Home

Walker MC (18 HP) Lawn Mower User Manual

1. Turn the ignition switch ON and move the blade clutch to the ENGAGED position engine not running Open the catcher back door and trigger the Grass Pak vane by hand as it oscillates The horn should sound as the switch is moved in both directions If the horn does not sound the switch is bad and needs to be replaced DO NOT test the Grass Pak switch with the engine running Projectiles CAN be thrown out of the grass delivery spout and CAN cause serious injury to bystanders or property damage Maintenance Instructions Grass Pak Vane Switch Checking the Grass Pak Switch ELECTRICAL SYSTEM For troubleshooting refer to Wiring Diagram IMPORTANT Disconnect both battery cables be fore unplugging any wiring connectors or making re pairs on the electrical system Circuit Breakers A master circuit breaker is mounted on a bracket be hind the battery The circuit breaker may have either the manual or automatic reset function both types have been used See Circuit Breaker Location photo 30 Amp j Circuit Breaker EP uem p E Mounting Bracket E iia Circuit Breaker Location ADJUSTMENTS ELECTRICAL SYSTEM 79 Maintenance Instructions ELECTRICAL SYSTEM Wiring Diagram Model MC WALKER MODEL MC Beginning S N 2001 49399 IGNITION SWITCH CIRCUITS POWERFIL MOTOR CASE GROUND _ TO MOTOR MOUNT a ORG RELAY B START RELAY OFF S1 START CIRCUIT S2 START ACCESSORY CIRCUI
2. p v Mower Blade Profile For Sharpening CHECKING SERVICING Check blade balance by positioning the blade horizontally on a blade balancer or use a nail or shaftthrough the center hole If either end of the blade rotates downward grind remove metal on that end until the blade will balance The blade is properly balanced when neither end drops Balance of a blade is generally main tained by removing an equal amount of material from each end of the blade when sharpening Blade Balancer Blade Balanced on Magnetic Wall Mounted Balancer 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 N m NOTE When reinstalling blades on GHS models remember the blades turn toward each other counter rotate and the RH and LH blade cannot be switched Check for proper blade rotation before in stalling blades on the deck Refer to Blade Rota tion for GHS Mower Deck illustration shown in Clogging Checklist in Operating Instructions for correct blade rotation Drive Belts Raise the body and inspect the condition of the four 4 belts 3 belts on SD models every 25 hours of operation engine PTO drive jackshaft drive hy drostatic ground drive and GHS blower drive If the belts show signs of cracking or deteriorating the belts should be replaced Refer to REPLACING REPAIRING the Drive Belts in this section 57 58 Maintenanc
3. valve Check that these com ponents are in good condition The Vacuator valve is subject to wear and deterioration and should be replaced yearly or when damaged The lips of the valve should close and fit togeth er any cracks deformation or wear in the valve is cause for replacement Remove the filter element by pulling it out of the canister There will be some initial resistance as the filter seal breaks loose and slides off of the outlet tube Gently move the end of the filter up and down and side to side or twist to loosen the seal Use gentle action to minimize the amount of dust dislodged as the filter is removed Clean the filter element using low pressure compressed air less than 100 PSI 689 kPa Blow out the filter from the interior of the ele ment while turning the element NOTE Washing the element in water or clean ing solution is not recommended Replace the element if it does not clean up with compressed air 51 52 Maintenance Instructions Use a bright light inside the element to inspect for damage Check the element very carefully for pin holes or other damage that will allow dirt to leak through the paper media Replace element if necessary Check the condition and resilience of the radial sealing surface inside of the open end of the filter Replace the filter if any cracks tears or other damage to the sealing surface are noted Use aclean damp cloth and wipe the interior of the ai
4. 30 41 2500 1200 75 Champion RC12YC 030 in 76 mm 2 gts 1 9 liters API SG or SH Grade Oil Only with 10W 30 Viscosity above 0 F 18 C or 5W 20 or 5W 30 Viscosity below 32 F 0 C 3 Gallons 11 4 liters Regular Grade Unleaded Gasoline 87 Octane Air Cooled ELECTRICAL SYSTEM Battery Charging System Charging Output System Polarity Ignition Starter Interlock Switch Circuit Breaker 12 Volt 35 AH 295 CCA Flywheel Alternator 15 Amp DC Regulated Negative Ground Electronic Capacitive Discharge 12 Volt Electric Ring Gear Type Solenoid Shift Ignition Lockout by Seat Switch Transmission Neutral and Blade Clutch Auto Reset 30A TRANSMISSION Manufacturer Model Steering Forward Speed Control Service Brake Parking Brake Neutral Final Drive Dual Hydrostatic Eaton Model 7 Each Wheel Independently Driven Hand Lever Control Individual Wheel Precision Friction Lock Lever Cruise Control with Neutral Park Position Dynamic Braking through Hydrostatic Transmission Mechanical Pin Lock in Transmission Gear Transmission Release by Manual Dump Valve Gear Drive Axle Specifications MODEL TRANSMISSION continued Transmission Fluid Factory Service Alternate Transmission Fluid Transmission Fluid Capacity Transmission Cooling Ground Travel Speed Forward m p h km h Reverse m p h km h Mobil 1 Synthetic Motor Oil 15W 50 SAE 30W Straight Viscosity Mo
5. IMPORTANT CUTTING HEIGHT ADJUSTMENT WHEN GRASS IS DIRTY AND DAMP ESPECIALLY SPRINGTIME INSIDE BLOWER HOUSING MAY CUTTING HEIGHT INCHES ACCUMULATE A DEPOSIT OF DIRT CAUSING TOP HOLE WEAR AND BINDING OF BLOWER WHEEL UNDER THESE CONDITIONS CHECK BLOWER DECK WHEEL FREQUENTLY FOR BINDING AND USE PRESSURE WASHER TO CLEAN DEPOSITS SUPPORT BLOWER WHEEL MUST SPIN FREELY 5819 PIN n Top of Blower Housing 5819 zw Rd BOTTOM HOLE CHECK OIL Q EVERY 25 HOURS A CAUTION gt T STOP ENGINE BEFORE ADJUSTING S CUTTING HEIGHT Deck Gearbox Cover 5807 3 IMPORTANT TIGHTEN BLADE MOUNTING NUTS TO 60 FT LBS DO NOT UNDERTORQUE OR OVERTORQUE FOR PROPER SHOCK LOAD PROTECTION USE TORQUE WRENCH H Jackshaft Support Adjacent to Dipstick 7827 dE DESIGNED AND BUILT BY WALKER MFG COMPANY FORT COLLINS CO 80528 4b FAST THROTTLE Af os A WARNING READ AND UNDERSTAND OWNERS MANUAL BEFORE OPERATING THIS MACHINE KEEP ALL GUARDS IN PLACE OPERATOR HEARING PROTECTION IS RECOMMENDED FOR CONTINUOUS OPERATION OF GHS MODEL DO NOT DRIVE TRACTOR WITHOUT DECK OR IMPLEMENT INSTALLED Deck Carrier Frame 5865 A DANGER E A DANGER ENGINES PRODUCE CARBON MONOXIDE DO NOT OPERATE MOWER WITH WHICH IS AN ODORLESS DEADLY POISON DO NOT OPERATE IN AN ENCLOSED AREA DECK IN TILT U P POS ITION aie On Engine 6810 Deck Carrier Frame 8647 PARKING NE Right Side Below
6. LpA General Condition Cloudy 92 Temperature 32 F 0 C General Condition Cloudy Wind Speed 5 mph lt 8 kmh Temperature 32 F 9 0 C 9 OPERATOR a Humidity 58 Wind Speed lt 5 mph lt 8 kmh Barometric Pressure 25 0 HG 636 mm Hg Humidity 58 Barometric Pressure 25 0 HG 636 mm Hg WALKERGZSMOWERS WALKER MFG CO e 5925 E HARMONY ROAD FORT COLLINS CO 80528 e 970 221 5614 FORM NO 041503 PRINTED IN USA www walkermowers com 2003 WALKER MFG CO
7. 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 Maintenance Instructions The mower deck gearboxes tee gearbox and blade drive gearboxes are connected as a unitized assem bly and oil flows freely between them The gearboxes are permanently lubricated oil filled and sealed re quiring no scheduled lubrication However the gear box oil seals should be checked every 25 hours for indication of an oil leak particularly the lower seals on the blade drive gearboxes should be inspected since they operate in a dirty environment If an oilleak is noted replace the oil seal and relubricate the gear box assembly as follows 1 Remove gearbox cover footrest Deck orien tation should be the normal operating position Blade Drive Gearboxes Gearbox o Mower Deck Gearboxes shown with gearbox cover removed for clarity Clean the area around the individual gearbox cover plates to prevent contaminants from en tering the gearcase Remove the screws securing the cover plates on the blade drive gearboxes 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 Incase the gearboxes are completely
8. 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 67 68 Maintenance Instructions Mower Deck Gearboxes Mower Deck Gearboxes Shown with Gearbox Cover Removed for Clarity GHS Blower Assembly and or Blower Wheel GHS Blower Assembly Removal 1 Remove the mower deck Refer to Deck Instal lation in Assembly Instructions and reverse the procedure to remove the deck Skid Bar Blower Assembly Remove Skid Bar for GHS Blower Removal 2 Remove the blower faceplate by removing six 6 1 4 20 nuts Remove the GHS blower drive belt Refer to REPLACING REPAIRING the Drive Belts in this section for instructions REPLACING REPAIRING Remove the blower assembly from the chassis as follows a Remove the blower skid bar by removing front and rear mounting bolts from the skid bar underneath the blower and removing the bolt connecting the blower housing to the skid bar Remove the blower belt tightener idler arm assembly by removing the pivot bolt Remove two 2 bolts mounting the blower housing to the frame Lower the blower assembly straight down out of the chassis frame and remove Blower Wheel Removal When required replace the blower wheel using the fol
9. Ground Drive and GHS Blower Drive if equipped CHECK HYDROSTATIC TRANSMISSION OIL LEVEL Refer to LUBRICATION for Checking Hydrostatic Transmission Fluid Level in Maintenance Instruc tions CHECK BATTERY ELECTROLYTE LEVEL Refer to CHECKING SERVICING the Battery in Maintenance Instructions CHECK FUNCTION OF OIL PRESSURE WARNING LIGHT Turn ignition key to the RUN position The oil pres sure light should operate indicating normal function CHECK TIRE PRESSURE Deck Caster Wheel 20 PSI 137 kPa Drive 15PSI 103 kPa Rear 20 PSI 137 kPa CHECK AND CLEAN GRASS BUILDUP UN DERNEATH MOWER DECK and inside GHS blower if equipped Refer to CLEANING the GHS Blower in Mainte nance Instructions for blower cleaning information Never operate cutter blades with deck in raised position because it is hazardous The tilt up deck can be secured in the raised position by unlocking the deck lock levers on each side of the carrier frame and inserting the deck hook into the 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 Tilt Up Lift Handle Deck Secured in TILT UP Position Do not operate machine with deck tilt up pivot joint unlocked Do not operate the mower with deck in tilt up position Do not move the tractor with the deck in the tilt up position CHECK MOWER BLAD
10. PTO Switch Adjustment Locknut Slide Position If any of the following conditions occur during start ing or operating a safety interlock switch may be malfunctioning Contact your Walker dealer for trou bleshooting and or replacement Slight adjustments can be made by carefully bend ing the leaf switch up or down as needed With an operator in the seat the engine starts with the Forward Speed Control FSC and or the PTO engaged With an operator in the seat the engine starts but dies soon after the Forward Speed Control FSC or PTO is engaged Without an operator on the seat the engine starts and continues to run with the Forward Speed Con Steering Lever Adjustment trol FSC and or PTO engaged With an operator in the seat the Forward Speed Control FSC and PTO disengaged and panel horn works but the starter is not engaging Maintenance Instructions Blade Clutch PTO Clutch Engagement Belt Tension The clutch engagement and PTO belt tension are ad justed using the clutch actuator rod Initially after in stalling a new PTO belt after 10 hours and every 100 hours thereafter check and adjust for the two di mensions in the clutch actuator rod as shown in the PTO Clutch Engaged and PTO Clutch Disen gaged illustrations Clutch Actuator Rod PTO Belt Tightener Arm Locknut Spring Compressed ADJUSTMENTS Adjust the bolt head clearance 1 4 in to 3 8 in 6 35 mm to 9 53 mm first
11. threads on the brake band for adjustment lengthen the brake actuator rod Blade Brake Band Adjustment Nut Brake Actuator Rod Blade Brake Band Adjustment 73 74 Maintenance Instructions Blade Clutch Idler Pulley Stop Block PTO Belt Tightener N Chassis Blade Brake Band Adjustment NOTE The length of the actuator rod is adjusted by disconnecting the bottom clevis and shortening or lengthening accordingly The standard pre set length of the actuator rod is set at the factory at 8 1 4 in 209 mm Locknuts Bottom Clevis Brake Actuator Rod Adjustment ADJUSTMENTS After adjustments are complete check blade brake action as described in CHECKING SER VICING the Blade Brake Action in this section If blades do not stop within five 5 seconds check the following a Recheck 1 8 in 3 mm gap between stop block and chassis Make sure clutch and brake linkage are working freely no binding Check the brake band lining Check the brake drum on the pulley If excessive wear is present it will be neces sary to replace worn parts Transmission Control 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 NOTE It would not be unusual for a n
12. BLADES NEVER operate the GHS blower with the blower discharge chute uncovered grass catcher in the dump position since dan gerous projectiles may be thrown NEVER put hands into the blower discharge chute for any reason Use a stick or similar in strument to remove any material if clog ging has occurred NEVER leave grass clippings in the grass catcher after mowing Damp clippings generate heat as they decompose This MAY cause spontaneous combustion Operating Instructions Clogging Checklist In case of clogging there will be a distinct change in the sound of the blower i e the blower sound will stop Also the mower deck will begin to leave a trail of grass clippings When this occurs stop the engine disconnect the spark plug wires and make sure all movement has stopped before attempt ing to unclog NEVER place hands under the mower deck orinthe GHS blower discharge chute Use a stick or similar tool to remove any clogged material Normally any clogging will first develop at the back of the mower deck in the discharge opening into the blower chute Clogging at this point does not indi cate a particular problem in this part of the system but is a symptom of something restrict ing the flow of material throughout the entire system The following list of items should be checked if a pattern of clogging begins to develop All of these items are capable of causing clogging at the back of the deck e Check t
13. Dumping Using the Dump Bag Table of Contents Maintenance Instructions MAINTENACE SCHEDULE CHART IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE Fuel System Starting Stopping Cooling System Air Cleaner System Oil LUBRICATION Engine Oil Engine Break In Oil Checking Engine Crankcase Oil Level Changing Engine Crankcase Oil Oil Filter Grease Fitting and Oil Point Lubrication Mower Deck Gearbox Lubrication DSD52 Mower Deck Lubrication Tractor PTO Gearbox Lubrication Checking Gearbox Oil Level Changing Gearbox Oil Gear Axle Lubrication Hydrostatic Transmission Fluid Checking Hydrostatic Transmission Fluid Level Changing Hydrostatic Transmission Fluid _ CLEANING Engine Air Cleaner System Turbine Precleaner Donaldson Radialseal Air Cleaner Engine Cooling System Air Intake System Cylinder Head Cooling Fins Grass Buildup in Mower Housing GHS Blower GHS Exhaust Screen Hydrostatic Transmission Cooling Fins CHECKING SERVICING Security of Air Filtration Components Battery Electrolyte Level Cleaning the Terminals Charging the Battery Tire Pressure Sharpen Mower Blades Drive Belts Mower Deck Gearbox Oil Seals Spark Plugs Fuel Lines and Clamps Engine Starter Engine Valve Clearance Blade Brake Action 41 41 42 42 42 42 42 42 43 43 43 43 43 44 44 45 46 46 46 46 REPLACING REPAIRING Drive Bel
14. LOOK to make sure blade drive shaft and blower drive pulley movement has stopped before trying to unclog the system Disconnect the spark plug wires Never place hands under the deck or in the GHS blower 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 To prevent accidental starting disconnect the spark plug wires Thoroughly inspect the mower and repair any damage before restarting the engine and operating the mower Make sure cutter blades are in good condition and blade nuts are torqued to 60 ft lb 81 3 N m Do not touch the engine or muffler while the engineis running or immediately 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 Safety Instructions 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
15. clutch engaged then adjust uncompressed spring length clutch dis engaged The spring must be adjusted to an un compressed overall length of 2 in 51 mm If ad justments are needed more frequently than every 100 hours to maintain the linkage dimensions it may suggest problems with pulley wear or belt misalign ment 1 4 in to 3 8 in 6 35 mm to 9 53 mm Blade Clutch Lever Engaged PTO Clutch Engaged 71 72 Maintenance Instructions Clutch Disengagement Brake Action It is important to check and maintain blade brake action for safe operation of the machine x yf Blade Clutch Idler Pulley PTO Clut ADJUSTMENTS The declutched or disengaged position of the blade clutch idler pulley is adjustable and is set to give belt release without excessive slack and to apply the blade brake The blade brake is activated by the brake actuator rod linkage to the clutch idler pulley mechanism The brake is designed to stop the blades within five 5 seconds after disengaging the clutch p c no NC Joint Spring Uncompressed Blade Clutch Lever Disengaged ch Disengaged Maintenance Instructions Use the following procedures to check and adjust clutch disengagement and brake action Stop Block Eccentric Adjustment Step 1 Use the stop block attached to PTO belt tightener arm to set the bottom position of the clutch idler pul ley in the disengaged position The stop block should co
16. clutch lever engage position to lift the clutch idler away from the belt d Next remove the belt from the engine pul ley and then the PTO drive pulley Install the PTO drive belt by reversing the re moval procedure IMPORTANT Make sure the belt is installed inside the four 4 belt guide pins Refer to ADJUSTMENTS of Blade Clutch PTO in this section to check and make the fol lowing adjustments a Clutch engagement for proper belt tension b Clutch disengagement and brake action Clutch PTO Belt Linkage Tightener Arm PTO Belt Tightener Stop Block Pull UP to Engage Engine PTO Belt Blade Clutch Lever ad S d Engine in the DOWN Position ub SZ Pulley Belt Guides CS Bottom Guide Not Visible 3 PTO Drive Pulley Engine PTO Drive Belt Removal 61 62 Maintenance Instructions REPLACING REPAIRING Jackshaft Drive Belt b Relax the belt by depressing the spring 1 Toremove the jackshaft drive belt loaded idler arm a Remove the engine PTO drive belt as c Roll the belt off the jackshaft pulley and described in previous section remove Push Idler Pulley Jackshaft Jackshaft Drive Belt Jackshaft Drive Belt Disengaged 2 Reverse the removal procedure to replace the jackshaft drive belt Jackshaft Jackshaft Drive Belt Engine Pulley Jackshaft Drive Belt Engaged Maintenance Instructions REPLACING REPAIRING GHS Blower Drive Belt 1 Remove the GHS blowe
17. lever in the NEUTRAL PARK position the transmission control needs to be adjusted Refer to ADJUSTMENTS of Trans mission Control in Maintenance 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 seat switch will cause the engine to stop if the blade clutch is engaged and the operator is not in the seat The function of this switch should be checked by the operator rais ing off the seat 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 disconnected 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 othe
18. loose battery may cause damage to the case resulting in acid leakage and severe dam age to the machine A hazard may be created by damage to critical working parts and safety systems Electrolyte Level The battery electrolyte level should be checked af ter every 25 hours of operation To check electro lyte level 1 Remove battery cell filler caps 2 Checkthe electrolyte level If the level is below the bottom of the vent well fill with drinking wa ter to the bottom of the vent wells 1 4 to 1 2 in 6 to 13 mm above the plates Replace filler caps 55 56 Maintenance Instructions IMPORTANT DO NOT overfill the battery Electro lyte will overflow through the vented caps onto parts of the machine and WILL result in severe corrosion Cleaning the Terminals If battery terminals are corroded remove battery from the mower Using a wire brush remove corro sion with a solution of one part baking soda and four parts water Rinse with clean water Coat the terminals with petroleum jelly or terminal protector spray to retard further corrosion Charging the Battery Check the battery charge by measuring the specific gravity of electrolyte if specific gravity is less than 1 225 the battery will need to be charged as follows 1 Charge the battery at 15 amps for 10 minutes DO NOT exceed 20 amps maximum recom mended charging rate Charge until specific gravity is at least 1 250 Total charging time should not
19. one wheel stationary and the other moving for ward slightly Check and adjust the neutral safety switch for closure and function with the FSC in neutral the engine will not start when the switch is open Use panel nuts on the switch body to adjust switch position for closure in neutral Re fer to adjustment description for Safety Switch es in this section 75 76 Maintenance Instructions Straight Ground Travel Adjustment Step 4 1 Sit in the seat start the engine operate at nor mal speed and with the FSC in the NEUTRAL PARK position check for forward movement of either drive wheel if either wheel moves back ward refer back to Neutral Function Adjust ment Step 3 and readjust Tighten the steering lever adjustment nut on the side of the mower with the wheel moving forward until wheel movement stops Check for straight ground track on a level sur face with hands off the steering levers Set the FSC at several different speeds and ob serve if the mower moves in a straight line use cement joint or other line on the ground for ref erence NOTE The final tracking adjustment is made with the mower moving since the adjustment is quite sensitive and is more easily fine tuned when moving If travel is not straight tighten the adjustment nut that is on the same side of the mower as the wheel that is moving too fast e g the mower tracks to the right indicating the LH wheel is moving too fast t
20. owner s packet of mater ials Drive tires are 18 x 8 50 8 4 ply rear tire is 13 x 6 50 6 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 Tilt mower body up lift on rear of body for battery access Check the battery for electrolyte level and charge The electrolyte level should be at the bot tom of the vent wells 1 4 to 1 2 in 6 to 18 mm above plates If the specific gravity is less than 1 225 the battery needs charging If the battery has been shipped dry or is wet but needs service refer to the following instructions IMPORTANT Make sure battery is securely mounted in the frame A loose battery may cause damage to the case resulting in acid leakage and se vere damage to the machine A hazard may be cre ated by damage to critical working parts and safety systems Wet Battery Service If the battery has been shipped wet but the electro lyte level is low or the battery needs to be charged then 1 Fill each battery cell with drinking water to the bottom of the vent wells Charge battery Refer to Battery Charging in this section Dry Battery Service Activating a battery can be dangerous The battery should be taken to a reliable service station battery store or power equipment dealer where a trained techni cian can activate the battery safely DO NOT attempt to activate the battery unless
21. pivot joint unlocked GHS Blower Normally the GHS blower operates with no mainte nance or cleaning However when mowing grass that is dirty and damp especially springtime mow ing a deposit of dirt may accumulate inside the blower housing causing wear and binding of the blower wheel When operating in these conditions inspect the blower frequently for dirt buildup NOTE A visual clue of binding of the blower wheel is the blower blade tips are polished from rubbing on dirt When a dirt deposit is found use a high pressure washer or water spray to clean the inside of the housing as follows Before attempting to wash the blower stop the engine remove the ignition key and disconnect the spark plug wires 1 CLEANING Remove the GHS blower drive belt by unhook ing the belt tension spring from the hook on the chassis frame located above the blower pul ley Lift the belt tightener idler pulley up and roll the belt off of the blower pulley The belt should be clear of the blower pulley allowing free movement of the blower wheel IMPORTANT With the belt removed the blow er wheel must spin freely Any binding or drag ging of the wheel is an indication of dirt buildup This buildup must be cleaned to avoid abrasive wear of the blower blades ex cessive power loss and eventual loss of blower performance clogging Use a pressure washer or water spray and di rect the spray inside the blower housing against t
22. respective manufacturers Kohler Engine Kubota Engine Kawasaki Engine Eaton Hydraulic Transmission Peerless Gearboxes Battery Tires The available warranties covering these items are furnished with each mower Walker does not assume any warranty obli gation liability or modification for these items which are covered exclusively by the stated warranty of the respective man ufacturers noted above An extended three 3 year warranty is offered on the Walker P N 6200 8 Gear Axle Assembly 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 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 PARTICULA
23. the caps are open 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 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 14 Safety Instructions SAFETY CONTROL AND INSTRUCTION DECALS Safety Control and Instruction Decals are installed on the machine if any are missing illegible or damaged a replacement should be ordered and installed before putting the machine into operation The Decal Part Number is listed below and in the Parts Manual A DANGER ROTATING CUTTING BLADES DO NOT PUT HANDS OR FEET UNDER OR INTO ANY PART OF THIS MOWER DECK OR DISCHARGE CHUTE OBJECTS MAY BE THROWN FROM MOWER gt CLEAR LAWN OF DEBRIS AND OBJECTS gt DO NOT MOW WITH BYSTANDERS IN AREA 5808 KEEP SHIELD IN LOWEST POSSIBLE POSITION DO NOT REMOVE THIS DISCHARGE SHIELD THROWN OBJECTS SD Deck Discharge Shield 5848 ADANGER GRASS CATCHER SHOULD BE EMPTY WITH BODY RAISED e TO PREVENT ACCIDENTAL LOWERING OF BODY INSTALL A SAFETY PROP FROM BODY TO LOWER FRAME ESPECIALLY WHEN PERFORMING MAINTENANCE WITH BODY RAISED Underside of Body 5861 Gear Axle 5810 1 Front Body Adjacent to RH Steering Lever 6807 Catcher Sa
24. the operator from personal harm or injury However it is necessary for the operator to use safe operating procedures at all times Failure to follow safety instructions con tained in this manual may result in personal in jury or damage to equipment or property If 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 Never allow children to operate rider mower Do not allow adults to operate without proper instruction Clear the area to be mowed of any foreign objects which may be picked up and thrown by cutter blades Pick up all sticks stones wire and any other debris Keep everyone especially children and pets a safe distance away from the area being mowed Do not mow with bystanders in the area Do not operate the machine barefoot or wearing sandals sneakers tennis shoes or similar light weight footwear Wear substantial protective footwear Safety Instructions Do not wear loose fit
25. the vane on the Grass Pak switch If the signal is coming on too soon catcher not completely full or too late grass clogging in catcher spout and deliv ery chute refer to ADJUSTMENTS of GHS Full Signal Horn in Maintenance Instructions NOTE The horn signal should be adjusted to sound BEFORE the catcher is completely full to give the operator time to react and stop mowing An indication the horn signal is coming on too late de layed too much is if grass clippings are falling out of the grass catcher delivery chute when the catcher is dumped Cleaning the GHS Exhaust Screen To remove the grass catcher screen for cleaning open the catcher door push forward and pull down on the grass catcher screen knobs on either side of the screen and slide the screen out Use a high pressure washer or water spray and brush to clean the screen Keeping the catcher exhaust screen clean and open is essential to good performance of the catching system In some mowing conditions e g wet and dirty it will be necessary to clean the screen fre quently to avoid clogging the mower deck blower and chutes due to airflow restriction Grass Catcher Screen Removal Knobs Grass Catcher Screen Removal for Cleaning Operating Instructions Dumping the Catcher For dumping the catcher either tailgate dumps into a disposal area or dumps into the optional dump bag The dump bag is a reusable nylon fabric bag designed to conveniently m
26. the washers above the deck pin bushing Ona level surface if any pin is sticking up likely the front pins tighten the opposite side or loosen the same side to lower the pin Adjustments are made by loos ening the jam nut and tightening or loosening the set screws on the Deck Mount Pivot Brackets Retighten the jam nut when the adjustment is complete Tilt Up Deck Adjustable Stop 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 The fixed main jet carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The high idle is set at the fac tory and cannot be adjusted The low idle mixture screw is also set at the factory and normally does not need adjustment The only adjustment normally made to the carburetor is to set the idle speed However if the engine exhibits any of the following symptoms it may be necessary to adjust or service the carburetor black sooty exhaust smoke lack of power engine miss or backfire hard to start rough running stalls at low idle speed ADJUSTMENTS NOTE Due to the technical requirements of mod ern carburetors refer to the Kohler Service Manual or contact an authorized Kohler engine dealer for carburetor adjustments and service not described in this section ALWAYS use the proper engine service manual when working on the engine
27. you are experienced in battery service work The following activation and charg ing instructions are provided for use by a trained battery technician Battery electrolyte is a poisonous and cor rosive sulfuric acid solution Avoid spillage and contact with skin eyes and clothing causes severe burns e To prevent accidents wear safety gog gles and rubber gloves when working with electrolyte Neutralize acid spills with baking soda and water solution To fill activate battery with electrolyte if battery has been shipped dry 1 Remove the battery hold down bar disconnect the battery cables and lift the battery out of the tray IMPORTANT Battery must be removed from the mower before filling with electrolyte IMPORTANT Obtain and use only battery grade sulfuric acid electrolyte with a 1 265 spe cific gravity to activate the battery DO NOT use water or any other liquid during initial activation Remove the filler caps and carefully fill each cell until the electrolyte is just above the plates Assembly Instructions 3 After the battery is filled with electrolyte replace the filler caps and charge the battery Refer to Battery Charging Battery Charging BATTERIES PRODUCE EXPLOSIVE GASES Charge the battery in a well ventilated area so that gases produced while charg ing can dissipate Keep sparks flames and smoking mate rials away from the battery at all times Make sure the bat
28. CK ENGINE CRANKCASE OIL LEVEL Check the engine crankcase oil level before use and after each 5 hours of continuous operation Refer to LUBRICATION for Checking Engine Crankcase Oil Level in Maintenance Instructions CHECK AND SERVICE ENGINE AIR CLEAN ER SYSTEM Check air restriction gauge to make sure there is no red indication showing Check condition cleanliness and security of the complete air cleaner system clean air filter every 100 hours For detailed procedures refer to CLEANING the Engine Air Cleaner System in Maintenance Instructions C ADJUST CARBURETOR Initial Start up Only Refer to ADJUSTMENTS of Carburetor in Mainte nance Instructions CHECK ENGINE COOLING SYSTEM Check that the engine cooling air intake screen is free of obstruction by grass clippings or debris and clean if required Also cylinder head cooling fins should be inspected and cleaned if any build up of debris is noted remove two 2 cylinder head ac cess panels to inspect and clean Check performance of the cooling system by start ing the engine holding a hand adjacent to the cylin der heads and feeling the cooling airflow Make sure to keep hands clear of exhaust pipe muffler and moving parts when checking airflow Assembly Instructions CHECK GEAR AXLE OIL LEVEL Refer to Gear Axle Lubrication in Maintenance In structions INSPECT FOUR 4 DRIVE BELTS Engine PTO Drive Jackshaft Drive Hydrostatic
29. E CONDITION SHARP NESS AND SECURITY OF MOUNTING The blade mounting nut should be tightened to 60 ft Ib 81 3 N m If blade sharpening is required refer to CHECKING SERVICING for Sharpen Mower Blades in Maintenance Instructions L 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 C PERFORM ANY ADDITIONAL PROCEDURES called for on the MAINTENANCE SCHEDULE CHART in Maintenance Instructions 23 Operating Instructions CONTROL IDENTIFICATION LOCATION AND Ignition Switch FUNCTION The ignition switch is located on the right front of the body and is used to start and stop the engine The A CAUTION switch has three positions O is the OFF position RUN is the position the key returns to after starting Before operating the mower become fa and S is the START position When starting the miliar with the location and function of engine turn the key clockwise to the S position all operator controls Knowing the loca Do not hold the key in the S position longer than 10 tion function and operation of these seconds If the engine does not start return the key controls is important for safe and effi to the O position for at least 60 seconds before cient operation of the mower making a restart attempt Prolonged cranking can damage the starter motor and shorten battery life Rele
30. Move the FSC to the NEUTRAL PARK posi tion When the machine is stopped or moving slowly engage the parking brake NOTE This is exactly the same procedure used to normally stop and park the machine 6 Disengage the blade clutch and put the FSC in the NEUTRAL PARK position before starting the engine an ignition interlock switch normally prevents starting of the machine if these 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 Do not carry passengers maximum seating capacity is one 1 person 12 Safety Instructions 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 no one is behind the machine Watch carefully for traffic when crossing or working near roadways Disengage the blade drive when transporting the machine across drives sidewalks etc Ne ver 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 speed and use caution to start stop and ma neuver To prevent tipping or loss of control of the machine avoid sharp
31. Mower blades are removed 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 con ditions of wear or damage blades should be re placed for reasons of safety and performance of the machine An excessive amount of the flat section of the blade has been ground away removed when the blade is sharpened Replace the blade when less than a 3 4 in 19 mm flat section remains at the blade tip 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 mm the blade is bent and should be replaced e Inspect the blade surface especially in formed
32. Operator Seat 7809 A DANG ER SPRING LOADED DOOR KEEP HANDS CLEAR OF DOOR j PINCH HINGE BARS AND DOOR FRAME POINT WITH THE DOOR OPEN 5568 Catcher Door Hinge Bar LH and RH Sides 5868 TO RAISE BODY LIFT HERE 5815 Fender LH Side 5802 2 Rear Bumper 5815 CAUTION DO NOT OPERATE MACHINE WITH PIVOT JOINT UNLOCKED v Deck Carrier Frame 8653 TO SIART TRANSMISSION MUST BE IN NEUTRAL AND BLADE CLUTCH DISENGAGED FORWARD SPEED CONTROL FAST 4M SLOW ye NEUTRAL PARK P TOGO ADJUST LEVER FORWARD TO OESIRED GROUND SPEED TO STOP PULL STEERING LEVERS TO NEUTRAL BEFORE MOVING SPEED CONTROL TO NEUTRAL BLADE GLURGHC gt LIFT LEVER TO ENGAGE N Cu x 4 PTO d or fa IMPORTANT ENGAGE CLUTCH WITH NO MORE THAN Y2 ENGINE SPEED MOVE LEVER SLOWLY AND SMOOTHLY TO ENGAGE CLUTCH 7802 Fender RH Side 7802 15 16 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 Install the drive tires using the eight 8 lug bolts that are supplied with the
33. R PURPOSE IS HEREBY LIMITED TO THE DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you 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 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 This warranty gives you specific legal rights and you may also have other rights which vary from state to state 83 Sound Model MC Vibration Model MC Sound Test Vibration Level Vibration levels at the operators handles Lwa Sound test conducted was in accordance 0 7 were measured in the vertical lateral and 1 0 with 79 113 EEC and was performed on D g longitudinal directions using calibrated 5 28 January 98 under the conditions listed vibration test equipment Tests were performed on 28 January 98 under the conditions listed
34. RAL PARK position When the FSC lever is moved into the FORWARD posi tion a friction lock holds any forward speed setting from 0 to 5 mph 0 to 8 km h The ground speed is proportional to the lever position the further the le ver is advanced forward the faster the tractor moves It is not necessary to hold the FSC in posi tion since the friction lock maintains the selected le ver position Pulling back on the steering levers overrides the FSC setting and slows or stops for ward travel Releasing the steering levers allows the tractor to resume forward travel at the speed set by the FSC lever To stop and park the machine the FSC lever is moved backward to the NEUTRAL PARK position Steering Levers Each drive wheel is controlled by its own indepen dent steering lever for both steering function and FORWARD REVERSE motion The FSC lever sets the maximum forward speed and also sets the for ward position of the steering levers The steering le vers operate only with a backward pulling movement of the lever which causes the drive wheel for that lever to first slow down stop and then reverse with a full backward lever stroke The levers are released to the FORWARD position for straight ahead ground travel NOTE Pushing forward on the steering levers will not cause any change in tractor motion there will be no steering lever reaction and there will be no machine damage Blade Clutch PTO The blade clutch lever ha
35. T M MAGNETO GROUND CIRCUIT B BATTERY CIRCUIT A ACCESSORY CIRCUIT G GROUND CIRCUIT RELAY A IGNITION RELAY 30 87A 30 87A GRASS PAK SWITCH BLK a BLK gr smear ow RUN OPEN STARTER STARTER SOLENOID PUR RECTIFIER REGULATOR ENGINE WHT MAGNETO GRN OIL PRESSURE SWITCH OPTIONALS LIGHT GRA NEUTRAL INTERLOCK SWITCH PTO INTERLOCK PUR SWITCH 30 AMP CIRCUIT BREAKER RED RED TIME DELAY MODULE 5 AMP OIL CIRCUIT PRESSURE BREAKER LIGHT BLK WHT OPTIONAL LIGHTS Saul O GRA BATTERY 80 S 1 CHASSIS GROUND LS HOUR METER alo Oj Operator s Notes 81 82 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 pur chaser 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
36. UCTIONS Tire Installation Tractor Battery Service Wet Battery Service Dry Battery Service Battery Charging Battery Installation Mower Deck Assembly Deck Caster Wheels Installation Deck Discharge Chute Installation Deck Discharge Shield Installation PTO Shaft Guard Installation Tilt Up Roller Wheel Installation Mower Deck Installation on Tractor Deck Installation 18 Deck Leveling PREOPERATING CHECKLIST OO OO OO SS oo 0 Cu N 10 10 11 12 14 16 16 16 16 16 16 17 17 17 17 18 18 18 19 19 21 22 Operating Instructions CONTROL IDENTIFICATION LOCATION AND FUNCTION Ignition Switch Engine Choke Engine Throttle Forward Speed Control FSC Steering Levers Blade Clutch PTO Parking Brake Transmission Lockout Levers Hourmeter Oil Pressure Warning Light Circuit Breaker 5 Amp Light Switch For Optional Lights STARTING THE ENGINE ADJUSTING GROUND SPEED AND STEERING ENGAGING THE MOWER STOPPING THE MACHINE ADJUSTING CUTTING HEIGHT TRANSMISSION LOCKOUT RECOMMENDATIONS FOR MOWING RECOMMENDATIONS FOR TILT UP DECK OPERATION TRANSPORT GRASS HANDLING SYSTEM GHS General Information Clogging Checklist Using the Tilt Up Deck Using the GHS Catcher Powerfil Full Signal Horn Cleaning the GHS Exhaust Screen Dumping the Catcher Tailgate
37. Un authorized maintenance operations or modifications to the engine MAY result in unsafe operating conditions Since the carburetor main jet is non adjustable for operation above 5000 ft 1 524 m above sea level it may be necessary to change the carburetor main jet for best fuel economy and power Contact an au thorized Kohler dealer to change the carburetor main jet Engine Idle Adjustment IMPORTANT Some emission certified engines may not have an adjustable idle mixture needle valve it is fixed from the factory and the adjustable screw is capped In this case only the idle speed is adjustable and only Step 4 of the instructions be low applies 1 Gently close the idle mixture needle valve by turning it clockwise until it bottoms lightly IMPORTANT The needle valve and carburetor seat may be damaged by turning the adjust ment screw too tight Preliminary Setting Turn the idle mixture nee dle valve out counterclockwise 1 1 2 turns from the closed position This initial adjust ment will allow the engine to be started and warmed up prior to the final adjustment 77 78 Maintenance Instructions Low Idle Mixture Needle Valve May be Non Adjustable Idle Speed Fixed Main Jet Under Screw Shutdown Solenoid The engine must be running to adjust the carburetor for engine idle To guard against injury keep hands feet face and other parts of body away from the muffler exhaust pipe other hot parts o
38. Walker Rider Lawnmowers OWNER S MANUAL Safety Assembly Operating and Maintenance Instructions Model MC 18 HP Covers Serial Numbers 03 61061 and on CC Please Read and Save These Instructions Effective Date 04 15 03 For Safety Read All Safety and Operation P N 6000 8 Instructions Prior to Operating Machine Price 5 00 Foreword Thank you for purchasing a Walker mower Every effort has been made to provide you with the most reliable mower on the market and we are sure you will be among our many satisfied custom ers If for any reason this product does not perform to your expectations please contact us at 970 221 5614 Every customer is important to us Your satisfaction is our goal Please read this manual thoroughly This manual is to be used in conjunction with the engine manufacturer s manual for the specific engine on the mower model you have purchased Before you operate your new mower please read this entire manual Some of the information is crucial for prop er operation and maintenance of this mower it will help protect your investment and ensure that the mower performs to your satisfaction Some of the information is important to your safety and must be read and understood to help prevent possible injury to the operator or others If anything in this manual is confusing or hard to understand please call our service department at 970 221 5614 for clarification before operating or servicing this mo
39. adjustment nut is too loose end play exists excessive loads are placed on transmission internal control stops If the adjust ment nut is too tight preferred condition the max imum forward travel speed is reduced Neutral Function Adjustment Step 3 1 Move the FSC lever to the NEUTRAL PARK position rear travel limit Start the engine operate first at idle and then normal operating speeds and check for move ment of the drive wheels NOTE Ifthe engine will not start check and ad just the neutral safety switch see item 4 below ADJUSTMENTS 3 NEVER attempt to disconnect any safety devices or defeat the purpose of these safety devices LH Steering Lever For Orientation PS a eae Neutral Function Adjustment If drive wheels are moving stop the engine and adjust the FSC neutral stop by adjusting the FSC actuator clevis see Neutral Function Ad justment photo for clevis location If the drive wheels are moving backward remove the cotter pin and clevis pin and screw the clevis forward If the drive wheels are moving forward screw the clevis backward Restart the engine and check for wheel movement Several trial and er ror adjustments may be required At this point it may not be possible to adjust both wheels stationary since the differential adjustment has not been made This is covered by the Straight Ground Travel Adjustment Step 4 n this case the neutral adjustment should be made for
40. and Air Bleed Plug Location If the fluid is below the COLD mark or the trans mission is not performing properly loosen the air bleed plug located on the top of transmis sion case next to the plastic reservoir a lf asmall amount of fluid leaks from around the air bleed plug The transmission is full of fluid Tighten the plug and fill the reservoir to the COLD level mark If no fluid leaks from around the air bleed plug Slowly add fluid into the reservoir until fluid starts to leak from around the plug Transmissions are serviced from the factory with Mobil 1 15W50 Synthet ic Oil When it is necessary to add flu id refer to Specifications for the proper fluid As soon as there is fluid leaking from around the air bleed plug tighten the plug and fill the reservoir to the COLD level mark Wipe any excess oil off of the transmission housing IMPORTANT DO NOT overfill the transmission reservoir This will result in oil leaking out of the res ervoir cap vent when the transmission warms up It is preferable to add fluid to the transmission when it is cold and make sure the oil is not above or be low the COLD level mark LUBRICATION IMPORTANT The transmission reservoir has a fine mesh screen in the bottom to trap dirt and foreign particles from entering the transmission When fill ing the reservoir fluid will flow quite slowly through this screen so it is essential that there is fluid at the blee
41. areas for cracks Replace the blade if any cracks are found Maintenance Instructions 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 Sharp en Mower Blades instructions If blades are re placed always use Walker original equipment blades to ensure safety and optimum performance The quality and performance of replacement blades offered by other manufacturers cannot be guar anteed they could be dangerous 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 Remove gearbox cover two machine screws and PTO shaft guard two 1 4 20 bolts 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 REPLACING REPAIRING Remove the screws securing the cov
42. ase the key when the engine starts and it will return to the RUN position To stop the engine rotate the key counterclockwise to the O position Forward Speed Control FSC Steering Levers Parking Brake fa 3 Blade Clutch Warning Light PTO x Oil Pressure Light Switch Optional Not Shown 5 Amp Ignition Switch Circuit Breaker Operating Controls Operating Instructions Ignition Switch Engine Choke The choke control lever black knob is located on the left side of the seat To start a cold engine move the choke control forward to the ON position After engine starts move the choke control toward the OFF position keeping enough choke to allow the engine to run smoothly as it warms up As soon as possible move the choke to the OFF position A warm engine requires little or no choke for starting IMPORTANT Make sure the choke is in the OFF position during normal engine operation running with the choke in the ON position CAN damage the engine Engine Throttle The throttle control lever red Knob is located on the left side of the seat and is used to control engine speed Moving the lever forward toward the FAST position increases engine speed moving it back ward toward the IDLE position decreases engine speed Choke and Throttle Location Forward Speed Control FSC Forward Speed Control FSC has two functions One is to set forward travel speed and the other is to establish the NEUT
43. cleaner and a Donald son Radialseal air cleaner Each component is checked cleaned and maintained on a different schedule based on the filtering action required Each component is serviced as follows Air Intake Precleaner Tube VP Turbine Precleaner CLEANING Turbine Precleaner The turbine precleaner is mounted on a remote air intake tube connected to the Donaldson air cleaner A spinning fan driven by the intake airflow separates dust from the air giving the initial stage of air clean ing Dust particles are exhausted through a single small vent in the side of the housing Since no dust is trapped the precleaner operates without clean ing The only maintenance required is to check the operation of the internal fan every 100 hours Verify operation 1 Look into the exhaust vent while shining a light into the intake 2 Startthe engine and watch the fan begin to spin as the throttle is advanced If the fan is not spinning service or replace the pre cleaner as required Donaldson Air Cleaner Safety Filter Air Cleaner Cartridge Brass Elbow Air Restriction Gauge Donaldson Air Cleaner Cover Vacuator Valve Engine Air Cleaner System Components Maintenance Instructions Donaldson Radialseal Air Cleaner A remote mounted Donaldson Radialseal air cleaner provides the air filtering function The paper filter element slides over an outlet tube inside the air
44. cleaner canister with radial sealing action eliminat ing the possibility of dust leaks due to improper filter installation Intake design internal baffling and a Vacuator valve provide dust separation and auto matic precleaning action Daily or frequent servicing of the air cleaner is not required Use the air re striction gauge on the air cleaner outlet to indicate when the air filter needs servicing a red flag will appear when the filter is overly restricting airflow into the engine IMPORTANT Use only Donaldson air filter ele ments for replacement Donaldson P822686 or Walker 5090 1 Aftermarket filters may not seal properly or filter efficiently Canister Radialseal NS 5 o e Filter Element fl Vacuator A d Valve d Air Cleaner Components shown with cover being removed IMPORTANT The Donaldson air cleaner uses a dry paper type air filter element NEVER apply oil to the paper element CLEANING Push Button to Reset Air Restriction Gauge Air Restriction Gauge Location Clean and inspect the paper element after every 100 hours of service and replace the element year ly or after six 6 cleanings or when dirty or dam aged More frequent cleaning may be required when operating in extremely dusty conditions as in dicated by the air restriction gauge Service the air cleaner as follows 1 Release the top and bottom cover latches and remove the air cleaner cover Wash the cover and Vacuator
45. d plug before the transmission is considered full IMPORTANT Any attempt to remove or in any way alter the filtering screen in the transmission reservoir could cause damage to the transmission and will VOID any transmission warranty Changing Hydrostatic Transmission Fluid The hydrostatic fluid should be changed every 1000 hours or two 2 years Also the fluid should be changed if the natural color of the fluid has be come black or milky indicating possible over heating or water contamination of fluid The trans mission is refilled using the factory service fluid noted in TRANSMISSION Specifications The fluid is changed as follows 1 Parkthe mower on a level surface and stop the engine Remove the lower drain plug and the air bleed plug Allow the fluid to drain out IMPORTANT Clean any dirt from around the plugs and reservoir cap before removing them Reinstall the lower drain plug making sure the rubber O ring on the plug is in place and in good condition Refill the transmission through the air bleed plug hole until it is as full as possible IMPORTANT Avoidfluidcontaminationwhenfill ingthe reservoir Use clean container spout fun nel etc when pouring the fluid into the reservoir Rotate the transmission input shaft about five 5 revolutions to allow any trapped air to escape Before installing the air bleed plug fill the reser voir with fluid allowing a small amount to leak out of the air bleed pl
46. 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 LUBRICATION 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 Check condition of the cover gasket and replace if worn or damaged Reinstall gearbox cover plates torque screws to 24 in lb 2 7 N m 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 Dolly Wheel and U Joint Lubrication photos and check and maintain oil in the belt drive gearbox 1 Lubricate the blade spindles every 25 hours with two 2 shots of SAE general purpose lithi um or molybdenum base grease Blade Spindles Blade Spindle Lubrication 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 Pre
47. duce engine life When the filter is reinstalled make sure the element is held tight and straight in the canister for proper seating and sealing Periodically check the air intake hose for cuts nicks etc and the hose clamps for tightness Oil Use only multi viscosity oils as specified with the viscosity matching ambient temperatures for the en gine operating conditions This will aid starting in cold weather and assure proper lubrication in hot weather Use only Kohler oil filters Aftermarket filters may not seal properly and or have the incorrect pressure relief valve for proper lubrication Maintenance Instructions LUBRICATION 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 qui eter 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 Checking Engine Crankcase Oil Level Check the engine crankcase oil level before use and after each 8 hours of continuous operation IMPORTANT The importance of checking and maintaining the proper crankcase oil level cannot be overemphasi
48. e d VA transmission lockout engaged Towing can produce excessive internal pressure and damage the trans mission To move the mower with the engine NOT running dead battery maintenance etc the hydrostatic transmissions are unlocked released Camiin Plunger UNLOCKED 1 Raise the body Released Position 2 Lift the transmission lockout lever on both the RH and LH transmissions and secure into place with the locking cam Lockout Lever Normal Operating Position The mower will freewheel with the levers in the LOCKOUT position The levers must be in the highest position to completely unlock the trans missions Operating Instructions RECOMMENDATIONS FOR MOWING IMPORTANT Operate the engine at full speed when mowing to allow the engine to produce full horsepower and to increase efficiency of the engine cooling system Keep the mower deck and discharge chute clean Mow with sharp blades A dull blade tears the grass resulting in poor lawn appearance and uses extra power slowing the mowing speed 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 When mowing operate the engine at or near full throttle for the best cutting action and performance of the grass handling system GHS Mowing with a lower engine RPM causes the mowing blade to not cut clean and tear the gras
49. e Instructions Mower Deck Gearbox Oil Seals The mower deck gearbox seals should be inspected every 25 hours for evidence of oil leaking particu larly the lower oil seal on the blade drive gear box This seal is protected by the trash guard on the blade hub and seal protector plate on the housing but is still vulnerable to seal damage due to operat ing in an adverse environment The mower blade must be removed for inspection of the seal so it is recommended to inspect the gearbox seals when blades are removed for sharpening If an oil leak is noted the seal should be replaced and the gear box assembly relubricated Refer to Mower Deck Gearbox Lubrication in this section Spark Plugs Every 200 hours of operation remove the spark plugs inspect clean and reset the gap or replace with new plugs Before removing the spark plugs clean the area around the base of the plugs to keep dirt and debris out of the engine Clean spark plugs with a wire brush DO NOT use an abrasive grit type cleaner If the electrodes are burned short or pitted replace plugs with Champion type RC12YC or equivalent Check spark plug gap with a wire type feeler gauge and set the gap at 0 030 in 76 mm Reinstall and tighten to between 18 and 22 ft lb 24 4 to 29 8 N m Fuel Lines and Clamps Every year inspect the fuel supply line from the tank to engine for deterioration or damage Also inspect the fuel line clamps for tightness Good prevent
50. e cam and lowering the lever the transmissions are en gaged for normal operation The transmission lever in the LOCKOUT position is used to enable moving the machine without the engine running e g for ser vice Refer to TRANSMISSION LOCKOUT in this section for operating instructions Lockout Levers Transmission Plunger Lockout Lever Location NOTE Thetransmission plunger on the side of the transmission case activated by the LOCKOUT LE VER must be completely released during operation of the mower otherwise operation of the transmis sion will be erratic Hourmeter The hourmeter which is located on the left front of the body displays operating time accumulated while the ignition switch is in the ON position Oil Pressure Warning Light The oil pressure warning light indicates that engine oil pressure is below the safe operating range below 3 to 5 PSI 21 to 34 kPa This light will come on when the ignition is turned ON but should go off after the engine is started Ifthe light fails to come on when the ignition switch is turned ON it could indicate a burned out bulb If the light comes on during engine operation stop the engine immediately and correct the source of the problem before further engine op eration IMPORTANT Continued operation of the engine with an illuminated oil pressure warning light MAY cause severe engine damage if a low oil pressure condition exists Circuit Breaker 5 Amp A 5 a
51. e choke to the OFF position keeping enough choke on to allow the engine to run smoothly as it warms up As soon as possible move the choke to the OFF position IMPORTANT Make sure the choke is in the OFF position during normal engine operation running with the choke in the ON position CAN damage the engine ADJUSTING GROUND SPEED AND STEERING IMPORTANT If the DSD52 Mower deck is in stalled 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 ma chine with LEVER STEERING OR DUAL HYDROSTATIC TRANSMISSIONS steer ing and ground operation should be learned and practiced until the operator is completely comfortable handling the ma chine BEFORE ATTEMPTING TO MOW Keep feet on footrests at all times when the machine is moving Operating Instructions Move the FSC out of NEUTRAL PARK position to the desired forward speed DO NOT hold for ward on steering levers It is not necessary to hold the FSC lever in position since a friction lock maintains the selected lever position and forward travel speed In case either of the transmission drive belts break during operation and if the machine is on a slope the machine will freewheel down the slope To maintain control immediately 1 Release the steering levers and simultaneously 2 Move the FSC to the NEUTRAL PARK position When the machine is stopp
52. e wheel into reverse for a smooth rolling turn one wheel roll ing forward while the other rolls backward Practice maneuvering the mower until you can make it go exactly where you are aiming Remember for an emergency stop or in case of loss of control machine movement can always be stopped quickly by pulling the Forward Speed Control into the NEU TRAL PARK position 29 30 Operating Instructions 3 Pull Steering Levers With Left Hand Forward Speed Control FSC Keep Feet On Footrest When Moving Correct Operator Hand Position on the Controls Reverse direction of the mower by pulling both levers backward NOTE Smooth action on the steering levers will produce smooth mower operation Remem ber to keep the engine and ground speed slow until learning the control response The FSC may be adjusted forward for faster ground speed and backward for slower ground speed When mowing ground speed should be adjusted to match the load on the cutter blades i e as the engine pulls down in heavy cutting pull back on the FSC lever to reduce ground speed Adjusting ground speed helps maintain a balance between engine power and blade speed for high quality cutting action Stop ground travel by pulling both steering le vers backward to the NEUTRAL position trac tor not moving and then moving the FSC lever to the NEUTRAL PARK position NOTE f the tractor creeps forward or back ward with the FSC
53. eaning required How ever under certain operating conditions the inside of the blower housing may accumulate a deposit of dirt causing wear and binding of the blower wheel Normally dirt buildup occurs when mowing a com bination of dirty and damp grass especially in the springtime When operating in these condi tions check the blower wheel frequently for binding and clean the blower housing as required Refer to CLEANING the GHS Blower in Mainte nance Instructions NOTE In Autumn when using the GHS mower to vacuum leaves it is recommended to raise the front of the mower deck 2 to 3 notches 1 to 1 1 2 in 25 to 38 mm higher than the rear This will avoid bulldozing leaves particularly when the leaves are piled in a thick layer To make this ad justment the hitch pins in the two 2 front deck support pins are repositioned 2 to 3 notches higher while leaving the rear pins in their original position NEVER operate the GHS catcher with the back door open Objects may be thrown out the back of the catcher with sufficient force to cause serious injury to bystand ers or property damage NOTE When a side discharge or mulching mow er deck is installed on the GHS model a blower intake cover should be installed in the blower intake tube This cover unloads the blower and seals the intake to effectively eliminate power loss and blower noise when the blower is not being used Blower Intake Cover ROTATING BLOWER
54. ed or moving slowly engage the parking brake NOTE This is exactly the same procedure used to normally stop and park the machine NOTE If the FSC lever will not stay in the selected position the friction lock needs to be adjusted Refer to ADJUSTMENTS of Forward Speed Control Friction Lock in Maintenance Instructions Steer by pulling the lever on the side of desired direction of turn e g pull the LH lever to turn left To minimize the possibility of overcontrol use only one hand on both steering levers 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 operat ing characteristics Remember it is not necessary to hold the steering levers forward a unique Walker feature always PULL on the levers for steering or for reverse motion of the mower Learn to operate the mower with your left hand on the steering levers and right hand on Forward Speed Control The use of two hands on the steering levers tends to cause overcontrol Learn to operate the steering levers with smooth action Jerky movements are hard on the transmission and lawn For sharp turns do not allow the inside wheel to stop and twist on the grass Pull the steering le ver controlling the insid
55. ed requiring no scheduled lubrication Parking Brake Lever Grease Oil level should be checked only when an oil Gear Axle Oil leak is noted Refer to Mower Deck Gear c NM oe m oe ackshaft Drive Clutch Actuator Push Rod Grease 2 Refer to Gear Axle Lubrication Engine PTO Clutch Lever Pivot Grease Oil Tractor PTO Gearbox Lubrication and Belt Tightener Pivot Grease Hydrostatic Transmission Fluid in this sec PTO Clutch tion NOTE DGHS42 Tilt Up Deck is shown for reference For other Deck Lubrication Points Refer to Deck and Carrier Frame Illustrated Parts Manual LUBRICATION Maintenance Instructions Chassis and Deck Lubrication Points 49 50 Maintenance Instructions CLEANING Engine Air Cleaner System There are two main components in the engine air cleaner system a turbine pre
56. er 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 Drain and properly dispose of oil Remove the four 4 bolts mounting the gearbox to the connector tube and slide the gearbox off the splined drive shaft coupling 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 assembly Reinstall the four 4 bolts mounting the gearbox to the connector tube but do not tighten them at this time leave connector tube bolts finger 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 in lb 9 N m then tighten the deck mount bolts NOTE This fastener tightening sequence aligns the gearbox assembly with the deck housing and eliminates the possibility of mounting the unitized assembly in a bind Fill gearbox assembly with oil Refer to Mower
57. ew machine after initial 5 or 10 hours of operation to begin to not travel straight this is due to the break in of the transmissions In this case proceed to Straight Ground Travel Adjustment Step 4 IMPORTANT Thefollowing adjustment procedures are sequential Check and adjust each function in the order given Set Forward Travel Limit Stop Step 1 1 Movethe Forward Speed Control FSC lever to the most FORWABD position Check clearance of the RH and LH steering le ver actuator arms with the frame and adjust for ward stop bolt so each lever clears the frame by at least 1 16 in 1 6 mm Clearance of the arm to the frame should be checked while ap plying pressure back on the arm to remove any slack in the linkage Tighten the jam nut on the forward travel stop adjusting bolt Maintenance Instructions Steering Lever Actuator Arms Forward Travel l Stop Bolt Steering Adjustment Nut Forward Speed Control Stop and Steering Lever Adjustment Steering Lever End Play Adjustment Step 2 1 Position the FSC lever to the most FORWARD position Loosen the adjustment nut on each steering le ver actuator until end play develops between the lever actuator and the adjustment nut slid ing on transmission control rod Hold the actuator back as shown against the spring pressure and tighten the nut to the point where the end play is removed and then tight en two additional turns IMPORTANT If the
58. exceed one 1 hour After charging the battery use drinking water to adjust the electrolyte level to the bottom of the vent wells 1 4 to 1 2 in 6 to 13 mm above the plates BATTERIES PRODUCE EXPLOSIVE GASES Charge the battery in a well ventilated area so that gases produced while charg ing can dissipate e Keep sparks flames and smoking ma terials away from the battery at all times Make sure the battery cap vents are open check manifold vent on each cap e Make sure the battery charger is un plugged before connecting or discon necting cables to the battery CHECKING SERVICING 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 causes extra wear on the engine and blade drive by pulling hard Stop the engine remove ignition key and dis connect the spark plug wires before raising t
59. f the engine and moving or rotating parts of the engine Start the engine and allow it to warm up by run ning at 1 2 throttle for approximately five 5 minutes The engine must be warm before making final settings Move the throttle to the idle position Adjust idle speed for 1200 rpm 75 rpm by adjusting the idle speed screw Check the idle speed using a tachometer With the engine idling adjust the idle mixture by turning the idle mixture needle valve in slowly from the preliminary setting until engine speed decreases and then back out approximately 3 4 to 1 turn to obtain the best low speed perfor mance Recheck idle speed after the final idle mixture adjustment ADJUSTMENTS GHS Full Signal Horn with Grass Pak Switch If the GHS full signal horn is not sounding when the catcher is full the following troubleshooting instruc tions apply Troubleshooting When Horn Fails to Operate 1 Check the horn a Disconnect the two wires from the Grass Pak switch electric connector plug and make a jumper wire connection between these wires bypassing switch Turn the ignition switch ON and move the blade clutch to the ENGAGED position engine not running to make the horn sound If the horn does not sound the horn is bad and needs to be replaced d Ifthe horn does sound proceed to step 2 Check the Grass Pak switch a Reconnect the wires to the Grass Pak switch electric connector plug
60. fety Latch RH Side 5874 A DANGER ROTATING BLOWER BLADES DO NOT PUT HANDS INTO DISCHARGE CHUTE BLADES MAY CONTINUE TO SPIN AFTER DISENGAGING CLUTCH DO NOT OPERATE MOWER WITH GRASS CATCHER IN DUMP POSITION OBJECTS MAY BE THROWN FROM DISCHARGE CHUTE 5804 DISCHARGE CHUTE Adjacent to Blower Discharge Chute through Body 5804 WARNING BEFORE REMOVING CAP CLEAN DIRT FROM RESERVOIR THIS UNIT IS FACTORY SERVICED WITH MOBIL 1 SAE 15W 50 SYNTHETIC OIL FILL TO LOWER LINE 5810 2 Hydrostat Oil Reservoir 5810 2 IMPORTANT ENGINE COOLING SYSTEM MAINTENANCE CHECK AND CLEAN ENGINE ROTATING INLET SCREEN AND STATIC SCREEN GUARD DAILY EVERY 8 HOURS OR MORE OFTEN IN DIRTY CONDITIONS CYLINDER HEAD COOLING FINS SHOULD BE CHECKED AND CLEANED BY REMOVING ENGINE SHROUD EVERY 100 HOURS 5858 Engine Shroud 5855 REMOVE SCREEN FOR CLEANING TO RELEASE AND REMOVE SCREEN OPEN CATCHER DOOR AND USE KNOBS TO PUSH BACK OF SCREEN FORWARD AND DOWN 5869 Rear of Grass Catcher Exhaust Screen 5869 ACAUTION PUSH TO HOT EXHAUST RELEASE y x 5805 5874 LH Side of Body Above Muffler 5805 Safety Instructions SAFETY CONTROL AND INSTRUCTION DECALS Safety Control and Instruction Decals are installed on the machine if any are missing illegible or damaged a replacement should be ordered and installed before putting the machine into operation The Decal Part Number is listed below and in the Parts Manual
61. g fins with oily dirt If this condition occurs replace the seal immediately to avoid overheating and dam aging the transmission The input shaft assembly and seal are easily replaced without removing the transmission from the machine An additional procedure in maintaining transmission cooling is to inspect the cooling fans Replace the fan s if blades are missing or damaged Hydrostatic Transmission Cooling Fins CLEANING CHECKING SERVICING 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 Security of Air Filtration Components NOTE The following inspection is only an exter nal inspection and should be done without dis turbing the filtration components On a daily basis visually inspect the external condi tion of the complete air cleaner system The follow ing items should be inspected 1 Check the Donaldson Radialseal air cleaner canister for damage Make sure the cover is in place and the cover latches are secure do not run the engine without the air cleaner cover in place and secure Inspect the air intake hose for cracks nicks cuts etc and check the hose clamps for tight ness Battery NOTE For initial battery service during setup re fer to Battery Service in Assembly Instructions IMPORTANT Make sure battery is securely mount ed in the frame A
62. g heights tend to restrict airflow from moving into and under the deck Raising the deck cutting height will signifi cantly increase airflow and reduce clogging when working in thick tall grass e Check the interior of the chute connecting the mower deck to the blower for smoothness and freedom from obstruction e Check the blower wheel for bent blades and excessive clearance between the blade tip and the blower housing A clearance greater than 1 8 in 8 mm will cause a significant loss of blower performance e Check the blower discharge chute into the grass catcher for smoothness and freedom from ob struction Check the elbow inside the grass catcher for a buildup of material in the radius of the elbow In certain conditions damp dirty grass a considerable clump of material can accumulate at this point greatly restricting material and airflow e Check that the openings in the removable air exhaust screen in the grass catcher are not plugged Ifthe screen is clogged refer to Cleaning the GHS Exhaust Screen in this section 37 38 Operating Instructions Remember anything that restricts airflow or material flow along the entire path from the mower deck to the grass catcher can cause clogging Using the Tilt Up Deck Refer to CLEANING of Grass Buildup in Mower Housing in Maintenance Instructions Using the GHS Catcher Powerfil 9 The GHS catcher has an oscillating grass delivery spout POWERFIL w
63. he mower deck to service blades Raise the deck and secure it in either the UP po sition using the deck lift rod non tilt deck or in the TILT UP position Refer to CLEANING the Grass Buildup in Mower Housing in this sec tion for deck raising instructions NEVER operate cutter blades with the deck in the raised position 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 mm the blade is bent and should be re placed Maintenance Instructions 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 If the blade cutting edge is dull or nicked it should be sharpened Remove blades for sharpening by grasping the end of the blade us ing a rag or a thick padded glove while loosen ing and removing the nut lock washer and flat washer that mounts the blade 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 Sharpen at Intersection Original 30 Angle Wear Area d VU o Do Not Grind or Sharpen on Underside
64. he blower blades Water pressure will cause the blower wheel to begin to spin and the com bination of spinning action and water will effec tively wash the inside of the housing Spray may be directed against the blower blades vertically and horizontally to cause rotation in both direc tions for thorough washing action Wash blow er until the blower wheel spins freely in both directions Reinstall the GHS blower drive belt by reversing the removal procedure Blower Drive Pulley GHS Blower Drive Belt Belt Tightener Idler Pulley Collapse Blower Belt Tightener to Remove GHS Blower Drive Belt Maintenance Instructions GHS Exhaust Screen Refer to Cleaning the GHS Exhaust Screen in Op erating Instructions Hydrostatic Transmission Cooling Fins Keeping the cooling fins on the hydrostatic transmis sions clean and free of obstruction is essential to avoid overheating the transmission fluid and short ening transmission life The cooling fins should be checked every 100 hours and cleaned if neces sary To clean the fins use compressed air and or a pres sure washer The cooling fins extend all the way around the housing the fins underneath need to be clean as well as the more visible fins above Also pay close attention to the area under the drive pul ley IMPORTANT In case an oil leak develops on the input shaft the cooling fan blowing dusty air and oil on the transmission will quickly pack the coolin
65. he housing Install the locking collar on the rear bearing and install the blower pulley to complete the blower assembly Torque the blower pulley set screws to 250 in Ib 28 3 N m GHS Blower Assembly Installation Reinstall the blower assembly into the mower using the reverse procedures of GHS Blower Assembly Removal Bearing 3 4 Face Plate Blower Pulley 5 16 18 x 5 8 SQH Set Screw 5 16 18 x 3 4 SQH Set Screw 3 16 x 3 16 x 1 Key 1 4 20 x 3 8 Set Screw Housing 1 4 20 x 3 8 Set Screw EN Blower Wheel 3 7 16 14 Hex Nut 5 16 18 Whiz Locknut Skid Bar 7 16 Split Lock Washer Intake Tube 3 8 16 x 1 Hex Bolt 3 8 16 Keps Nut 7 16 14 x 1 1 4 Hex Bolt GHS Blower Components 69 Maintenance Instructions ADJUSTMENTS ADJUSTMENTS Steering Levers An adjustment range of approximately 3 inches is available on the steering levers the levers can be adjusted forward or aft depending on the arm length If the engine must be running to perform of the operator The levers can be adjusted by loos a maintenance adjustment keep hands ening the locknut at the pivot point and the locknut feet and clothing from moving parts DO holding the lever in position in the adjustment slide NOT wear jewelry or loose clothing Adjust levers into most comfortable position and tighten both locknuts Safety Switches There are three 3 safety interlock switches on the tractor Seat Switch FSC Neutral Park Switch and
66. hich is designed to spread grass clippings throughout the interior of the grass catcher even when mowing wet heavy grass The oscillating action may be checked by turning the ignition switch to the ON position and moving the blade clutch to the ENGAGED position The spout should oscillate approximately 25 cycles per minute NOTE Ifthe grass spout fails to oscillate the clutch switch should be checked for function the switch closure is adjustable Full Signal Horn The GHS catcher has a full signal horn to alert the operator to dump the catcher when it is full to prevent overfilling and clogging The full signal horn is activated by a vane switch Grass Pak switch mounted on the grass delivery spout Oscil lating action of the spout triggers the vane switch as grass begins to fill in around the spout when the catcher is almost full The full signal function may be checked by turning the ignition switch ON engaging the blade clutch engine not running opening the catcher back door and triggering the Grass Pak vane by hand as it oscillates The horn should sound as the switch is moved in both directions DO NOT test the Grass Pak switch with the engine running Projectiles may be thrown out of the grass delivery spout and COULD cause serious injury The full signal horn is designed to operate sound when the grass catcher is almost full The timing of the signal is adjustable by changing the position of
67. ighten the LH adjustment nut Straight Ground Travel Adjustment ADJUSTMENTS Forward Speed Control Friction Lock The FSC friction lock is adjusted to hold the select ed forward speed when the steering levers are moved and yet the friction is not too heavy to make moving the control difficult too much friction The procedure for checking and adjusting the FSC friction lock is as follows Friction Adjustment Nut Forward Speed Control Friction Lock Place the FSC in the full FORWARD position and pull both steering levers back the FSC le ver should not move If the FSC lever moves back when the steering levers are pulled back the friction needs to be increased With the steering levers held back move the FSC lever back from the FORWARD position With a proper amount of friction adjusted the FSC lever should move back with a slight amount of resistance friction If the FSC lever movements stiff the friction needs to be de creased The FSC friction is increased or decreased by tightening or loosening the friction adjust ment nut Loosen or tighten the nut and check the control function until conditions of both steps 1 and 2 above are met Maintenance Instructions 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
68. ing a hand adjacent to the cylinder head and feeling the cooling airflow Make sure to keep hands clear of exhaust pipe muffler and moving parts when checking airflow e Operate the engine at full speed when mowing This allows the engine to produce full horsepower and move more cooling air through the engine cool ing fins KOHLER TIPS Air Cleaner System Use only Donaldson air cleaner elements After market elements may not seal in the air cleaner housing allowing dirt to enter the engine Also af termarket filters often skimp on the filtration media and require more frequent cleaning and replace ment see following instructions Use the air flow restriction gauge to indicate the need to service the air filter e Do frequently check the Turbine Precleaner for free movement of the internal fan DO NOT overservice or frequently disturb the air filter A dirty air filter actually cleans better than a new one Changing and cleaning the air filter too often can actually reduce filter efficiency and in crease the opportunity for traces of dust to enter the engine Wait until the element really needs servicing as indicated by the air flow restriction gauge e When the air filter element is removed or re placed make sure all dust is cleaned out of the air cleaner housing and hose Use a damp cloth and wipe the interior of the canister and hose clean a lit tle dirt left here will be sucked into the engine and re
69. ing is incorrect refer to Mower Deck Gearbox Replacement in this section PTO Shear Pin The PTO drive shaft connection to the deck gearbox has a shear pin to provide shock load protection to the mower deck drive This system provides prima ry shock protection in case of blade impact and will normally shear before the individual shear bolts on the blade hub When the PTO pin has sheared use the following procedure to replace it 1 Loosen the two bolts securing the PTO shaft guard on the deck lift the guard off Holes in guard are slotted for easy removal 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 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 10 shear pins for replacement to provide proper shock protection these pins are hardened to shear under a specific amount of load Reinstall the PTO shaft guard REPLACING REPAIRING 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 Replacement in this section Mower Blades
70. 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 purpose of these safety devices 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 Substitute 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 Make sure the battery charger is unplugged before connecting or disconnecting cables to the battery Charge the battery in a well ventilated space so gases produced while charging can dissipate Make sure the battery vents in
71. ition the bolt with the head inside of the chute and the nut on the outside Carrier Frame Sockets Attach Discharge Chute and PTO Shaft Guard Installation on Rear Discharge Deck 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 Discharge Shield Installation on Side Discharge Deck PTO Shaft Guard Installation Position the shaft guard as shown and mount with two 1 4 20 x 1 2 in bolts Tilt Up Roller Wheel Installation Mount the two 2 tilt up roller wheels on the brack ets on the rear skirt of the deck housing using the P N 8490 axle bolt 3 8 in wave spring washer and 3 8 16 in Whiz locknut Tighten the axle bolt until the wheel rolls freely but is not loose Assembly Instructions 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 Reaching under the
72. ive maintenance calls for complete replacement of fuel lines and clamps every two 2 years CHECKING SERVICING Engine Starter Yearly or every 500 hours disassemble and clean the solenoid shift starter Refer to the Kohler Service Manual for this procedure or contact an authorized Kohler engine dealer to perform this service Engine Valve Clearance Yearly or every 500 hours check and adjust the Kohler engine valve clearance Refer to the Kohler Service Manual for specifications and procedure to check the valve clearance or contact an authorized Kohler engine dealer to perform this service Blade Brake Action It is important to check and maintain blade brake action for safe operation of the ma chine Check the function of the cutter blade brake and blower brake on GHS models by engaging the blade clutch PTO operating the engine at full throt tle then disengaging the clutch and measuring how quickly the blades stop Watch the rotation of the blade drive shaft and blower pulley as a visual indi cation that movement has stopped If the brake is working properly all rotation will stop five 5 seconds after disengagement of the clutch If the brake system malfunctions blades do not stop in five 5 seconds adjust or repair the brake before operating the mower Refer to ADJUSTMENTS of Blade Clutch PTO in this section Maintenance Instructions REPLACING REPAIRING To prevent accidental starting of the en gi
73. ling potentially causing deck or tractor damage Damage to other items parked in front of the deck may also occur Operating Instructions GRASS HANDLING SYSTEM GHS GHS Model Only Catcher Door Exhaust Screen Safety Latch Removable Grass Pak Vane Switch Powerfil 9 Drive Motor Exhaust Deflector Actuator Rod Full sina AC Horn r Delivery Catcher Door Clutch Shear Pin F i Ee Catcher i A Door Spring PTO and Blade Gear Drive Grass Catcher Dump Handle Powerfil 9 Delivery Spout Body Chute Assembly Discharge Chute Rear Discharge Mower Deck GHS Flow and Components 35 36 Operating Instructions General Information The Grass Handling System GHS consists of a rear discharge mower deck connected to a 10 in 25 cm blower and a rear mounted grass catcher with 6 7 bushel 238 liters capacity or optional 9 5 bushel 335 liters capacity The GHS blower oper ates any time the mower blade clutch is engaged and moves grass through the rear discharge deck chute into the grass catcher Blower airflow is ex hausted out the back of the grass catcher through a filtering screen When the grass catcher is full and needs to be emptied a full signal horn alerts the operator When the full signal horn sounds it is important to stop mowing to prevent overfilling and clogging of the blower system IMPORTANT Normally the GHS blower operates with no maintenance or cl
74. lowing procedure 1 Loosen blower pulley set screws and remove the pulley using a wheel puller Remove the locking collar from the back bear ing closest to the pulley by loosening the set screw and rotating the collar counterclockwise use punch to drive Press blower wheel out of the housing using a wheel puller hooked to lugs on the bearing hous ing The bearings have been secured in the housing with a retaining compound Loctite RC 680 and considerable force will be re quired to break this bond After the bearings have broken loose from the housing only light pressure should be required to remove the wheel assembly out of the housing NOTE It may or may not be possible to remove the front bearing from the blower wheel without damaging it If the bearing is damaged it will need to be replaced along with the wheel Maintenance Instructions REPLACING REPAIRING Blower Wheel Installation 1 Wheel Puller Hooked to Lugs on Bearing Housing To install the blower wheel reverse the remov al procedures The front bearing is mounted on the blower wheel shaft secured by a locking collar Drive the locking collar clockwise with a punch and tighten the set screw Press blower wheel and front bearing into the blower housing Use Loctite RC 680 retaining compound on the outer bearing race and inside the bearing housing Press the rear bearing into place using Loctite on both the outer bearing race and t
75. mote mounted Donaldson Radialseal be installed from back of body to chassis unit replace filter every year or after 6 cleanings frame fail safe protection in case of fail AA Change engine oil and filter after first 5 hours of ure of body lift support For GHS Model operation of a new engine break in period empty grass catcher before raising body AAA Change every 2 years or 1000 hours 42 Maintenance Instructions IMPORTANT TIPS FOR CARE OF THE KOHLER ENGINE Fuel System e Fuel must be clean free from water dirt and or ganic material e Change fuel filter on a regular basis and when contamination is suspected or found in the fuel Starting Stopping e Start engine with the throttle advanced off idle 1 4 to 1 2 throttle This will aid starting especially in cold weather e Keep the battery fully charged e Match crankcase oil viscosity to the ambient tem perature allowing the engine to crank faster and start easier Allow engine to run at idle for a few seconds be fore stopping engine to avoid run on or backfiring Cooling System Keep engine air intake screen and cylinder head fins free of grass clippings chaff and dirt Inspect intake screen and cooling fins for cleanliness and no damage Periodically remove two access panels in the en gine shroud to inspect and clean cylinder head cool ing fins e Check performance of the cooling system by starting the engine hold
76. mp manual reset circuit breaker is located be low the ignition switch The button pops up if the cir cuit breaker trips This circuit breaker protects the circuits to the safety switch relays time delay mod ule and GHS Light Switch For Optional Lights Operates headlights when installed Operating Instructions FORWARD SPEED The Forward Speed Control also Establishes the Neutral Park Position of the Steering Levers LEFT WHEEL RIGHT WHEEL STEERING LEVER STEERING LEVER Forward Position No Control Change Neutral Park Position Reverse Drive Wheel Motion Position St YINIV Y i Ss zi Throttle Position Idle Position THROTTLE ON Position OFF Position CHOKE CONTROL LEVER FSC Full Forward Ground Speed Position Intermediate Ground Speed Position Neutral Park Position une 27 BRAKE Disengaged Position Disengaged Position Engaged Position BLADE CLUTCH PTO Pull Up to Engage Operating Controls Top View from Drivers Point of View 27 28 Operating Instructions STARTING THE ENGINE Before operating the mower read and un derstand all Safety Instructions and Operat ing Instructions NEVER run the engine in an enclosed or poorly ventilated area Engine exhaust contains carbon monoxide an odorless and deadly gas Before attempting to start the engine make sure the operator is in the seat the Fo
77. ne 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 four 4 individual belts on GHS models or three 3 belts on SD models e Engine PTO Drive Belt 3 Groove Power Band e Jackshaft Drive Belt e GHS Blower Drive Belt GHS Model Only e Hydrostatic Ground Drive Belt The belts may be removed and replaced using the procedures described on the following pages REPLACING REPAIRING 59 60 Maintenance Instructions Jackshaft Drive Belt K D SN Hydrostatic Ground Drive Belt Belt Locations N v Lae h A Ly Gf REPLACING REPAIRING Engine PTO GHS Blower Belt GHS Model Only Maintenance Instructions Engine PTO Drive Belt 3 Groove Power Band 1 Toremove the engine PTO drive belt a Remove the jackshaft drive belt from its idler pulley by pushing down on idler pul ley and let the belt drop down out of the way NOTE Step a is not essential to removing the PTO belt but it makes more room to work with the PTO belt b Push the clutch idler pulley down until the PTO belt tightener stop block contacts the frame and then shift the belt off the idler pulley to the inside REPLACING REPAIRING Raise the
78. ntact the chassis to stop the clutch idler pulley from moving further down in the disengaged position If the stop block is not contacting the chassis in the disengaged position it will be neces sary to loosen the brake band adjustment nut The stop block is an eccentric block that will allow four adjustment positions from 5 16 in 8 mm to 11 16 in 17 mm Me H 9 16 in 14 mm 11 16 in 17 mm EE 5 16 in 8 mm 7 16 in 11 mm PTO Belt Tightener Stop Block Adjustments Clutch Idler Pulley Travel Adjustment Step 2 Adjust the stop block to give 1 in 25 mm to 1 1 2 in 38 mm pulley travel from clutch engaged to clutch disengaged To check and adjust the pulley travel first engage the clutch then measure the dis tance the pulley moves down as the clutch is disen gaged and the stop block contacts the frame NOTE The importance of this adjustment is if the pulley travel is excessive and the belt develops too much slack the belt will derail when disengaged ADJUSTMENTS Disengage Stop Block Contacting Frame 1 in to 1 1 2 in 25 mm to 38 mm Clutch Idler Pulley Travel Adjustment Blade Brake Band Adjustment Step 3 After the pulley travel is set make the following ad justment as needed 1 Adjust the blade brake band using the adjust ment nut until there is a gap of approximately 1 8 in 3 mm between the PTO belt tightener stop block and chassis If there are not enough
79. nterior of the grass catcher by an oscillating delivery spout RIGHT HAND RH refers to the right hand side of the tractor when the operator is seated facing forward in the tractor seat SIDE DISCHARGE SD mows but does not collect the mowed material STEERING LEVERS steer the tractor by con trolling the dual hydrostatic transmissions TRACTOR is the prime mover including the en gine drive train operator seat and controls to operate the mower TRANSMISSION LOCKOUT releases the hy drostatic transmissions to permit freewheeling the tractor IDENTIFYING NUMBER LOCATIONS The tractor serial number plate is affixed to the trac tor body just below the left rear corner of the seat The mower deck serial number plate is affixed alongside the angle iron framing on the RH side of the RH mower blade drive Model and serial num bers 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 General Information SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS The detailed servicing and repair of the engine hydrostatic transmission and gearboxes are not cov ered in this manual Only routine maintenance and general service instructions are provided For the service of these compone
80. nts during the limited war ranty period it is important to find a local authorized servicing agent of the component manufacturer Any unauthorized work done on these components dur ing the warranty period may void the warranty If you have any difficulty finding an authorized outlet or obtaining warranty service please contact our Ser vice Department for assistance Walker Manufacturing Company 5925 E Harmony Road Fort Collins CO 80528 1 970 221 5614 Service manuals are available for each of these components from their respective manufacturers as follows Kohler Engines Kohler Company Kohler WI 53044 Transmissions 15151 Highway 5 Eden Prairie MN 55344 ENGINE SERIAL NUMBER LOCATION Gearboxes Deck Tecumseh Products Co 900 North Street Grafton WI 53024 Refer to the engine manual that accompanies this manual for the location of the engine serial number For the mower model covered by this manual an engine manual is available covering the Kohler Command CH18 gasoline engine Serial Number Engine Serial Number Location Specifications MODEL ENGINE Manufacturer Model Displacement HP 3600 RPM Max RPM No Load Governed RPM Max Torque ft lb N m RPM Idle RPM Spark Plug Type Spark Plug Gap Crankcase Capacity Crankcase Lubricant Fuel Tank Capacity Fuel Cooling System Capacity MC Kohler Command CH18 2 Cyl Gasoline Air Cooled 38 0 cu in 624 cc 18 0 3750 3600
81. o property by thrown objects Side Discharge Shield in Lowest Position When operating on a slope reduce speed and use caution to start stop and maneuver Avoid sharp turns or sudden changes in direction The maximum recommended side slope operating angle is 20 degrees or 33 grade Maximum Recommended Side Slope Do Not Operate on Steep Slopes Maximum Recommended Side Slope 33 34 Operating Instructions RECOMMENDATIONS FOR TILT UP DECK OPERATION TRANSPORT To avoid potential deck and or tractor damage while using the tilt up deck the following recommenda tions are offered Do not move the tractor with the deck in the tilt up position since both the roller wheels on the back of the deck and the GHS discharge chute may be damaged by moving the tractor The tilt up configu ration should only be used when the tractor is parked e The tractor body should never be tilted for ward with the deck in the tilt up position This can cause the deck to unhook from the tractor and fall with considerable force potentially causing deck or tractor damage and or bodily injury 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 This will also prevent the deck from unhooking from the tractor and fal
82. o see if the RH and LH mower blades are installed for the correct rotation install blades so the cutting edges move toward each other Blades Must Operate at Right Angles 90 Degrees FORWARD Mounting Nut Torque 60 ft lb Rear Discharge 81 3 N m Blade Rotation for GHS Mower Deck view from underneath e Check the amount of flat section remaining at blade tip This is the area that is ground away re moved when the blades are sharpened If too much of the flat section is removed the air lift performance or shovel effect of the blade deteriorates to the point that discharge of grass clippings into the blower chute is marginal Replace cutter blades if less than 3 4 in 19 mm flat section remains at the blade tip e Check that the interior of the deck housing and baffling is reasonably clean and free of grass and dirt buildup While some degree of material buildup can be tolerated a point is finally reached where the flow of air and grass clippings is restricted NOTE One condition that quickly causes a buildup of material in the deck housing is mowing grass and or weeds which are juicy The material collects under the deck with sticky green juice Clo ver and weeds are especially a problem The mower deck will need to be cleaned frequently when operating in these conditions e Check the deck cutting height setting When working in thick tall grass lower deck settings 1 to 2 in 25 to 51 mm cuttin
83. ons section Grass Handling System 9 5 Bushel Catcher Spring Clip Counterweight Spring and Protective Cover Transmission Control Rod Adjustment Nut LH Deck Support Pins and Height Adjustment Hitch Pins Footrests Tilt Up Deck Handle Deck Caster Wheels Front View and Right Side View Component Identification Removable Grass Catcher Screen Catcher Door SR Catcher Exhaust Deflector Gas Spring Catcher Door Gas Spring Protective Cover Catcher Lift Dump Handle Catcher Door Catcher Door Handle Anti Scuff Roller Muffler Oil Drain Left Hand Tailpipe Plug Drive Wheel Oil Filter Tailwheel Fork and Wheel Rear View and Left Side View Component Identification Air Restriction Indicator Donaldson Rubber Bumper Not Visible Air Cleaner Body Support Fuel Pump Air Intake Hose Precleaner Jackshaft PTO Gearbox Dipstick Turbine gt Precleaner RH Transmission Lockout Lever PTO Clutch Lever 30 Amp Circuit Breaker Positive Battery Cable Negative Battery Cable Battery Air Cleaner Cover Rubber Bumper Body Support Muffler Throttle and Choke Linkage Muffler Heat Shield Oil Fill Dipstick GHS Blower RH Hyarostatic Transmission Neutral Safety Switch LH Hydrostatic Transmission LH Transmission Lockout Lever Top View Engine Compartment 10 Safety Instructions Pay particular a
84. ove grass clippings from the catcher to a remote disposal area or container Tailgate Dumping 1 Open the back door by lifting on the door handle NOTE To prevent accidental door closure a safety latch locks the door open in the fully opened position while the catcher is being dumped Tilt the catcher back to dump by lifting on the catcher lift handle on the lower front corner of the catcher Lower the catcher smoothly down to the normal operating position DO NOT allow the catcher to drop down Close the door by holding the door handle with the left hand and releasing the safety latch on the door hinge mechanism with the right hand The safety latch is released by pressing in on the top of the latch Then smoothly close the door working against the spring pressure that holds the door closed DO NOT let the door slam shut by releasing the door before it is closed Catcher Door Safety Latch Using the Dump Bag 1 Open the back door by lifting on the door han dle NOTE To prevent accidental door closure a safety latch locks the door open in the fully opened position while the catcher is be ing dumped Orient the dump bag with one of the handle straps on the bag opening facing up Tailgate Door Handle Hook Bag on Bumper Positioning Dump Bag on Catcher 39 40 Operating Instructions Hook the bottom of the bag over the rear bumper while lifting on the handle strap Tilt the catcher back
85. ower body may be help ful in fitting and guiding the deck chute into the blower Install the hitch pin through the hole on the end of each support arm to lock the deck in place Coupler Ring Locked Position refer to Deck Counterweight Spring Installa tion photo Two 2 hitch pins are included in the owner s packet of materials 20 Assembly Instructions Raise the mower body instead of lifting the front of deck and clip the counterweight springs to the receptacle on front of body Lower the body to tension the springs Refer to Deck Counterweight Spring Installation Photo Mower Deck Installation PTO Shaft Connection With the counterweight springs connected the weight on the deck caster wheels should be 15 to 25 Ib 6 8 to 11 3 kg Check this weight by lifting on the front of the deck carrier frame If required the spring tension can be adjusted by tightening or loosening the elastic stop nuts located underneath the lower spring hook Refer to Deck Counterweight Spring Installa tion photo Spring Tension Adjustment Nut Located Under Lower Y Spring Hook Not Visible f E st Hitch Pins Lock Deck On Support Arms A A Counterweight Springs Clip Onto Body With Body Tilted Up Deck Counterweight Spring Installation Assembly Instructions Deck Leveling T Position mower on a smooth level surface Set the cutting height to the highest position 4 in 102 mm for easy access
86. p Secured by m Wing Nut s Battery Cable Connection Battery Installation Mower Deck Assembly Deck Caster Wheels Installation 1 Remove the bolt nut axle spacer tube and spacer washers from each deck caster wheel fork NOTE Spacer washers are used only when the optional semi pneumatic deck wheels 8 25 x 2 75 are installed Fit the axle spacer tube through the wheel hub position the spacer washer on each side of the hub if used and fitthe assembly into the wheel 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 18 Assembly Instructions Grease Fitting Locations Deck Caster Wheel Installation NOTE If semi pneumatic wheels are installed make sure the spacer washers fit over the spacer tube and are not caught between the fork and the end of the tube The washers should move freely on the axle spacer tube Grease the caster wheel bearings and caster pivot bearings one grease fitting for each wheel and each pivot Deck Discharge Chute Installation GHS Rear Discharge Models Only Mount the discharge chute hinge on top of the deck discharge opening using the 1 4 20 x 1 2 in socket button head bolt and 1 4 20 ESNA nut Pos
87. r Refer to REPLACING RE PAIRING the Blade Overload Shear Bolts in Maintenance Instructions if blades are out of time Also make sure the blade retain ing nuts are torqued to 60 ft lb 81 3 N m Operating Instructions A brake stops the cutter blades and blower on GHS equipped models from freewheeling within five 5 seconds after disengaging the clutch If the brake sys tem malfunctions and the blades do not stop within five 5 seconds the brake should be adjusted or repaired before op erating the mower Refer to ADJUST MENTS of Blade Clutch PTO in Engaged Maintenance Instructions Position Blade Clutch Engaged Slow the engine to idle put throttle in IDLE po sition and turn the ignition switch OFF Remove the key from the ignition switch when leaving the mower unattended This will prevent children and inexperienced operators from starting the engine Engage the parking brake Disengaged Position IMPORTANT The hydrostatic transmissions lock to prevent the mower from rolling freely with the engine stopped However if the mower is Blade Clutch Disengaged 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 slip page in the hydrostatic transmissions especially when transmission fluid is warm STOPPING THE MACHINE 1 Slow the engine to a fast idle put the throttle in tne lie hrote postia ADJUSTING CUTTING HEIGHT Pull
88. r cleaner canister clean Use special care to clean both the inside and outside surfaces of the outlet tube IMPORTANT Any dust left on the inside of the outlet tube will go into the engine and cause wear Check the outside surface of the outlet tube for smoothness and cleanness this is the sealing surface Insert and seat the filter element carefully into the canister applying pressure at the outer rim of the filter not at the flexible center Make sure the filter element is completely in place before installing the cover IMPORTANT DO NOT use the cover latches to force the filter into the canister the cover should fit on with no extra force NOTE DO NOT use petroleum based lubri cants on the sealing surfaces of the filter use tal cum powder or dry silicone lubricants if required for filter installation Fo e J Y J Canister NN p P a Radial Sealing Radialseal Surface Filter Element Air Filter Element Replacement CLEANING 9 Install the cover with the word TOP properly oriented to the top of the canister Give the cov er a slight twist as it reaches the canister to make sure the tab inside the cover goes into a slot otherwise the cover will not fit properly Make sure both the top and bottom cover latch es are securing the cover in place Cover Latch Orient to Top of Canister Vacuator M Valve over Latch Proper Orientation of Air Cleaner Cover Check the air intake hose for c
89. r drive belt by unhook ing the belt tension spring from the hook on the chassis frame located above the blower pul ley Lift the belt tightener idler pulley up and roll belt off the pulleys Blower Drive Blower Pulley i Pulley d a GHS Blower Drive Belt Belt Tightener a Idler Pulley Disengaged GHS Blower Drive Belt Assembly Disengaged Blower Drive Belt Spring Removal 2 Reverse the procedure to install the GHS blow er drive belt and spring Idler Pulley Engaged GHS Blower Drive Belt Assembly Engaged 63 64 Maintenance Instructions REPLACING REPAIRING Hydrostatic Ground Drive Belt 1 To remove the hydrostatic ground drive belt b Slide belt off pulleys then release the idler a Raise the spring loaded belt tightener arm and idler pulley to relax belt Belt Tightener Arm Transmission Drive Pulley Hydrostatic Ground Drive Belt Hydrostatic Ground Drive Belt Assembly Disengaged 2 Reverse the procedure to install the hydrostatic ground drive belt Hydrostatic Ground Drive Belt Hydrostatic Ground Drive Belt Assembly Engaged Maintenance Instructions Fuel Filter Model MC is equipped with an in line fuel filter Vi sually inspect the filter periodically and replace the filter yearly In Line Fuel Filter Fuel Filter Location IMPORTANT Replace the fuel filter only in a clean area where the fuel line and connections will not be contaminated by any du
90. ration and replace the oil filter every other oil change every 200 hours of operation 43 44 Maintenance Instructions Park the mower on a level surface with the en gine stopped The engine oil should be warm before draining If not warm from operation start the engine and run a few minutes to warm the oil Before removing the dipstick clean the area around it to keep any dirt or debris out of the en gine Remove the dipstick and oil drain plug and drain the oil into a suitable container Be sure to allow ample time for complete drainage Drain Plug Oil Drain Oil Filter Location 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 Kohler 12 050 01 After market 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 Reinstall the drain plug Make sure it is tight ened to 10 ft lb 13 6 N m LUBRICATION Fill the crankcase with new clean oil Use only crankcase lubricants recommended by the en gine man
91. rd Tires Optional Tires 37 1 2 in 95 cm 44 1 2 in 112 cm 42 1 4 in 107 cm 28 1 4 in 72 cm 29 3 4 in 76 cm MOWER DECK Width of Cut SD GHS Cutting Height Height Adjustment Blade Size 36 in 91 cm SD Model 36 in 91 cm GHS Model 42 in 107 cm SD Model 42 in 107 cm GHS Model Deck Suspension 36 or 42 in 91 or 107 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 20 in 51 cm Two 2 Clockwise Rotating Blades with a 4 in 10 cm Center Overlap 20 in 51 cm Two 2 Counter Rotating Blades with a 4 in 10 cm Center Overlap 22 in 56 cm Two 2 Clockwise Rotating Blades with a 2 in 5 cm Center Overlap 22 in b6 cm Two 2 Counter Rotating Blades with a 2 in 5 cm Center Overlap Torsion Flex Frame with Caster Wheels and Counterweight Springs CURB WEIGHT Approximate SD Tractor Only GHS Tractor Only SD Tractor and 36 in SD Deck SD Tractor and 42 in SD Deck GHS Tractor and 36 in GHS Deck GHS Tractor and 42 in GHS Deck 645 Ib 293 kg 735 Ib 334 kg 775 Ib 352 kg 810 Ib 368 kg 860 Ib 390 kg 895 Ib 406 kg DRIVE BELTS Engine PTO Jackshaft Drive Ground Drive Micro V Blower GHS Model Walker P N 8230 Gates 3VX395 or Walker P N 6251 Walker P N 7248 Walker P N 7234 1 Specifications MODEL GHS SYSTEM Optional Blower Blower Brake Ma
92. recautions 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 using 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 conirols the maximum forward speed of the tractor functioning as a cruise control GRASS HANDLING SYSTEM GHS collects mowed material and deposits it in the catcher GRASS PAK SWITCH is mounted on the grass delivery spout in the catcher and acti vates the full signal horn when the grass catcher is full GROUND DRIVE refers to the dual hydrostatic transmissions which drive the main wheels HYDROSTATIC TRANSMISSION transmits and controls power from the ground drive belt to the main drive wheel LEFT HAND LH refers to the left hand side of the tractor when the operator is seated facing forward in the tractor seat POWER TAKE OFF PTO transmits engine power to run the cutter blades and GHS blower POWERFIL spreads the mowed material throughout the i
93. rward Speed Control is in NEUTRAL PARK position and the blade clutch and parking brake are DISENGAGED NOTE Release parking brake to prevent extra load on the starter if the transmission neutral is slightly out of adjustment 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 Move the choke lever to the ON position and move the throttle 1 4 to 1 2 open toward FAST Turn the ignition switch to the START position to start the engine Release the key to RUN position as soon as the engine starts NOTE The choke may not be required if the engine is warm IMPORTANT If the engine fails to start after approximately 10 seconds of cranking the engine should be checked before further crank ing Turn the key to the OFF position and allow a 60 second cool down period between starting attempts Failure to follow these guidelines can damage the starter motor and shorten battery life After the engine starts make sure the oil pres sure light goes off If not stop the engine imme diately and find the cause of the problem Make sure the oil pressure light is off prior to engaging the mower blades and beginning operation Gradually move th
94. s 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 Lubricate the dolly wheel pivot every 25 hours with general purpose grease 45 46 Maintenance Instructions 4 Lubricate the U Joint in the drive shaft every 8 hours with SAE general purpose lithium or molybdenum base grease Belt Drive Gearbox Dolly Wheel Pivot Level Plug U Joint Gearbox Dolly Wheel and U Joint Lubrication Tractor PTO Gearbox Lubrication Checking Gearbox Oil Level Check the gearbox oil level every 25 hours and if necessary add oil SAE E P Extreme Pressure 90W gear lube to maintain oil level to the FULL mark on the dipstick IMPORTANT DO NOT overfill the PTO gearbox to avoid oil leakage out of the dipstick standpipe If the oil level is low check the gearbox for any indi cation of an oil leak If an oil leak is noted the gear box will need to be removed and rebuilt AE F T i Dipstick Location Tractor PTO Gearbox LUBRICATION Changing Gearbox Oil The tractor PTO gearbox is oil filled and vented No scheduled oil change is required However chang ing the oil after the first 100 hour break in period will extend gearbox life and is recommended 1 Remove the drain plug in the bottom of the gearcase drain the oil and reinstall the plug Refill the gearbox thro
95. s The engine is designed to be operated at full speed When mowing in adverse conditions tall and or wet grass mow the grass twice Raise the mower to the highest setting 4 in 102 mm for the first pass and then make a second pass cutting to the desired height Use a slow setting on the FSC for trimming operations Make sure the mower is leveled properly for a smooth cut Refer to Deck Leveling in Assembly Instructions Use an alternating stripe mowing pattern for best appearance and vary the direction of the stripe each time the grass is mowed to avoid wear patterns in the grass Avoid damage to the grass by slipping and skid ding of the drive tires Use smooth control move ments of the steering levers since the hydrostatic transmissions are power boosted controls and jerk ing the levers can easily slip the tires For sharp turns do not allow the inside wheel to stop and twist on grass pull inside steering lever into reverse for a smooth rolling turn one wheel rolling forward while the other rolls backward When using a side discharge mower deck the side discharge 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 When mowing close to obstacles orient the side dis charge away from obstacles to reduce the chance of damage t
96. s two positions Pulling the lever UP engages the PTO that drives the mower blades Pushing the lever DOWN disengages the PTO and engages the blade brake NOTE On GHS equipped models the Powerfil 9 motor and Grass Pak full signal switch are activat ed by engaging the blade clutch Refer to Using the GHS Catcher in this section for a complete descrip tion of GHS operation 25 26 Operating Instructions Parking Brake The parking brake functions by locking a pin into the hydrostatic transmission pinion gear teeth Moving the lever FORWARD engages the parking brake moving the lever BACKWARD releases the brake IMPORTANT Stop the tractor completely before engaging the parking brake The parking brake uses a positive mechanical lock similar to the PARK po sition on an automotive automatic transmission If the tractor is moving when the brake is engaged it will result in sudden stoppage and possible internal damage to the axle drive NOTE f pressure on the parking brake pin e g parked on a hill makes it impossible to release the parking brake with the parking brake lever move the mower gently forward or backward to release the pin Transmission Lockout Levers The transmission lockout levers disengage the hy drostatic transmissons By lifting the lever on top of the transmission and locking it into place with the lockout cam the hydrostatic transmissions are re leased to permit freewheeling By releasing th
97. st and dirt Gasoline is extremely flammable and can be highly explosive To minimize danger Use only an approved fuel container for gasoline DO NOT allow open flames or sparks near the machine while performing main tenance or refueling DO NOT smoke while working with fuel Wipe up spilled gasoline immediately and completely Expand and slide clamps on either side of the filter away from filter and pull fuel lines off filter Replace filter REPLACING REPAIRING Blade Overload Shear Bolts The cutting blade is keyed to the blade hub by two 2 shear bolts 10 24 x 5 8 in stainless steel ma chine screws These bolts are 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 N m 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 65 66 Maintenance Instructions 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 tim
98. surfaces using compressed air Make sure to reinstall the access panels before op erating the engine Engine Cooling Fin Access Panels Kohler Engine Shroud Engine Air Intake Screen Engine Air Intake Screen and Cooling Fin Access Panels CLEANING Cooling System Airflow 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 Raise the deck lock lever handle on each side of the carrier frame and pull out to release car rier frame for tilting action Using the carrier frame lift handle raise deck to the TILT UP position and insert the deck hook into the tilt up latch on the tractor body Tilt Up Lift Handle Tilt Up Hook Ech on Deck E Deck Lock Lever Deck Secured in TILT UP Position 53 54 Maintenance Instructions Do not operate the mower with deck in tilt up position Do not move the tractor with the deck in the tilt up position 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 Lower the deck to the normal operating position and re engage the deck lock levers Do not operate machine with deck tilt up
99. tery cap vents are open after the battery is filled with acid check manifold vent on each cap Make sure the battery charger is unplug ged before connecting or disconnecting cables to the battery Charge the battery at 15 amps for 10 minutes DO NOT exceed 20 amps maximum recom mended charging rate Charge until specific gravity is at least 1 250 Total charging time should not exceed one 1 hour After charging the battery adjust the electrolyte levelto the bottom of the vent wells 1 4 to 1 2 in 6 to 13 mm above the plates IMPORTANT DO NOT overfill the battery Electrolyte will overflow through the vented caps onto parts of the machine and WILL result in severe corrosion 3 Install battery Battery Installation IMPORTANT Make sure battery is securely mounted in the frame A loose battery may cause damage to the case resulting in acid leakage and se vere damage to the machine A hazard may be cre ated by damage to critical working parts and safety systems Install the battery in the mower as shown in Battery Installation photo Connect the positive and nega tive cables to the proper battery terminal red cable and boot connects to the Positive terminal Slide the rubber boot up and over the battery post making sure it covers the post completely to pre vent an electrical short Make sure the battery cap vents are open Improper venting of the battery COULD cause a battery explosion Battery Clam
100. the steering levers to the NEUTRAL posi tion and then move the FSC lever backward to A WARNING the NEUTRAL PARK position The engine must be stopped before ad Disengage the blade clutch justing cutting height Disengage the blade clutch PTO stop the engine and IMPORTANT DO NOT disengage the blade inniti X clutch with high engine speed above 1 2 throt remove the ignition key Wait for all move tle since the brake action on the blade drive will mant to stop peters getting oH Ole seat cause premature wear of the brake band Operating Instructions 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 incre ments Lockout Lever Plunger Depressed Cam in LOCKOUT Sa Position Lockout Lever Freewheel Position After moving the mower release the locking cam placing the lever DOWN in the normal OP ERATING position Make sure the transmission lockout plunger on the side of the transmission case activated by the lockout lever is com Cutting Height Adjustment pletely released otherwise the transmission operation will be erratic TRANSMISSION LOCKOUT Lockout Lever IMPORTANT DO NOT TOW this mower with th
101. 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 If the engine is hot allow to cool before refueling Use an approved fuel container Fuel the mower outdoors e DO NOT smoke while refueling Avoid spilling fuel use a funnel or spout DO NOT overfill the fuel tank fill up to about 1 in 25 mm below the top of tank IMPORTANT DO NOT permit dirt or other foreign matter to enter the fuel tank Wipe dirt from around the filler cap before removing Use a clean fuel 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 blended with methyl alcohol CHE
102. ting clothing that could get caught in moving parts Do not operate this machine while wearing shorts always wear adequate protective clothing including long pants Wearing safety glasses safety shoes and a helmet is advisable and required by some local ordinances and insurance regulations Prolonged exposure to loud noise can cause impairment or loss of hearing Operator hear ing protection is recommended particularly for continuous operation of the GHS Model due to blower noise level Wear a suitable hearing protective device such as earmuffs or earplugs Keep all protective shields and safety de vices in place If a protective shield safety device or decal is damaged unusable or miss ing repair or replace it before operating the ma chine Be sure interlock switches are functioning correctly so the engine cannot be started un less the Forward Speed Control lever 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 off the seat with the PTO clutch in the ENGAGED position Handle gasoline with care Gasoline is highly flammable and its vapors are explosive a Use an approved fuel container b Never add fuel to a running engine or hot engine allow hot engine to cool several minutes Keep matches cigarettes cigars pipes open flames or sparks away from the fuel tank and fuel container Always fill the fuel tank outdoors
103. to dump into the bag by lift ing on the catcher lift handle on the lower front corner of the catcher with the one hand while continuing to hold up on the bag strap with the other hand Refer to photos for posi tioning the bag and dumping Catcher Lift Dump Handle Dumping Catcher into Dump Bag Lower the catcher smoothly down to the normal operating position DO NOT allow the catcher to drop down Close the door by holding the door handle with the left hand and releasing the safety latch on the door hinge mechanism with the right hand The safety latch is released by pressing in on the top of the latch Then smoothly close the door working against the spring pressure that holds the door closed DO NOT let the door slam shut by releasing the door before it is closed Maintenance Instructions CAUTION Maintenance procedures requiring special training or tools should be performed by a trained technician MAINTENANCE SCHEDULE CHART RECOMMENDED SERVICE INTERVALS MODEL MC 25 100 200 Every Ref Service Item Daily Hours Hours Hours Yearly 2Years Page Check Engine Crankcase Oil Level X 43 Check Clean Engine Air Cooling System D 52 Check Security of Air Filtration Components D 55 Check Air Filter Restriction Gauge D 51 Clean Grass Buildup Under Deck X 53 Clean GHS Exhaust Screen D 38 Clean GHS Blower X 54 Service Mower Blades D 56 Check F
104. tor Oil 1 qt 1 liter Cooling Fan Mounted on Drive Pulley 5 0 8 Infinitely Variable 5 0 8 Infinitely Variable BLADE DRIVE PTO Shaft Blade Spindle Blade Drive Clutch and Brake Max Blade Speed 22 in 56 cm Blade 3600 RPM Engine Quick Disconnect Spline Shaft with Two 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 2900 RPM 16700 FPM 5090 m min TIRE SIZE Deck Caster Wheel Deck Caster Wheel Optional Drive Drive Optional Narrow Tire Rear 2 80 2 50 4 Pneumatic 4 Ply 8 25 x 2 75 Semi Pneumatic 18 x 8 50 8 4 Ply 18 x 6 50 8 4 Ply 13 x 6 50 6 4 Ply TIRE PRESSURE Deck Caster Wheel Drive Rear 20 PSI 137 kPa 15 PSI 103 kPa 20 PSI 137 kPa DIMENSIONS Tractor and Mower Length 36 in 91 cm GHS Model 42 in 107 cm GHS Model Width 36 in 91 cm SD Model with Deflector 42 in 107 cm SD Model with Deflector 36 in 91 cm GHS Model 42 in 107 cm GHS Model 87 in 221 cm 89 in 226 cm 41 3 4 in 106 cm 47 3 4 in 121 cm 37 in 94 cm 43 in 109 cm Specifications MODEL DIMENSIONS continued Height SD Model GHS Model Wheel Base Tractor Tread Width Tractor Standa
105. 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 Roller Wheels on the tractor with the locking balls fully seated in the groove and the ring in the full forward position refer Tilt Up Spring and Roller Wheel to the Coupler Ring Locked Position photo Af Installation on Rear Discharge Deck ter installation pull on the shaft to check for security Pull Back Spring Loaded Mower Deck Installation on Tractor Coupler Ring 8 Deck Installation 1 Lightly grease each deck support arm 2 on the tractor Refer to Mower Deck Installation pho to on next page for location of deck support arm Engage the deck carrier frame tube sockets on the tractor support arms refer to Discharge Chuteand PTO Shaft Guard Installation photo forsocketlocation Slide the deck onto the sup port arms all the way if SD equipped model approximately 3 in 76 mm if GHS equipped model NOTE When installing the DSD52 Mower deck make sure to retract the dolly wheel after mounting the deck on the tractor If the deck is rear discharge GHS equipped di E model the rear discharge chute will need to be aligned and connected to the blower inlet dur ing the last 2 in 51 mm of slide action on the support arms Spring Loaded Coupler Ring In Fully Forward Position NOTE Raising the m
106. ts Engine PTO Drive Belt Jackshaft Drive Belt GHS Blower Drive Belt Hydrostatic Ground Drive Belt Fuel Filter Blade Overload Shear Bolts PTO Shear Pin Mower Blades Mower Deck Gearbox Replacement GHS Blower Assembly GHS Blower Assembly Removal Blower Wheel Removal Blower Wheel Installation GHS Blower Assembly Installation ADJUSTMENTS Safety Switches Steering Levers Blade Clutch PTO Clutch Engagement Belt Tension Clutch Disengagement Brake Action Stop Block Eccentric Adjustment Clutch Idler Pulley Travel Adjustment Blade Brake Band Adjustment Transmission Control Set Forward Travel Limit Stop Steering Lever End Play Adjustment Neutral Function Adjustment Straight Ground Travel Adjustment Forward Speed Control Friction Lock Tilt Up Deck Adjustable Stop Carburetor Engine Idle Adjustment GHS Full Signal Horn with Grass Pak Switch Troubleshooting When Horn Fails to Operate ELECTRICAL SYSTEM Circuit Breakers Wiring Diagram Model MC Operator s Notes Warranty 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 opera tion or maintenance of a Walker Mower are caused by disregarding basic safety p
107. ttention 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 WARNING A POTENTIAL hazard that COULD result in severe personal injury or DEATH if warn ing is ignored and proper safety precau tions are not taken 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 de manding special attention since it deals with the pos sibility 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 Manufacturing must take full responsibility for safety The Walker Rider Lawnmower has been designed with many safety features to protect
108. turns or sudden changes in direction Never adjust cutting height with the engine running Before adjusting cutting height or servicing disengage the blade clutch PTO stop the engine and remove the ignition key Wait for all movement to stop before getting off the seat NOTE A blade blower brake should normally stop drive line rotation within five 5 seconds of disengaging the PTO clutch 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 observe the following recommendations a Do not move tractor with deck in tilt up po sition b Never tilt body forward with deck in tilt up position For GHS equipped models do not operate the machine with the grass catcher in the DUMP position or with the back door OPEN Dan gerous projectiles may be thrown out of the dis charge chute or the back of the grass catcher 17 For GHS equipped models use care when closing the grass catcher door Keep fingers and hands away from the hinge and pinch points when the door is being closed Also keep fingers and hands clear of the door frame The door is held closed with springs and the door may slam shut with considerable force In case of a clogged or plugged mower deck or GHS catching system a Disengage the blade clutch PTO and turn the engine off before leaving the seat
109. ufacturer 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 assure proper lubrication in hot weather Fill up to but not above the F mark on the dipstick Crankcase capacity is 1 85 quarts 1 75 liters plus 1 2 pint 24 liters for the new oil filter IMPORTANT Check the dipstick reading be fore adding the last 1 2 pint of oil and fill only to the F mark DO NOT overfill the crankcase oil above F mark as this CAN result in en gine overheating loss of power and possible 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 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
110. ug hole Install the air bleed plug and fill the reservoir to the COLD level line 47 Maintenance Instructions LUBRICATION Lubrication No Lubrication No Location Type Places 1 Location Type Places Brake Actuator Rod and Brake Oil Band Pivot Pins Clevis Brake Actuator Pivot Grease Anti Scuff Roller Wheel Oil Catcher Hinge Point Oil Choke Control Cable Ends Oil Throttle Control Cable Ends Oil Engine Oil oil Belt Tightener Pivot Grease Blower Drive GHS Model Only Deck Caster Wheel Fork Pivot Grease Deck Caster Wheel Bearing Grease Tee Gearbox Deck Oil Blade Drive Gearbox Oil PTO Shaft Guard Hinge Oil Universal Joint Shaft Assembly Grease Pivot Assembly Tilt Up Deck Grease Deck Support Arm Socket Grease Body Hinge Point Oil FSC Actuator Rod Pivot Pins Oil i e FSC Lever Pivot Grease Belt Tightener Pivot Grease FSC Lever Fork Grease Ground Drive EM EXE Grease Slide Area PTO Gearbox Dipstick Oil FSC Friction Body Pivot Grease Hydrostatic Drive oil Steering Lever Pivot Grease Choke Control Pivot Oil Deck Roller Wheel Oil Throttle Control Pivot Oil Deck Support Arm Pivot Grease Discharge Chute Hinge Oil Deck to PTO Coupling Grease Tilt Up Latch Assembly Oil Grease Slide Area Steering Lever Support Oil Universal Joint Tube Assembly Grease NNNNA lt N NN NNA A Universal Joint Quick Connect Grease Gearboxes are permanently lubricated and Spline Grease Slide Area seal
111. ugh the dipstick stand pipe using 7 to 8 fl oz 21 to 24 cl of SAE E P Extreme Pressure 90W gear lube Check that the oil level is at the FULL mark on the dipstick DO NOT overfill Gear Axle Lubrication The gear axle oil lubrication is SAE 80W 90 API GL 5 gear lube Check the axle oil level after every 100 hours of operation by removing the oil level plug If additional oil is needed remove the breather vent on top of ax le and fill until oil is at the level plug Change axle oil every 1000 hours or two 2 years Hydrostatic Transmission Fluid Checking Hydrostatic Transmission Fluid Level Hydrostatic transmission fluid level should be checked every 25 hours of machine operation It is preferable to check the fluid level when fluid is cold Check fluid level as follows 1 Park the mower on a level surface Stop the engine and wipe dirt and contaminants from around the reservoir cap and air bleed plug IMPORTANT Before removing the reservoir cap clean any dirt from around it Any dirt or con taminants entering the transmission will acceler ate wear and eventually cause loss of power to the drive wheels Remove the reservoir cap and check the level of the fluid The reservoir has a fluid level COLD mark and HOT mark The reservoir oil level should ALWAYS be at or above the COLD mark and NEVER above the HOT mark Maintenance Instructions y i gt Pa Reservoir Cap d Transmission Reservoir
112. unction of Oil Pressure Warning Light D 23 Lubricate Grease Fittings and Oil Points X 44 Check PTO Gearbox Oil Level X 46 Check Battery Electrolyte Level X 55 Check Hydrostatic Transmission Fluid X 46 Check Tire Pressure D 56 Check Drive Belts Jackshaft Engine PTO x 57 GHS Blower Ground Drive Check Gearbox Oil Seals X 58 Check Turbine Precleaner X 50 Check Clean Air Filter Element X 51 Change Engine Crankcase Oil X 43 Check Adjust Blade Clutch PTO x 71 Brake Action Check Oil Level in Gear Axle X 46 x Wu oa Clean Hydrostatic Transmission Cooling Fins Clean Engine Cooling Fins D 52 Check Regap Spark Plugs X 58 Change Engine Oil Filter D 43 Check Fuel Lines and Clamps X 58 Replace Air Filter Element 51 and Vacuator Valve Replace Fuel Filter D 65 Service Battery X 55 Check Adjust FSC Friction Lock X 76 Service Solenoid Shift Starter D 58 Check Engine Valve Clearance D 58 Change Gear Axle Oil 444 x 46 Change Hydrostatic Transmission Fluid X 47 Replace Fuel Lines and Clamps X 58 More often in extremely dusty or dirty conditions refer to notes about air cleaner element in A CAUTION IMPORTANT TIPS FOR CARE OF KOHLER ENGINE i E Change PTO gearbox oil and filter after first When performing maintenance with the 100 hours of operation break in period mower body raised a safety prop should A Air cleaner is re
113. under the deck to measure blade height Refer to ADJUSTING CUTTING HEIGHT in Operating Instructions NOTE Ablock 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 KAN AM Should not vary more than 1 8 in 3 mm side to dus Deck Leveling Checkthe side to side level Rotate each blade sideways and measure the distance from blade tip to ground on each side If measurements vary more than 1 8 in 3 mm add a washer shim under the deck support pins on the low side to level the deck 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 m 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 4 in 102 mm Wood Block 21 22 Assembly Instructions PREOPERATING CHECKLIST Before operating the mower for the first
114. 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 Never attempt to make any adjustments while the engine is running except where specifically instructed to do so 12 The electrical system battery contains sulfuric acid Avoid any contact with skin eyes and clothing Keep the battery and acid out of reach of children OPERATING ils Operate the mower only in daylight or in good artificial light with good visibility of the area being mowed Sit on the seat when starting the engine and operating the machine Keep feet on the deck footrests at all times when the tractor is moving and or mower blades are operating For a beginning operator learn to steer ma neuver the tractor with a slow engine speed before attempting any mowing operation Be aware that with the front mounted mower configuration the back of the tractor swings to the outside during turns Remember for an emergency stop the forward motion of the tractor can always be stopped by pulling the Forward Speed Control FSC into the NEUTRAL PARK position In case either of the transmission drive belts break during operation and if the machine is on a slope the machine will freewheel down the slope To maintain control immediately 1 Release the steering levers and simultaneously 2
115. uts nicks etc and the hose clamps for tightness 11 Reset the air restriction indicator press button on bottom Engine Cooling System Air Intake System To prevent engine overheating and possible engine damage clean grass clippings chaff and dirt from the rotating engine air intake screen after every 8 hours of operation In certain mowing conditions dry grass leaves tree cotton etc it may be nec essary to check and clean the screen several times each day to prevent engine overheating Operating the engine with a blocked air intake screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage from overheating Maintenance Instructions Cylinder Head Cooling Fins It is essential for performance and longevity of the air cooled engine to keep the cylinder head cooling fins clean and free of obstruction After every 8 hours of operation check the performance of the cooling system by starting the engine holding a hand adjacent to the cylinder head and feeling the cooling airflow If there is little or no airflow clean the cooling fins as described below Make sure to keep hands clear of exhaust pipe muffler and moving parts when checking airflow Every 100 hours inspect and clean the cooling fins more often when operating in extremely dusty dirty conditions Remove the two 2 cooling fin access panels in the engine shroud and clean the cooling fins and external
116. wer This manual covers Model MC with the Kohler Command CH18 18 0 HP gasoline engine All shields and guards must be in place for the proper and safe operation of this machine Where they are shown removed in this manual it is for illustration purposes only Do not operate this machine unless all shields and guards are in place Specifications given are based on the latest 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 Kat d UU Luo Bob Walker President Table of Contents General Information HIGHLIGHTED INFORMATION GLOSSARY IDENTIFYING NUMBER LOCATIONS ENGINE SERIAL NUMBER LOCATION SERVICING OF ENGINE AND DRIVETRAIN COMPONENTS po sch a N Specifications ENGINE ELECTRICAL SYSTEM TRANSMISSION BLADE DRIVE TIRE SIZE TIRE PRESSURE DIMENSIONS Tractor and Mower MOWER DECK CURB WEIGHT DRIVE BELTS GHS SYSTEM Optional SEAT FRAME BODY CONSTRUCTION Component Identification Safety Instructions BEFORE OPERATING OPERATING MAINTENANCE SAFETY CONTROL AND INSTRUCTION DECALS Assembly Instructions SETUP INSTR
117. x Blower Speed Grass Catcher Capacity Optional Grass Catcher Capacity Full Signal Powerfil 9 MC 4 x 10x 1 4 in 10 x 25 x 1 cm Three Blade Paddle Wheel Driven by Mower Engine Band Brake Works in Combination with PTO Clutch Stops Blower within Five 5 Seconds of PTO Disengagement 3600 RPM 63 Gallons 238 liters 6 7 Bushels 89 Gallons 335 liters 9 5 Bushels Oscillating Vane Switch Mounted on Grass Delivery Spout Triggers Horn Signal Oscillating Delivery Spout Driven by 12 Volt Electric Gearmotor Spreads Material throughout Interior of Catcher 25 Cycles Minute SEAT Contour Molded with Nylon Backed Vinyl Cover and Integral Foam Cushion FRAME BODY CONSTRUCTION Frame Body Deck GHS Catcher and Chutes All Welded Unitized Steel Chassis 14 Gauge Steel 11 Gauge Steel Molded Cross Linked Polyethylene UV Stabilized Optional 9 5 Bushel Grass Catcher adds approx 5 Ib 2 kg and 5 in 13 cm in Height NOTE The manufacturer reserves the right to make changes in specifications shown herein at any time without notice or obligation Component Identification Catcher Door Safety Latch Turbine Precleaner Anti Scuff Roller Catcher Lift A Dump r n Fuel Tank and Cap Transmission Control Rod Adjustment Nut RH Deck Support Arms Deck Lift Handle Cutting Height Adjustment Tilt Up Hook Not Visible NOTE Control Identification shown in Operating Instructi
118. zed Check the oil level BEFORE EACH USE 1 Park the mower on a level surface with the en gine stopped Also make sure the engine is cool and oil has had time to drain into the sump allow at least five 5 minutes after stopping the engine IMPORTANT NEVER check or add oil with the engine running Before removing the dipstick clean the area around the dipstick to keep any dirt or debris out of the engine Remove the dipstick wipe off with a clean rag then reinsert the dipstick into the tube and press all the way down LUBRICATION Remove the dipstick again and check the oil lev el on the dipstick The oil level should be within the Operating Range on the dipstick between the L mark and the F mark IMPORTANT DO NOT operate engine without a sufficient oil supply in the crankcase DO NOT operate with the oil level below the L mark or above the F mark on the dipstick If additional oil is needed refer to Specifications for proper crankcase lubricant Fill up to but not above the F mark on the dipstick IMPORTANT DO NOT overfill the crankcase oil above F mark as this CAN result in engine overheating loss of power and possible en gine damage Full Mark Low Mark OPERATING RANGE A Av 4011087001 QQv SIDZ XOUddY ALOY N9 110 Dipstick Operating Range Changing Engine Crankcase Oil Oil Filter Change the engine crankcase oil after every 100 hours of ope

Walker MC (18 HP) Lawn Mower User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents