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Walker MW 15 HP User's Manual

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1. e 9801 MODEL MW A WARNING FORWARD READ AND UNDERSTAND S P E 0 CONTROL Control Panel Walker P N 9801 BLADE CLUTCH PARKING LIFT LEVER P TO 3 RELEASE PARK On Body Adjacent On Body Adjacent to Clutch Control Lever to Parking Brake Lever P N 9803 P N 9802 NEUTRAL LOCKOUT On Rear of Body Above Neutral Lockout Arms 2 P N 9804 13 14 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 dam aged or missing parts should be noted and reported 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 e Install the drive tires using the eight 8 lug bolts that are supplied with the owner s packet of materi als Drive tires are 18 x 8 50 10 4 ply rear tire is 2 80 2 50 4 Pneumatic 4 Ply e 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 The battery is a completely sealed non serviceable battery IMPORTANT Make sure battery is securely mounted in the frame A loose battery may cause damage to the case resulting in acid lea
2. 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 Forward Speed Control FSC rocker switch is in NEUTRAL PARK position and the blade clutch and parking brake DISENGAGED A safety interlock switch system PRE VENTS CRANKING the engine with either the Forward Speed Control or the blade clutch PTO out of neutral If the engine cranks otherwise the safety system is not working and should be repaired or ad justed before operating the mower DO NOT disconnect safety switches they are for the operator s protection 2 Turn the ignition key to the RUN position Move the throttle choke lever into the CHOKE position NOTE The choke not be required if the engine is warm 3 Make sure you have secure footing and pull the recoil starter handle toward you IMPORTANT f the engine fails to start after approximately 5 attempts the engine and safety switch circuit should be checked before any fur ther attempts Turn the key to the OFF posi tion to begin these checks 4 After the engine starts gradually move the throttle choke lever to the THROTTLE position keeping enough choke on to allow the engine to run smoothly as it warms up As soon as possible move the lever past the detent into the THROTTLE position IMPORTANT Make sure the choke is in the OFF position du
3. Use Ball Joint End to Adjust Pistol Grip Position Adjustment Handlebar Height Adjustment The height of the handlebar position for operators can be adjusted taller for taller operators shorter for shorter operators using the following steps 1 Unbolt the handlebar connection at the body on both sides Unbolt the steering control arms ADJUSTMENTS 2 Heattach handlebar and control arms in corre sponding holes aa Handle Bar Attachment to Bod ustable Steering Control Rod Tilt Up Deck Adjustable Stop Tilt Up Deck Adjustable Stop When the carrier frame hinge joint is properly adjust ed the deck lock levers should move in and out of the engaged and disengaged positions freely All four hitch pins used for height adjustment should sit flush on the washers above the deck pin bushing On a level surface if any pin is sticking up likely the front pins tighten the opposite side or loosen the existing side to lower the pin Adjustments are made by loosening the jam nut and tightening or loosening the set screws on the Deck Mount Pivot Brackets Retighten the jam nut when the adjustment is com plete Maintenance Instructions Carburetor DO NOT change the engine governor set tings or overspeed the engine The gov ernor has been factory set for maximum safe engine operating speed Carburetor adjustments are required to compensate for differences in altitude temperature and fuel Once the
4. Dipstick Oil Drain Dipstick Oil Fill and Oil Filter Location Maintenance Instructions Before removing the oil filter clean the area around the filter to keep dirt and debris out of the engine Remove the old oil filter and wipe off the filter mounting surface on the engine Apply a thin coating of clean oil to the rubber gasket on the replacement oil filter IMPORTANT Use ONLY oil filters from the en gine manufacturer Kawasaki 49065 2078 Af termarket oil filters may not seal properly and or may not have the correct pressure relief valve for proper lubrication Install the new oil filter on the engine Turn the filter clockwise until the rubber gasket contacts the sealing surface then tighten an additional 1 2 turn Close drain valve Fill the crankcase with new clean oil Use only crankcase lubricants recommended by the en gine manufacturer Refer to Specifications in this manual or the engine owner s manual Use the recommended oil viscosity for the expected ambient temperature Oil with the correct vis cosity will aid starting in cold weather and as sure proper lubrication in hot weather Fill up to but not above the upper mark on the dip stick Crankcase capacity is 1 6 quarts 1 5 li ters plus 0 2 quart 0 2 liters for the new oil filter IMPORTANT Check the dipstick reading be fore adding the last 1 2 pint of oil and fill only to the upper mark DO NOT overfill the crankcase abo
5. Engine Air Cleaner System There are two components in the engine air cleaner system a foam prefilter element and a paper ele ment Each component is checked cleaned and maintained on a different schedule based on the fil tering action required Each component is serviced as follows Engine Air Cleaner Foam and Paper Element Foam Precleaner Element Clean and inspect the foam element after every 25 hours of service and replace the element yearly or when dirty or damaged Wash the element in de tergent and water and dry it thoroughly More fre quent cleaning may be required when operating in extremely dusty conditions Paper Precleaner Element Inspect the paper element after every 50 hours of service and replace the element every 200 hours or when dirty or damaged More frequent replace ment may be required when operating in extremely dusty conditions Be careful to reinstall the foam element and the pa per element into the air cleaner case Carefully re install the air cleaner cover into the air cleaner body by putting the hooks on the bottom of the air cleaner cover into the air cleaner body bottom Engine Cooling System Air Intake Screen Before each use check that the air intake rotary screen is free from grass and debris and clean if necessary CLEANING Engine Cooling Fins Every 100 hours check and clean the cooling fins and inside of engine shrouds to remove grass chaff or dirt clogging the
6. 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 high lighted in bold type in this manual Refer to Safety Instructions for the meanings of DANGER WARN ING CAUTION IMPORTANT and NOTE GLOSSARY There are many terms that are either unique to this equipment or that are used as acronyms The fol lowing terms and their definitions will help while us ing this manual e DECK is the mowing attachment mounted on the front of the tractor which includes the carrier frame deck housing blade drive gearboxes and cutter blades FORWARD SPEED CONTROL FSC SWITCH controls the maximum forward speed of the tractor functioning as a cruise control e GROUND DRIVE refers to the dual hydrostatic transmissions which drive the main wheels LEFT HAND LH refers to the left hand side of the tractor when the operator is seated facing forward from the operator position e NEUTRAL LOCKOUT releases the hydrostatic transaxles to permit freewheeling the tractor e PISTOL GRIPS steer the tractor by controlling the dual hydrostatic transaxles e POWER TAKE OFF PTO transmits engine power to run the cutter blades e RIGHT HAND refers to the right hand side of the tractor when the operator is facing for ward from the operator position e SIDE DISCHARGE SD mows but does n
7. fork 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 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 Deck Caster Wheel Installation 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 DO NOT operate the machine without the grass deflector chute attached and in the lowest possible position a 8 3 Er Attach Shield LL NER S Deck Discharge Shield Installation 16 Assembly Instructions PTO Shaft Guard Installation Position the shaft guard as shown and mount with two 1 4 20 x 1 2 in bolts Attach Guard PTO Shaft Guard Installation Tilt Up Roller Wheel Installation NOTE 2 1 2 diameter tilt up roller wheel P N 9772 is required for decks installed on the walk behind Mount the two 2 tilt up roller wheels on the brack ets on the rear skirt of the deck housing using the P N 8490 axle bolt 3 8 in wave spring washer
8. 10 RED 92 TOGGLE SWITCH CIRCUIT co BREAKER 7 1 BLK G _ GENE PUR RECTIFIERREGULATOR GRN ENGINE GROUND BLK WHT OPERATOR PRESENCE FSC ACTUATOR ee a ee GRA WHT S 6 NEUTRAL PTO SWITCH SWITCH BLK GRA BLK BATTERY RED BLK Use only genuine Walker replacement parts Effective Date 11 01 03 60 MAINTENANCE AND SERVICE RECORD SHEET DATE SERVICE ENGINE ITEM HOURS Effective Date 11 01 03 Use only genuine Walker replacement parts 61 62 Operator s Notes LIMITED WARRANTY FOR WALKER COMMERCIAL RIDER MOWER 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 Kawasaki Engine HydroGear Transaxles Peerless Gearboxes Battery Tires The available war
9. 10 Amp Boot Circuit Breaker Ignition Switch with Keys Includes Items 9 10 amp F349 Hourmeter SenDec Ignition Key 1 Set Plastic Tip Red oafety Switch Operator PTO Safety Switch Safety Switch Neutral Riser Plate Seat Switch Battery 12V 5 Amp SLA Cable Clamp 1 2 Use only genuine Walker replacement parts 58 c A gt gt gt ITEM PART DESCRIPTION NO NO NO REQ D Fasteners F002 10 24 Keps Nut T F025 10 24 x 3 8 PPHMS 2 F026 10 24 x 1 2 PPHMS 5 F349 Washer 835 ID 1 122 OD SS 1 Service Part Only Effective Date 11 01 03 ELECTRICAL ASSEMBLY Refer to Forward Speed amp 1 Steering Controls Refer to Engine Group DETAILA DETAIL B DETAIL C DETAIL D DETAIL E BLUE Fined BRN MES BLKWHT A BLK Ged vi ORD RED BRN Rd mem wur a GRA BLK Effective Date 11 01 03 Refer to Body Chassis Assembly DETAIL F DETAIL G DETAIL H DETAIL GRA GRA GRA BLK GRN Q v 6 BLK BLK BLK BLK Use only genuine Walker replacement parts 59 WIRING SCHEMATIC RED YEL WALKER MODEL MW ee Beginning S N 2004 68081 BRN WHT ae NE S1 START CIRCUIT S2 START ACCESSORY CIRCUIT MAGNETO GROUND CIRCUIT BATTERY CIRCUIT l ACCESSORY CIRCUIT GROUND CIRCUIT HOUR METER RED YEL GRN Lr N e A RED
10. 3 16 Plate Steel 11 Gauge Steel NOTE 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 Throttle Choke Control amp Cable 4 Engine Engine J Cover Latch a Gover E Latch Fuel Tank og ap and Cap Counterweight Spring and Protective Cover Deck Support Pins Parking 4 Mee 0 and Height Adjustment Brake Handle 1 Hitch Pins d Footrests Tilt Up Fuel Filter Tail Wheel ec Caster Wheels Right Hand Deck Support Drive Wheel Arms Tilt Up MOOR Discharge Shield Deck Lift Handle Cutting Height Adjustment Front View and Right Side View Component Identification Operator Presence Switch Control PTO Clutch Lever m 2 af Tailpipe Muffler Au Steering Control Rod RH Steering Control Rod LH Transaxle LH Transmission Left Hand Drive Wheel out Rear View and Left Side View Component Identification Fuel Pickup 1 Line FSC Electric Actuator Oil Dipstick Oil Fill Recoil Starter Handle Oil Filter Fuel Pump Parking Brake Transaxle Linkage Pressure Relief Valve LH Not Visible Transaxle Pressure Relief Valve RH i p x ig Counterweight Batte
11. 5103 2 Pivot Bushing 5 16 ID 2 30 9309 9 16 Tab Lock Washer 2 3 9742 2 Plastic Bushing 5 8 x 3 8 1 31 9480 Belt Guide 1 4 9742 1 Compression Spring 3 8 x 5 8 1 Includes Item F009 5 9742 oafety Switch Actuator 1 32 9301 Brake Band 1 6 9743 Safety Switch Lever LH 1 33 9236 Pulley 5 3V 1 Includes Items 34 F067 F168 amp F181 PTO Drive Assembly 34 9051 9 8 x 1 1 8 x 3 8 Washer 1 T 9230 PTO Drive Belt 1 Fasteners 8 7380 5 Knuckle Joint 3 8 ID 1 9 Plastic Washer 7 16 x 1 x 025 2 F005 1 4 20 ESNA Nut 2 10 7378 Pivot Bearing 7 16 x 9 16 1 F007 5 16 18 Jam Nut 1 11 5830 Grease Fitting 2 F009 9 16 18 Whiz Locknut 5 12 9358 Clutch Lever Includes Item 11 1 F010 5 16 24 ESNA Nut 1 13 5830 4 Grease Fitting 90 Deg 1 F012 3 8 16 Keps Nut 2 14 9130 1 Clutch Actuator Spring 1 F013 3 8 16 Whiz Locknut 2 15 9130 2 Clutch Actuator Rod 1 F020 5 16 18 ESNA Nut 8 16 9130 3 Clevis 1 F026 10 24 x 1 2 PPHMS 1 17 9130 4 5 16 x 1 Clevis Pin 1 F029 1 4 20 x 1 2 Hex Bolt 3 18 9359 Lower Clutch Pivot 1 F034 5 16 18 x 3 4 Hex Bolt 2 19 9359 1 Pivot Mount Clutch Includes Item 11 1 F049 5 16 SAE Washer 4 20 9307 Link PTO Actuator 2 F061 1 4 Star Lock Washer 1 21 5221 Extension Spring 3 4 x 4 1 F093 9 16 18 x 1 Hex Bolt 6 22 9306 1 Plastic Bushing Rear Pivot 4 F111 1 8 x 3 4 Cotter Pin 1 23 9302 PTO Gearbox Mount Plate 1 F151 3 8 16 x 7 8 Hex Bolt 4 24 9305 1 Plastic Bushing Front Pivot 8 F168 9 16 Split Lock Washer 1 25 9305 Sw
12. Clamps Every year inspect the fuel supply line from the tank to engine for deterioration or damage Also inspect the fuel line clamps for tightness Good preventive maintenance calls for complete replacement of fuel lines and clamps every two 2 years Blade Balancer 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 Ib 81 3 Drive Belts Look under the body and inspect the condition of the two 2 belts every 25 hours of operation engine PTO drive and ground drive belt If the belts show signs of cracking or deteriorating the belts should be replaced Refer to REPLACING RE PAIRING the Drive Belts in this section Maintenance Instructions Blade Brake Action Itis important to check and maintain blade brake action for safe operation of the ma chine Check the function of the cutter blade brake by en gaging the blade clutch operating the engine at full throttle then disengaging the clutch and mea suring how quickly the blades stop Watch the rota tion of the blade drive shaft as a visual indication that movement has stopped If the brake is working properly all rotation will stop five 5 seconds af ter disengagement of the clutch If the brake sys tem malfunctions blades do not stop in five 5 seconds adjust or repair the brake before operating
13. SAE Washer AN960516 Washer 3 32 x 1 2 Cotter Pin 5 16 18 x 1 Hex Bolt 1 8 x 3 4 Cotter Pin 1 4 20 x 1 1 4 Hex Bolt 5 16 18 Hex Nut 1 4 20 x 1 1 2 Hex Bolt 1 4 20 x 7 8 Hex Bolt 5 16 18 x 2 1 2 Hex Bolt 1 4 20 x 1 3 4 Hex Bolt 3 8 x 3 8 Shoulder Bolt 5 32 x 3 4 Roll Pin 5 16 24 x 3 1 2 Hex Bolt 3 8 x 1 2 Shoulder Bolt 5 16 18 x 4 1 2 Hex Bolt 5 16 24 LH Hex Nut 1 4 20 Hex Nut a M5 gt Effective Date 11 01 03 FORWARD SPEED amp STEERING CONTROLS 008 D p T F369 D gt 6 X 1 oo d F167 3 N F373 4 F032 F116 an i F060 ij 9 F005 Refer to Body Chassis Assembly LN N S im F367 F008 43 20 030 6 Engine Group F004 2 d 2 Cy Effective Date 11 01 03 Use only genuine Walker replacement parts 55 SULKY ATTACHMENT ITEM PART DESCRIPTION NO ITEM PART DESCRIPTION NO NO NO REQ D NO NO REQ D Sulky Attachment Fasteners 1 9504 Front Arm Mount Sulky 1 F009 5 16 18 Whiz Locknut 4 2 9506 Front Arm Sulky 2 F012 3 8 16 Keps Nut 2 3 9509 T Bolt Arm Lock 1 F014 3 0 16 ESNA Nut 2 4 9510 Front Pivot 5 16 18 x 6 5 8 2 F020 5 16 18 ESNA Nut T 5 9511 Center Pivot 5 16 18 x 5 1 4 1 F034 5 16 18 x 3 4 Hex Bolt 2 6 NS Serial Number Plate 1 F047 3 8 16
14. cooling system and causing overheating When cleaning remove the recoil starter and the fan housing Grass Buildup in Mower Housing Before raising or removing the mower deck for cleaning stop the engine re move the ignition key and disconnect the spark plug wires 1 Raise the deck lock lever handle on each side of the carrier frame and pull out to release car rier frame for tilting action 2 Using the carrier frame lift handle raise deck to the TILT UP position and insert the deck hook into the tilt up latch on the tractor body Do not operate the mower with deck in tilt up 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 baffling and housing 4 Lower the deck to the normal operating position and reengage the deck lock levers NEVER operate the cutter blades with the deck in the raised position Maintenance Instructions CHECKING SERVICING To prevent accidental starting of the en gine when servicing or adjusting the ma chine remove the key from the ignition switch and disconnect the spark plug wires Battery Charging the Battery Limit initial charging cur
15. for the engine operating conditions This will aid starting in cold weather and assure proper lubri cation in hot weather e Use only Kawasaki oil filters Aftermarket filters may not seal properly and or have the incorrect pressure relief valve for proper lubrication Maintenance Instructions Maintenance procedures requiring special training or tools should be performed by a trained technician MAINTENANCE SCHEDULE CHART RECOMMENDED SERVICE INTERVALS MODEL MW Ref ouy AE ES wem aene weww ee ox E ox x 0 Weweweame p nnee YL often extremely dusty or dirty conditions see notes about air cleaner element in IMPORTANT TIPS FOR CARE OF KAWASAKI ENGINE Change engine oil and filter after first 8 hours of operation of a new engine break in period 29 30 Maint
16. 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 Lubricate every eight 8 hours Refer to Engine Oil in this section NOTE DSD42 Deck is shown for reference For oth er Deck Lubrication Points Refer to Deck and Carrier Frame Illustrated Parts Manual Maintenance Instructions I LS SS Chassis and Deck Lubrication Points LUBRICATION 35 36 Maintenance Instructions CLEANING
17. not operate the mower with deck in tilt up position Do not move the tractor with the deck in the tilt up position With the deck in the tilt up position the U joint tube and shaft may separate Check after lowering deck and before operating Never operate cutter blades with deck in raised position because it is hazardous Do not operate machine with deck tilt up pivot joint unlocked CHECK MOWER BLADE CONDITION SHARP NESS AND SECURITY OF MOUNTING The blade mounting nut should be tightened to 60 ft lb 81 3 N m If blade sharpening is required 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 PERFORM ANY ADDITIONAL PROCEDURES called for on the MAINTENANCE SCHEDULE CHART in Maintenance Instructions Operating Instructions CONTROL IDENTIFICATION LOCATION AND FUNCTION Operating Controls Before operating the mower become fa miliar with the location and function of all operator controls Knowing the loca tion function and operation of these controls is important for safe and effi cient operation of the mower Blade Clutch PTO IDLE Engine Throttle Choke Positions Engine Throttle Choke Lever Operator Presence Control Ignition Switch Engine Throt
18. plates on the gearboxes and remove the covers Re move all covers to be sure oil is completely drained from all gearboxes NOTE With oil flow throughout the unitized gear drive assembly if one gearbox has internal damage or excessive wear the remaining gear boxes and connector tubes should be complete ly disassembled and thoroughly flushed out with solvent before reassembly 5 Drain and properly dispose of oil 6 Remove the four 4 bolts mounting the gearbox to the connector tube and slide the gearbox off the splined drive shaft coupling Maintenance Instructions Install the new gearbox on the spline coupling of the drive shaft Establish correct timing of the blade drive gearboxes by setting flats on the output shaft at 90 degrees when connecting the gearbox es to the spline coupling Make sure the timing is correct before proceeding with as sembly Reinstall the four 4 bolts mounting the gear box to the connector tube but do not tighten them at this time leave connector tube bolts fin ger tight Position the gear drive assembly on the deck and install the 3 8 16 bolts mounting the entire assembly Leave the mount bolts finger tight Torque all the connector tube bolts to 80 9 then tighten the deck mount bolts NOTE This fastener tightening sequence aligns the gearbox assembly with the deck hous ing and eliminates the possibility of mounting the unitized assembly in a bind Fil
19. seal on the blade drive gearbox This seal is protected by the trash N guard on the blade hub and seal protector plate on Wi the housing but is still vulnerable to seal damage ing dr Tip due to operating in an adverse environment The mower blade must be removed for inspection of the Do Not Grind or seal so it is recommended to inspect the gearbox Sharpen on Underside seals when blades are removed for sharpening If an oil leak is noted the seal should be replaced Mower Blade Profile For Sharpening and the gearbox assembly relubricated Refer to mE Mower Deck Gearbox Lubrication in this section 6 Check blade balance by positioning the blade Spark Plugs horizontally on a blade balancer or use a nail or shaft through the center hole If either end of the Every 100 hours remove the spark plugs inspect blade rotates downward grind remove metal clean and reset the gap or replace with new on that end until the blade will balance The plugs Clean spark plugs with a wire brush If the blade is properly balanced when neither end electrodes are burned short or pitted replace the drops Balance of a blade is generally main plug refer to Specifications for the proper type of tained by removing an equal amount of material replacement plug Check the spark plug gap with a from each end of the blade when sharpening wire type feeler gauge and set the gap to 0 030 in 0 75 mm Reinstall and tighten to 16 ft lb 22 Fuel Lines and
20. the mower Refer to ADJUSTMENTS of Blade Clutch PTO in this section PTO Gearbox Brake Band Adjustment Nuts on These Ends Should Be Adjusted Out Evenly Brake Band View with PTO Geabox Assembly Removed CHECKING SERVICING 39 40 Maintenance Instructions REPLACING REPAIRING To prevent accidental starting of the en gine when replacing parts or repairing the machine remove the key from the ignition switch and disconnect the spark plug wires IMPORTANT ALWAYS use genuine factory re placement parts Substitute parts CAN result in product malfunction and possible injury to the oper ator and or others Drive Belts There are two 2 individual belts e Ground Drive Belt e PTO Drive Belt 3 Groove Power Band The belts may be removed and replaced using the following procedures Ground Drive Idler Pulley Remove Spring and Linkage REPLACING REPAIRING PTO Drive Belt 1 Remove the two mounting bolts holding the PTO belt guide in place and loosen the front mounting bolts of PTO actuator assembly as shown Remove belt guide Remove nuts on the front of brake band and remove 2 Unhook spring and unbolt actuator clevis at tached to the PTO gearbox assembly Pull gearbox assembly to the rear and remove belt 3 Install the PTO drive belt by reversing removal procedure Ground Drive Belt NOTE The PTO drive belt must be removed for re moval of the ground drive belt 1 Relax t
21. 15700 FPM 4785 m min Engine 48 Deck TIRE SIZE Deck Caster Wheel 2 80 2 50 4 Pneumatic 4 Deck Caster Wheel Optional Drive Hear Rear Wheel Optional 8 25 x 2 75 Foamed Rubber 18 x 8 50 10 Low Profile 2 80 2 50 4 Pneumatic 4 Ply 8 25 x 2 75 Foamed Rubber TIRE PRESSURE Deck Caster Wheel Drive Hear 20 PSI 137 kPa 15 PSI 103 kPa 20 PSI 137 kPa DIMENSIONS Tractor and Mower Length Width Height Wheel Base Tractor Tread Width Tractor 80 in 203 cm 48 3 4 in 124 cm 44 3 4 in 114 cm 22 in 56 cm 29 1 4 in 74 cm Specifications MODEL MOWER DECK Width of Cut Cutting Height Height Adjustment Blade Size 42 in 107 cm 48 in 122 cm Deck Suspension MW 36 42 48 52 or 56 in 91 107 122 132 or 142 cm 1 to 4 in 3 to 10 cm 7 Positions 1 2 in 1 cm Increment Hitch Pins Installed in Multi Position Deck Support 22 in 56 cm 2 in 5 cm Center Overlap Two Blades CW Rotation 48 in 122 cm 25 in 64 cm 2 in b cm Center Overlap Two Blades CW Rotation Torsion Flex Frame with Caster Wheels and Counterweight Springs CURB WEIGHT Approximate Tractor Only Tractor and Deck 370 Ib 168 kg 520 Ib 236 kg Dimensions and weight shown are for 48 in 122 cm SD Deck Typical DRIVE BELTS Engine PTO Ground Drive Walker P N 9230 Walker P N 9248 FRAME BODY CONSTRUCTION Frame Body Deck
22. 16 18 x 3 4 Hex Bolt 5 16 18 x 1 1 4 Hex Bolt 3 8 16 x 4 1 2 Hex Bolt 5 8 SAE Washer 1 4 Wave Spring Washer 1 8 x 1 Cotter Pin 5 16 18 x 1 Hex Bolt 5 8 18 Slotted Hex Nut 3 8 16 x 7 8 Hex Bolt 1 4 x 5 8 x 1 8 Washer 5 16 18 x 2 1 2 Hex Bolt 5 16 18 x 1 1 2 Hex Bolt 5 16 18 x 2 Hex Bolt Coil Roll Pin 7 64 x 9 16 5 16 Conical Washer 64AAD Alum Pop Rivet 3 16 DIA x 1 4 Grip gt gt gt RMA A BRANDY DO BR gt Effective Date 11 01 03 BODY CHASSIS ASSEMBLY NOTE A2 1 2 diameter tilt up roller wheel P N 9772 is 1 required for decks installed on the walk behind Refer to page 16 for Installation Instructions C 5 22 lt N EE m 5 So Np 53 F020 55 5590 sl ut 39 40 PA 2 F279 LOAN WSs 5552 22 SS WA F259 26 ET Effective Date 11 01 03 Use only genuine Walker replacement parts 49 MAIN COMPONENT POWER TRANSMISSION ITEM PART DESCRIPTION NO ITEM PART DESCRIPTION NO NO NO REQ D NO NO REQ D Safety Switch Actuator Assembly 27 9050 Gearbox 1 28 9304 Mount Side Plate RH 1 1 9744 oafety Switch Lever RH 1 29 9303 PTO Mount Side Plate LH 1 2
23. 6 NS 15 HP Kawasaki Engine FH430VAS14 1 17 Washer Kawasaki 92002 1982 1 18 5 Bolt Kawasaki 92151 7010 1 Use only genuine Walker replacement parts 52 Effective Date 11 01 03 ENGINE GROUP 4 9 eos SS CS 4 b Refer to Body Chassis Assembly Effective Date 11 01 03 Use only genuine Walker replacement parts o3 FORWARD SPEED amp STEERING CONTROLS ITEM PART NO NO DESCRIPTION NO REQ D ITEM PART DESCRIPTION NO NO NO REQ D Steering Lever Assembly 1 5103 2 Pivot Bushing 5 16 ID 4 2 9701 Contol Handle LH 1 3 5214 3 Ball Joint 5 16 24LH Nylon Lined 4 4 9703 2 Linkage Rod Upper Lever LH Threaded 2 5 9706 1 Extension Spring 3 4 x 4 2 6 5214 2 Ball Joint 5 16 24 Nylon Lined 4 7 9703 1 Linkage Rod Lower Lever 2 8 9702 Control Handle RH 1 FSC Linkage amp Steering Linkage Assembly 9 9622 Plastic Bushing Actuator 4 10 9621 FSC Actuator 1 11 9623 switch Bushing Actuator 1 12 9704 Steering Pivot Rod 1 13 9705 2 Bearing Speed Actuator 4 14 9706 Speed Control Actuator RH 1 Includes Items 13 amp 25 15 9704 2 opeed Control Stop RH 1 16 9704 3 Pivot Rod Bushing Plastic 2 17 9705 1 opring Bushing 1 4 x 1 8 2 18 9708 1 Control Arm Rod LH Thread 2 19 5551 1 Pivot Bearing S3PP 2 20 9707 3 Bearing Housing Control Arm 2 21 9707 2 Spacer Tube Control Arm 2 22 9707 1 Extension Nut Hydrogear 2 23 9024 1 6 x 7
24. 7 Bearing 2 32 5830 3 Grease Fitting 45 Deg 1 33 5714 3 Axle Spacer Tube 1 Deck Support Arm amp Hitch Assemblies 34 9430 1 Spacer Tube MW Deck Arm 2 35 9434 Deck Arm Mount RH 1 Includes Item 26 36 9023 6mm x 20mm Dowel Pin 2 37 0431 Deck Arm LH 1 38 9432 1 Dampener Bushing 4 39 9432 2 Dampener Spacer 3 8 x 1 2 4 40 9432 Dampener Deck Arm 2 41 9430 Deck Arm RH 1 Use only genuine Walker replacement parts 48 ITEM PART DESCRIPTION NO NO REQ D 42 9433 Deck Arm Mount LH 1 Includes Item 26 43 5862 FSC Knob 1 44 9347 1 spring Lift Rod 1 45 9344 Deck Spring Hitch 1 46 9346 opring Clip Lock 1 47 9345 Lock Arm Spring Hitch 1 48 7222 Extension Spring 1 1 4 x 3 1 Tilt Up Latch Assembly 49 5847 50 5744 20 91 5744 10 52 5744 15 53 5744 14 54 5744 12 55 5744 13 Fasteners F002 F004 F005 F009 F012 F013 F015 F020 F023 F025 F026 F027 F029 F031 F032 F034 F035 F047 F055 058 F068 F093 F098 F151 F182 F235 F255 275 F341 F342 F375 Plastic Tip spring Arm Tilt Up Latch spring Pivot Bushing Compression Spring 3 8 x 5 8 Mount Angle RH Hook Tilt Up Latch Mount Angle LH 10 24 Keps Nut 1 4 20 Keps Nut 1 4 20 ESNA Nut 5 16 18 Whiz Locknut 3 8 16 Keps Nut 3 8 16 Whiz Locknut 1 2 Wheel Lug Nut 5 16 18 ESNA Nut 10 24 ESNA Nut 10 24 x 3 8 PPHMS 10 24 x 1 2 PPHMS 10 24 x 5 8 PPHMS 1 4 20 x 1 2 Hex Bolt 1 4 20 x 5 8 Hex Bolt 1 4 20 x 3 4 Hex Bolt 5
25. 8 Washer 2 24 9707 Control Arm Hydro gear 2 25 5830 Grease Fitting 3 26 9705 Speed Control Actuator LH 1 Includes Items 13 amp 25 2 9704 1 Speed Control Stop LH 1 Brake Assembly 28 9406 1 Park Brake Lever Mount 1 29 9407 Park Brake Actuator Rod 1 30 9407 2 Brake Actuator Rod Mount 2 31 9407 1 Park Brake Actuator Link 2 32 17523 2 Clevis Pin 1 4 x 5 8 1 33 5225 Extension Spring 1 2 x 2 1 4 1 34 9406 4 Clevis Half 1 35 9406 3 Clevis Half Spring Side 1 36 5665 Compression Spring 1 2 x 1 1 37 9406 2 Brake Actuator Pull 1 38 9406 Park Brake Lever 1 Includes Item 39 39 1406 1 Handle Grip Red 1 Use only genuine Walker replacement parts 54 Ground Drive Assemblies 40 9027 41 9248 42 5221 43 9349 1 44 5245 45 9349 46 7201 3 47 1201 4 48 5841 49 9025 50 9026 Fasteners F004 F005 F008 F009 F024 F029 F031 F032 F039 F042 F049 F060 F069 F093 F111 F116 F167 F187 F211 F235 F236 F312 F363 F365 F367 F369 F373 F381 Lockout Rod Ground Drive Belt Extension Spring 3 4 x 4 Pulley Spacer Belt Tightener Idler Pulley 3 Hydro Belt Tightener Arm Includes Items 25 46 amp 47 DU Bearing Inner Race 1 1 2 3 8 x 1 1 4 Retainer Washer Hydro Gear LH Hydro Gear RH 1 4 20 Keps Nut 1 4 20 ESNA Nut 9 16 24 Keps Nut 5 16 18 Whiz Locknut 5 16 24 Jam Nut 1 4 20 x 1 2 Hex Bolt 1 4 20 x 5 8 Hex Bolt 1 4 20 x 3 4 Hex Bolt 3 8 16 x 1 1 4 Hex Bolt 3 8 16 x 2 1 4 Hex Bolt 5 16
26. E po sition and turn the ignition switch OFF WARNING Remove the key from the ignition switch when leaving the mower unattended This will prevent children and inexperienced operators from starting the engine 5 Engage the parking brake IMPORTANT The transaxles lock to prevent the mower from rolling freely with the engine stopped However if the mower is parked on a slope it is necessary to ENGAGE the parking BRAKE to prevent the mower from creeping This is due to a small amount of slippage in the transaxles especially when transmission fluid is warm ADJUSTING CUTTING HEIGHT The engine must be stopped before ad justing cutting height Disengage the blade clutch PTO stop the engine and remove the ignition key Wait for all move ment to stop before leaving the operator position Cutting height is adjusted by positioning the four re tainer hitch pins in a series of seven vertical holes on the deck support pins Lift handles have been pro vided on each end of the deck to assist in raising the deck while positioning the hitch pins Cutting heights range from 1 in 25 mm top holes to 4 in 102 mm bottom holes in 1 2 in 13 mm increments Deck Support Pin Cutting Height Adjustment TRANSAXLE LOCKOUTS IMPORTANT DO NOT TOW this mower with the transaxle lockouts engaged Towing can produce ex cessive internal pressure and damage the transaxle To move the mower with the engin
27. NING the Grass Buildup in Mower Housing in this section for deck rais ing instructions NEVER operate cutter blades with the deck in the raised position 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 dif ference in blade tip track is more than 1 8 in 3 the blade is bent and should be re placed WARNING DO NOT try to straighten a blade that is bent NEVER weld a broken or cracked blade ALWAYS replace with a new blade to assure safety 4 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 loosen ing 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 elec tric blade sharpener conventional electric grind er or a hand file ALWAYS wear eye protection and gloves when sharpening a blade 37 Maintenance Instructions CHECKING SERVICING Mower Deck Gearbox Seals Sharpen at Intersection Original 30 Angle Wear Area The mower deck gearbox seals and gaskets should be inspected every 25 hours for evidence of oil leaking particularly the lower oil
28. RD position for straight ahead ground travel is achieved by squeezing the pistol grips past the NEUTRAL PARK position For better con trol it is recommended that this is done in conjunc tion with toggling the FSC switch back to the NEUTRAL PARK position Blade Clutch PTO The blade clutch lever has two positions Pulling the lever BACK engages the PTO that drives the mow er blades Pushing the lever FORWARD disengag es the PTO and engages the blade brake Parking Brake The parking brake functions by locking a detent arm into the transaxle outer control 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 transaxle NOTE on the parking brake lever is no ticed when engaging the brake move the mower gently forward or backward to allow the brake detent to set into the teeth Engine Cover Latch The engine cover hinges forward for maintenance access and is latched down in the OPERATING po sition To raise the body unhook the rubber latch lo cated between the fuel tank and engine Transaxle Lockout Rods The trans
29. Wheel and U Joint Lubrication Maintenance Instructions Tractor PTO Gearbox Lubrication Checking Gearbox Oil Level The tractor PTO gearbox is permanently lubricated oil filled and sealed requiring no scheduled lubrica tion However the gearbox oil seals should be checked every 25 hours for indication of oil leaks If evidence of an oil leak is noted replace the oil seal and relubricate the gearbox The gearbox can be drained by removing the plug on the gearbox cover Replace plug and refill gearbox using 5 fl oz 15cl of SAE E P Extreme Pressure 90W oil With the deck removed the tractor unit may need to be tilted forward resting on deck support arms for positioning purposes to add oil into the PTO gear box Do not leave the mower in this position for an extended period of time to prevent oil from draining into the heads and causing possible engine damage lei om i PTO Gearbox Fill Plug Tractor PTO Gearbox Location view from underside of tractor LUBRICATION Transaxle Lubrication e The transaxle oil lubrication is SAE 20W 50 en gine oil Inspect both transaxle cases after every 100 hours of operation for visible leaks If a leak is de tected the oil level should be checked through the breather port on top of the transaxle Using clean rod measure the oil level by placing the rod in the fill port and bottoming out the rod on the bottom of the case Remove the rod and measure the oil level o
30. ain and check the oil lev el on the dipstick The oil level should be be tween the FULL and LOW mark on the dipstick LUBRICATION IMPORTANT DO NOT operate engine without a sufficient oil supply in the crankcase DO NOT operate with the oil level below the lower mark or above the upper mark on the dipstick 5 If additional oil is needed refer to Specifications for proper crankcase lubricant Fill up to but not above the upper mark on the dipstick IMPORTANT DO NOT overfill the crankcase oil above F mark as this CAN result in en gine overheating loss of power and possible engine damage 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 or more often in extremely dusty or dirty conditions 1 Parkthe mower on a level surface with the en gine stopped The engine oil should be warm before draining If not warm from operation start the engine and run a few minutes to warm the oil 2 Before removing the dipstick and oil fill cap clean the area around them to keep any dirt or debris out of the engine 3 Remove the dipstick oil fill cap and unscrew the oil drain plug 4 1 2 revolutions to prevent the drain plug from coming out completely do not exceed 4 1 2 turns Drain oil into a suitable container Be sure to allow ample time for com plete drainage SEXE
31. ance of the deck 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 e 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 Use a slow setting on the FSC for trimming operations e 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 move ments of the pistol grips 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 squeeze the inside pistol grip into reverse for a smooth rolling turn one wheel rolling forward while the other rolls backward When using a side discharge mower deck the side discharge shield must not be removed and must be kept in the lowest possible position to deflect grass clippings and thrown objects down ward Orient the side discharge away from side walks or streets to minimize cleanup of clippings Wh
32. and 3 8 16 in Whiz locknut Tighten the axle bolt until the wheel rolls freely but is not loose Tilt Up Roller Wheel Installation Mower Deck Installation on Tractor Deck Installation 1 Lightly grease each deck support arm 2 on the tractor Refer to Mower Deck Installation photo for location of deck support arm Engage the deck carrier frame tube sockets on the tractor support arms Slide the deck onto the support arms NOTE When installing the DSD52 Mower deck make sure to retract the dolly wheel after mounting the deck on the tractor Install the hitch pin through the hole on the end of each support arm to lock the deck in place refer to Counterweight Spring Receptacle Assembly photos Two 2 hitch pins are included in the owner s packet of materials Connect the mower deck PTO drive shaft assembly to the tractor with the splined quick disconnect coupler This coupler simplifies shaft alignment and installation a Use the arrows on the shaft and tube to align and slide the PTO quick coupler onto the deck splined shaft b Reaching under the tractor pull the ring back on the coupler slide onto the spline shaft on the tractor and release the ring IMPORTANT To prevent damage to the mower make sure the PTO shaft assembly is securely locked on the tractor with the locking balls fully seated in the groove and the ring in the full forward position refer to the Coupler Ring Locked Position pho
33. and remounted as de scribed in Sharpen Mower Blades instructions During the course of sharpening and inspecting mower blades if there are any of the following conditions of wear or damage blades should be replaced for reasons of safety and performance of the machine 41 42 Maintenance Instructions e 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 e 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 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 e Check the blades for straightness by marking blade tip position inside the deck housing and then rotating the opposite end of the blade to the same position and comparing If the difference in blade tip track is more than 1 8 in 3 the blade is bent and should be replaced e nspect the blade surface especially
34. ar that will improve footing on slippery surfaces 6 Ground cover or leaves can sometimes hide ob jects that might cause damage to the mower or make unstable footing for the operator Clear the area of objects and mark all sprinkler heads and or utility box covers 10 Safety Instructions Do not wear loose fitting clothing that could get caught in moving parts Always wear ade quate protective clothing including long pants Wearing safety glasses and safety shoes is advisable and required by some local ordinances and insurance regulations Prolonged exposure to loud noise can cause impairment or loss of hearing Operator hear ing protection is recommended Wear a suit able hearing protective device such as earmuffs or earplugs Keep all protective shields and safety de vices in place protective shield safety device or decal is damaged unusable or miss ing repair or replace it before operating the ma chine Be sure interlock switches are functioning correctly so the engine cannot be started un less the Forward Speed Control switch is in the NEUTRAL PARK position and the PTO clutch is in the DISENGAGED position Also the en gine should stop if the operator lifts their hands off the operator presence control with the PTO clutch the ENGAGED position and or moving forward FSC switch out of neutral Never attempt to make any adjustments while the engine is running except where specifically ins
35. arly the lower seals on the blade drive gearboxes should be inspected since they operate in a dirty en vironment If an oil leak is noted replace the oil seal and relubricate the gearbox assembly as follows 1 Remove gearbox cover footrest Deck orien tation should be in the normal operating position Blade Drive Gearboxes Gearbox Mower Deck Gearboxes shown with gearbox cover removed for clarity 31 32 Maintenance Instructions 2 Clean the area around the individual gearbox cover plates to prevent contaminants from en tering the gearcase 3 Remove the screws securing the cover plates on the blade drive gearboxes 4 Check the level of lubricant in the gearboxes If the lubricant is low add SAE E P Extreme Pressure 90W oil until the oil level is up to sub merges the horizontal shaft in the gearbox shaft parallel to cover plate NOTE n 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 gear boxes The gearbox assembly is not vented and overfilling with oil will cause excessive pres sure and result in oil leaks 5 Check co
36. axle lockout rods disengage the transax les By pulling the rods toward the rear of the mow er and locking them into place with the shoulder on the rod in the body the transaxles are released to permit freewheeling By releasing the rods and pushing it back into the body the transaxles are en gaged for normal operation The transaxle rods in the LOCKOUT position are used to enable moving the machine without the engine running e g for service Refer to TRANSAXLE LOCKOUT in this section for operating instructions NOTE The transaxle lockout rods ends should be completely retracted against the body otherwise op eration of the transaxle may be erratic Hourmeter The hourmeter displays operating time accumulat ed while the ignition switch is in the ON position with the engine running It also gives service indications for oil changes and lubrication Circuit Breaker A manual reset circuit breaker is located on the op erator panel It has a button that pops out if the cir cuit breaker trips The circuit breaker protects the safety switches Operating Instructions Ignition Switch The ignition switch has two positions a RUN and an OFF position The RUN position should be used when starting using the recoil starter and running the engine The OFF position stops the engine Ignition Switch STARTING THE ENGINE Before operating the mower read and un derstand all Safety Instructions and Operat ing Instructions
37. carburetor has been set no further adjust ments should be required However if the engine exhibits any of the following symptoms the carbure tor adjustment should be checked by an authorized Kawasaki engine dealer black sooty exhaust smoke lack of power engine miss or backfire hard to start rough running or idle ADJUSTMENTS 47 BODY CHASSIS ASSEMBLY ITEM PART DESCRIPTION NO NO REQ D Body Assembly 1 9800 Decal Walker By Walker 1 2 5805 Decal Engine Exhaust 1 3 9100 Hood Includes Items 1 amp 2 1 4 9110 Hood Latch Assembly 1 5 5803 Decal Walker Manufacturing 1 6 9801 Decal Control Panel 1 9851 Handlebar End Plug 2 8 9850 Handlebar Grip Foam 2 9 5856 Decal Made In USA 1 10 9700 Handlebar Includes Items 7 amp 8 1 11 9700 1 Cover Plate Control 1 12 9101 Hood Support Rear 1 13 9046 Gas Tank Mount 1 Chassis Assembly 14 9803 Decal Blade Clutch 1 15 9804 Decal Gearaxle Lockout 2 16 9300 Chassis Frame 1 17 5075 LP Wheel amp Tire 18 x 8 5 10 2 18 9102 Cable 2 19 9310 Battery Strap 1 20 9620 Actuator Mount Tab 1 21 9802 Decal Parking Brake 1 Tail Wheel Assembly 22 8769 0 Dust Cap Deck Caster 1 23 8037 Bearing Cone 3 4 ID 4 24 8769 1 Bearing Cup Caster Fork 4 25 9771 Mount Caster Fork 1 Includes Item 24 amp 26 26 5830 Grease Fitting 4 27 8768 1 Seal 1 28 5770 1 Caster Wheel Fork 1 29 5 15 4 Caster Wheel Pneu 8 x 3 00 4 1 30 5 15 5 Bearing Caster Wheel 4 31 5714
38. cking Adjust ment Step 4 IMPORTANT The following adjustment proce dures are sequential Check and adjust each func tion in the order given FSC Actuator Stop Adjustment Step 1 1 Loosen jam nut and back off the adjustment bolt located in the steering pivot rod as shown 2 Turnthe ignition key to the ON position and tog gle the FSC switch to the Neutral position fully retracted 3 Tighten the adjustment bolt until it contacts the chassis and turn an additional 1 2 turn Tighten jam nut Hod FSC Actuator Stop Adjustment View from underside of tractor Maintenance Instructions Control Arm Adjustment Step 2 1 For both control arm rods loosen jam nut on ball joint end of control arm rod and adjust to ob tain a 1 1 4 measurement between jam nuts 4 1 2 measurement between centers of ball joints Tighten jam nuts Control Arm Rod Adjustment Both Transaxles view from underside of tractor Neutral Adjustment Step 3 1 Turn the ignition key to the ON position and tog gle the FSC switch to the Neutral position fully retracted Tighten adjustment bolt in speed control actua tor to achieve approximately an 1 8 to 3 16 gap between speed control actuator and speed control stop Make identical adjustment to the other side of tractor Start engine If one or both drive wheels creep forward turn corresponding adjustment bolt in toward rear of mower If drive w
39. cturing must take full responsibility for safety The mower 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 Fail ure to follow safety instructions contained in this manual may result in personal injury or damage to equipment or property you have any questions concerning setup opera tion 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 operat ing 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 Walker Manufacturing Company 5925 East Harmony Road Fort Collins CO 80528 2 Never allow children to operate the ma chine Do not allow adults to operate without proper instruction The mower shouldbe operated by one 1 person at a time do not give rides on the engine cover 4 Keep everyone especially children and pets a safe distance away from the area being mowed Do not operate with bystanders in the area 5 Do operate the machine wearing sneakers tennis shoes or similar lightweight footwear Wear substantial protective footwe
40. d 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 e Check condition cleanliness and security of the air cleaner system clean air filter every 100 hours For detailed procedures refer to CLEANING the Engine Air Cleaner System in Maintenance Instructions ADJUST CARBURETOR Initial Start up Only Hefer to ADJUSTMENTS of Carburetor in Mainte nance Instructions L CHECK ENGINE COOLING SYSTEM Check condition and cleanliness of engine air intake screen located on top of engine For detailed proce dures refer to CLEANING the Engine Cooling System in Maintenance Instructions 20 Assembly Instructions INSPECT TWO 2 DRIVE BELTS PTO Drive and Hydrostatic Ground Drive CHECK TIRE PRESSURE Deck Caster Wheel 20 PSI 137 kPa Drive 15 103 kPa Rear 20 137 kPa CHECK AND CLEAN GRASS BUILDUP UNDERNEATH MOWER DECK The tilt up deck can be secured in the raised position by unlocking the deck lock levers on each side of the carrier frame and inserting the deck hook into the tilt up latch on the tractor body Before operating the tractor make sure to re engage the deck lock levers after lowering the deck to the normal operating po sition Do
41. e verse for a smooth rolling turn one wheel rolling forward while the other rolls back ward 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 the machine is equipped with an operator presence switch on the handlebars Releasing this when the machine is driving or the PTO is engaged will make the engine shut down Operating Instructions ENGAGING THE MOWER 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 Pull the blade clutch lever SLOWLY up to en gage the mower blades A safety interlock switch operator pres ence on handle grips will cause the en gine to stop if the blade clutch is engaged and the operator presence control is not depressed The function of this switch should be checked by the operator lifting off of the control and engaging the blade clutch the engine should stop If the switch is not working it should be re paired or replaced before operating the mower DO NOT disconnect the safety switches they are for the operator s pro tection IMPORTANT DO NOT engage the blade clutch when transporting the mower across drives side walks loose materials etc DO NOT engage the blade clutch with the PTO shaft disconn
42. e RH pistol grip This rocker switch controls an electric actuator that has two functions One is to set forward travel speed and the other is to establish the NEUTRAL PARK position When the FSC switch is moved into the FORWARD position it sets the forward speed from 0 to 5 mph 0 to 8 km h The ground speed is proportional to how long the rocker switch is held for ward the longer the switch is held forward the faster the tractor moves It is not necessary to hold the FSC switch in position since the electric actuator maintains the selected position Squeezing the pis tol grips steering control levers overrides the FSC setting and slows or stops forward travel Releasing the pistol grips steering control levers allows the tractor to resume forward travel at the speed set by the FSC switch To stop and park the machine the FSC switch is depressed backward until the NEU TRAL PARK position is achieved Pistol Grips Steering Control Levers Each drive wheel is controlled by its own indepen dent pistol grip located below the operators han dles for both steering function and FORWARD REVERSE motion The FSC switch sets the maxi mum forward speed and also sets the forward posi tion of the pistol grips The pistol grips operate only with a squeezing movement of the grip which causes the drive wheel for that lever to first slow down stop and then reverse with a full backward le ver stroke The grips are released to the FOR WA
43. e NOT running will not start maintenance etc unlock release the transaxles 1 Locate each lockout rod at the rear of the mow er on either side of the tail wheel below the fuel tank 2 Pull each rod out and lock them on the body us ing the shouldered part of the rod 3 The mower will freewheel with the rods in the LOCKOUT position The rods must be shoul dered on the body to completely unlock the transmissions 4 After moving the mower release the rods plac ing them in the normal OPERATING position The transmission rod ends should be complete ly retracted against the body otherwise opera tion of the transmission may be erratic Operating Instructions Neutral Lockout Rod LH Freewheel Position Neutral Lockout Rod LH Operating Position RECOMMENDATIONS FOR MOWING IMPORTANT Operate the engine at full speed when mowing to allow the engine to produce full horsepower and to increase efficiency of the engine cooling system e Keep the mower deck and discharge chute clean e Mow with sharp blades A dull blade tears the grass resulting in poor lawn appearance and uses extra power slowing the mowing speed e tis 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 e When mowing operate the engine at or near full throttle for the best cutting action and perform
44. ected the mower deck removed from tractor If the cutting blades strike a stationary ob ject while mowing stop the mower imme diately disconnect the spark plug wires lift the deck and inspect the deck and blades thoroughly for damage Make sure that the blade timing has not been dis turbed the blades should be at 90 degrees to each other on gear driven decks Refer to REPLACING REPAIRING the Blade Overload Shear Bolts in Maintenance In structions if blades are out of time Also make sure the blade retaining nuts are torqued to 60 ft lb 81 3 N m Blade Clutch Disengaged STOPPING THE MACHINE 1 Slow the engine to a fast idle put the throttle in the 1 2 throttle position Squeeze the pistol grips to the NEUTRAL posi tion and toggle the FSC switch back to the NEUTRAL PARK position Disengage the blade clutch IMPORTANT DO NOT disengage the blade clutch with high engine speed above 1 2 throt tle since the brake action on the blade drive will cause premature wear of the brake band 25 26 Operating Instructions A brake stops the cutter blades from free wheeling within five 5 seconds after dis engaging the clutch If the brake system malfunctions and the blades do not stop within five 5 seconds the brake should be adjusted or repaired before operating the mower Refer to ADJUSTMENTS of Blade Clutch PTO in Maintenance Instruc tions 4 Slow the engine to idle put throttle in IDL
45. en mowing close to obstacles orient the side dis charge away from obstacles to reduce the chance of damage to property by thrown objects Discharge n Shield Side Discharge Shield in Lowest Position 27 28 Operating Instructions e 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 3396 grade Maximum Recommended Side Slope RECOMMENDATIONS FOR TILT UP DECK OPERATION TRANSPORT To avoid potential deck and or tractor damage while using the tilt up deck the following recommenda tions are offered e Do not move the tractor with the deck in the tilt up position since both the roller wheels on the back of the deck may be damaged by moving the tractor The tilt up configuration should only be used when the tractor is parked e When transporting a tractor with the deck in the tilt up position on a truck or trailer the deck should be secured to the vehicle with a strap or rope stop vertical movement This will prevent the deck from bouncing on the rear roller wheels caus ing breakage Maintenance Instructions IMPORTANT TIPS FOR CARE OF THE KAWASAKI ENGINE Fuel System e Fuel must be clean free from water dirt and organic material e Change fuel filter on a regular basis and when contamination is suspected or found in the fuel Sta
46. enance Instructions LUBRICATION DO NOT attempt to lubricate the machine with the engine running Disengage the PTO clutch shut off the machine and re move the ignition key Proper lubrication is an important maintenance pro cedure 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 or more often in ex tremely dusty or dirty conditions Checking Engine Crankcase Oil Level Check the engine crankcase oil level before use and after each 5 hours of continuous operation IMPORTANT The importance of checking and maintaining the proper crankcase oil level can not be overemphasized Check the oil level BE FORE EACH USE 1 Parkthe mower on a level surface with the en gine stopped Also make sure the engine is cool and oil has had time to drain into the sump allow at least 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 without screwing it in 4 Remove the dipstick ag
47. gage the blade clutch PTO stop the engine and remove the ignition key Wait for all movement to stop before leaving the operator position NOTE A blade brake should normally stop drive line rotation within five 5 seconds of dis engaging the PTO clutch For side discharge mower decks do not oper ate with the grass deflector chute removed Keep the deflector in the lowest possible posi tion For tractors equipped with tilt up deck do not move tractor with deck in tilt up position case of clogged or plugged mower deck a Disengage the blade clutch PTO and turn the engine off before leaving the operator position behind the handles b LOOK to make sure blade drive shaft movement has stopped before trying to unclog the deck c Disconnect the spark plug wires d Never place hands under the deck use a stick or similar tool to remove clogged material 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 prevent accidental starting discon nect the spark plug wires Thoroughly inspect 17 18 the mower and repair any damage before re starting 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 Do not touch the engine engine cover muffler whi
48. he belt by releasing spring tension from the ground drive belt idler arm 2 Slide the belt over both transaxle pulleys and feed it toward the back of the mower 3 Install ground drive belt by reversing removal procedure Ground Drive Belt PTO Drive Belt Loosen Front Bolts IUE not shown PTO Drive and Ground Drive Belt Removal view from underside rear of tractor Maintenance Instructions Blade Overload Shear Bolts NOTE Shear bolts are not used on the DSD52 mower deck 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 designed 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 is also important for proper shock load protection It is important to not over tighten the mounting nut since this defeats over rides the function of the shear bolts If these bolts shear remove the blade and install new bolts Refer to CHECKING SERVICING in this sec tion for Sharpen Mower Blades which describes the blade removal and installation procedure 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 refer to Mower Dec
49. heels creep backwards turn corresponding adjustment bolt out toward front of mower ADJUSTMENTS NOTE If the 1 8 to 3 16 gap between speed control actuator and speed control stop can not be maintained as neutral adjustments are made it will be necessary to adjust the length of the control rod Step 2 Increasing the length of the control rod decreases the gap Shortening the control rod increases the gap 1 8 to 3 16 Gap Adjust Bolt to Achieve 1 8 to 3 16 Gap Speed Control Actuator Adjustment LH Tracking Adjustment Step 4 If the engine must be running to perform a maintenance adjustment keep hands feet and clothing from moving parts DO NOT wear jewelry or loose clothing Start engine and set the FSC switch to a normal walking speed Check for equal drive speed for both wheels 45 46 Maintenance Instructions 2 l fonewheel is moving too fast bring the mower back into NEUTRAL using the FSC switch and slightly tighten the adjustment bolt on the speed control actuator on the side that is moving faster Tighten Bolt to Slow Down Travel Speed Tracking Adjustment Control Handle Pistol Grip Adjustment Step 5 1 Loosen jam nut and adjust upper ball joint on upper lever linkage to achieve a 1 gap between control handle and pistol grip 2 Make identical adjustment to the other side of handle It may be necessary to adjust both wheels in order to achieve tracking and neutral
50. ider Lawnmowers OWNER S MANUAL Safety Assembly Operating and Maintenance Instructions and ILLUSTRATED PARTS MANUAL Model MW Walk Behind 15 HP _ Please Read and Save These Instructions Effective Date 11 01 03 For Safety Read All Safety and Operation P N 9001 Instructions Prior to Operating Machine Price 5 00 Foreword Thank you for purchasing a Walker by Walker Model MW Every effort has been made to pro vide you with the most reliable product 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 an authorized servicing dealer or Walker Manufacturing 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 are using Before you op erate your new mower please read this entire manual Some of the information is crucial for proper operation and maintenance of this product it will help protect your investment and ensure that the tractor performs to your satisfaction Some of the information is important to your safety and must be read and understood to help prevent possible injury to the operator or others If anything in this manual is confusing or hard to understand please call our service depart
51. in formed areas for cracks Replace the blade if any cracks are found DO NOT try to straighten a blade that is bent NEVER weld a broken or cracked blade ALWAYS replace with a new blade to assure safety Reinstall the blades following procedure from Sharpen Mower Blades instructions If blades are replaced always use Walker original equipment blades to ensure safety and optimum performance The quality and performance of replacement blades offered by other manufacturers cannot be guaranteed they could be dangerous REPLACING REPAIRING ALWAYS use genuine factory replacement parts Substitute parts CAN result in prod uct malfunction and possible injury to the operator Mower Deck Gearbox Replacement NOTE Deck gearbox es may be changed with the deck mounted on the tractor However the deck may be removed from the tractor making the overall job of removing the gearbox assembly easier Refer to Deck Installation in Assembly Instructions and re verse the procedure to remove the deck To replace the mower deck gearbox es use the fol lowing procedure 1 Remove mower blades Refer to procedure in Sharpen Mower Blade instructions 2 Remove gearbox cover two machine screws and PTO shaft guard two 1 4 20 bolts 3 Remove two 2 3 8 16 mounting bolts from each blade drive gearbox and lift the entire gearbox assembly from the deck including PTO drive shaft 4 Remove the screws securing the cover
52. ingarm PTO Gearbox 2 F178 1 4 x 1 Fender Washer 1 26 7275 16 U Jnt Tube Assy Spline 1 F181 5 16 24 x 1 Hex Bolt 1 F235 5 16 18 x 2 1 2 Hex Bolt 4 F371 5 16 18 x 6 Hex Bolt 2 Use only genuine Walker replacement parts 50 Effective Date 11 01 03 MAIN COMPONENT POWER TRANSMISSION F026 Refer to Engine Group Refer to Engine Group 22 _ Refer to gt Body Chassis Assembly Use only genuine Walker replacement parts Effective Date 11 01 03 51 ENGINE GROUP ITEM DESCRIPTION NO ITEM PART DESCRIPTION NO NO NO REQ D NO NO REQ D Engine Assembly Fasteners 1 9020 Fuel Filter 1 F002 10 24 Keps Nut 2 2 5879 3 Hose Clamp 1 2 3 F009 5 16 18 Whiz Locknut 4 3 5086 18 Fuel Line 1 F025 10 24 x 3 8 PPHMS 2 4 9082 Fuel Tank Cap Includes Item 5 1 F035 9 16 18 x 1 1 4 Hex Bolt 4 5 5082 2 Fuel Cap Seal 1 F163 5 16 18 x 3 4 Set Screw 2 6 9083 2 Tank Tube Elbow 1 F184 1 4 20 x 1 2 Hex Bolt SS 2 7 5083 1 Bushing Rubber 1 F185 1 4 Internal Star Lock Washer 2 8 9121 10 Throttle Control amp Cable 1 F240 1 4 x 1 4 x 2 1 4 Key 1 9 9108 5 Throttle Control Knob Red 1 10 5020 1 Fuel Filter In Tank 1 11 5086 Fuel Line In Tank P U 1 12 6046 2 Fuel Tank 3 0 Gal Gas 1 Includes Items 4 amp 5 13 901 Oil Pressure Switch 1 14 NS Oil Filter Kawasaki 49065 2078 1 15 9237 Engine Pulley 4 3V 3A 1 Includes Items F163 amp F240 1
53. k Gearbox Replacement in this section PTO Shear Pin The PTO drive shaft connection to the deck gearbox has a shear pin to provide shock load protection to the mower deck drive This system provides prima ry shock protection in case of blade impact and will normally shear before the individual shear bolts on the blade hub REPLACING REPAIRING 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 Cotter Pin PTO Shear Pin IMPORTANT Use only Walker P N 8067 13 shear pins for replacement to provide proper shock protection these pins are hardened to shear under a specific amount of load 4 Reinstall the PTO shaft guard Before operating the deck inspect the blade over load 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 refer to Mower Deck Gearbox Replacementin this section Mower Blades Mower blades are removed
54. kage and se vere damage to the machine A hazard may be cre ated by damage to critical working parts and safety systems Ref Engine Battery Location Battery Charging BATTERIES PRODUCE EXPLOSIVE GASES e Charge the battery in a well ventilated area so that gases produced while charg ing can dissipate e Keep sparks flames and smoking mate rials away from the battery at all times e Make sure the battery charger is unplug ged before connecting or disconnecting cables to the battery Limit initial charging current to 1000mA Charge un til battery voltage under charge reaches 14 40 to 14 70 volts at 68 F 20 C Hold at 14 40 to 14 70 volts until current drops to approximately 50mA Battery is fully charged under these conditions and charger should be disconnected NOTE Due to the self discharge characteristics of this type of battery it is imperative that it be charged after 6 9 months of storage otherwise permanent loss of capacity might occur as a result of sulfation Assembly Instructions 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 2 75 are installed 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
55. l gearbox assembly with oil Refer to Mower Deck Gearbox Lubrication in this section for instructions Reassemble remaining items onto deck to com plete installation After installing blades check that the blade timing is correct by moving the blades through one 1 complete revolution Make sure blade tips pass clear of each other Mower Deck Gearboxes Shown with Gearbox Cover Removed for Clarity REPLACING REPAIRING ADJUSTMENTS ADJUSTMENTS If the engine must be running to perform a maintenance adjustment keep hands feet and clothing from moving parts DO NOT wear jewelry or loose clothing Blade Clutch PTO Clutch Disengagement Brake Action Itis important to check and maintain blade brake action for safe operation of the ma chine The blade brake is activated by linkage to the clutch pulley mechanism The brake is designed to stop the blades within five 5 seconds after disengaging the clutch Use the following procedure to check and adjust clutch disengagement and brake action 1 Evenly adjust the nuts on the end of the brake band to achieve 1 4 of travel of the PTO gear box assembly between the engaged and the disengaged position refer to PTO Gearbox En gagement Photo Assembly Should Move 1 4 Between Engaged and Disengaged Position Brake Band Adjustment Nuts Located at Front of Assembly Not Visible 7 Gearbox Engagement view from underside
56. le the engine is running or imme diately after stopping the engine These areas may be hot enough to cause serious burns When leaving the machine unattended dis engage the blade clutch PTO stop the en gine and remove the key MAINTENANCE 1 To prevent accidental starting of the engine when servicing or adjusting the machine re move the key from the ignition switch and dis connect the spark plug wires To reduce fire hazards keep the engine free of grass leaves excessive grease and dirt Keep all nuts bolts and screws tight to ensure the machine is in a safe working condition Check the blade mounting nuts frequently mak ing sure they are tight Perform only maintenance instructions de scribed in this manual Unauthorized main tenance operations or machine modifications may result in unsafe operating conditions If the engine must be running to perform a main tenance adjustment keep hands feet and clothing away from moving parts Do not wear jewelry or loose clothing Always use the proper engine service man ual when working on the engine Unautho rized maintenance operations or modifications to the engine may result in unsafe operating conditions Altering the equipment or engine in any manner which adversely affects its operation perfor mance durability or use will VOID the warran ty and may cause hazardous conditions Never attempt to disconnect any safety devices or defeat the purpo
57. ment at 970 221 5614 for clarification before operating or servicing this product This manual covers the Model MW Walk Behind 15 HP mower shields and guards must be in place for the proper and safe operation of this mower Where they are shown removed in this manual it is for illustration purposes only Do not operate this product unless all shields and guards are in place Specifications given are based on the latest information available at the time this manual was pro duced Walker Mfg Co is continually striving to improve the design and performance of its products We reserve the right to make changes in specifications and design without thereby incurring any obli gation relative to previously manufactured products Sincerely WALKER MANUFACTURING COMPANY Rr Welle Bob Walker President Table of Contents Owner s Manual General Information HIGHLIGHTED INFORMATION GLOSSARY IDENTIFYING NUMBER LOCATIONS ENGINE SERIAL NUMBER LOCATION SERVICING OF DRIVETRAIN GEARBOX Specifications ENGINE ELECTRICAL SYSTEM TRANSMISSION BLADE DRIVE TIRE SIZE TIRE PRESSURE DIMENSIONS Tractor and Mower MOWER DECK CURB WEIGHT DRIVE BELTS FRAME BODY CONSTRUCTION Component Identification Safety Instructions BEFORE OPERATING OPERATING MAINTENANCE SAFETY CONTROL AND INSTRUCTION DECALS Assembly Instructions SETUP INSTRUCTIONS Tire Installation Tractor Battery Service Battery Charging Mo
58. n the rod It should measure 4 to 4 1 4 in 10 to 10 75 cm total depth of oil DO NOT overfill Steering Linkage and PTO Linkage Lubrication The steering and PTO linkage are located at the rear of the tractor below the body The grease and oil points should be lubricated every 25 hours PTO Linkage Lubrication Points Steering Linkage Lubrication Points Steering and Linkage Location view from underside of tractor 33 34 Maintenance Instructions Ident Lubrication No No Location Type Places 1 Deck Caster Wheel Fork Pivot Grease 2 2 Deck Caster Wheel Bearing Grease 2 3 Gearbox Deck 1 4 Blade Drive Gearbox Oil 2 5 PTO Shaft Guard Hinge Oil 1 6 Universal Joint Shaft amp Grease 1 Tube Assembly 7 Pivot Assembly Tilt Up Deck Grease 4 8 Deck Support Arm Socket Grease 2 9 Universal Joint Quick Connect Grease 1 Spline Grease Slide Area 10 Tilt Up Roller Wheel Oil 2 11 Ground Drive Belt Idler Arm Grease 1 not visible access side of body 12 Throttle Choke Control Pivot Oil 1 on Control Panel amp Cable End LUBRICATION Ident Lubrication No No Location Type Places 13 Clutch Lever Pivot Grease 3 14 Parking Brake Pivot Oil 1 15 Engine Oil 1 16 Steering Control Linkage Grease 2 17 Tail Wheel Fork Pivot amp Grease 2 Wheel Bearing not shown 18 Clutch Actuator Push Rod Grease 1 19 Deck Support Pivot Arm Grease 2 kk Gearboxes are permanenily
59. n in heavy cutting toggle back the FSC switch to re duce ground speed Adjusting ground speed helps maintain a balance between engine power and blade speed for high quality cutting action Stop ground travel by squeezing both pistol grips to the NEUTRAL position tractor not moving and depressing the FSC switch back to the NEUTRAL PARK position NOTE f the tractor creeps forward or back ward with the FSC switch in the NEUTRAL PARK position the transmission control needs to be adjusted Refer to ADJUSTMENTS of Transmission Control in Maintenance In structions Operator Presence Controls Depressed RH Thumb Control FSC Switch Correct Operator Hand Position Beginning Recommendations are Learn operation of the mower in an open area away from buildings fences and ob structions Learn operation on flat ground BEFORE operating on slopes Start maneuvering the mower with SLOW engine speed and SLOW Forward Speed Control setting until familiar with all operating characteristics Remember the forward speed of the mower is controlled by the FSC toggle switch a unique Walker feature always squeeze the pistol grips for steering or for reverse motion of the mower Learn to operate the pistol grips with smooth action Jerky movements are hard on the transaxles and lawn For sharp turns do not allow the inside wheel to stop and twist on the grass Squeeze the pistol grip controlling the inside wheel into r
60. ndition of the cover gasket and replace if worn or damaged Reinstall gearbox cover plates torque screws to 24 in lb 2 7 N m DSD52 Mower Deck Lubrication There are several special lubrication requirements for the DSD52 mower deck in addition to the require ments 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 lithi um or molybdenum base grease LUBRICATION Blade Spindles Blade Spindle Lubrication DSD52 2 Check the oil level in the belt drive gearbox ev ery 100 hours or sooner if a visible oil leak has developed With the deck in the normal oper ating position remove the level plug in the side of the gearcase Add SAE E P Extreme Pres sure 90W oil to maintain the oil 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 Belt Drive Gearbox LN Dolly Wheel Pivot Level Plug U Joint Gearbox Dolly
61. o you B WALKER WILL NOT BE LIABLE FOR ANY INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES AND OR EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation s or exclusion s may not apply to you C Only the warranty expressed in this limited warranty shall apply and no dealer distributor or individual is authorized to amend modify or extend this warranty in any way Accordingly additional statements such as dealer advertising or presentations whether oral or written do not constitute warranties by Walker and should not be relied upon D This warranty gives you specific legal rights and you may also have other rights which vary from state to state 63 WALKERGFSMOWERS WALKER MFG e 5925 HARMONY ROAD FORT COLLINS CO 80528 e 970 221 5614 FORM NO 110103 PRINTED IN USA www walkermowers com 2004 WALKER MFG CO
62. of tractor 43 44 Maintenance Instructions 2 Usethe adjustment nut on the PTO clutch actu ator assembly refer to PTO Clutch Linkage Adjustment photo to set the tension applied by the PTO clutch lever The adjustment nut is initially set to achieve an approximate measure ment of 2 3 4 between the jam nut and the knuckle joint As the belt and pulleys wear it will be necessary to tighten the adjustment nut in order to prevent belt slippage this adjustment is the same in the Engaged and Disengaged positions Do not overtighten the adjustment nut This may cause damage to the clutch linkage and the PTO belt Adjustment Nut Spring Length Should be 2 3 4 i Clutch Linkage Adjustment Transmission Control DANGER If the engine must be running to perform a maintenance adjustment keep hands feet and clothing from moving parts DO NOT wear jewelry or loose clothing IMPORTANT The proper adjustment of the trans mission control stops is essential for efficient oper ation and life of the transmission These stops are properly adjusted at the factory and should only re quire readjustment if the transmission or related control linkage is removed or changed ADJUSTMENTS NOTE It would not be unusual for a new machine after initial 5 or 10 hours of operation to begin to not travel straight this is due to the break in of the trans missions In this case proceed to Tra
63. ot collect the mowed material e TRACTOR is the prime mover including the en gine drive train and controls to operate the mower IDENTIFYING NUMBER LOCATIONS The mower serial number is affixed to RH side of the inside of the unit housing Model and serial numbers are helpful when obtaining replacement parts and maintenance assistance For ready reference please record these numbers in the space provided Tractor Model No Tractor Serial No Deck Serial No Engine Model No Engine Serial No Date of Purchase Fill In By Purchaser Ref Engine Air Cleaner Serial Number Plate Tractor Serial Number Location Top View of Tractor General Information y b 3 A o ex J i Serial Number Deck Serial Number Location ENGINE SERIAL NUMBER LOCATION The Kawasaki engine model type and code num bers are located on the side of the engine opposite the recoil starter handle on the aluminum housing For the mower model covered by this manual an en gine manual is available to cover the Kawasaki FH430V Engine Serial Number Location SERVICING OF DRIVETRAIN GEARBOX The detailed servicing and repair of the engine hy drostatic transmission and gearboxes are not cov ered in this manual Only routine maintenance and general service instructions are provided For the service of these components during the limited war ranty period it is important to find a local au
64. r Cleaner System Foam Precleaner Element Paper Precleaner Element Engine Cooling System Air Intake Screen Engine Cooling Fins Grass Buildup in Mower Housing CHECKING SERVICING Battery Charging the Battery Tire Pressure Sharpen Mower Blades Drive Belts Mower Deck Gearbox Oil Seals Spark Plugs Fuel Lines and Clamps Blade Brake Action REPLACING REPAIRING Drive Belts PTO Drive Belt Ground Drive Belt Blade Overload Shear Bolts PTO Shear Pin Mower Blades Mower Deck Gearbox Replacement ADJUSTMENTS Blade Clutch PTO Clutch Disengagement Brake Action Transmission Control FSC Actuator Stop Adjustment Control Arm Adjustment Neutral Adjustment Tracking Adjustment Control Handle Pistol Grip Adjustment Handlebar Height Adjustment Tilt Up Deck Adjustable Stop Carburetor Illustrated Parts Manual BODY CHASSIS ASSEMBLY MAIN COMPONENT POWER TRANSMISSION ENGINE GROUP FORWARD SPEED amp STEERING CONTROLS SULKY ATTACHMENT ELECTRICAL ASSEMBLY WIRING SCHEMATIC 48 50 52 54 56 58 60 Maintenance And Service Record Sheet Operator s Notes Warranty 61 62 63 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 sev eral general practices to be aware of in the area of safety Most accidents associated with the oper ation or maintenance of a Walker product are
65. ranties covering these items are furnished with each mower Walker does not assume any warranty obli gation liability or modification for these items which are covered exclusively by the stated warranty of the respective man ufacturers noted above 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 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 Man ufacturing Company 5925 East Harmony Road Ft Collins CO 80528 Proof of the date of purchase may be required to verify warranty coverage 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 t
66. rd motion of the tractor can always be stopped by allowing the operator presence control on top of handle bars to raise up 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 con trols are in the OPERATING position Do not run the engine in a confined area without adequate ventilation Exhaust fumes are hazardous and can be deadly 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 Avoid sudden starts or stops Before backing the machine up look to the rear to be sure the area behind you is clear of obstacles Watch carefully for traffic when crossing or working near roadways Safety Instructions 10 Disengage the blade drive when transporting the machine across drives sidewalks etc Never raise the mower deck while blades are rotating The maximum recommended side slope op erating angle is 20 degrees or 33 grade When operating the machine on a slope reduce ground speed and use caution to start stop and maneuver To prevent tipping or loss of control of the machine avoid sharp turns or sudden changes in direction Never adjust cutting height with the engine running Before adjusting cutting height or servicing disen
67. rent to 1000mA Charge un til battery voltage under charge reaches 14 40 to 14 70 volts at 68 F 20 C Hold at 14 40 to 14 70 volts until current drops to approximately 50mA Battery is fully charged under these conditions and charger should be disconnected NOTE Due to the self discharge characteristics of this type of battery it is imperative that it be charged after 6 9 months of storage otherwise permanent loss of capacity might occur as a result of sulfation 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 RE PAIRING 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 caus es extra wear on the engine and blade drive by pulling hard 1 Stop the engine remove ignition key and dis connect the spark plug wires before raising the mower deck to service blades CHECKING SERVICING 2 Raise the deck and secure it in the TILT UP po sition Refer to CLEA
68. ring normal engine operation running with the choke in the ON position CAN damage the engine ADJUSTING GROUND SPEED AND STEERING IMPORTANT If the DSD52 Mower deck is installed on the tractor make sure the dolly wheel is retracted BEFORE moving Learn to START STOP and MANEUVER the mower in a large open area If the operator has not operated a machine with DUAL TRANSAXLES or PISTOL GRIPS steering and ground operation should be learned and practiced until the operator is completely comfortable han dling the machine BEFORE ATTEMPTING TO MOW 23 24 Operating Instructions Place both hands on their respective grips and using your RH thumb toggle the FSC switch out of NEUTRAL PARK position to the desired for ward speed It is not necessary to hold the FSC switch in position since the electric actuator holds the selected switch position and forward travel speed Steer by squeezing the pistol grip on the side of desired direction of turn e g squeeze the LH grip to turn left Reverse direction of the mower by squeezing both grips NOTE Smooth action on the pistol grips will produce smooth mower operation Remember to keep the engine and ground speed slow until learning the control response The FSC switch 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 cut ter blades i e as the engine pulls dow
69. rity Ignition otarter Interlock Switch 12 Volt Interstate PC1250 12 5 Amp Alternator 15 Amp DC Regulated Negative Ground Electronic Magneto Recoil Starter Ignition Lockout by Operator Presence Lever Transmission Neutral and Blade Clutch TRANSMISSION Manufacturer Model oteering Forward Speed Control Service Brake Neutral Dual Independent Hydro Gear Integrated Transaxles Handle Pistol Grips Variable Speed Controlled by Rocker Switch Near RH Thumb with Neutral Park Setting Mechanical Lockout for each Transmission Single Lever Control Transmission Release by Manual Dump Valve Specifications MODEL TRANSMISSION continued Transmission Fluid Factory Service Transmission Fluid Capacity Transmission Cooling Ground Travel Speed Forward m p h km h Reverse m p h km h MW 20W50 Multi Viscosity Motor Oil 79 fl oz 2336 ml Cooling Fan Mounted on Drive Pulley 0 5 0 8 Infinitely Variable 0 2 0 3 Infinitely Variable BLADE DRIVE PTO Shaft Blade Spindle Blade Drive Clutch and Brake Quick Disconnect Splined Shaft with Two 2 High Speed U Joints Each Blade 2 Mounts Direct on Peerless Right Angle Gearbox with Tee Gearbox in Center Connected to PTO Shaft Complete Geared Drive Peerless Model 1000 Gearboxes Manual Belt Tightener Clutch and Band Brake Stops Blades within Five 5 Seconds of Disengagement Max Blade Speed 2400 RPM 25 in 64 cm Blade 3600
70. rting Stopping e Match crankcase oil viscosity to the ambient tem perature allowing the engine to crank faster and start easier Cooling System Operate the engine at full speed when mowing This will allow the engine to produce full horsepower and move more cooling air through the cooling fins Air Cleaner System e Use only Kawasaki air cleaner elements After market elements may not seal in the air cleaner housing allowing dirt to enter the engine Also aftermarket filters often skimp on the filtration media and require more frequent cleaning and replace ment see following instructions e 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 e When the air filter element is removed or replaced make sure all dust is cleaned out of the air cleaner housing Use a damp cloth and wipe the interior of the air cleaner case clean a little dirt left here will be sucked into the engine and reduce engine life When the filter is installed make sure the element is held tight and straight in the hous ing for proper seating and sealing Cil e DO NOT screw filler cap into crankcase when checking oil level e Single viscosity or multi viscosity oils may be used with the viscosity matching ambient tempera tures
71. ry Counterweight Dampening Spring Dampening Spring al Top View Cover Removed 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 A read understand and follow the instructions Fail ure to comply with safety instructions may result in personal injury The seriousness or degree of importance of each type of information is defined as follows An IMMEDIATE hazard that WILL result in severe personal injury or DEATH if warn ing is ignored and proper safety precau tions are not taken A POTENTIAL hazard that COULD result in severe personal injury or DEATH if warn ing is ignored and proper safety precau tions are not taken Possible hazards or unsafe practices that MAY result in MODERATE personal injury or property damage or machine damage if warning is ignored and proper safety pre cautions 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 cannot predict every poten tially 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 Manufa
72. se of these safety devices 12 Safety Instructions Do not change the engine governor settings or overspeed the engine The governor has been factory set for maximum safe engine operating speed Use genuine factory replacement parts oubstitute parts may result in product malfunc tion and possible injury to the operator and or others Use care when charging the battery or per forming maintenance on the battery and electri cal system a 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 Keep sparks flames and smoking materi als away from the battery at all times To avoid sparks use care when removing bat tery cables from posts d Disconnect both battery cables before unplugging any wiring connectors or mak ing repairs on the electrical system IMPORTANT Keep all applicable manuals immediately accessible to anyone who may operate or service this machine 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 List M TO START HOKE TRANSMISSION MUST BE
73. sy 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 The machine must be shut off during this procedure 4 in 102 mm Wood Block Should not vary more than 1 8 in 3 mm side to side Deck Leveling 18 Check the side to side level Rotate each blade sideways and measure the distance from blade tip to ground on each side If mea surements vary more than 1 8 in 3 adda washer shim under the deck support pins on the low side to level the deck 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 possi ble cause of the deck not being level Should be 1 8 in 3 mm to 1 4 in 6 mm higher at the rear of the blade 22 4 102 Wood Block Assembly Instructions PREOPERATING CHECKLIST Before opera
74. thorized servicing agent of the component manufacturer Any unauthorized work done on these compo nents during the warranty period may void the war ranty If you have any difficulty finding an authorized outlet or obtaining warranty service please contact our Service Department for assis tance Walker Manufacturing Company 5925 E Harmony Road Fort Collins CO 80528 1 970 221 5614 Service manuals are available for each of these components from their respective manufacturers as follows Kawasaki Engines Kawasaki Tractor Corp P O Box 888285 Grand Rapids MI 49588 8285 Transmissions HydroGear Corporation Sullivan IL Tecumseh Products Co 900 North Street Grafton WI 53024 Gearboxes Deck amp PTO Specifications MODEL ENGINE Manufacturer Model Displacement HP 3600 RPM Max RPM No Load Governed RPM Max Torque ft lb RPM Idle RPM Spark Plug Spark Plug Gap Crankcase Capacity Crankcase Lubricant Fuel Tank Capacity Fuel MW Kawasaki 430 2 V Twin Air Cooled 431 26 3 cu in 15 4000 3600 23 6 32 2400 1500 Champion RCJ8Y 030 in 75 mm 1 8 qts 1 7 liters SC SD SE SF SG SH Grade Oil Only with 10W 30 10W 40 Viscosity or 40W Above 68 F 20 C Only 3 Gallons 11 4 liters Automotive Grade Unleaded Gasoline 87 Octane ELECTRICAL SYSTEM Battery Charging System Charging Output System Pola
75. ting 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 ev ery day but the operator should be aware of the con dition 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 Handle gasoline with care Gasoline is highly flammable and its vapors are ex plosive Use safe refueling procedures e DO NOT fill fuel tank with the engine run ning e f the engine is hot allow to cool before refueling e Use an approved fuel container e Fuel the mower outdoors e DO NOT smoke while refueling Avoid spilling fuel use a funnel or spout e 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 stor age container and funnel 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 blende
76. tle Choke The throttle choke control lever red knob is located to the left hand side of the operator s control panel This control is a dual functioning control choke and throttle The control is equipped with a detent be tween the choke position full forward and the throt tle control range To start a cold engine push the control to the CHOKE position After the engine starts pull the control back past the detent into the THROTTLE CONTROL range A warm engine requires little or no choke for starting Moving the lever forward into the FAST position in creases engine speed moving it backward toward the IDLE position decreases engine speed Parking Brake Lever Operating Controls Not Located on Control Panel Top View 10 Amp Circuit Breaker Operator Presence Control Pistol Grip 2 ect Go Steering Control LH gt EET 2 Not Visible Forward Speed PARE E Control Switch Control Positions Operating Control on Control Panel Top View Operating Controls PAST Forward Speed SLOW ir Pistol Grip Steering Control RH Not Visible 21 22 Operating Instructions 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 Forward Speed Control FSC The Forward Speed Control FSC is a rocker switch located adjacent to the RH thumb position near th
77. to After installation pull on the shaft to check for security Assembly Instructions 3 Grease Deck m TI PTO Shaft Connection Pull Back Spring Loaded Coupler Ring v Spring Loaded Coupler Ring In Fully Forward Position a F Coupler Ring Locked Position Counterweight Spring Receptacle Assembly in Pull out counterweight spring receptacle assist handle and lift up on locking finger slightly to unlock the receptacle assembly Lower this assembly toward the deck and attach the coun terweight springs to the receptacle Raise the assist handle until the assembly locks into the raised position to tension the springs 1 Install Counterweight Spring Clip into Receptacle Retain Spring Clip Using Tab Raising Assembly to Locked Position Unlocked Position Locking Finger Snaps to Hold Assembly in Locked Position Lift Up on Locking Finger to Lower Assembly Locked Position With the counterweight springs connected the weight on the deck caster wheels should be 15 to 25 Ib 7 to 11 kg Check this weight by lift ing 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 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 ea
78. tructed to do so Handle gasoline with care Gasoline is highly flammable and its vapors are explosive a Use approved fuel container b Never add fuel to a running engine or hot engine allow hot engine to cool several minutes 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 Replace the machine fuel cap and container cap securely and clean up any spilled fuel before starting the engine 13 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 the mower only in daylight or in good artificial light with good visibility of the area being mowed Keep feet behind the tractor at all times and al ways maintain secure footing when the tractor is moving and or mower blades are operating Use extreme caution when reversing the ma chine towards you 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 can raise off the ground slightly when going into reverse at high speeds Hemember for an emergency stop the forwa
79. ve upper mark as this CAN result in engine overheating loss of power and possi ble engine damage Start the engine and check for oil leaks around the oil filter Stop the engine recheck the oil lev el 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 LUBRICATION 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 Mower Deck Gearbox Lubrication NOTE These instructions apply to all mower decks with gear driven blades Refer to DSD52 Mower Deck Lubrication in this section for the DSD52 deck with belt driven blades The mower deck gearboxes tee gearbox and blade drive gearboxes are connected as a unitized as sembly and oil flows freely between them The gearboxes are permanently lubricated oil filled and sealed requiring no scheduled lubrication Howev er the gearbox oil seals should be checked every 25 hours for indication of an oil leak particul
80. wer Deck Assembly Deck Caster Wheels Installation Deck Discharge Shield Installation PTO Shaft Guard Installation Tilt Up Roller Wheel Installation Mower Deck Installation on Tractor Deck Installation Deck Leveling PREOPERATING CHECKLIST N O 10 11 13 Operating Instructions CONTROL IDENTIFICATION LOCATION AND FUNCTION Operating Controls Engine Throttle Choke Forward Speed Control FSC Pistol Grips Steering Control Levers Blade Clutch PTO Parking Brake Engine Cover Latch Transaxle Lockout Rods Hourmeter Circuit Breaker Ignition Switch STARTING THE ENGINE ADJUSTING GROUND SPEED AND STEERING ENGAGING THE MOWER STOPPING THE MACHINE ADJUSTING CUTTING HEIGHT TRANSAXLE LOCKOUTS RECOMMENDATIONS FOR MOWING RECOMMENDATIONS FOR TILT UP DECK OPERATION TRANSPORT Maintenance Instructions IMPORTANT TIPS FOR CARE OF THE KAWASAKI ENGINE Fuel System Starting Stopping Cooling System Air Cleaner System Cil MAINTENANCE SCHEDULE CHART LUBRICATION Engine Oil Engine Break In Oil Checking Engine Crankcase Oil Level Changing Engine Crankcase Filter Grease Fitting and Oil Point Lubrication __ Mower Deck Gearbox Lubrication DSD52 Mower Deck Lubrication Tractor PTO Gearbox Lubrication Checking Gearbox Oil Level Transaxle Lubrication Steering Linkage and PTO Linkage Lubrication Table of Contents CLEANING Engine Ai
81. x 4 1 2 Hex Bolt 2 7 9512 Rear Pivot 5 16 18 x 5 5 8 2 F049 9 16 SAE Washer 8 8 9507 1 Rear Arm RH Sulky 1 F055 5 8 SAE Washer 2 9 9505 Rear Arm Mount Sulky 1 F060 AN960516 Washer 4 10 5693 Pivot Bearing 2 F098 5 8 18 Slotted Hex Nut 2 11 5830 Grease Fitting 3 F151 3 8 16 x 7 8 Hex Bolt 2 12 9503 1 Decal Max Load Warning 1 F226 5 16 18 x 7 8 Hex Bolt 2 13 5267 1 Retainer Collar 1 1 F316 9 16 18 x 1 3 4 Hex Bolt 2 14 9502 1 Support Arm Bushing 4 F348 1 8 x 1 1 2 Cotter Pin 2 15 9502 Support Arm Foot Tray 2 16 9501 Foot Tray Sulky 1 17 8769 0 Dust Cap Deck Caster 2 18 8037 Bearing Cone 3 4 ID 4 19 8769 1 Bearing Cup Caster Fork 4 20 9503 Fork Mount Tube 1 Includes Items 10 11 amp 12 21 8768 1 Seal 2 22 5770 1 Caster Wheel Fork 2 23 5715 4 Caster Wheel Assembly Pneu 8 x 3 00 4 2 24 5714 3 Axle Spacer Tube 2 25 9507 Rear Arm LH Sulky 1 26 9508 Wing Nut 1 Use only genuine Walker replacement parts 56 Effective Date 11 01 03 SULKY ATTACHMENT Refer to d Body Chassis Assembly E Effective Date 11 01 03 Use only genuine Walker replacement parts 57 ELECTRICAL ASSEMBLY ITEM NO PART NO DESCRIPTION NO REQ D Electrical Assembly NO OP WYP 0975 3 9940 9941 2 9941 1 7941 2 7941 3 8960 15 8990 1 8960 2 7854 9942 9943 9944 7203 6 9910 0832 Cable Tie 50 x 7 Wire Harness FSC Thumb Guard FSC Switch Circuit Breaker

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