Inset)

START

7 Amp

Circuit Breaker

Oil Pressure

Warning Horn

Operating Controls

Hourmeter

Operating Instructions

Engine Throttle

The throttle control lever (red knob) is located on the left side of the seat and is used to control engine speed. Moving the lever forward toward the FAST position increases engine speed; moving it back- ward toward the IDLE position decreases engine speed.

Throttle Choke

Choke and Throttle Location

Forward Speed Control (FSC)

Forward Speed Control (FSC) has two functions: One is to set forward travel speed, and the other is to establish the NEUTRAL-PARK position. When the FSC lever is moved into the FORWARD position, a friction lock holds any forward speed setting from 0 to 6.5 mph (0 to 10.5 km/h). The ground speed is proportional to the lever position; the further the lever is advanced forward, the faster the tractor moves. It is not necessary to hold the FSC in position since the friction lock maintains the selected lever position. Pulling back on the steering levers overrides the FSC setting and slows or stops forward travel. Releasing the steering levers allows the tractor to resume forward travel at the speed set by the FSC lever. To stop and park the machine, the FSC lever is moved backward to the NEUTRAL-

PARK position.

NOTE: Pushing forward on the steering levers will

not cause any change in tractor motion - there will be no steering lever reaction and there will be no machine damage.

Blade Clutch (PTO)

The blade clutch lever has two positions. Pulling the lever UP engages the PTO that drives the mower blades. Pushing the lever DOWN disengages the PTO and engages the blade brake.

NOTE: The Powerl signal switch are activated by engaging the blade clutch. Refer to Using the GHS Catcher in this sec- tion for a complete description of GHS operation.

Parking Brake

The parking brake functions by locking a pin into the hydrostatic transmission pinion gear teeth. Moving 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 mechanical lock similar to the PARK position on an automotive automatic transmission. If the tractor is moving when the brake is engaged, it will result in sudden stoppage and possible internal damage to the axle drive.

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

motor and Grass-Pak® full

Steering Levers

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

Parking Brake Engaged

Operating Instructions

Parking Brake Disengaged

Transmission Lockout Levers

The transmission lockout levers disengage the hydrostatic transmissions. By lifting the lever on top of the transmission and locking it into place with the lockout cam, the hydrostatic transmissions are released to permit freewheeling. By releasing the cam and lowering the lever, the transmissions are engaged 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.

Front Body Latch Release

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

Front Body

Latch Release

Front Body Latch Release

Lockout

Levers

Transmission

Plunger

Lockout Lever Location

NOTE: The transmission plunger on the side of the transmission case (activated by the LOCKOUT LEVER) must be completely released during operation

of the mower, otherwise operation of the transmission will be erratic.

Operating Instructions

Hourmeter

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

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

function.

Procedure Interval* Reminder

Oil Change (Break-In)**

Lubricate and Check Levels

Oil Change 49-51 Hours***

4-6 Hours

24-26 Hours

C H G

OIL

LUBE

OIL

* These intervals reect the actual time that the

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

** This reminder is only used one time.

*** In normal operating conditions, oil changes in

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

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

Hourmeter

Oil Pressure Warning Horn

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

IMPORTANT: Continued operation of the engine with oil pressure warning horn sounding MAY cause severe engine damage (if a low oil pressure condition exists).

Circuit Breaker (7 Amp)

A 7-amp, manual-reset circuit breaker is located to the right of the hourmeter. The button pops up if the circuit breaker trips. This circuit breaker protects the circuits to the safety switch relays, time delay module, and GHS.

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)

Neutral-Park

Position

Reverse Drive

Wheel Motion

Position

RIGHT WHEEL

STEERING LEVER

1. 2.

FORWARD SPEED

CONTROL LEVER (FSC)

Full Forward

Ground Speed

Position

Intermediate

Ground Speed

Position

Neutral-Park

Position

PARKING

BRAKE

Engaged

Position

THROTTLE

ON Position

OFF Position

Fast

Throttle

Position

Idle

Position

BLADE CLUTCH (PTO)

Pull Up to Engage

CHOKE

Operating Controls (Top View from Drivers Point of View)

Disengaged

Position

Disengaged

Position

Engaged

Position

Operating Instructions

STARTING THE ENGINE

CAUTION

Before operating the mower, read and understand all Safety Instructions and Operat- ing Instructions.

WARNING

NEVER run the engine in an enclosed or poorly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

1. Before attempting to start the engine, make sure the operator is in the seat, the Forward Speed Control is in NEUTRAL-PARK position, and the blade clutch and parking brake are DIS-

ENGAGED.

NOTE: Release parking brake to prevent extra

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

CAUTION

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

3. After the engine starts, make sure the oil pressure horn goes off. If not, stop the engine immediately and nd the cause of the problem. Make sure the oil pressure horn is off prior to engaging the mower blades and beginning operation.

4. Gradually move the choke to the OFF position, keeping enough choke on 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 DS52 or DS62 Mower deck is

in stalled on the tractor, make sure the dolly wheel is retracted BEFORE moving.

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 ad justed 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 switch to the START position to start the engine. Release the key to RUN position as soon as the engine starts.

NOTE: The choke may not be required if the engine is warm.

CAUTION

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

If the operator has not operated a ma chine with LEVER STEERING OR DUAL HYDROSTATIC TRANSMISSIONS, steer ing and ground operation should be learned and practiced until the operator is completely comfortable handling the ma chine BEFORE ATTEMPTING TO MOW.

DANGER

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

Operating Instructions

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

Beginning Recommendations are:

♦ Learn operation of the mower in an open area away from buildings, fences, and obstructions. Learn operation on at ground BEFORE operating on slopes.

WARNING

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

NOTE: This is exactly the same procedure

used to normally stop and park the machine.

CAUTION

An operator presence switch (seat switch) will cause the engine to stop if the FSC is out of the NEUTRAL-PARK position and the operator is not in the seat. The function of this switch should be checked by the operator raising off the seat with the tractor moving forward (allow a 1/2 second off the seat for the time delay function); the engine should stop. If the safety sys tem is not working, it should be repaired or replaced before operating the mower. DO NOT disconnect the safety switches; they are for the operator’s protection.

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

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

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

♦ Learn to operate the steering levers with smooth action. Jerky movements are hard on the transmission and lawn. For sharp turns, do not allow the inside wheel to stop and twist on the grass. Pull the steering le ver controlling the inside wheel into reverse for a smooth “rolling” turn (one wheel roll ing forward while the other rolls backward).

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

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

NOTE: If the FSC lever will not stay in the selected position, the friction lock needs to be adjusted. Contact your Walker dealer.

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

Operating Instructions

Pull Steering

Levers With

Left Hand

5. Stop ground travel by pulling both steering le-

vers backward to the NEUTRAL position (tractor not moving) and then moving the FSC lever to the NEUTRAL-PARK position.

NOTE: If the tractor creeps forward or backward with the FSC lever in the NEUTRAL-PARK position, the transmission control needs to be adjusted. Contact your Walker dealer.

ENGAGING THE BLADE DRIVE

Forward Speed Control

(FSC)

Keep Feet on Footrest

When Moving

Correct Operator Hand Position

on the Controls

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

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

WARNING

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

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

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

2. Engage the blade clutch by pulling the blade clutch lever SLOWLY up. For disengagement, push the blade clutch lever down SLOWLY.

CAUTION

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

IMPORTANT: DO NOT engage the blade clutch

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

blade clutch with the PTO shaft disconnected

(the mower deck removed from tractor).

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

Operating Instructions

CAUTION

If the cutting blades strike a stationary object while mowing, stop the mower immediately, disconnect the spark plug wires, lift the deck, and inspect the deck and blades thoroughly for damage. Make sure that the blade timing has not been dis turbed (the blades should be at 90 degrees to each other). Refer to REPLACING/RE PAIRING the Blade Overload Shear Bolts in Mainte-

nance Instructions

Also, make sure the blade retain ing nuts are torqued to 60 lb·ft (81 N·m).

if blades are out of time.

STOPPING THE MACHINE

1. Pull the steering levers to the NEUTRAL-PARK

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

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

3. Disengage the blade clutch.

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

WARNING

A brake stops the cutter blades and blower from freewheeling within ve (5) seconds after disengaging the clutch. If the brake sys tem malfunctions and the blades do not stop within ve (5) seconds, the brake should be adjusted or repaired before operating the mower. Contact your Walker dealer.

Engaged

Position

Blade Clutch Engaged

Disengaged

Position

Blade Clutch Disengaged

4. Slow the engine to idle, put throttle in IDLE position; and turn the ignition switch OFF.

WARNING

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

5. Engage the parking brake. Also, engaging the parking brake is recommended when stopping or parking the machine in a conned space with little tolerance for movement.

IMPORTANT: The hydrostatic 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 transmissions, especially when transmission uid is warm.

Operating Instructions

WARNING

NOTE: The emergency stop procedure is ex-

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

ADJUSTING CUTTING HEIGHT

TRANSMISSION LOCKOUT

IMPORTANT: DO NOT TOW this mower with the

transmission lockout engaged. Towing can produce excessive internal pressure and damage the transmission.

To move the mower with the engine NOT running (dead battery, maintenance, etc.), the hydrostatic transmissions are unlocked (released).

1. Raise the body.

2. Lift the transmission lockout lever on both the 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.

WARNING

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

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

Lift Handle

Deck Support

Lockout Lever

Plunger

Depressed

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 transmission case (activated by the lockout lever) is com pletely released, otherwise the transmission operation will be erratic.

Cam in

LOCKOUT

Position

Hitch Pin

Cutting Height Adjustment

Operating Instructions

Lockout Lever

Cam in

Plunger

Released

Lockout Lever - Normal Operating Position

RECOMMENDATIONS FOR MOWING

UNLOCKED

Position

DANGER

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

• Keep the mower deck and discharge chute clean.

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

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

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

too tall. Mow frequently and do not cut grass too

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

• When mowing, operate the engine at full throttle

for the best cutting action and performance of the grass handling system (GHS). Mowing with a lower engine RPM causes the mowing blade to not cut clean and tear the grass. The engine is designed to

be operated at full speed.

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

wet grass), mow the grass twice. Raise the mower to the highest setting - 4 in. (102 mm) - for the rst pass and then make a second pass cutting to the desired height.

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

erations.

• Make sure the mower is leveled properly for a

smooth cut. Refer to Deck Leveling in Assembly Instructions.

Avoid Low Hanging Branches

IMPORTANT: Operate the engine at full throttle

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

• Use an alternating stripe mowing pattern for

best appearance and vary the direction of the stripe

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

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

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

• When using a side discharge mower deck, the

side discharge deector shield must not be removed and must be kept in the lowest possible position to deect grass clippings and thrown objects down ward. Orient the side discharge away from side walks or streets to minimize cleanup of clippings. When mowing close to obstacles, orient the side dis charge away from obstacles to reduce the chance of damage to property by thrown objects.

Operating Instructions

MINIMUM

Side Discharge Deector Shield in

Lowest Position

• When operating on a slope, reduce speed and

use caution to start, stop, and maneuver. Avoid

sharp turns or sudden changes in direction. The

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

Maximum Recommended

Slope - Do Not Operate

on Steep Slopes

15°

52 in.

16 in.

Maximum Recommended Slope

DANGER

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

5 FT

No Driving Zone

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) and the GHS discharge chute may be damaged by moving the tractor. The tilt-up conguration should only be used when the tractor is parked.

• The tractor body should never be tilted for-

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

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

• When transporting a tractor with the deck in the

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

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

Operating Instructions

GRASS HANDLING SYSTEM (GHS)

PTO and Blade

Gear Drive

Shear

Bolt

PTO Clutch

Shear Pin

“Full” Signal

Horn

Powerl

Drive Motor

Actuator

Rod

Grass-Pak

Vane Switch

Powerl

Delivery Spout

Exhaust Screen

(Removable)

Catcher

Door Spring

(Not Visible)

Catcher

Door

Grass Catcher

Dump Handle

Rear Discharge

Mower Deck

Body Chute

Assembly

Blower

Deck

Discharge Chute

GHS Flow and Components

Operating Instructions

General Information

The Grass Handling System (GHS) consists of a rear discharge mower deck connected to a 10.5 in. (27 cm) blower and a rear mounted grass catcher with 7.0 bushel (246 liters) capacity. The GHS blower oper ates any time the mower blade clutch is engaged and moves grass through the rear discharge deck chute into the grass catcher. Blower airow is ex hausted out the back of the grass catcher, through a ltering screen. When the grass catcher 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 overlling and clogging of the blower system.

IMPORTANT: Normally, the GHS blower operates with no maintenance or cleaning required. How ever, under certain operating conditions, the inside 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, especially in the springtime. When operating in these condi tions, check the blower wheel frequently for binding and clean the blower housing as required. Refer to

CLEANING the GHS Blower in Mainte nance Instructions.

NOTE: In Autumn, when using the GHS mower to vacuum leaves, it is recommended to raise the front of the mower deck 2 to 3 notches [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 ad justment, the hitch pins in the two (2) front deck support pins are repositioned 2 to 3 notches higher 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 sufcient force to cause serious injury to bystand ers or property damage. NOTE: For noncatching operation, the “No-Catch” Deector is an available accessory item.

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

NOTE: An alternative to using the blower intake

cover when a side discharge or mulching deck is installed on a GHS model is the blower lockout kit (P/N 7541). The blower lockout kit releases ten sion on the blower drive belt and does not require the blower intake cover.

DANGER

ROTATING BLOWER BLADES

NEVER operate the GHS blower with the blower discharge chute uncovered (grass catcher in the dump position) since dangerous 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 clog ging 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.

Operating Instructions

Clogging Checklist

In case of clogging, there will be a distinct change in the sound of the blower, i.e., the blower sound

will stop. Also, the mower deck will begin to leave a trail of grass clippings. When this occurs, stop the engine, disconnect the spark plug wires, 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 rst develop at the back 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 restrict ing the ow of material throughout the entire system.

The following list of items should be checked if a pattern of clogging begins to develop. 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.

Blades Must Operate at

Right Angles (90 Degrees)

FORWARD

• Check the amount of at section remaining at

blade tip. This is the area that is ground away (removed) when the blades are sharpened. If too much of the at 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) at section remains at the blade tip.

• Check that the interior of the deck housing and

bafing is reasonably clean and free of grass and dirt buildup. While some degree of material buildup

can be tolerated, a point is nally reached where the ow of air and grass clippings is restricted.

NOTE: One condition that quickly causes a buildup of material in the deck housing is mowing grass and/ or weeds which are “juicy.” The material collects under the deck with sticky, green juice. Clo ver 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 airow from moving into and under the deck.

Raising the deck cutting height will signi cantly increase airow 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.

• 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 signicant loss of blower performance.

Rear Discharge

Chute

Blade Rotation for GHS Mower Deck

(View from Underneath)

Mounting Nut

Torque = 60 lb·ft

(81 N·m)

• Check the blower discharge chute into the grass

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 airow.

• 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.

Operating Instructions

NOTE: An optional exhaust screen with larger holes (3/4") is available for use when mowing in wet grass; the screen provides less airow restriction and more clog resistance (use standard screen in dry conditions to avoid excessive material blowing out of the catcher).

Remember, anything that restricts airow or material ow 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 Buildup in Mower Deck Housing in Maintenance Instructions.

Using the GHS Catcher

Powerl

The GHS catcher has an oscillating grass delivery spout (POWERFIL®) which is designed to spread grass clippings throughout 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 moving 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 checked for function (the switch closure is adjustable).

“Full” Signal Horn

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.

The “full” signal horn is designed to operate (sound) when the grass catcher is almost full. The timing of the signal is adjustable by changing the position of the vane on the Grass-Pak is coming on too soon (catcher not completely full) or too late (grass clogging in catcher spout and deliv ery chute), refer to ADJUSTMENTS for GHS

Signal Horn Adjustment

NOTE: The horn signal should be adjusted to

sound BEFORE the catcher is completely full to give the operator time to react and stop mowing. An indication the horn signal is coming on too late (delayed 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 for cleaning, open the catcher door, push forward and pull down on the grass catcher screen knobs (on either side of the screen), and slide the screen out. Use a high pressure washer or water spray and brush to clean the screen.

switch. If the signal

Maintenance Instructions

The GHS catcher has a “full” signal horn to alert the operator to dump the catcher when it is full (to prevent overlling and 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 ll in around the spout when the catcher is almost full.

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 horn should sound as the switch is moved in both directions.

Keeping the catcher exhaust screen clean and open is essential to good performance of the catching system. In some mowing conditions, e.g., wet and dirty, it will be necessary to clean the screen frequently to avoid clogging the mower deck, blower, and chutes due to airow restriction.

Grass Catcher

Screen

Removal Knobs

(Not Visible)

Grass Catcher Screen Removal for Cleaning

Operating Instructions

Dumping the Catcher

DANGER

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

For dumping, the catcher either tailgate dumps into a disposal area or dumps into the optional dump bag. The dump bag is a reusable nylon fabric bag designed to conveniently move grass clippings from the catcher to a remote disposal area or container.

CAUTION

Use leg muscles and rm footing when lifting the catcher to dump; avoid bending at the waist and using back muscles in order to prevent back injury.

Using the Dump Bag

1. Open the back door by lifting on the door handle.

2. Orient the dump bag with one (or two) of the handle straps on the bag opening facing up.

Tailgate Door

Handle

Hook Bag

on Bumper

Tailgate Dumping

1. Open the back door by lifting on the door handle.

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 - the gas spring, that holds the catcher in the raised position, is not a shock absorber for lowering the catcher.

4. Close the door by holding the door handle. The door will close smoothly with the assistance of the gas springs. If the dampening springs are not functioning properly, they should be replaced to prevent the door from slamming closed and possibly causing a pinch point.

Positioning Dump Bag on Catcher

Operating Instructions

3. Hook the bottom of the bag over the rear bumper while lifting on the handle strap(s).

4. Tilt the catcher back to dump into the bag by lifting on the catcher lift handle on the lower front corner of the catcher with the one hand while continuing to hold up on the bag strap(s) with the other hand. Refer to photos for positioning the bag and dumping.

Catcher Lift /

Dump Handle

5. Lower the catcher smoothly down to the normal

operating position. DO NOT allow the catcher

to drop down - the gas spring, that holds the catcher in the raised position, is not a shock absorber for lowering the catcher.

6. Close the door by holding the door handle. The door will close smoothly with the assistance of the gas springs. If the dampening springs are not functioning properly, they should be replaced to prevent the door from slamming closed and possibly causing a pinch point.

Dumping Catcher into Dump Bag

Maintenance Instructions

CAUTION

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

MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL MC19

Service Item

Check Engine Crankcase Oil Level x 47 Check/Clean Engine Air Cooling System* x 56 Check Security of Air Filtration Components x 59 Check Air Filter Restriction Gauge x 54 Clean Grass Buildup Under Deck x 57 Clean GHS Exhaust Screen* x 59 Clean GHS Blower* x 58 Service Mower Blades x 60 Check Function of Oil Pressure Warning Horn x 25 Lubricate Grease Fittings and Oil Points* x 51 Check PTO Gearbox Oil Level** x 50 Check Battery Electrolyte Level x 59 Check Hydrostatic Transmission Fluid Check Tire Pressure x 60 Check Drive Belts (Jackshaft, Engine PTO,

GHS Blower, Ground Drive) Check Deck Gearbox Oil Seals x 62 Check Safety Switch System x 62 Check Turbine Precleaner* x 54 Check Air Filter Element *** x 55 Change Engine Crankcase Oil Check Oil Level in Gear Axle x 50 Clean Hydrostatic Transmission Cooling Fins x 59 Clean Engine Cooling Fins x 57 Check Blade Brake Action x Check Wheel Bolt Torque (75 to 85 Check/Regap Spark Plugs x 62 Change Engine Oil Filter x 47 Replace Air Filter Element,

and Dust Ejection Valve *** Check Fuel Lines and Clamps x 62 Replace Fuel Filter x 69 Service Battery x 59 Check FSC Friction Lock x 63 Service Solenoid Shift Starter x 62 Check Engine Valve Clearance x Change Gear Axle Oil Replace Fuel Lines and Clamps x 62 Change Hydrostatic Transmission Fluid

∗ More often in extremely dusty or dirty conditions ∗∗ Change PTO gearbox oil after rst 100 hours of operation (break-in period) ∗∗∗ Air cleaner is remote mounted Enginaire™ unit, replace lter(s) every 400 hours and dust ejection valve every two years or when worn or damaged Δ Change engine oil and lter after rst 5 hours of operation of a new engine (break-in period) ΔΔ Change every 2 years or 1000 hours ΔΔΔ See your Walker dealer for this service or refer to the Walker Service Manual

◊

Hydrostatic transmissions are sealed - DO NOT OPEN

RESERVOIR CAPS - refer to Hydrostatic Transmission Fluid

ΔΔ

◊

lb·ft)

ΔΔ

Daily

Hours

x 50

x 61

100

Hours

x 47

x 60

200

Hours

400

Hours Yearly

x 55

Every

2 Years

x 50

CAUTION

When performing maintenance with the mower body raised, a safety prop should be installed from back of body to chassis frame (fail-safe protection in case of fail ure of body lift support). Empty grass catcher before raising body.

Ref.

Page

ΔΔΔ

Maintenance Instructions KOHLER TIPS

IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE

Fuel System

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

ganic material.

• Change fuel lter 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 viscosity to the ambient tem-

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

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

fore stopping engine to avoid run-on or backring.

Cooling System

CAUTION

DO NOT use a pressure washer to clean the cooling system on an air-cooled engine, mud may form under the cooling shroud on the cylinder head and cooling fan.

• Keep engine air intake screen and cylinder head

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

• Periodically remove two access panels in the en-

gine shroud to inspect and clean cylinder head cooling ns.

• Check performance of the cooling system by

starting the engine, holding a hand adjacent to the cylinder head, and feeling the cooling airow.

DANGER

Make sure to keep hands clear of exhaust pipe, mufer, and moving parts when checking airow.

• Operate the engine at full speed when mowing.

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

Air Cleaner System

• Use only Enginaire

After market elements may not seal in the air cleaner housing, allowing dirt to enter the engine. Also, aftermarket lters often skimp on the ltration media and require more frequent replace ment (see following instructions).

air cleaner elements.

• Use the air lter restriction gauge to indicate the

need to service the air lter.

• Do frequently check the Turbine Precleaner (lo-

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

• DO NOT overservice or frequently “disturb” the

air lter. A dirty air lter actually cleans better than

a new one. Changing and cleaning the air lter too often can actually reduce lter efciency and increase the opportunity for traces of dust to enter the engine. Wait until the element really needs servicing as indicated by the air lter restriction gauge.

• When the air lter element is removed or re placed,

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

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

• Periodically check the air intake hose for cuts,

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

Oil

• Use only multi-viscosity oils as specied with the

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

• Use only Kohler oil lters. Aftermarket lters

may not seal properly and/or have the incorrect

pressure relief valve for proper lubrication.

Maintenance Instructions LUBRICATION

LUBRICATION

WARNING

DO NOT attempt to lubricate the machine with the engine running. Disengage the PTO clutch, shut off the machine, and remove the ignition key.

Proper lubrication is an important maintenance procedure. It reduces wear and makes the machine quieter and easier to operate.

Engine Oil

Engine Break-In Oil

No special break-in oil is required. The engine is serviced with 10W-30, Service Class 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 sufcient oil supply in the crankcase. DO NOT operate with the oil level below the “L” mark or above the “F” mark on the dipstick.

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

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

IMPORTANT: DO NOT overll the crankcase

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

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

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

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

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

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 lter every

other oil change (every 200 hours of operation).

Maintenance Instructions LUBRICATION

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

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

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

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

Drain PlugOil Filter

Oil Drain/Oil Filter Location

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

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

IMPORTANT: Check the dipstick reading before adding the last 1/2 pint of oil and ll only to the “F” mark. DO NOT overll the crankcase (oil above “F” mark) as this CAN result in engine overheating, loss of power, and possible engine damage.

10. Start the engine and check for oil leaks around the oil lter. Stop the engine, recheck the oil level, and add oil if necessary. (When the engine is rst operated with a new oil lter, the oil level drops slightly as the lter is lled with oil.)

Mower Deck Gearbox Lubrication

NOTE: These instructions apply to all mower decks with gear-driven blades. Refer to DS52 or DS62 Mower Deck Lubrication in this section for the

DS52 or DS62 deck with belt-driven blades. Refer to Mower Deck Spindle Lubrication in this section for the DS42 Belt Drive deck with belt-driven blades.

Specications in

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

6. Apply a thin coating of clean oil to the rubber gasket on the replacement oil lter.

IMPORTANT: Use ONLY oil lters from the en- gine manufacturer (Kohler 28-050-01). Aftermarket oil lters may not seal properly and/or may not have the correct pressure relief valve for proper lubrication.

7. Install the new oil lter on the engine. Turn the lter clockwise until the rubber gasket contacts the sealing surface, then tighten an additional

1/2 turn.

8. Reinstall the drain plug. Make sure it is tightened to 10 lb

·ft (14 N·m).

On gear driven decks, the mower deck gearboxes (tee gearbox and blade drive gearboxes) are connected as a unitized as sembly, and oil ows freely between them. The gear boxes are permanently lubricated (oil lled) and sealed requiring no scheduled lubrication. Howev er, the gearbox oil seals should be checked every 25 hours for indication of an oil leak; particularly the lower seals on the blade drive gearboxes should be inspected, since they operate in a dirty en vironment. 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.

Maintenance Instructions LUBRICATION

Blade Drive

Gearboxes

Tee

Gearbox

Mower Deck Gearboxes

(Shown with Gearbox Cover

Removed for Clarity)

2. Clean the area around the individual gearbox cover plates to prevent contaminants from entering the gearcase.

3. Remove the screws securing the cover plates on the blade drive gearboxes.

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

DS52 or DS62 Mower Deck Lubrication

There are several special lubrication requirements for the DS52 or DS62 mower deck in addition to the require ments detailed in the Chassis and Deck Lubrica tion illustration. Lubricate the locations shown in the Gearbox, Dol ly Wheel, and U-Joint Lubrication photo and check and maintain oil in the belt drive gearbox.

1. Check the oil level in the belt drive gearbox ev- ery 100 hours (or sooner if a visible oil leak has developed). With the deck in the normal operating position, remove the level plug in the side of the gearcase. Add SAE E.P. (Extreme Pressure) 80W-90 (API GL-5) gear lube to maintain the oil level to the plug. If the oil level is low, check the gear box for any indication of an oil leak. If an oil leak is noted, the gearbox will need to be removed and rebuilt.

2. Lubricate the dolly wheel pivot every 25 hours with general purpose grease.

3. Lubricate the U-Joint in the drive shaft every 8 hours with SAE general purpose lithium or molybdenum base grease.

Belt Drive

Gearbox

NOTE: In case the gearboxes are completely drained of oil, approximately 5 . oz. (15 cl) of oil per gearbox is required to rell the gear drive assembly.

NOTE: Since the gearboxes are connected as a unit by connector tubes, it is necessary to add oil slowly. Allow a few minutes after adding oil for the oil to ow throughout the assembly and the oil level to stabilize before reassembly.

IMPORTANT: DO NOT overll the deck gearboxes. The gearbox assembly is not vented, and overlling with oil will cause excessive pressure and result in oil leaks.

5. Check condition of the cover gasket and replace if worn or damaged. Reinstall gearbox cover plates; torque screws to 24 lb·in. (3 N

·m).

Dolly Wheel

Pivot

U-Joint

Gearbox, Dolly Wheel, and U-Joint Lubrication

Mower Deck Spindle Lubrication

For the DS42 Belt Drive mower deck, lubricate each deck spindle grease tting every 25 hours. Use SAE general purpose lithium or molybdenum base grease for grease ttings.

Maintenance Instructions LUBRICATION

Tractor PTO Gearbox Lubrication

Checking Gearbox Oil Level

Check the gearbox oil level every 25 hours, and if necessary, add oil [SAE E.P. (Extreme Pressure) 80W-90 (API GL-5) gear lube] to maintain oil level to the FULL mark on the dipstick.

IMPORTANT: DO NOT overll the PTO gearbox to avoid oil leakage out of the dipstick standpipe.

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

Changing Gearbox Oil

The tractor PTO gearbox is oil lled. No scheduled oil change is required. However, changing the oil af ter the rst 100 hour break-in period will extend gearbox life and is recommended.

1. Remove the drain plug in the bottom of the gearcase, drain the oil, and reinstall the plug.

2. Rell the gearbox through the dipstick standpipe using 7 to 8 . oz. (21 to 24 cl) of SAE E.P. (Extreme Pressure) 80W-90 (API GL-5) gear lube. Re move plug in top of gearcase to vent air when relling.

3. Check that the oil level is at the FULL mark on the dipstick. DO NOT overll.

Gear Axle Lubrication

• The gear axle oil lubrication is SAE E.P. 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 ax le and ll until oil is at the level plug.

Dipstick Location, Tractor PTO Gearbox

• Change axle oil every 1000 hours or two (2)

years.

Hydrostatic Transmission Fluid

Checking Hydrostatic Transmission Fluid Level

The hydrostatic transmissions are sealed units and do not need to be opened to check the uid level. Hydrostatic uid level should be checked ev- ery 25 hours of machine operation. It is preferable

to check the uid when the uid is cold. Check uid levels as follows:

IMPORTANT: Removing or breaking the seal on the hydrostatic reservoir cap within the rst 1000 hours will VOID THE TRANSMISSION WARRANTY.

1. Park the mower on a level surface. Stop the engine and wipe dirt and contaminants from around the base of the reservoir to better see the COLD mark.

2. The level of the oil can be seen through the side of the opaque reservoir (DO NOT REMOVE RESERVOIR CAP); using a light next to the

reservoir will help make the level more visible.

Maintenance Instructions LUBRICATION

Grease Fitting and Oil Point Lubrication

Reservoir Cap

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

in the Chassis and Deck Lubrication Points illustration.

Cold LevelAir Bleed Plug

Transmission Reservoir and

Air Bleed Plug Location

3. The reservoir has a uid level COLD mark. The reservoir oil level should ALWAYS be at or

slightly above the COLD mark.

4. If the uid is below the COLD mark (or the trans- mission is not performing properly) contact

your local dealer. Attempting to add uid or service the transmission may VOID THE TRANSMISSION WARRANTY.

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

tor) require routine lubrication after every 8 hours of running time. Remove tractor PTO quick disconnect tube assembly for easy access to grease ttings.

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

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

Maintenance Instructions LUBRICATION

Ident Lubrication No. No. Location Type Places

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

9 DollyWheelPivot Grease 1 10 IdlerArmPivot GreaseΔ 1 11 TeeGearbox,Deck Oil* 1 12 BladeDriveGearbox Oil* 2 13 SteeringLeverPivot Grease 4 14 BodyHingePoint Oil 2 15 Deck-to-PTOCoupling Grease 1   (GreaseSplineSlideArea) 16 (FSC)FrictionBodyPivot Grease 1 17 FSCActuatorRodPivotPins Oil 2 18 FSCLeverPivot Grease 1 19 FSCLeverFork Grease 1   (GreaseSlideArea)  20 DeckSupportArmPivot Grease 2 21 GearAxle Oil*** 2 22 UniversalJointTubeAssembly Grease** 1 23 ParkingBrakeLever Grease 1 24 UniversalJointQuickConnect Grease 1   Spline(GreaseSlideArea) 25 BeltTightenerPivot, Grease 1   JackshaftDrive 26 PTOClutchLeverPivot Grease 1

Ident Lubrication No. No. Location Type Places

27 ClutchActuatorPushRod Grease 2 28 BeltTightenerPivot, Grease 1   PTOClutch 29 BrakeActuatorRodandBrake Oil 3   BandPivotPins(Clevis) 30 ChokeControlCableEnds Oil 2 31 BrakeActuatorPivot Grease 1 32 CatcherHingePoint Oil 2 33 ThrottleControlCableEnds Oil 2 34 EngineOil Oil*** 1 35 BeltTightenerPivot, Grease 1   BlowerDrive 36 BeltTightenerPivot, Grease 1   GroundDrive 37 PTOGearboxDipstick Oil*** 1 38 HydrostaticDrive Oil*** 2 39 ChokeControlPivot Oil 1 40 ThrottleControlPivot Oil 1

* Gearboxesarepermanentlylubricatedandsealedre-

quiringnoscheduled lubrication.  Oil levelshouldbe checkedonly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 TransmissionFluidinthissection.

 BeltDrivenDecksOnly

NOTE: DC42andDS62Tilt-UpDecksareshownforreference.

ForotherDeckLubricationPoints, Refer to Deck and CarrierFrameIllustrated Parts Manual.

4 895 7 6 5 4

Lubrication Points for Optional Belt Driven Decks (DS62 Shown)

Maintenance Instructions LUBRICATION

33 & 40

20 38 21

30 & 39

4 13

20 21

Chassis and Deck Lubrication Points (DS42 Shown)

Maintenance Instructions CLEANING

CLEANING

CAUTION

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

Engine Air Cleaner System

Turbine Precleaner

Do frequently check the Turbine Precleaner (located in the end cap of the air cleaner assembly) for free movement of the internal fan. Shine light into end cap to verify movement of fan with engine running.

Air Filter

Restriction Gauge

Safety

Filter

Enginaire™ Air Cleaner

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

IMPORTANT: Use only Enginaire™ air lter elements for replacement (Walker 5090-1 or 5090-3). Aftermarket lters may not seal properly or lter efciently.

Enginaire™

Air Cleaner Cover

Primary Filter

Element

Turbine

Precleaner

Hose

Clamp

Air Intake

Hose

Enginaire™

Air Cleaner

Band

Dust Ejection

Valve

Engine

Hose

Clamp

Engine Air Cleaner System Components

Maintenance Instructions CLEANING

Cover

Canister

Filter

Element

Air Cleaner Components

(Shown with Cover Being Removed)

IMPORTANT: The Enginaire™ air cleaner uses a

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

Push Button to Reset

Indicator After Service

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

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

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

Air Filter Restriction

Gauge

Air Filter Restriction Gauge Location

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

1. Unlatch and remove Enginaire™ air cleaner cover. Wash the cover and dust ejection valve. Check that these components are in good condition. The dust ejection valve is subject to wear and deterioration and should be inspected carefully and replaced every 2 years or when damaged. The lips of the valve should close and t together; any cracks, deformation, or wear in the valve is cause for replacement.

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

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

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

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

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

Maintenance Instructions CLEANING

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

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

9. Insert and seat the safety lter and primary lter el ement carefully into the canister, applying pres sure at the outer rim of the lter; not at the exible center. Make sure the lter element is completely in place before installing the cover.

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

Cover

Latch

Cover

Latch

Safety Filter

Canister

Primary

Radial Sealing

Surface

Air Filter Element Replacement

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

Filter Element

Proper Orientation of Air Cleaner Cover

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

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

Engine Cooling System

Cooling Air Intake System

To prevent engine overheating and possible engine damage, clean grass clippings, chaff, 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 this area several times each day to prevent engine overheating. Also, visually check inside cylinder head shroud and between cylinder head ns for material packed in this area which would prevent cooling airow; remove shroud and clean as required.

CAUTION

Operating the engine with a blocked air intake screen, dirty or plugged cooling ns, and/or cooling shrouds removed will cause engine damage from overheating.

Maintenance Instructions CLEANING

Cylinder Head Cooling Fins

It is essential for performance and longevity of the air-cooled engine to keep the cylinder head cooling ns clean and free of obstruction. After every 8 hours of operation, check the performance of the cooling system by starting the engine, holding a hand adjacent to the cylinder head, and feeling the cooling airow. If there is little or no airow, clean the cooling ns as described below.

DANGER

Make sure to keep hands clear of exhaust pipe, mufer, and moving parts when checking airow.

Every 100 hours, inspect and clean the cooling ns

(more often when operating in extremely dusty, dirty conditions). Remove the two (2) cooling n access panels in the engine shroud and clean the cooling ns and external surfaces using compressed air. Make sure to reinstall the access panels before operating the engine.

NOTE: If dirt is packed into the cooling ns it may be necessary to remove the engine shroud in order to thoroughly clean the cooling ns.

Engine Cooling

Fin Access Panels

Kohler Engine

Shroud

Check Airow

with Hand

Cooling System Airow

Grass Buildup in Mower Deck Housing

DANGER

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

1. Raise the deck lock lever handle on each side of the carrier frame and pull out to release car- rier frame for tilting action.

2. Using the carrier frame lift handle, raise deck to the TILT-UP position and insert the deck hook into the tilt-up latch on the tractor body.

Tilt-Up Hook and

Latch Connected

Engine Cooling Air

Intake Screen

Engine Cooling Air Intake Screen and

Cooling Fin Access Panels

IMPORTANT: Yearly, it is good maintenance prac-

tice to remove the engine cooling shroud and clean the cylinder head cooling ns thoroughly to prevent overheating and extend engine life. Make sure cooling shroud is reinstalled properly. This procedure will require removing the engine from the chassis.

Tilt-Up

Latch

Tilt-Up

Hook

Deck Lock Lever

Deck Secured in TILT-UP Position

Maintenance Instructions CLEANING

1. Remove the GHS blower drive belt tension by

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 nally reached where cutting quality deteriorates and clogging begins to occur because of too much buildup on the bafing 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.

depressing the idler pulley on the tightener arm. Roll the belt off 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, ex cessive 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 action and water will effectively wash the inside of the housing. Spray may be directed against the blower blades vertically and horizontally to cause rotation in both directions for thorough washing action. Wash blower until the blower wheel spins freely in both directions.

3. Reinstall the GHS blower drive belt by reversing the removal procedure.

GHS Blower

Normally, the GHS blower operates with no maintenance or cleaning. However, when mowing grass that is dirty and damp (especially springtime mowing), a deposit of dirt may accumulate inside the blower housing, causing wear and binding of the blower wheel. When operating in these conditions,

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. Wear goggles or face shield.

Blower

Drive Pulley

Depress Idler Pulley

Down to Relax Belt

Collapse Blower Belt Tightener

to Remove GHS Blower Drive Belt

Pulley

Belt Tightener

Idler Pulley

GHS Blower

Drive Belt

Maintenance Instructions

CLEANING/

CHECKING/SERVICING

GHS Exhaust Screen

Refer to Cleaning the GHS Exhaust Screen in Op- erating Instructions.

Hydrostatic Transmission Cooling Fins

Keeping the cooling ns on the hydrostatic transmissions clean and free of obstruction is essential to avoid overheating the transmission uid and shortening transmission life. The cooling ns should be checked every 100 hours; and cleaned if necessary.

To clean the ns, use compressed air and/or a pressure washer. The cooling ns extend all the way around the housing -- the ns underneath need to be clean as well as the more visible ns above. Also, pay close attention to the area under the drive pulley.

IMPORTANT: In case an oil leak develops on the input shaft, the cooling fan blowing dusty air and oil on the transmission will quickly pack the cooling ns with oily dirt. If this condition occurs, replace the seal immediately to avoid overheating and damaging the transmission. The input shaft assembly and seal are easily replaced without removing the transmission from the machine.

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

Cooling Fins

Cooling Fan

CHECKING/SERVICING

DANGER

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

Security of Air Filtration Components

NOTE: The following inspection is only an exter nal inspection and should be done without “disturbing” the ltration components.

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

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

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

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

Battery

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

IMPORTANT: Make sure battery is securely mount-

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

Hydrostatic Transmission Cooling Fins

Electrolyte Level

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

lyte level:

1. Remove battery cell ller caps.

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

3. Replace ller caps.

Maintenance Instructions

CHECKING/SERVICING

IMPORTANT: DO NOT overll the battery. Electro-

lyte will overow through the vented caps onto parts of the machine and WILL result in severe corrosion.

Cleaning the Terminals

If battery terminals are corroded, remove battery from the mower. Using a wire brush, remove corrosion with a solution of one part baking soda and four parts water. Rinse with clean water. Coat the terminals with petroleum jelly or terminal protector spray to retard further corrosion.

Charging the Battery

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

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

1. Charge the battery at 15 amps for 10 minutes.

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

2. After charging the battery, use distilled water to

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

Tire Pressure

Inate tires to pressures shown below:

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

Wheel Bolt Torque

Check the eight (8) lug bolts that mount the drive tires. Every 100 hours they should be torqued to 75 to 85 lb·ft (102 to 115 N·m).

Sharpen Mower Blades

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

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

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

the following procedure to check and sharpen blades:

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

DANGER

BATTERIES PRODUCE EXPLOSIVE GASES

• Charge the battery in a well-ventilated

area, so that gases produced while charging can dissipate.

• Keep sparks, ames, and smoking ma-

terials away from the battery at all times.

• Make sure the battery cap vents are

open (check manifold vent on each cap).

• Make sure the battery charger is un-

plugged before connecting or disconnecting cables to the battery.

1. Stop the engine, remove ignition key, and disconnect the spark plug wires before raising the mower deck to service blades.

2. Raise the deck and secure it in the TILT-UP po sition. Refer to CLEANING the Grass Build- up in Mower Deck Housing in this section for deck rais ing instructions.

DANGER

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

NOTE: PTO shaft must be disconnected be-

fore checking blades for straightness.

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

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

Maintenance Instructions

WARNING

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

4. If the blade cutting edge is dull or nicked, it

should be sharpened. Remove blades for sharpening by grasping the end of the blade using a rag or a thick, padded glove, while loosening and removing the nut, lock washer, and at 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.

CHECKING/SERVICING

6. Check blade balance by positioning the blade

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

Blade Balancer

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

CAUTION

ALWAYS wear eye protection and gloves when sharpening a blade.

Sharpen at

Original 30° Angle

30°

Do Not Grind or

Sharpen on Underside

Intersection

Wear Area

Wing

Tip

Blade Balanced on Magnetic

Wall-Mounted Balancer

7. Mount the blade with wing tips pointing up into

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

en the nut to 60 lb·ft (81 N·m). For belt driven decks reinstall the spacer (if applicable), blade, washer, and bolt. Tighten the bolt to 70 lb·ft (90 N·m).

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 deck. 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

Mower Blade Prole For Sharpening

four (4) belts 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.

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; particu- larly the lower oil seal on the blade drive gearbox.

This seal is protected by the trash guard on the blade hub and seal protector plate on the housing, but is still vulnerable to seal damage due to operating in an adverse environment. The mower blade must be removed for inspection of the seal, so it is recommended to inspect the gearbox seals when blades are removed for sharpening. If an oil leak is noted, the seal should be replaced and the gearbox assembly relubricated. Refer to LUBRICATION for

Mower Deck Gearbox Lubrication in this section.

Spark Plugs

Every 200 hours of operation, remove the spark

plugs, inspect, clean, and reset the gap (or replace 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 engine. Clean spark plugs with a wire brush. DO NOT use an abrasive grit type cleaner. If the electrodes are burned short or pitted, replace plugs with Champion‚ type RC12YC (or equivalent). Check spark plug gap with a wire-type feeler gauge and set the gap at 0.030 in. (0.76 mm). Reinstall and tighten to between 18 and 22 lb·ft (24 to 30 N·m).

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 calls for complete replace-

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

Engine Starter

Yearly or every 500 hours disassemble and clean

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

Blade Brake Action

WARNING

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

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

rotation will stop ve (5) seconds after disengagement of the clutch. If the brake system mal-

functions - blades do not stop in ve (5) seconds adjust or repair the brake before operating the mower. Contact your Walker dealer for this service or refer to the Walker Service Manual.

Safety Switch System

WARNING

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

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

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

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

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

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

Maintenance Instructions

CHECKING/SERVICING/

REPLACING/REPAIRING

With an operator in the seat, the engine starts but

•

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

• Without an operator in the seat, the engine starts

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

• With an operator in the seat, the Forward Speed

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

Forward Speed Control Friction Lock

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

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

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

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

decreased.

REPLACING/REPAIRING

DANGER

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

IMPORTANT: ALWAYS use genuine factory re-

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

Drive Belts

There are four (4) individual belts on GHS models:

• Engine PTO Drive Belt (3 Groove Power Band)

• Jackshaft Drive Belt

• GHS Blower Drive Belt

• Hydrostatic Ground Drive Belt

The belts may be removed and replaced using the

procedures described on the following pages.

If the FSC friction lock needs to be adjusted, contact your Walker dealer or refer to the Walker Service Manual.

Maintenance Instructions REPLACING/REPAIRING

Jackshaft Drive Belt

Engine PTO

Belt

Hydrostatic Ground

Drive Belt

GHS Blower Belt

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 pushing 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 idler pulley down (until the

PTO belt tightener stop block contacts the frame) and then shift the belt off the idler pulley (to the inside).

Pull UP to Engage

c. Raise the clutch lever (engage position) to

lift the clutch idler away from the belt.

d. Next remove the belt from the engine pulley

and then the PTO drive pulley.

2. Install the PTO drive belt by reversing the removal procedure.

IMPORTANT: Make sure the belt is installed inside the four (4) belt guide pins.

Check and make the following adjustments:

a. Clutch engagement for proper belt tension

b. Clutch disengagement and brake action

PTO Belt Tightener

Stop Block

Clutch

Linkage

PTO Belt

Tightener Arm

Blade Clutch Lever

in the DOWN Position

Belt Guides

(Bottom Guide Not Visible)

Engine

PTO Belt

PTO Drive

Pulley

Belt

Guide

Engine

Pulley

Clutch Idler

Pulley

Belt

Guide

Micro-V Pulley

(GHS Blower Drive)

Engine PTO Drive Belt Removal

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 Down to Relax Belt

Idler Pulley

Jackshaft

Jackshaft Drive Belt

Jackshaft Drive Belt (Disengaged)

c. Roll the belt off the jackshaft pulley and

remove.

Engine

Pulley

Tension Spring

2. Reverse the removal procedure to replace the jackshaft drive belt.

Idler Arm

Jackshaft

Drive Belt

Jackshaft Drive Belt (Engaged)

Engine

Pulley

Tension Spring

Maintenance Instructions REPLACING/REPAIRING

GHS Blower Drive Belt

1. Remove the GHS blower drive belt tension by depressing the idler pulley on the tightener arm. Roll the belt off the blower pulley. The belt should be clear of the blower pulley, allowing free movement of the blower wheel.

Blower Drive

Pulley

Depress Idler Pulley

Down to Relax Belt

GHS Blower Drive Belt Assembly (Disengaged)

2. Reverse the procedure to install the GHS blower drive belt.

GHS Blower

Drive Belt

Blower

Pulley

Belt Tightener

Idler Pulley

(Disengaged)

Idler Pulley

(Engaged)

GHS Blower Drive Belt Assembly (Engaged)

Maintenance Instructions REPLACING/REPAIRING

Hydrostatic Ground Drive Belt

1. To remove the hydrostatic ground drive belt:

a. Raise the spring-loaded belt tightener 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

Hydrostatic Ground Drive Belt Assembly (Engaged)

Maintenance Instructions REPLACING/REPAIRING

Fuel Filter

DANGER

Gasoline is extremely ammable and can be highly explosive. To minimize danger:

• Use only an approved fuel container for

gasoline.

• DO NOT allow open ames or sparks

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

• Wipe up spilled gasoline immediately

and completely.

Model MC19 is equipped with an in-line fuel lter. Visually inspect the lter periodically, and replace the lter yearly.

Blade Overload Shear Bolts

NOTE: Blade shear bolts are not used on belt driv-

en decks.

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

Cutting Blade

Shear Bolts

In-Line

Fuel Filter

Fuel Filter Location

IMPORTANT: Replace the fuel lter only in a clean

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

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

2. Replace lter, making sure that the arrow on the lter is aligned with the fuel ow through the lter.

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

Cutting Blade Shear Bolts

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

rides) the function of the shear bolts.

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

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

Maintenance Instructions REPLACING/REPAIRING

PTO Shear Pin (If Equipped)

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

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

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

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

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

Split Spring Pin

(Retains U-Joint Held on Shaft

with Broken Shear Pin)

Shear Pin

Mower Blades

Mower blades are removed 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

conditions of wear or damage, blades should be replaced for reasons of safety and performance of

the machine:

• An excessive amount of the at section of the

blade has been ground away (removed) when the blade is sharpened. Replace the blade when less than a 3/4 in. (19 mm) at section remains at the blade tip.

• Examine ends of the blade carefully, especially

the intersection where the at section of the blade turns up to form the “wing tip” (refer to Mower Blade

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

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

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

DANGER

U-Joint

Tube Assembly

U-Joint

Shaft Assembly

Cotter Pin

PTO Shear Pin

IMPORTANT: Use only Walker P/N 8067-13

shear pins for replacement to provide proper shock protection -- these pins are hardened to shear under a specic amount of load.

4. Reinstall the PTO shaft guard.

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

NOTE: Use Walker P/N 8067-10 for heavy duty gearboxes.

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

• Check the blades for straightness by marking

blade tip position inside the deck housing and then rotating the opposite end of the blade to the same position and comparing. If the difference in blade tip track is more than 1/8 in. (3 mm), the blade is bent and should be replaced.

• Inspect the blade surface, especially in formed

areas, for cracks. Replace the blade if any cracks are found.

WARNING

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

Maintenance Instructions

REPLACING/REPAIRING/

ADJUSTMENTS

Reinstall the blades following procedure in CHECKING/SERVICING for Sharpen Mower Blades in- structions. If blades are replaced, always use Walker original equipment blades to ensure safety and

optimum performance. The quality and performance of replacement blades offered by other manufac-

turers cannot be guaranteed, they could be dangerous.

CAUTION

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

ADJUSTMENTS

Steering Handles

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

Tilt-Up Deck Adjustable Stop

When the carrier frame hinge joint is properly adjusted, the deck lock levers should move in and out of the engaged and disengaged positions freely. All four (4) hitch pins used for height adjustment should sit ush on the washers above the deck pin bushing. On a level surface, if any pin is sticking up (likely the front pins), tighten the opposite side or loosen the same side to lower the pin. Adjustments are made by loosening the jam nut and tightening or 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

GHS Signal Horn Adjustment (When Horn Sounds at Wrong Time)

The vertical position of the Grass-Pak critical to make sure the catcher box does not overll causing the delivery chute to clog. The vertical position can be adjusted by moving the aluminum

Adjustment

Slide

Steering Handle Adjustment

Locknut

(Position)

Locknut

(Pivot Point)

shaft and vane on the Grass-Pak® switch.

1. Position the discharge chute so that it is pointing straight back.

a. Turn the ignition switch ON and move the

blade clutch to the ENGAGED position (engine not running).

b. Open the catcher back door and monitor

the spout position (as it oscillates) and move the blade clutch to the DISENGAGED position and turn the ignition switch to the OFF position.

switch is

Maintenance Instructions ADJUSTMENTS

DANGER

PINCH POINT - SPRING LOADED DOOR

When lowering the door on the GHS catcher, BE VERY CAREFUL to keep hands, ngers, etc. out of the hinging mechanism and away from the door frame as the door closes. The springs that hold the door closed during operation are very powerful, and the door can slam shut with considerable force.

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.

2. Measure from the exhaust screen (top of catcher) to the top of the Grass-Pak® switch actuator vane, refer to Adjusting the Grass-Pak® Switch illustration. The proper measurement should be between 4 and 4-1/2 inches (10.16 and 11.43 cm).

Exhaust

Screen

Adjusting the Grass-Pak

(Side View of Catcher Box)

3. If adjustment is required, loosen front adjustment nut then move aluminum shaft and vane to the recommended measurement. Adjustments should be done in very small increments checking the measurement each time until the recommended measurement is achieved.

NOTE: It will not be possible to adjust the switch to give a signal at the precise instant the catcher is full for a wide variety of mowing conditions. For example, wet heavy grass will ll the catcher differently than dry uffy grass, causing the signal to come on a little sooner or later than usual. Primarily, the switch should be adjusted to give the “full” signal with a little advance warning before overlling and clogging of the grass delivery chute begins (regardless of mowing conditions).

4 to 4-1/2 in.

(10.16 to 11.43 cm)

Adjustment Nut

Switch

Operator’s Notes

LIMITED WARRANTY

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 part covered by this warranty which is found to be defective in material and/or workmanship within one (1) year* after date of sale to the original retail purchaser unless the product is used for rental purposes, in which case this warranty is limited to ninety (90) days. At Walker’s request, customer will make the defective part available for inspection by Walker and/or return the defective part to Walker, transportation charges prepaid. All parts and components of the Walker Mower are covered by this warranty except the following components which are warranted separately by their respective manufacturers:

Kohler Engine Battery

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

* Extended warranties are offered for the following powertrain components:

• A three (3) year unlimited hour warranty is offered for the Walker P/N 6200-9 Gear Axle Assembly.

• A three (3) year or 3000 hour (whichever comes rst) warranty is offered for Eaton Model 7 Hydrostatic transmissions;

covers full cost of replacement up to 1000 hours of use, and after 1000 hours warranty coverage is prorated against 3000 hours.

2. WHAT THIS WARRANTY DOES NOT COVER:

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

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

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

where the inspection and/or warranty work is performed.

3. HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:

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

4. WARRANTY LIMITATION:

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

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

above limitations may not apply to you.

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

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

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

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

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

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

Walker MC19 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual