Walker MC 20 HP User Manual

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OWNER’S MANUAL

Safety, Assembly, Operating, and Maintenance Instructions

Model MC (20 HP)

™

Please Read and Save These Instructions Effective Date: 03-01-07

For Safety, Read All Safety and Operation P/N 6000-13 Instructions Prior to Operating Machine

Foreword

Thank you. . .for purchasing a Walker mower. Eve ry ef for t has been made to provid e you with th e most reliable mower on the market, and we are sure you will be among our many satisfied customers. If for any reason this product does not perform to your expectations, please contact us at (970) 221-5614. Every customer is important to us. Your satisfaction is our goal.

Please. . .read this manual thoroughly! This manual is to be used in conjunction with the engine manufacturer's manual for the specific engine on the mower model you have purchased. Before you operate your new mower , please read this entire manual. Some of the information is crucial for proper operation and maintenance of this mower - it will help protect your investment and ensure that the mower performs to your satisfaction. Some of the info rma ti on is important to your safety and must be read and understood to help prevent possible injury to th e oper ator or ot hers. If anything in this manual is confusing or hard to understand, please call our service departmen t, at (970) 221-5614, for clarification before operating or servicing this mower.

This manual covers Model MC with the Kohler Command CH20 (20.0 HP) gasoline engine.

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

Specifications given are based on the latest information available at the time this manual was produced.

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

Sincerely, WALKER MANUFACTURING COMPANY

Bob Walker, President

General Information ________________ 1

HIGHLIGHTED INFORMATION _____________ 1 GLOSSARY ____________________________ 1 IDENTIFYING NUMBER LOCATIONS________ 1 ENGINE SERIAL NUMBER LOCATION ______ 2 SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS ______________ 2

Specifications________________________ 3

ENGINE________________________________ 3 ELECTRICAL SYSTEM ___________________ 3 TRANSMISSION_________________________ 3 BLADE DRIVE __________________________ 4 TIRE SIZE______________________________ 4 TIRE PRESSURE ________________________ 4 DIMENSIONS (Tractor and Mower) _________ 4 MOWER DECK__________________________ 5 CURB WEIGHT__________________________ 5 DRIVE BELTS___________________________ 6 GHS SYSTEM (Optional)__________________ 6 SEAT__________________________________ 6 FRAME/BODY CONSTRUCTION ___________ 6

Component Identification_ 7 Safety Instructions _______ 10

BEFORE OPERATING___________________ 10 OPERATING___________________________ 11 MAINTENANCE ________________________ 12 SAFETY, CONTROL, AND INSTRUCTION DECALS _________________ 14

Assembly Instructions _____________ 16

SETUP INSTRUCTIONS _________________ 16

Tire Installation (Tractor)_______________ 16 Battery Service_______________________ 16

Wet Battery Service __________________ 16 Dry Battery Service __________________ 16 Battery Charging ____________________ 17 Battery Installation ___________________ 17

Mower Deck Assembly ________________ 17

Deck Caster Wheels Installation ________ 17 Deck Discharge Chute Installation ______ 18 Deck Discharge Shield Installation ______ 18 PTO Shaft Guard Installation __________ 18 Tilt-Up Roller Wheel Installation ________ 18

Mower Deck Installation on Tractor ______ 19

Deck Installation ____________________ 19 Deck Leveling ______________________ 21

PREOPERATING CHECKLIST ____________ 22

Operating Instructions_____________ 24

CONTROL IDENTIFICATION, LOCATION, AND FUNCTION _____________ 24

Ignition Switch_______________________ 24 Engine Choke________________________ 24 Engine Throttle ______________________ 25 Forward Speed Control (FSC) __________ 25 Steering Levers ______________________ 25 Blade Clutch (PTO) ___________________ 25 Parking Brake _______________________ 25 Transmission Lockout Levers __________ 25 Hourmeter __________________________ 26 Oil Pressure Warning Horn_____________ 26 Circuit Breaker (7 Amp) _______________ 26 Light Switch (For Optional Lights)_______ 26

STARTING THE ENGINE_________________ 28 ADJUSTING GROUND SPEED AND STEERING _________________ 28 ENGAGING THE MOWER________________ 30 STOPPING THE MACHINE _______________ 31 ADJUSTING CUTTING HEIGHT ___________ 31 TRANSMISSION LOCKOUT ______________ 32 RECOMMENDATIONS FOR MOWING ______ 33 RECOMMENDATIONS FOR TILT-UP DECK OPERATION/TRANSPORT_______________ 34 GRASS HANDLING SYSTEM (GHS) _______ 35

General Information __________________ 36 Clogging Checklist ___________________ 37 Using the Tilt-Up Deck ________________ 38 Using the GHS Catcher________________ 38

Powerfil “Full” Signal Horn ___________________ 38

Cleaning the GHS Exhaust Screen ______ 38 Dumping the Catcher _________________ 39

Tailgate Dumping ___________________ 39 Using the Dump Bag _________________ 39

_________________________ 38

Table of Contents

Maintenance Instructions__________ 41

MAINTENANCE SCHEDULE CHART _______ 41 IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE _______________ 42

Fuel System _________________________ 42 Starting/Stopping_____________________ 42 Cooling System ______________________ 42 Air Cleaner System ___________________ 42 Oil _________________________________ 42

LUBRICATION _________________________ 43

Engine Oil ___________________________ 43

Engine Break-In Oil __________________ 43 Checking Engine Crankcase Oil Level ___ 43 Changing Engine Crankcase Oil/Oil Filter _43

Mower Deck Gearbox Lubrication _______ 44 DSD52 Mower Deck Lubrication_________ 45 Tractor PTO Gearbox Lubrication _______ 46

Checking Gearbox Oil Level ___________ 46 Changing Gearbox Oil ________________ 46

Gear Axle Lubrication _________________ 46 Hydrostatic Transmission Fluid _________ 46

Checking Hydrostatic Transmission Fluid Level ______________ 46

Grease Fitting and Oil Point Lubrication__ 47

CLEANING ____________________________ 50

Engine Air Cleaner System_____________ 50

Turbine Precleaner __________________ 50 Donaldson Radialseal™ Air Cleaner _____ 51

Engine Cooling System________________ 52

Air Intake System ___________________ 52 Cylinder Head Cooling Fins ____________ 53

Grass Buildup in Mower Housing________ 53 GHS Blower _________________________ 54 GHS Exhaust Screen __________________ 55 Hydrostatic Transmission Cooling Fins __ 55

CHECKING/SERVICING _________________ 55

Security of Air Filtration Components ____ 55 Battery______________________________ 55

Electrolyte Level ____________________ 55 Cleaning the Terminals _______________ 56 Charging the Battery _________________ 56

Tire Pressure ________________________ 56 Sharpen Mower Blades ________________ 56 Drive Belts __________________________ 57 Mower Deck Gearbox Oil Seals _________ 58 Spark Plugs _________________________ 58 Fuel Lines and Clamps ________________ 58 Blade Brake Action ___________________ 58

REPLACING/REPAIRING ________________ 58

Drive Belts __________________________ 58

Engine PTO Drive Belt _______________ 60 Jackshaft Drive Belt GHS Blower Drive Belt _______________ 62 Hydrostatic Ground Drive Belt _________ 63

Fuel Filter ___________________________ 64 Blade Overload Shear Bolts ____________ 64 PTO Shear Pin _______________________ 65 Mower Blades _______________________ 65

ADJUSTMENTS________________________ 66

Steering Levers ______________________ 66 Tilt-Up Deck Adjustable Stop ___________ 66

_________________ 61

Warranty___________________________ 67

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

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

Instructions for the meanings of DANGER, WARNING, CAUTION, IMPORTANT, and NOTE.

GLOSSARY

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

• DECK is the mowing attachment moun ted on

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

• FORW ARD 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.

) collects

• 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) mows but does not

collect the mowed material.

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

• 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

• GROUND DRIVE refers to the dual hydr os tatic

transmissions which drive the main wheels.

• HYDROSTATIC TRANSMISSION transmits

and controls power from the ground drive belt to the main drive wheel.

• LEFT HAND (LH) refers to the left-hand side of

the tractor when the operator is seated facing forward in the tractor seat.

Tractor Model No. _______________________ Tractor Serial No. _______________________ Deck Serial No. _______________________ Engine Model No. _______________________ Engine Serial No. _______________________ Date of Purchase _______________________

Fill In By Purchaser

General Information

Serial Number

Tractor Serial Number Location

Serial Number

SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS

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

Walker Manufacturing Company

5925 E. Harmony Road

Fort Collins, CO 80528

1-970-221-5614

Mower Deck Serial Number Location

ENGINE SERIAL NUMBER LOCATION

Refer to the engine manual th at accompanies this manual for the location of the engine serial number. For the mower model covered by this manual, an engine manual is available from Kohler covering the Kohler Command CH20 gasoline engine.

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

Kohler Engines Kohler Company

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

Hydrostatic Eaton Corporation Transmissions 15151 Highway 5

Eden Prairie, MN 55344

Gearboxes (Deck) Tecumseh Power Co.

1555 S. Jackson Street Salem, IN 47167 812-883-3575

Serial Number

Engine Serial Number Location

Specifications

MODEL MC

ENGINE

Manufacturer/Model Kohler Command CH20, 2 Cyl., Gasoline (Air-Cooled) Displacement 38.1 cu. in. (624 cc) HP (@ 3600 RPM) 20.0 Max. RPM (No Load) 3750 Governed RPM 3600 Max. Torque [ft-lb (N Idle RPM 1200 ± 75 Spark Plug Type Champion Spark Plug Gap .030 in. (.76 mm) Crankcase Capacity 2 qts (1.9 liters) Crankcase Lubricant API SG, SH, SJ or higher Grade Oil Only with 10W-30 Viscosity above

Oil Filter 28-050-01 Fuel Tank Capacity 3 Gallons (11.4 liters) Fuel Regular Grade Unleaded Gasoline (87 Octane) Cooling System Capacity Air Cooled

ELECTRICAL SYSTEM

Battery 12 Volt, 35 AH, 295 CCA Charging System Flywheel Alternator Charging Output 15 Amp DC (Regulated) System Polarity Negative Ground

·m) @ RPM] 32 (43) @ 2500

RC12YC

0° F (-18° C), or 5W-20 or 5W-30 Viscosity below 32° F (0° C)

Ignition Electronic Capacitive Discharge Starter 12 Volt Electric Ring-Gear Type, Solenoid Shift Interlock Switch Ignition Lockout by Seat Switch, Transmission Neutral and Blade Clutch Circuit Breaker Auto Reset (30A)

TRANSMISSION

Manufacturer/Model Dual Hydrostatic, Eaton Model 7, Each Wheel Independently Driven Steering Hand Lever Control / Individual Wheel Forward Speed Control Precision Friction Lock Lever, Cruise Control, with Neutral-Park

Position Service Brake Dynamic Braking through Hydrostatic Transmission Parking Brake Mechanical Pin Lock in Transmission Gear

Specifications

MODEL MC

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) Alternate Transmission Fluid SAE 30W Straight Viscosity Motor Oil Transmission Fluid Capacity 1 qt (1 liter) Transmission Cooling Cooling Fan Mounted on Drive Pulley

Ground Travel Speed

Forward m.p.h. (km/h) Reverse m.p.h. (km/h)

BLADE DRIVE

PTO Shaft Quick Disconnect Spline Sha ft with Two High-Speed U-Joints Blade Spindle Each Blad e (2) Mo u nts Direct on Pee rle ss Right Angle

0-5 (0-8) Infinitely Variable

Gearbox with Tee Gearbox in Center Connected to PTO Shaft

(Complete Geared Drive, Peerless Model 1000 Gearboxes) Blade Drive Clutch and Brake Manual Belt Tightener Clutch and Band Brake

(Stops Blades within Five (5) Seconds of Disengagement) Max. Blade Speed

[22 in. (56 cm) Blade] @ 3600 RPM Engine

TIRE SIZE

Deck Caster Wheel 36, 42, 48, 56 52, 62, 74

Deck Caster Wheel (Optional) 36, 42, 48, 56 8 x 3.00-4 Foamed Rubber

Drive 18 x 8.50-10 (4-Ply Low-Profile) Drive (Optional Narrow Tire) 18 x 7.00-8 (4-Ply) Rear 13 x 6.50-6 (4-Ply)

TIRE PRESSURE

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

Rear

DIMENSIONS (Tractor and Mower) Length

36 in. (91 cm) GHS Model 87 in. (221 cm) 42 in. (107 cm) GHS Model 89 in. (226 cm)

2900 RPM

[16700 FPM (5090 m/min)]

8 x 3.00-4 Pneumatic (4-Ply)

11 x 4.00-5 Pneumatic

20 PSI (137 kPa)

Specifications

MODEL MC

DIMENSIONS (continued) Width

36 in. (91 cm) SD Model (with Deflector)

42 in. (107 cm) SD Model (with Deflector)

36 in. (91 cm) GHS Model 37 in. (94 cm) 42 in. (107 cm) GHS Model 43 in. (109 cm)

Height

SD Model 37-1/2 in. (95 cm) GHS Model 49-1/2 in. (112 cm) Wheel Base (Tractor) 42-1/4 in. (107 cm) Tread Width (Tractor)

Standard Tires 28-1/4 in. (72 cm)

41-3/4 in. (106 cm)

47-3/4 in. (121 cm)

Optional Tires 29-3/4 in. (76 cm)

MOWER DECK

Width of Cut SD/GHS 36 or 42 in. (91 or 107 cm) Cutting Height 1 to 4 in. (3 to 10 cm) Height Adjustment 7 Positions - 1/2 in. (1 cm) Increment Hitch Pins Installed in

Multi-Position Deck Support

Blade Size

36 in. (91 cm) SD Model 20 in. (51 cm) Two (2) Clockwise-Rotating Blades with a 4 in.

(10 cm) Center Overlap 36 in. (91 cm) GHS Model 20 in. (51 cm) Two (2) Counter-Rotating Blades with a 4 in.

(10 cm) Center Overlap 42 in. (107 cm) SD Model 22 in. (56 cm) Two (2) Clockwise-Rotating Blades with a 2 in.

(5 cm) Center Overlap 42 in. (107 cm) GHS Model 22 in. (56 cm) Two (2) Counter-Rotating Blades with a 2 in.

(5 cm) Center Overlap Deck Suspension Torsion-Flex Frame with Caster Wheels and

Counterweight Springs

CURB WEIGHT (Approximate)

SD Tractor Only 622 lb (282 kg) GHS Tractor Only 753 lb (342 kg) SD Tractor and 36 in. SD Deck 752 lb (341 kg) SD Tractor and 42 in. SD Deck 787 lb (357 kg) GHS Tractor and 36 in. GHS Deck 878 lb (398 kg) GHS Tractor and 42 in. GHS Deck 954 lb (433 kg)

Specifications

MODEL MC

DRIVE BELTS

Engine PTO Walker P/N 8230 Jackshaft Drive Gates 3VX385 (or Walker P/N 6251-1) Ground Drive, Micro-V Walker P/N 7248 Blower (GHS Model) Walker P/N 7234-1

GHS SYSTEM (Optional)

Blower 4-1/2 x 10-1/2 x 1/2 in. (11 x 27 x 1 cm) Three-Blade Paddle Wheel

Blower Brake Band Brake (Works in Combination with PTO Clutch, Stops

Max. Blower Speed 3600 RPM Grass Catcher Capacity* 89 Gallons (335 liters)/9.5 Bushels Optional Grass Catcher Capacity 63 Gallons (238 liters)/6.7 Bushels

(Driven by Mower Engine)

Blower within Five (5) Seconds of PTO Disengagement)

Full Signal Oscillating Vane Switch Mounted on Grass Delivery Spout T riggers

Horn Signal Powerfil

SEAT

FRAME/BODY CONSTRUCTION

Frame All Welded Unitized Steel Chassis Body 14 Gauge Steel Deck 11 Gauge Steel GHS Catcher and Chutes Molded Cross-Linked Polyethylene (UV Stabilized)

Oscillating Delivery Spout Driven by 12 Volt Electric Gearmotor

Spreads Mate rial throughout Interior of Catcher @ 25 Cycles/Minute

Contour-Molded, with Nylon Backed Vinyl Cover and Integral

Foam Cushion

*Optional (6.7 Bushel) Grass Catcher subtracts approx. 5 lb (2 kg) and 5 in. (13 cm) in Height

NOTE: The manufacturer reserves the right to make changes in specifications shown herein at any time without notice or obligation.

Component Identification

NOTE: Control Identification

shown in Operating Instructions section.

Catcher Door

Safety Latch

Anti-Scuff

Roller

Catcher Lift /

Dump Handle

Fuel Tank and Cap

Transmission Control

Rod Adjustment Nut

(RH)

Turbine

Precleaner

Grass Handling System

9.5 Bushel Catcher

Tilt-Up

Latch

Spring Clip

Counterweight Spring

and Protective Cover

Transmission Control Rod

Adjustment Nut (LH)

Deck Support Pins

and Height Adjustment

Hitch Pins

Deck Support Arms

Deck Lift Handle

(Cutting Height Adjustment)

Tilt-Up Hook (Not Visible)

Front View and Right Side View

Tilt-Up

Deck Handle

Footrests

Deck

Caster Wheels

Component Identification

Catcher Door

Gas Spring

Protective Cover

Catcher Lift /

Dump Handle

Catcher Door

Gas Spr ing

Removable Grass

Catcher Screen

(Not Visible)

Catcher Exhaust

Deflector

Catcher

Door

Left Hand

Drive Wheel

Muffler

Tailpipe

Oil

Filter

Rear View and Left Side View

Oil Drain

Plug

Tailwheel Fork

and Wheel

Catcher

Door Handle

Anti-Scuff

Roller

Component Identification

Air Restriction

Indicator

Rubber Bumper

(Body Support)

(Not Visible)

Donaldson

Air Cleaner

Cover

Rubber Bumper

(Body Support)

Fuel Pump

Air Intake

Hose

Precleaner

Tube

Fuel Tank Cap

Jackshaft

PTO Gearbox

Dipstick

Turbine

Precleaner

RH Transmission

Lockout Lever

PTO

Clutch Lever

Positive (+)

Battery Cable

Muffler

Muffler Heat Shield

Throttle and

Choke Linkage

Oil Fill/

Dipstick

GHS Blower

RH Hydrostatic

Transmission

Neutral Safety

Switch

LH Hydrostatic

Transmission

Negative (-)

Battery Cable

Top View (Engine Compartment)

Battery

30 Amp

Circuit Breaker

LH Transmission

Lockout Lever

Safety Instructions

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. Failure to comply with safety instructions may result in personal injury.

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

DANGER

An IMMEDIATE hazard that WILL result in severe personal injury or DEATH, if 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

Owner's Manual before starting and operating the machine. Become thoroughly familiar

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

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 s afety precautions are not taken.

IMPORTANT: Identifies mechanical information

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

NOTE: Identifies information worthy of special attention.

Walker Manufacturing Company

5925 East Harmony Road

Fort Collins, CO 80528

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 ever yone, e specia lly child ren a nd 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

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

7. Prolonged exposure to loud noise can cause impairment or loss of 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 functionin g 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 the PTO clutch in the ENGAGED position.

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

a. Use an approved fuel container. b. Never add fuel to a running engine or hot

engine (allow hot engine to cool several minutes).

c. Keep matches, cigarettes, cigars, pipes,

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

d. Always fill the fuel tank outdoors using care.

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

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

OPERATING

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

2. Sit on the seat when starting the engine and operating the machine. Keep feet on the deck footrests at all times when the tractor is moving and/or mower blades are operating.

3. For a beginning operator, learn to steer (ma-

neuver) the tractor with a slow engine speed before attempting any mowing operation.

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

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

5. In case either of the transmission drive belts break during operation, and if the machine is on a slope, the machine will freewheel down the slope. To maintain control, immediately (1) Release the steering levers and simultaneously (2) Move the FSC to the NEUTRAL-P ARK 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.

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).

e. Replace the machine fuel cap and container

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

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

7. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and can be deadly.

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

Safety Instructions

9. 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.

10. Avoid sudden star ts or stops. Before backing the machine up, look to the rear to be sure no one is behind the machine. Watch carefully for traffic when crossing or working near r oadways.

11. Disengage the blade drive when transporting the machine across drives, sidewalks, etc. Ne-

ver raise the mower deck while blades are rotating.

12. The maximum recommended side slope operating angle is 20 degrees or 33% grade.

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

13. 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 five (5) seconds of disengaging the PTO clutch.

17. For GHS equipped models, use care when closing the grass catcher door . Keep fingers and hands away from the hinge and pinch points when the door is being closed. Also, keep fingers and hands clear of the door frame. The door is held closed with springs and the door may slam shut with considerable force.

18. In case of a clogged or plugged mower deck

or GHS catching system:

a. Disengage the blade clutch (PTO) and turn

the engine off before leaving the seat.

b. LOOK to make sure blade drive 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.

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

ately disengage the blade clutch (PTO), stop the engine, and wait for all moving parts to stop. T o prevent accidental starting, disconnect

the spark plug wires. Thoroughly inspect the mower and repair any damage be fore restarting the engine and operating the mower . Make sure cutter blades are in good condition and blade nuts are torqued to 60 ft-lb (81.3 N

·m).

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

ate with the grass deflector chute removed.

Keep the deflector in the lowest possible position.

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

the following recommendations:

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

sition.

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

position.

16. For GHS equipped models, do not operate the

machine with the grass catcher in the DUMP position or with the back door OPEN. Dan-

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

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

21. When leaving the machine unattended, dis-

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

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.

Safety Instructions

2. T o reduce fire hazards, keep the engine free of grass, leaves, excessive grease, and dirt.

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

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

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

jewelry or loose clothing.

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

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

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

c. Keep sparks, flames, and smok ing 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

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

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

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. Substitute parts may result in product malfunction and possible injury to the operat or and/or others.

11. Use care when charging the battery or performing 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.

Safety Instructions

SAFETY, CONTROL, AND INSTRUCTION DECALS

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

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

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

Each End of Mower Deck (5808)

SD Deck Discharge Shield (5848)

Adjacent to Blower Discharge Chute

through Body (5804)

Engine Shroud (5855)

Rear of Grass Catcher Exhaust Screen (5869)

Catcher Safety Latch,

RH Side (5874)

Hydrostat Oil

Reservoir (5810-2)

Gear Axle (5810-1)

Underside of Body (5861)

LH Side of Body,

Above Muffler (5805)

Lower Front Body (6807)

Bridge Assembly and LH Gear Axle (5810-3)

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.

Top of Blower Housing (5819)

Deck Gearbox Cover (5807-3)

Jackshaft Support Adjacent

to Dipstick (7827)

Right Side of Body (5806)

Deck Carrier Frame (5865)

Fender, LH Side (5802-2)

On Engine (6810)

Right Side, Below Operator Seat (7809)

Catcher Door Hinge Bar, LH and RH Sides (5868)

Deck Carrier Frame (8653)

Deck Carrier Frame (8647)

Rear Bumper (5815)

Fender , RH Side (7802)

Assembly Instructions

SETUP INSTRUCTIONS

Walker Mowers are shipped partially assembled. After uncrating the tractor and mower deck, initial setup is required.

NOTE: During the process of unpacking, any damaged or missing parts sh ould be note d and reporte d to the delivering carrier immediately (put in writing within 15 days). The carrier will provide directions for proceeding with a claim to receive compensation for damage.

Tire Installation (Tractor)

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

that are supplied with the owne r's packet of ma terials. Drive tires are 18 x 8.50-10, 4-ply; rear tire is 13 x 6.50-6, 4-ply.

• Check and adjust the inflation of the tires. The

tire inflation recommendations are:

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

Battery Service

Tilt mower body up (lift on rear of body) for battery access. Check the battery for electrolyte level and charge. The electrolyte level should be at the bottom of the vent wells [1/4 to 1/2 in. (6 to 13 mm) above plates]. If the specific gravity is less than

1.225, the battery needs charging. If the battery

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

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

Wet Battery Service

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

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

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

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 batter y 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 u se b y a trained battery technician.

DANGER

Battery electrolyte is a poisonous and corrosive sulfuric acid solution.

• Avoid spillage and contact with skin,

eyes, and clothing - causes severe burns.

• To prevent accidents, wear safety gog-

gles and rubber gloves when working with electrolyte.

• Neutralize acid spills with baking soda

and water solution.

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

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

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

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

2. Remove the filler caps and carefully fill each cell until the electrolyte is just above the plates.

Assembly Instructions

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

Battery Charging.

Battery Charging

DANGER

BA TTERIES PRODU CE EXPLOSIVE GASES

• Charge the battery in a well-ventilated

area, so that gases produced while charging can dissipate.

• Keep sparks, f lames, and smoking mate-

rials away from the battery at all times.

• Make sure the battery cap vents are open

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

• Make sure the battery charger is unplug-

ged before connecting or disconnecting cables to the battery.

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

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

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

3. Install battery.

Battery Installation

Install the battery in the mower as shown in Battery Installation photo. Connect the positive and negative cables to the proper battery terminal (red cable

and boot connects to the Positive (+) terminal).

Slide the rubber boot up and ov er the battery p ost, making sure it covers the post completely to pre-

vent an electrical short.

WARNING

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

Battery Clamp

Secured by

Wing Nut(s)

(+) Battery Cable

Connection

Battery Installation

Mower Deck Assembly

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 fit the assembly into the wheel fork.

3. Insert the 3/8-16 x 4-1/2 in. bolt through the wheel fork with the bolt head to the outside and install the 3/8-16 in. Keps nut.

4. Tighten the bolt and nut until the axle spacer tube bottoms against the inside of the wheel fork (will not turn) while the wheel and spacer washers (if used) spin freely without binding.

Assembly Instructions

Grease Fitting

Locations

Spacer Washer

Axle Spacer Tube

Deck Caster Wheel Installation

5. Grease the caster wheel bearings and caster pivot bearings - one grease fitting for ea ch wheel and each pivot.

Deck Discharge Chute Installation (GHS Rear Discharge Models Only)

Mount the discharge chute hinge on top o f the deck discharge opening using the 1/4-20 x 1/2 in. socket button head bolt and 1/4-20 ESNA nut. Position the bolt with the head inside of the chute and the n ut on the outside.

Deck Discharge Shield Installation (Side Discharge Models Only)

Attach the deck side discharge shield by positioning the shield hinge lug in front of the deck mount and fastening with two 3/8-16 x 1-1/4 in. bolts, 3/8-16 ESNA nuts, and 3/8 in. wave spring washers. The wave washers fit between the two hinging surfaces. Tighten the nuts until the shield moves freely but is not loose.

WARNING

DO NOT operate the machine without the grass deflector shield att ached a nd in the lowest possible position.

Attach Shield

Carrier Frame

Tube Sockets

Attach Guard

Nut on Top

Discharge Chute and PTO Shaft Guard

Installation on Rear Discharge Deck

Attach

Chute

Discharge Shield Installation

on Side Discharge Deck

PTO Shaft Guard Installation

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

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 , join the PTO tube to the PTO shaft (align arrow decals). Slide the PTO tube onto the spline shaft on the tractor PTO gearbox.

NOTE: When installing the DSD52 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 lnstallation 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 spring-loaded coupler ring on the PTO Tube (provided in Owner ’s Packet) and insert coupler tool. Refer to Quick Coupler Installa- tion Tool photo.

Quick Coupler

Installation Tool

PTO

Connection

Grease Deck

Support Arms

Mower Deck Installation (PTO Shaft Connection)

5. 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 fitting and guiding the deck chute into the blower .

6. Install the hitch pin through th e ho le 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.

PTO Tube

Pull Back Spring-Loaded

Coupler Ring

Quick Coupler Installation Tool

7. Remove Installation Tool from coupler ring and make sure the ring has “snapped” securely on the spline shaft.

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

Assembly Instructions

IMPORTANT: To prevent damage to the mower, make sure the PTO shaft assembly is securely locked on the tractor, with the locking balls fully seated in the groove and the ring in the full forward position (refer to the Coupler Ring “Locked” Position photo). After installation, pull on the shaft to check for security .

Spring-Loaded Coupler Ring

In Fully Forward Position

Coupler Ring “Locked” Position

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.)

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). Check this weight by lifting on the front of the deck carrier frame. If required, the spring tension can be adjusted by tightening or loosening the elastic stop nuts located underneath the lower spring hook. Refer to Deck Counterweight Spring Insta lla- tion photo.

Spring Tension Adjustment

Nut Located Under Lower

Spring Hook (Not Visible)

Counterweight Springs

Clip Onto Body

With Body Tilted Up

Deck Counterweight Spring Installation

Hitch Pins Lock Deck On Support Arms

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 ea ch 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 1/8 in. (3 mm) difference.

NOTE: The mower deck and support frame are jig welded; within normal tolerances, very little, if any, shimming should be required to level the deck. Tire pressure will influence the levelness of the deck. Check the tire pressure as a possible cause of the deck not being level.

4 in. (102 mm)

Wood Block

Should not vary more

than 1/8 in. (3 mm)

side-to-side

Should be 1/8 in. (3 mm)

to 1/4 in. (6 mm) higher

at the rear of the blade

4 in. (102 mm)

Wood Block

Deck Leveling

Assembly Instructions

PREOPERATING CHECKLIST

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

For proper fuels and lubricants refer to Specifica-

tions.

FILL FUEL TANK

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

DANGER

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

IMPORTANT: DO NOT mix oil with gasoline. Al- ways use fresh, automotive grade gasoline. DO NOT use premium, white, or high-test gasoline. DO NOT use additives, such as carburetor cleaners, de-

icers, or moisture removing agents. DO NOT use gasoline blended with methyl alcohol.

CHECK ENGINE CRANKCASE OIL LEVEL

Check the engine crankcase oil level before use and after each 5 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 restriction gauge to make sure there is

no red indication showing.

• Check condition, cleanliness, and security of the

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

• DO NOT fill fuel tan k 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 f uel; use a funnel or spout.

• DO NOT overfill the fuel tank; fill up to

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

IMPORTANT: DO NOT permit dirt or other foreign

matter to enter the fuel tank. Wipe dirt from around the filler cap before removing. Use a clean fuel storage container and funnel.

CHECK ENGINE COOLING SYSTEM

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

INSPECT FOUR (4) DRIVE BELTS

Engine PTO Drive, Jackshaft Drive, Hydrostatic Ground Drive, and GHS Blower Drive (if equipped).

CHECK HYDROSTATIC TRANSMISSION OIL

LEVEL

Refer to LUBRICATION for Checking Hydrostatic

Transmission Fluid Level in Maintenance Instructions.

CHECK FUNCTION OF OIL PRESSURE

WARNING HORN

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

Assembly Instructions

CHECK TIRE PRESSURE

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

Rear = 20 PSI (137 kPa)

CHECK AND CLEAN GRASS BUILDUP

UNDERNEATH MOWER DECK (and inside GHS blower, if equipped)

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.

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

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, SHARP-

NESS, AND SECURITY OF MOUNTING

The blade mounting nut should be tightened to 60 ft-lb (81.3 N refer to CHECKING/SERVICING for Sharpen Mower Blades in Maintenance Instructions.

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 DRIVE WHEEL BOLT TORQUE

The lug bolts mounting the drive tires should be tightened to 75 to 85 ft-lbs. (101.7-115.2 N

·m). If blade sharpening is required,

·m).

Tilt-Up Lift Handle

Tilt-Up Latch

Tilt-Up Hook

on Deck

Deck Lock Lever

Deck Secured in TILT-UP Position

CAUTION

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

PERFORM ANY ADDITIONAL PROCEDURES

called for on the MAINTENANCE SCHEDULE CHART in Maintenance Instructions.

Operating Instructions

CONTROL IDENTIFICATION, LOCATION, AND FUNCTION

CAUTION

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

Ignition Switch

The ignition switch is located on the right fro nt 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. T o 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. T o st art 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 da m ag e the engine.

Parking

Brake

Blade Clutch

(PTO)

Ignition Switch

(See Inset)

Light Switch

(Optional, Not Shown)

Oil Pressure

Warning Horn

Forward Spe ed

Control (FSC)

5 Amp

Circuit Breaker

OFF

Steering

Levers

START

Ignition Switch

Key Positions

Hourmeter

Operating Controls

Operating Instructions

Engine Throttle

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

Throttle

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 5 mph (0 to 8 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 an d slows or stops forward travel. Releasing the steering levers allows the tractor to resume forward travel at the speed set by the FSC lever. To stop and park the machine, the FSC lever is moved backward to the NEUTRAL-

PARK position. Steering Levers

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

Choke

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: On GHS equipped models, the Powerfil motor and Grass-Pak® full signal switch are activated by engaging the blade clutch. Refe r to Using the GHS Catcher in this section 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 leve r, move the mower gently forward or backward to release the pin.

Transmission Lockout Levers

The transmission lockout levers disengage the hydrostatic transmissons. By liftin g 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.

Operating Instructions

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 operatio n

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

Hourmeter

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

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

reset function.

Procedure Interval* Reminder

*** 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 pr essure condition exists).

Oil Change (Break-In)**

Lubricate and Check Levels

Oil Change

4-6 Hours

24-26 Hours LUBE

49-51 Hours***

OIL

H G

OIL

H G

* These intervals reflect the actu al time that the

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

** This reminder is only used one time.

Circuit Breaker (7 Amp)

A 7-amp, manual-reset circuit breaker is located below the ignition switch. 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)

RIGHT WHEEL

STEERING LEVER

FORWARD SPEED

CONTROL LEVER (FSC)

Full Forward

Ground Speed

Position

Neutral-Park

Position

Reverse Drive

Wheel Motion

Position

Fast

Throttle

Position

PARKING

BRAKE

Disengaged

Position

Intermediate

Ground Speed

Position

Neutral-Park

Position

Engaged

Position

Disengaged

Position

THROTTLE

ON Position

OFF Position

Idle

Position

Engaged

Position

BLADE CLUTCH (PTO)

Pull Up to Engage

CHOKE

Operating Controls (Top View from Drivers Point of View)

Operating Instructions

STARTING THE ENGINE

CAUTION

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

WARNING

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

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

DISENGAGED.

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.

3. After the engine starts, make sure the oil pressure horn goes off. If not, stop the engine immediately and find 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.

NOTE: Release parking brake to prevent extra load on the starter if the transmission neutral is slightly out of adjustment.

CAUTION

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

2. Move the choke lever to the ON position and move the throttle 1/4 to 1/2 open (toward FAST). Turn the ignition 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.

ADJUSTING GROUND SPEED AND STEERING IMPORTANT: If the DSD52 Mower deck is in-

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

CAUTION

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

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

DANGER

Keep feet on footrests at all times when the machine is moving.

Operating Instructions

1. Move the FSC out of NEUTRAL-PARK position to the desired forward speed. DO NOT hold forward on steering levers. It is not necessary to hold the FSC 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 flat ground BEFORE operating on slopes.

WARNING

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

NOTE: This is exactly the same procedure

used to normally stop and park the machine. NOTE: If the FSC lever will not stay in the

selected position, the friction lock needs to be adjusted. Contact your W a lke r 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.

♦ Start maneuvering the mowe r 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 ope rat e th e st ee rin g le ve rs wi th 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 lever controlling the inside wheel into reverse for a smooth “rolling” turn (one wheel rolling forward while the other rolls backward).

♦ Practice maneuvering the mower until you can make it go exactly 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 NEUTRAL-PARK position.

Operating Instructions

ENGAGING THE MOWER

Pull Steering

Levers With

Left Hand

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.

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. Pull the blade clutch lever SLOWLY up to en- gage the mower blades.

CAUTION

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

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 maint a in a balance between engine power and blade speed for high-quality cutting action.

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

NOTE: If the tractor creeps forward or backward with the FSC lever in the NEUTRAL-PARK position, the transmission control needs to be adjusted. Contact your W a lke r Dealer.

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).

CAUTION

If the cutting blades strike a st ationary object while mowing, stop the mower immediately, disconnect the spark plug wires, lift the deck, and inspect the deck and blades thoroughly for damage. Make sure that the blade timing has not been disturbed (the blades should be at 90 degrees to each other). Refer to REPLACING/REPAIRING the Blade Overload Shear Bolts in Maintenance Instructions if blades are out of time. Also, make sure the blade retaining nuts are torqued to 60 f t-lb (81.3 N

·m).

Operating Instructions

Engaged

Position

Blade Clutch Engaged

WARNING

A brake stops the cutter blades (and blower on GHS equipped models) from freewheeling within five (5) seconds after disengaging the clutch. If the brake system malfunctions and the blades do not stop within five (5) seconds, the brake should be adjusted or repaired before operating the mower. Contact your Walker Dealer.

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.

Disengaged

Position

Blade Clutch Disengaged

STOPPING THE MACHINE

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

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

3. Disengage the blade clutch. IMPORTANT: DO NOT disengage the blade

clutch with high engine speed (above 1/2 throttle) since the brake action on the blade drive will cause premature wear of the brake band.

5. Engage the parking brake. IMPORTANT: The hydrostatic transmissions

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

ADJUSTING CUTTING HEIGHT

WARNING

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

Operating Instructions

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

Lockout Lever

Lift Handle

Deck Support

Hitch Pin

Cutting Height Adjustment

TRANSMISSION LOCKOUT IMPORTANT: DO NOT TOW this mower with the

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

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.

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.

Plunger

Released

Cam in

LOCKOUT

Position

Lockout Lever

Cam in

UNLOCKED

Position

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

Lockout Lever - Normal Operating Position

Operating Instructions

RECOMMENDATIONS FOR MOWING IMPORTANT: Operate the engine at full speed

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

• 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 or nea r 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 first pass and then make a second pass cutting to the desired height.

• When using a side discharge mower deck, the

side discharge shield must not be removed and must be kept in the lowest possible position to deflect grass clippings and thrown objects downward. Orient the side discharge away from sidewalks or streets to minimize cleanup of clippings. When mowing close to obstacles, orient the side discharge away from obstacles to reduce the chance of damage to property by thrown objects.

Side Discharge Shield in Lowest Position

• When 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 side slope operating angle is 20 degrees or 33% grade.

• Use a slow setting on the FSC for trimming

operations.

• Make sure the mower is leveled properly for a

smooth cut. Refer to Deck Leveling in Assembly Instructions.

• Use an alternating stripe mowing pattern for

best appearance and vary the direction of the stripe

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

• Avoid damage to the grass by slipping and skid-

ding of the drive tires. Use 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).

Maximum Recommended

Side Slope - Do Not Operate

on Steep Slopes

20°

60 in.

Maximum Recommended Side Slope

22 in.

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 configuration should only be used when the tractor is parked.

• The tractor body should never be tilted for-

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

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

• 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 whee ls (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) GHS Model Only

PTO and Blade

Gear Drive

Shear

Bolt

PTO Clutch

Shear Pin

Powerfil

Drive Motor

Actuator

Rod

“Full” Signal

Horn

Delivery

Chute

Grass-Pak

Vane Switch

Catcher Door

Safety Latch

Exhaust Screen

(Removable)

Dump Handle

Powerfil

Delivery Spout

Exhaust

Deflector

Catcher

Door

Catcher

Door Spring

Grass Catcher

Rear Discharge

Mower Deck

Body Chute

Assembly

Blower

Deck

Discharge Chute

GHS Flow and Components

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 9.5 bushel (335 liters) capacity or optional 6.7 bushel (238 liters) capacity. The GHS blower operates any time the mower blade clutch is engaged and moves grass through the rear discharge deck chute into the grass catcher. Blower airflow is exhausted out the back of the grass catcher , through a filtering screen. When the grass catcher is full and needs to be emptied, a “full” signal horn alerts the operator . When the “fu ll” signal horn so unds, it is important to stop mowing to prevent overfilling and clogging of the blower system.

IMPORTANT: Normally, the GHS blower operates with no maintenance or cleaning required. However, under certain operating conditions, the 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 conditions, 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: 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 int ake 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 tension on the blower drive belt and does not require the blower intake cover.

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 adjustment, 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 suff icient force to cause serious injury to bystanders or property damage.

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 clogging has occurred.

CAUTION

NEVER leave grass clippings in the grass catcher after mowing. Damp clippings generate heat as they decompose. This MAY cause spontaneous combustion.

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 t he 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 first 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 restricting the flow 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 blad es are

installed for the correct rotation - install blades so the cutting edges move toward each other.

• Check the amount of flat section remaining at

blade tip. This is the area that is ground away (removed) when the blades are sharpened. If too much of the flat section is removed, the “air lift” performance or “shovel” effect of the blade deteriorates to the point that discharge of grass clippings into the blower chute is marginal. Replace cutter blades if less than 3/4 in. (19 mm) flat section remains at the blade tip.

• Check that the interior of the deck housing and

baffling is reasonably clean and free of grass and dirt buildup. While some degree of material buildup

can be tolerated, a point is finally reached where the flow of air and grass clippings is restricted.

NOTE: One condition that quickly causes a buildup of material in the deck housing is mowing grass and/or weeds which are “juicy.” The material collects under the deck with sticky , green juice. Clover and weeds are especially a problem. The mower deck will need to be cleaned frequently when operating in these conditions.

• Check the deck cutting height setting. When

working in thick, tall grass, lower deck settings [1 to 2 in. (25 to 51 mm) cutting heights] tend to restrict airflow from moving into and under the

deck. Raising the deck cutting height will significantly increase airflow and reduce clogging when working in thick, tall grass.

• Check the interior of the chute connecting the

mower deck to the blower for smoothness and freedom from obstruction.

Blades Must Operate at

Right Angles (90 Degrees)

Torque = 60 ft-lb

Rear Discharge

Chute

Blade Rotation for GHS Mower Deck

(view from underneath)

FORWARD

Mounting Nut

(81.3 N

·m)

• Check the blower wheel for bent blades and

excessive clearance between the blade tip and the

blower housing. A clearance greater than 1/8 in. (3 mm) will cause a significant loss of blower performance.

• Check the 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 consid erable “clump” of material can accumulate at this point, greatly restricting material and airflow.

• Check that the openings in the removable air

exhaust screen in the grass catcher are not plugged. If the screen is clogged, refer to Cleaning the GHS Exhaust Screen in this section.

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 airflow restriction and more clog resistance (use standard screen in dry conditions to avoid excessive material blowing out of the catcher).

Remember, anything that restricts airflow or material flow along the entire path from the mower deck to the grass catcher can cause clogging.

Using the Tilt-Up Deck

Refer to CLEANING of Grass Buildup in Mower Housing in Maintenance Instructions.

Using the GHS Catcher

Powerfil

The GHS catcher has an oscillating grass delivery spout (POWERFIL 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).

) which is designed to spread

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 coming on too soon (catcher not completely full) or too late (grass clogging in catcher spout and delivery chute), contact your Walker Dealer.

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 is

“Full” Signal Horn

The GHS catcher has a “full” signal horn to alert the operator to dump the catcher when it is full (to prevent overfilling 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 fill 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 oscillates. The horn should sound as the switch is moved in both directions.

vane by hand as it

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 airflow restriction.

Grass Catcher

Screen

Removal

Knobs

(Not Visible)

Grass Catcher Screen Removal for Cleaning

Operating Instructions

Dumping the Catcher

For dumping, the catcher eithe r tailgate dum ps into a disposal area or dumps into the optional dump bag. The dump bag is a reusable nylon fabric bag designe d t o conveniently move grass clippings from the catcher to a remote disposal area or container.

Tailgate Dumping

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

NOTE: To prevent accidental door closure, a safety latch locks the door open in the fully

opened position while the catcher is being dumped.

2. Tilt the catcher back to dump by lifting on the catcher lift handle on the lower front corner of the catcher.

3. Lower the catcher smoothly down to the n ormal operating position. DO NOT allow the catcher

to drop down.

4. Close the door by holding the door handle with the left hand and releasing the safety latch on the door hinge mechanism with the right hand. The safety latch is released by pressing in on the top of the latch. Then, smoothly close the door, working against the spring pressure that holds the door closed. DO NOT let the door slam shut by releasing the door before it is closed.

Using the Dump Bag

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

NOTE: To prevent accidental door closure, a safety latch locks the door open in the

fully opened position while the catcher is being dumped.

2. Orient the dump bag with one of the handle straps on the bag opening facing up.

Tailgate Door

Handle

Hook Bag

on Bumper

Safety

Latch

Catcher Door Safety Latch

Positioning Dump Bag on Catcher

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

4. Tilt the catcher back to dump into the bag by 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 with the other hand. Refer to photos for positioning the bag and dumping.

Operating Instructions

Catcher Lift /

Dump Handle

Dumping Catcher into Dump Bag

5. Lower the catcher smoothly down to the n ormal operating position. DO NOT allow the catcher

to drop down.

6. Close the door by holding the doo r handle with the left hand and releasing the safety latch on the door hinge mechanism with the right hand. The safety latch is released by pressing in on the top of the latch. Then, smoothly close the door, working against the spring pressure that holds the door closed. DO NOT let the door slam shut by releasing the door before it is closed.

Maintenance Instructions

CAUTION

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

MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL MC

Service Item

Check Engine Crankcase Oil Level x 43 Check/Clean Engine Air Cooling System* x 52 Check Security of Air Filtration Components x 55 Check Air Filter Restriction Gauge x 51 Clean Grass Buildup Under Deck x 53 Clean GHS Exhaust Screen* x 38 Clean GHS Blower* x 54 Service Mower Blades x 56 Check Function of Oil Pressure Warning Horn x 22 Lubricate Grease Fittings and Oil Points* x 47 Check PTO Gearbox Oil Level** x 46 Check Battery Electrolyte Level x 55 Check Hydrostatic Transmission Fluid x 46 Check Tire Pressure x 56 Check Drive Belts (Jackshaft, Engine PTO,

GHS Blower, Ground Drive) Check Gearbox Oil Seals x 58

Check Turbine Precleaner* x 50 Check/Clean Air Filter Element Change Engine Crankcase Oil Check Oil Level in Gear Axle x 46 Clean Hydrostatic Transmission Cooling Fins x 55 Clean Engine Cooling Fins x 53 Check/Regap Spark Plugs x 58 Change Engine Oil Filter x 43 Check Fuel Lines and Clamps x 58 Replace Air Filter Element

and Vacuator™ Valve Replace Fuel Filter x64

Service Battery x55 Change Gear Axle Oil Replace Fuel Lines and Clamps x58

ΔΔΔ

ΔΔ

Daily

Hours

x57

100

Hours

x51 x43

200

Hours Yearly

x51

Every

2Years

x46

Ref.

Page

∗ More often in extremely dusty or dirty conditions

∗∗ Change PTO gearbox oil after first 100 hours

of operation (break-in period)

Δ Air cleaner is remote mounted Donaldson Radialseal™

unit, replace filter every year or after 6 cleanings

ΔΔ Change engine oil and filter after first 5 hours of

operation of a new engine (break-in period)

ΔΔΔ Change every 2 years or 1000 hours

CAUTION

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

Maintenance Instructions KOHLER TIPS

IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE

Fuel System

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

ganic material.

• Change fuel filter on a regular basis and when

contamination is suspected or found in the fuel.

Starting/Stopping

• Start engine with the throttle advanced off idle

(1/4 to 1/2 throttle). This will aid starting, especially in cold weather.

• Keep the battery fully charged.

• Match crankcase oil 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 backfiring.

Cooling System

• Keep engine air intake screen and cylinder head

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

• Periodically remove two access panels in the en-

gine shroud to inspect and clean cylinder head cooling fins.

Air Cleaner System

• Use only Donaldson air cleaner elements. After-

market elements may not seal in the air cleaner housing, allowing dirt to enter the engine. Als o, aftermarket filters often skimp on the filtration me dia and require more frequent cleaning and replacement (see following instructions).

• Use the air flow restriction gauge to indicate the

need to service the air filter.

• Do frequently check the Turbine Precleaner for

free movement of the internal fan.

• DO NOT overservice or frequently “disturb” the

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

• When the air filter element is removed or re-

placed, make sure all dust is cleaned out of the air cleaner housing and hose. Use a damp clo th and

wipe the interior of the canister and hose clean (a little dirt left here will be sucked into the engine and reduce engine life). When the filter is reinstalled, make sure the element is held tight and st raight 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

• Check performance of the cooling system by

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

DANGER

Make sure to keep hands clear of exhaust pipe, muffler, and moving parts when checking airflow.

• Operate the engine at full speed when mowing.

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

• Use only multi-viscosity oils as specified with the

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

• Use only Kohler oil filters. Aftermarket filters

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 ch eck the oil level on the dipstick. The oil level should be within the “Operating Range” on the dipstick (between the “L” mark and the “F” mark).

IMPORTANT: DO NOT operate engine without a sufficient oil supply in the crankcase. DO NOT operate with the oil level below the “L” mark or above the “F” mark on the dipstick.

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

not above, the “F” mark on the dipstick. IMPORTANT: DO NOT overfill the crankcase

(oil above “F” mark) as this CAN result in engine overheating, loss of power, and possible engine damage.

Checking Engine Crankcase Oil Level

Check the engine crankcase oil level before use and

after each 8 hours of continuous operation. IMPORTANT: The importance of checking and

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

EACH USE.

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

cool and oil has had time to drain into the sump [allow at least five (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 filter every

other oil change (every 200 hours of operation).

Maintenance Instructions LUBRICATION

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

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

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

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

Oil Filter

Drain Plug

9. Fill the crankcase with new, clean oil. Use only crankcase lubricants 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 (.24 liters) for the new oil filter.

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

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

Mower Deck Gearbox Lubrication

Specifications in

Oil Drain/Oil Filter Location

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

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

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

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

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

1/2 turn.

8. Reinstall the drain plug. Make sure it is tightened to 10 ft-lb (13.6 N

·m).

NOTE: These instructions apply to all mower decks with gear-driven blades. Refer to DSD52 Mower Deck Lubrication in this section for the DSD52 deck with belt-driven blades.

The mower deck gearboxes (tee gearbox and blade drive gearboxes) are connected as a unitized assembly , and oil flows freely between them. The gearboxes are permanently lubricated (oil filled) and sealed requiring no scheduled lubrication. However, the gearbox oil seals should be checked every

25 hours for indication of an oil leak; particularly the lower seals on the blade drive gearboxes

should be inspected, since they operate in a dirty environment. If an oil leak is noted, replace the oil seal and relubricate the gearbox assembly as follows:

1. Remove gearbox cover (footrest). Deck orientation should be the normal operating position.

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.

DSD52 Mower Deck Lubrication

There are several special lubrication requirements for the DSD52 mower deck in addition to the requirements detailed in the Chassis and Deck Lubrica- tion illustration. Lubricate the locations shown in the Blade Spindle Lubrication and Gearbox, Dol- ly Wheel, and U-Joint Lubrication photos and check and maintain oil in the belt drive gearbox.

1. Lubricate the blade spindles every 25 hours with two (2) shots of SAE general purpose lithium or molybdenum base grease.

Blade

Spindles

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

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

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

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

5. Check condition of the cover gasket and replace if worn or damaged. Reinstall gearbox cover plates; torque screws to 24 in-lb (2.7 N

·m).

Blade Spindle Lubrication

2. Check the oil level in the belt drive gearbox every 100 hours (or sooner if a visible oil leak has

developed). With the deck in the normal operating position, remove the level plug in the side of the gearcase. Add SAE E.P. (Extreme Pressure) 80W-90 gear lube to maintain the level to the plug. 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.

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

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

Maintenance Instructions LUBRICATION

Belt Drive

Gearbox

Dolly Wheel

Pivot

U-Joint

Gearbox, Dolly Wheel, and U-Joint Lubrication

Tractor PTO Gearbox Lubrication

Checking Gearbox Oil Level

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

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

Changing Gearbox Oil

The tractor PTO gearbox is oil filled. No scheduled oil change is required. However , changing the oil af- ter the first 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. Refill the gearbox through the dipstick standpipe using 7 to 8 fl. oz. (21 to 24 cl) of SAE E.P. (Extreme Pressure) 80W-90 gear lube. Remove plug in top of gearcase to vent air when refilling.

3. Check that the oil level is at the FULL mark on the dipstick. DO NOT overfill.

Gear Axle Lubrication

• The gear axle oil lubrication is SAE 80W-90 (API

GL-5) gear lube.

• Check the axle oil level after every 100 hours of

operation by removing the oil level plug. If additional oil is needed, remove the breather vent on top of axle and fill until oil is at the level plug.

If the oil level is low, check the gearbox for any indication of an oil leak. If an oil leak is noted, the gearbox will need to be removed and rebuilt.

Jackshaft

Dipstick

PTO

Gearbox

Dipstick Location, Tractor PTO Gearbox

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

years. Hydrostatic Transmission Fluid

Checking Hydrostatic Transmission Fluid Level

Hydrostatic transmission fluid level should be checked every 25 hours of machine oper ation. It is preferable to check the fluid level when fluid is cold. Check fluid level as follows:

1. Park the mower on a level surface. Sto p t he engine and wipe dirt and contaminants from around the reservoir cap and air bleed plug.

IMPORTANT: Before removing the reservoir cap, clean any dirt from around it. Any dirt or contaminants entering the transmission will accelerate wear and eventually cause loss of power to the drive wheels.

NOTE: Check oil level of sealed hydrostatic transmission after first 500 hours using a light next to the reservoir.

Maintenance Instructions LUBRICATION

2. Remove the reservoir cap and check the level of the fluid. The reservoir has a fluid level COLD mark and HOT mark. The reservoir oil level

should ALWAYS be at or above the COLD mark and NEVER above the HOT mark.

Reservoir Cap

Hot Level

Cold Level

Air Bleed Plug

Transmission Reservoir

and Air Bleed Plug Location

3. If the fluid is below the COLD mark (or the transmission is not performing properly), loosen the air bleed plug (located on the top of transmission case next to the plastic reservoir).

a. If a small amount of fluid leaks from around

the air bleed plug: * The transmission is full of fluid.

* Tighten the plug and fill the reservoir to

the COLD level mark.

b. If no fluid leaks from around the air bleed

plug: * Slowly add fluid into the reservoir until

fluid starts to leak from around the plug. (Transmissions are serviced from the factory with Mobil 1 (15W50) Synthet- ic Oil). When it is necessary to add fluid, refer to Specifications for the proper fluid.

IMPORTANT: DO NOT overfill the transmission reservoir. This will result in oil leaking out of the reservoir cap vent when the transmission warms up. It is preferable to add fluid to the transmission when it is cold and make sure the oil is not above or be-

low the COLD level mark. IMPORTANT: The transmission reservoir has a fine

mesh screen in the bottom to trap dirt and foreign particles from entering the transmission. When filling the reservoir, fluid will flow quite slowly through this screen; so it is essential that there is fluid at the bleed plug before the transmission is considered full.

IMPORTANT: Any attempt to remove or in any way alter the filtering screen in the transmission reservoir could cause damage to the transmission and will

VOID any transmission warranty. Grease Fitting and Oil Point Lubrication Lubricate the grease fittings 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 fittings and light machine oil (SAE

10) to lubricate oil points. Lubricate the locations

shown in the Chassis and Deck Lubrication Points illustration.

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

tor) require routine lubrication after every 8 hours of running time.

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.

* As soon as there is fluid leaking from

around the air bleed plug, tighten the plug and fill the reservoir to the COLD level mark. Wipe any excess oil off of the transmission housing.

Maintenance Instructions LUBRICATION

Ident Lubrication No. No. Location Type Places

1 Deck Caster Wheel Fork Pivot Grease 2 2 Deck Caster Wheel Bearing Grease 2 3 Tee Gearbox, Deck Oil* 1 4 Blade Drive Gearbox Oil* 2 5 Universal Joint Shaft Assembly Grease** 1 6 Pivot Assembly, Tilt-Up Deck Grease 4 7 Deck Support Arm Socket Grease 2 8 Body Hinge Point Oil 2

9 FSC Actuator Rod Pivot Pins Oil 2 10 FSC Lever Pivot Grease 1 11 FSC Lever Fork Grease 1

(Grease Slide Area) 12 (FSC) Friction Body Pivot Grease 1 13 Steering Lever Pivot Grease 4 14 Deck Support Arm Pivot Grease 2 15 Deck-to-PTO Coupling Grease 1

(Grease Slide Area) 16 Universal Joint Tube Assembly Grease** 1 17 Universal Joint Quick Connect Grease 1

Spline (Grease Slide Area) 18 Parking Brake Lever Grease 1 19 Gear Axle Oil*** 2 20 Belt Tightener Pivot, Grease 1

Jackshaft Drive 21 Clutch Actuator Push Rod Grease 2 22 PTO Clutch Lever Pivot Grease 1 23 Belt Tightener Pivot, Grease 1

PTO Clutch

Ident Lubrication No. No. Location Type Places

24 Brake Actuator Rod and Brake Oil 3

Band Pivot Pins (Clevis) 25 Brake Actuator Pivot Grease 1 26 Catcher Hinge Point Oil 2 27 Choke Control Cable Ends Oil 2 28 Throttle Control Cable Ends Oil 2 29 Engine Oil Oil*** 1 30 Belt Tightener Pivot, Grease 1

Blower Drive (GHS Model Only) 31 Belt Tightener Pivot, Grease 1

Ground Drive 32 PTO Gearbox Dipstick Oil *** 1 33 Hydrostatic Drive Oil*** 2 34 Choke Control Pivot Oil 1 35 Throttle Control Pivot Oil 1

* Gearboxes are permanently lubricated and

sealed requiring 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, T rac tor PTO Gearbox Lub rication, and Hydrostatic T ransmission Fluid in this sec-

tion.

NOTE: DGHS42 Tilt-Up Deck is shown for reference.

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

Manual.

Maintenance Instructions LUBRICATION

6 7 6

14 19

28 & 35

6 7

6 8

14 15 16

27 & 34

32 31

26 26

Chassis and Deck Lubrication Points

Maintenance Instructions CLEANING

CLEANING Engine Air Cleaner System

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

Air Intake

Hose

Turbine Precleaner

The turbine precleaner is mounted on a remote air intake tube connected to the Donaldson air cleaner. A spinning fan driven by the intake airflow separates dust from the air, giving the initial st age of air cleaning. Dust particles are exhausted through a single small vent in the side of the housing. Since no dust is trapped, the precleaner operates without cleaning. The only maintenance required is to check the operation of the internal fan every 100 hour s. Verify operation:

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

2. Star t the engine and watch the fan begin to spi n as the throttle is advanced.

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

Donaldson

Air Cleaner

Precleaner Tube

Turbine Precleaner

Engine

Restriction

Hose

Clamp

Brass

Elbow

Air

Gauge

Donaldson Air Cleaner Cover

Safety

Filter

Air Cleaner

Cartridge

Vacuator™

Valve

Engine Air Cleaner System Components

Maintenance Instructions CLEANING

Donaldson Radialseal™ Air Cleaner

A remote mounted Donaldson Radialseal™ air cleaner provides the air filtering function. The paper filter element slides over an outlet tube inside the air cleaner canister with radial sealing action, eliminating the possibility of dust leaks due to improper filter installation. Intake design, internal baffling, and a V a cuator ™ valve provide dust separation and automatic precleaning action. Daily or frequent servicing of the air cleaner is not required. Use the air restriction gauge on the air cleaner outlet to indicate when the air filter needs servicing -- a red flag will appear when the filter is overly restricting airflow into the engine.

IMPORTANT: Use only Donaldson air filter elements for replacement (Donaldson P822686 or Walker 5090-1). Aftermarket filters may not seal properly or filter efficiently.

Cover

Latches

Vacuator™

Valve

Canister

Radialseal™

Filter Element

Push Button to Reset

Indicator After Service

Air Restriction

Gauge

Air Restriction Gauge Location

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

1. Release the top and bottom cover latches and remove the air cleaner cover. Wash the cover and Vacuator™ valve. Check that these components are in good condition. The Vacuator™ valve is subject to wear and deterioration and should be replaced yearly or when damaged. The lips of the valve should close and fit together; any cracks, deformation, or wear in the valve is cause for replacement.

Air Cleaner Components

(shown with cover being removed)

IMPORTANT: The Donaldson air cleaner uses a dry

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

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

3. Replace filter element. NOTE: Washing the element in water or clean-

ing solution is not recommended. Do not try to clean the element with compressed air.

Maintenance Instructions CLEANING

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

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

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

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

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

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

10. Install the cover with the word “TOP” properly oriented to the top of the canister. Give the cover a slight twist as it reaches the canister to make sure the tab inside the cover goes into a slot, otherwise the cover will not fit properly. Make sure both the top and bottom cover latches are securing the cover in place.

Cover Latch

Vacuator™

Valve

Proper Orientation of Air Cleaner Cover

1 1. Check the air int ake hose for cuts, nicks, cracks,

etc., and the hose clamps for tightness.

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

Engine Cooling System

Air Intake System

Orient to Top

of Canister

Cover Latch

IMPORTANT: DO NOT use the cover latches to force the filter into the canister -- the cover should fit on with no extra force.

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

Outlet Tube

Canister

Radial Sealing

Surface

Air Filter Element Replacement

Safety Filter

Radialseal™

Filter Element

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 the screen several times each day to prevent engine overheating.

CAUTION

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

Maintenance Instructions CLEANING

Cylinder Head Cooling Fins

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

DANGER

Check Airflow

with Hand

Make sure to keep hands clear of exhaust pipe, muffler, and moving parts when checking airflow.

Every 100 hours, inspect and clean the cooling fins

(more often when operating in extremely dusty, dirty conditions). Remove the two ( 2) co oling fin acces s panels in the engine shroud and clean the cooling fins and external surfaces using compressed air. Make sure to reinstall the access panels before operating the engine.

Engine Cooling

Fin Access Panels

Kohler Engine

Shroud

Cooling System Airflow

Grass Buildup in Mower Housing

DANGER

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

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

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

Tilt-Up Lift Handle

Tilt-Up Latch

Engine Air

Intake Screen

Engine Air Intake Screen

and Cooling Fin Access Panels

Tilt-Up Latch

Tilt-Up Hook

on Deck

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 finally reached where cutting quality

deteriorates and clogging begins to occur

because of too much buildup on the baf fling 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 ar m. 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 dragging of the wheel is an indication of dirt buildup. This buildup must be cleaned to avoid abrasive wear of the blower blades, excessive power loss and eventual loss of blower performance (clogging).

2. Use a pressure washer or water spray, and direct the spray inside the blower housing against the blower blades. Water pressure will cause the blower wheel to begin to spin and the combination of spinning 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.

Blower

Drive Pulley

Depress Idler Pulley

Down to Relax Belt

Collapse Blower Belt Tightener

to Remove GHS Blower Drive Belt

Pulley

GHS Blower

Drive Belt

Belt Tightener

Idler Pulley

Maintenance Instructions

CLEANING/

CHECKING/SERVICING

GHS Exhaust Screen

Refer to Cleaning the GHS Exhaust Screen in Operating Instructions.

Hydrostatic Transmission Cooling Fins

Keeping the cooling fins on the hydrostatic transmissions clean and free of obstruction is essential to avoid overheating the transmission fluid and shortening transmission life. The cooling fins should be checked every 100 hours; and cleaned if neces- sary.

To clean the fins, use compressed air and/or a pressure washer. The cooling fins extend all the way around the housing -- the fins underneath need to be clean as well as the more visible fins 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 fins 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.

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 filtration components.

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

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

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

3. Check to make sure the air flow indicator is in place and tight.

Cooling Fins

Cooling Fan

Hydrostatic Transmission Cooling Fins

Battery NOTE: For initial battery serv ice 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.

Electrolyte Level

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

lyte level:

1. Remove battery cell filler caps.

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

3. Replace filler caps.

Maintenance Instructions

CHECKING/SERVICING

IMPORT ANT: DO NOT overfill the battery. Electro-

lyte will overflow 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 part s water. Rinse with clean water. Coat the terminals with petroleum jelly or termin al protector spray to retard further corrosion.

Charging the Battery

Check the battery charge by measuring the specific gravity of electrolyte; if specific gravity is less than

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

2. After charging the battery, use drinking 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].

DANGER

Tire Pressure

Inflate tires to pressures shown below: Deck Caster Wheel = 20 PSI (137 kPa)

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

Sharpen Mower Blades Check mower blade(s) for straightness, sharp-

ness, condition of the cutting edge, and balance every 10 hours of operation (or more often when

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

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

following procedure to check and sharpen blades: NOTE: Keep blades sharp - cutting with dull

blades not only yields a poor mowing job but slows the cutting speed of the mower and causes extra wear on the engine and blade drive by pulling hard.

1. Stop the engine, remove ignition key, and disconnect the 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 Buildup in Mower Housing in this section for deck raising instructions.

BATTERIES PRODUCE EXPLOSIVE GASES

• Charge the battery in a well-ventilated

area, so that gases produced while charging can dissipate.

• Keep sparks, flames, and sm oking ma-

terials away from the battery at all time s .

• 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.

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 n e w b la d e 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 us ing a rag or a thick, padded glove, while loosening and removing the nut, lock washer, and flat washer that mounts the blade.

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

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

CHECKING/SERVICING

6. Check blade balance by positioning the blade horizontally on a blade balance r 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

CAUTION

ALWAYS wear eye protection and gloves when sharpening a blad e .

Sharpen at

Original 30° Angle

30°

Sharpen on Underside

Mower Blade Profile For Sharpening

Intersection

Wear Area

Wing

Do Not Grind or

Tip

Blade Balanced on Magnetic

Wall-Mounted Balancer

7. Mount the blade with wing tips pointing up into the housing. Reinstall the blade, washer, lock washer, and nut. Tighten the nut to 60 ft-lb

(81.3 N

NOTE: When reinstalling blades on GHS models,

remember, the blades turn toward each other (counter-rotate) and the RH and LH blad e 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 four (4) belts (3 belts on SD mo dels) every 25 hours of operation - engine PTO drive, jackshaft drive, hydrostatic ground drive, and GHS blower drive. If the belts show signs of cracking or deteriorating, the belts should be replaced. Refer to REPLACING/ REPAIRING the Drive Belts in this section.

·m).

Maintenance Instructions

CHECKING/SERVICING/

REPLACING/REPAIRING

Mower Deck Gearbox Oil Seals

The mower deck gearbox seals should be inspected

every 25 hours for evidence of oil leaking; particularly the lower oil seal on the 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 plug s, 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 th e electrodes are bur ned short or pitted, replace plugs with Champion equivalent). Check spark plug gap with a wire-type feeler gauge and set the gap at 0.030 in. (.76 mm). Reinstall and tighten to between 18 and 22 ft-lb (24.4 to 29.8 N

Fuel Lines and Clamps Every year , inspect the fuel supply line from the tank

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

Blade Brake Action

·m).

type RC12YC (or

Check the function of the cutter blade brake (and blower brake on GHS models) by engaging the blade clutch (PTO), operating the engine at full throttle, then disengaging the clutch and measuring how quickly the blades 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 five (5) seconds after disengagem ent of the clutch. If the

brake system malfunctions - blades do not stop in five (5) seconds - adjust or repair the brake befor e operating the mower.

REPLACING/REPAIRING

DANGER

To prevent accidental starting of the engine when replacing part s or rep airing 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 or three (3) belts on SD models:

• Engine PTO Drive Belt (3 Groove Power Band)

• Jackshaft Drive Belt

• GHS Blower Drive Belt (GHS Model Only)

• Hydrostatic Ground Drive Belt

WARNING

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

The belts may be removed and replaced using the

procedures described on the following pages.

Maintenance Instructions REPLACING/REPAIRING

Jackshaft Drive Belt

Engine PTO

Belt

GHS Blower Belt

(GHS Model Only)

Hydrostatic Ground

Drive 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. Ra ise the c lutch leve r (eng age positio n) to

lift the clutch idler away from the belt.

d. Next remove the belt from the engine pul-

ley 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

Clutch

Linkage

PTO Belt Tightener

Stop Block

PTO Belt

Tightener Arm

Blade Clutch Lever

in the DOWN Position

Belt Guides

(Bottom Guide Not Visible)

Engine

PTO Belt

PTO Drive

Pulley

Belt

Guide

Engine

Pulley

Clutch Idler

Pulley

Belt

Guide

Micro-V

Pulley

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

Jackshaft

Drive Belt

Idler Pulley

Jackshaft Drive Belt (Disengaged)

c. Roll the belt off the jackshaft pulley and

remove.

Engine

Pulley

Te n sio n Spring

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

Idler Arm

Jackshaft

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 be lt tension by depressing the idler pulley on the tightener a rm. 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)

Blower Drive Belt Spring Removal

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

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

Model MC is equipped with an in-line fuel filter. Visually inspect the filter periodically, and replace the filter yearly.

In-Line

Fuel Filter

Fuel Filter Location

IMPORTANT: Replace the fuel filter only in a clean

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

DANGER

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

• Use only an approved fuel container for

gasoline.

• DO NOT allow open flames or sparks

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

Blade Overload Shear Bolts The cutting blade is keyed to the blade hub by two

(2) shear bolts (10-24 x 5/8 in. stainless steel ma-

chine screws). These bolts are designe d to shear and protect the blade drive gearbox from damage if the blade encounters a shock load.

Cutting Blade

Shear Bolts

Cutting Blade Shear Bolts

NOTE: Tightening the 5/8-18 blade mounting nut to 60 ft-lb (81.3 N shock load protection. It is important to not overtighten the mounting nut since this de feats (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.

·m) is also important for proper

• Wipe up spilled gasoline immediately

and completely.

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

2. Replace filter.

After reinstalling the blade, check blade timing by moving blades through one (1) complete revolu- tion. Make sure blade tips pass clear of each other. If timing is incorrect, contact your Walker Dealer.

Maintenance Instructions REPLACING/REPAIRING

PTO Shear Pin

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

When the PTO pin has 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.

Shear Pin

Split Spring Pin

U-Joint

Tube Assembly

U-Joint

Shaft Assembly

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 con-

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

machine:

• An excessive amount of the flat 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) flat section remains at the blade tip.

• Examine ends of the blade carefully, especially

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

Profile 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

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.

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 hard ened to shear under a specific 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.

• 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 blad e 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 from Sharpen Mower Blades instructions. If blades are re- placed, always use Walker original equipment blades to ensure safety and optimum per formance. The quality and performance of replacement blades offered by other manufacturers cannot be guar- anteed, they could be dangerous.

CAUTION

ALW A YS use genuine factory replacement parts. Substitute parts CAN resu lt in product malfunction and possible injury to the operator.

ADJUSTMENTS Steering Levers

An adjustment range of approximately 3 inches is available on the steering levers - the levers can be adjusted forward or aft depending on the arm length of the operator . The levers can be adjusted by loos ening the locknut at the pivot point and the locknut holding the lever in position in the adjustment slide. Adjust levers into 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. Adjustments are made by loosening the jam nut an d 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

Adjustment

Slide

Steering Lever Adjustment

Locknut

(Position)

Locknut

(Pivot Point)

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 Kubota Engine Kawasaki Engine Eaton Hydraulic Transmission Peerless Gearboxes Battery Tires

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

* An extended three (3) year warranty is offered on the Walker P/N 6200-9 Gear Axle Assembly.

2. WHAT THIS WARRANTY DOES NOT COVER:

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

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

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

where the inspection and/or warranty work is performed.

3. HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:

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

4. WARRANTY LIMITATION:

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

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

lasts, so the above limitations may not apply to you.

B. W ALKER 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 war ranty shall apply and no dealer, distributor, or individual is authorized

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

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

Lwa

105

LpA

OPERATOR

Sound - Model MC

Sound Test

Sound test conducted was in accordance with 79/113/EEC and was performed on 28 January 98 under the conditions listed:

General Condition: Cloudy Temperature: 32 (F) Wind Speed: < 5 mph (< 8 kmh) Humidity: 58% Barometric Pressure: 25.0" HG (636 mm Hg)

0(C)o

Vibration - Model MC

Vibration Level

Vibration levels at the operators handles were measured in the vertical, lateral, and

0.7g

longitudinal directions using calibrated vibration test equipment.

Tests were performed on 28 January 98 under the conditions listed:

General Condition: Cloudy Temperature: 32 (F) Wind Speed: < 5 mph (< 8 kmh) Humidity: 58% Barometric Pressure: 25.0" HG (636 mm Hg)

0(C)o

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

Walker MC 20 HP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Foreword

Table of Contents

General Information ________________ 1

Specifications________________________ 3

Component Identification___________ 7 Safety Instructions _________________ 10

Assembly Instructions _____________ 16

Operating Instructions_____________ 24

Maintenance Instructions__________ 41

Warranty___________________________ 67

General Information

HIGHLIGHTED INFORMATION

GLOSSARY

IDENTIFYING NUMBER LOCATIONS

Tractor Serial Number Location

SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS

Mower Deck Serial Number Location

ENGINE SERIAL NUMBER LOCATION

Engine Serial Number Location

Specifications

ENGINE

ELECTRICAL SYSTEM

TRANSMISSION

BLADE DRIVE

TIRE SIZE

TIRE PRESSURE

MOWER DECK

CURB WEIGHT (Approximate)

DRIVE BELTS

GHS SYSTEM (Optional)

SEAT

FRAME/BODY CONSTRUCTION

Component Identification

Front View and Right Side View

Rear View and Left Side View

Top View (Engine Compartment)

Safety Instructions

BEFORE OPERATING

OPERATING

MAINTENANCE

SAFETY, CONTROL, AND INSTRUCTION DECALS

SAFETY, CONTROL, AND INSTRUCTION DECALS

Assembly Instructions

SETUP INSTRUCTIONS

Tire Installation (Tractor)

Battery Service

Wet Battery Service

Dry Battery Service

Battery Charging

Battery Installation

Battery Installation

Mower Deck Assembly

Deck Caster Wheels Installation

Deck Caster Wheel Installation

Deck Discharge Chute Installation (GHS Rear Discharge Models Only)

Deck Discharge Shield Installation (Side Discharge Models Only)

PTO Shaft Guard Installation

Tilt-Up Roller Wheel Installation

Mower Deck lnstallation on Tractor

Deck Installation

Mower Deck Installation (PTO Shaft Connection)

Quick Coupler Installation Tool

Coupler Ring “Locked” Position

Deck Counterweight Spring Installation

Deck Leveling

Deck Leveling

PREOPERATING CHECKLIST

Deck Secured in TILT-UP Position

Operating Instructions

CONTROL IDENTIFICATION, LOCATION, AND FUNCTION

Ignition Switch

Engine Choke

Operating Controls

Engine Throttle

Choke and Throttle Location

Forward Speed Control (FSC)

PARK position. Steering Levers

Component Identification_ 7 Safety Instructions _______ 10