Walker Mc 18 Hp Users Manual

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OWNER’S MANUAL

Safety, Assembly, Operating, and Maintenance Instructions

Model MC (18 HP)

(Covers Serial Numbers 03-61061 and on)

Please Read and Save These Instructions Effective Date: 04-15-03

For Safety, Read All Safety and Operation P/N 6000-8

Instructions Prior to Operating Machine Price $5.00

™

Foreword

Thank you. . .for purchasing a Walker mower. Every effort has been made to provide you with the

most reliable mower on the market, and we are sure you will be among our many satisfied 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 mower.

This manual covers Model MC with the Kohler Command CH18 (18.0 HP) gasoline engine.

All shields and guards must be in place for the proper and safe operation of this machine.

Where they are shown removed in this manual, it is for illustration purposes only. Do not operate

this machine unless all shields and guards are in place.

Specifications given are based on the latest 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

Bob Walker, President

Table of Contents

General Information ________________ 1

HIGHLIGHTED INFORMATION _____________ 1

GLOSSARY ____________________________ 1

IDENTIFYING NUMBER LOCATIONS________ 1

ENGINE SERIAL NUMBER LOCATION ______ 2

SERVICING OF ENGINE AND DRIVETRAIN

COMPONENTS__________________________ 2

Specifications________________________ 3

ENGINE________________________________ 3

ELECTRICAL SYSTEM ___________________ 3

TRANSMISSION_________________________ 3

BLADE DRIVE __________________________ 4

TIRE SIZE ______________________________ 4

TIRE PRESSURE ________________________ 4

DIMENSIONS (Tractor and Mower) _________ 4

MOWER DECK__________________________ 5

CURB WEIGHT__________________________ 5

DRIVE BELTS___________________________ 5

GHS SYSTEM (Optional)__________________ 6

SEAT__________________________________ 6

FRAME/BODY CONSTRUCTION ___________ 6

Component Identification___________ 7

Safety Instructions _________________ 10

BEFORE OPERATING___________________ 10

OPERATING___________________________ 11

MAINTENANCE ________________________ 12

SAFETY, CONTROL,

AND INSTRUCTION DECALS _____________ 14

Assembly Instructions _____________ 16

SETUP INSTRUCTIONS _________________ 16

Tire Installation (Tractor)_______________ 16

Battery Service_______________________ 16

Wet Battery Service __________________ 16

Dry Battery Service __________________ 16

Battery Charging ____________________ 17

Battery Installation ___________________ 17

Mower Deck Assembly ________________ 17

Deck Caster Wheels Installation ________ 17

Deck Discharge Chute Installation ______ 18

Deck Discharge Shield Installation ______ 18

PTO Shaft Guard Installation __________ 18

Tilt-Up Roller Wheel Installation ________ 18

Mower Deck lnstallation on Tractor ______ 19

Deck Installation ____________________ 19

Deck Leveling ______________________ 21

PREOPERATING CHECKLIST ____________ 22

Operating Instructions_____________ 24

CONTROL IDENTIFICATION,

LOCATION, AND FUNCTION _____________ 24

Ignition Switch_______________________ 24

Engine Choke________________________ 25

Engine Throttle ______________________ 25

Forward Speed Control (FSC) __________ 25

Steering Levers ______________________ 25

Blade Clutch (PTO) ___________________ 25

Parking Brake _______________________ 26

Transmission Lockout Levers __________ 26

Hourmeter __________________________ 26

Oil Pressure Warning Light ____________ 26

Circuit Breaker (5 Amp) _______________ 26

Light Switch (For Optional Lights)_______ 26

STARTING THE ENGINE_________________ 28

ADJUSTING GROUND

SPEED AND STEERING _________________ 28

ENGAGING THE MOWER________________ 30

STOPPING THE MACHINE _______________ 31

ADJUSTING CUTTING HEIGHT ___________ 31

TRANSMISSION LOCKOUT ______________ 32

RECOMMENDATIONS FOR MOWING ______ 33

RECOMMENDATIONS FOR TILT-UP DECK

OPERATION/TRANSPORT _______________ 34

GRASS HANDLING SYSTEM (GHS) _______ 35

General Information __________________ 36

Clogging Checklist ___________________ 37

Using the Tilt-Up Deck ________________ 38

Using the GHS Catcher________________ 38

Powerfil ® _________________________ 38

“Full” Signal Horn ___________________ 38

Cleaning the GHS Exhaust Screen ______ 38

Dumping the Catcher _________________ 39

Tailgate Dumping ___________________ 39

Using the Dump Bag _________________ 39

Table of Contents

Maintenance Instructions__________ 41

MAINTENACE SCHEDULE CHART ________ 41

IMPORTANT TIPS FOR CARE

OF THE KOHLER ENGINE _______________ 42

Fuel System _________________________ 42

Starting/Stopping_____________________ 42

Cooling System ______________________ 42

Air Cleaner System ___________________ 42

Oil _________________________________ 42

LUBRICATION _________________________ 43

Engine Oil ___________________________ 43

Engine Break-In Oil __________________ 43

Checking Engine Crankcase Oil Level ___ 43

Changing Engine Crankcase Oil/Oil Filter _43

Grease Fitting and Oil Point Lubrication __ 44

Mower Deck Gearbox Lubrication _______ 44

DSD52 Mower Deck Lubrication_________ 45

Tractor PTO Gearbox Lubrication _______ 46

Checking Gearbox Oil Level ___________ 46

Changing Gearbox Oil ________________ 46

Gear Axle Lubrication _________________ 46

Hydrostatic Transmission Fluid _________ 46

Checking Hydrostatic

Transmission Fluid Level ______________ 46

Changing Hydrostatic Transmission Fluid _47

CLEANING ____________________________ 50

Engine Air Cleaner System _____________ 50

Turbine Precleaner __________________ 50

Donaldson Radialseal™ Air Cleaner _____ 51

Engine Cooling System________________ 52

Air Intake System ___________________ 52

Cylinder Head Cooling Fins ____________ 53

Grass Buildup in Mower Housing________ 53

GHS Blower _________________________ 54

GHS Exhaust Screen __________________ 55

Hydrostatic Transmission Cooling Fins __ 55

CHECKING/SERVICING _________________ 55

Security of Air Filtration Components ____ 55

Battery______________________________ 55

Electrolyte Level ____________________ 55

Cleaning the Terminals _______________ 56

Charging the Battery _________________ 56

Tire Pressure ________________________ 56

Sharpen Mower Blades ________________ 56

Drive Belts __________________________ 57

Mower Deck Gearbox Oil Seals _________ 58

Spark Plugs _________________________ 58

Fuel Lines and Clamps ________________ 58

Engine Starter________________________ 58

Engine Valve Clearance________________ 58

Blade Brake Action ___________________ 58

REPLACING/REPAIRING ________________ 59

Drive Belts __________________________ 59

Engine PTO Drive Belt _______________ 61

Jackshaft Drive Belt _________________ 62

GHS Blower Drive Belt _______________ 63

Hydrostatic Ground Drive Belt _________ 64

Fuel Filter ___________________________ 65

Blade Overload Shear Bolts ____________ 65

PTO Shear Pin _______________________ 66

Mower Blades _______________________ 66

Mower Deck Gearbox Replacement______ 67

GHS Blower Assembly ________________ 68

GHS Blower Assembly Removal _______ 68

Blower Wheel Removal ______________ 68

Blower Wheel Installation _____________ 69

GHS Blower Assembly Installation ______ 69

ADJUSTMENTS________________________ 70

Safety Switches ______________________ 70

Steering Levers ______________________ 70

Blade Clutch (PTO) ___________________ 71

Clutch Engagement/Belt Tension _______ 71

Clutch Disengagement/Brake Action ____ 72

Stop Block Eccentric Adjustment _______ 73

Clutch Idler Pulley Travel Adjustment ___ 73

Blade Brake Band Adjustment _________ 73

Transmission Control _________________ 74

Set Forward Travel Limit (Stop) ________ 74

Steering Lever End Play Adjustment ____ 75

Neutral Function Adjustment __________ 75

Straight Ground Travel Adjustment _____ 76

Forward Speed Control Friction Lock ____ 76

Tilt-Up Deck Adjustable Stop ___________ 77

Carburetor __________________________ 77

Engine Idle Adjustment _______________ 77

GHS “Full” Signal Horn

with Grass-Pak® Switch _______________ 78

Troubleshooting

(When Horn Fails to Operate) __________ 78

ELECTRICAL SYSTEM __________________ 79

Circuit Breakers______________________ 79

Wiring Diagram - Model MC ____________ 80

Operator’s Notes___________________ 81

Warranty___________________________ 83

General Information

1

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 precautions or specific

warnings. Such accidents, in most cases, can be

prevented by being aware of the dangers present.

Information of special importance has been high-

lighted in bold type in this manual. Refer to Safety

Instructions for the meanings of DANGER, WARN-

ING, CAUTION, IMPORTANT, and NOTE.

GLOSSARY

There are many terms that are either unique to this

equipment or that are used as acronyms. The fol-

lowing terms and their definitions will help while

using this manual:

•DECK is the mowing attachment mounted on

the front of the tractor which includes the carrier

frame, deck housing, blade drive gearboxes,

and cutter blades.

•FORWARD SPEED CONTROL (FSC) controls

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 interior 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.

Fill In By Purchaser

Tractor Model No. _______________________

Tractor Serial No. _______________________

Deck Serial No. _______________________

Engine Model No. _______________________

Engine Serial No. _______________________

Date of Purchase _______________________

General Information

2

Tractor Serial Number Location

Mower Deck Serial Number Location

ENGINE SERIAL NUMBER LOCATION

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.

Engine Serial Number Location

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 components 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

Hydrostatic Eaton Corporation

Transmissions 15151 Highway 5

Eden Prairie, MN 55344

Gearboxes (Deck) Tecumseh Products Co.

900 North Street

Grafton, Wl 53024

Serial Number

Serial Number

Serial Number

Specifications

3

MODEL MC

ENGINE

Manufacturer/Model Kohler Command CH18, 2 Cyl., Gasoline (Air-Cooled)

Displacement 38.0 cu. in. (624 cc)

HP (@ 3600 RPM) 18.0

Max. RPM (No Load) 3750

Governed RPM 3600

Max. Torque [ft-lb (N⋅m) @ RPM] 30 (41) @ 2500

Idle RPM 1200 ± 75

Spark Plug Type Champion® RC12YC

Spark Plug Gap .030 in. (.76 mm)

Crankcase Capacity 2 qts (1.9 liters)

Crankcase Lubricant API SG or SH Grade Oil Only with 10W-30 Viscosity above 0° F

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

Fuel Tank Capacity 3 Gallons (11.4 liters)

Fuel Regular Grade Unleaded Gasoline (87 Octane)

Cooling System Capacity Air Cooled

ELECTRICAL SYSTEM

Battery 12 Volt, 35 AH, 295 CCA

Charging System Flywheel Alternator

Charging Output 15 Amp DC (Regulated)

System Polarity Negative Ground

Ignition Electronic Capacitive Discharge

Starter 12 Volt Electric Ring-Gear Type, Solenoid Shift

Interlock Switch Ignition Lockout by Seat Switch, Transmission Neutral and Blade Clutch

Circuit Breaker Auto Reset (30A)

TRANSMISSION

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

Steering Hand Lever Control / Individual Wheel

Forward Speed Control Precision Friction Lock Lever, Cruise Control, with Neutral-Park

Position

Service Brake Dynamic Braking through Hydrostatic Transmission

Parking Brake Mechanical Pin Lock in Transmission Gear

Neutral Transmission Release by Manual Dump Valve

Final Drive Gear Drive Axle

Specifications

4

MODEL MC

TRANSMISSION (continued)

Transmission Fluid

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

Alternate Transmission Fluid SAE 30W Straight Viscosity Motor Oil

Transmission Fluid Capacity 1 qt (1 liter)

Transmission Cooling Cooling Fan Mounted on Drive Pulley

Ground Travel Speed

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

Reverse m.p.h. (km/h) 0-5 (0-8) Infinitely Variable

0-5 (0-8) Infinitely Variable

BLADE DRIVE

PTO Shaft Quick Disconnect Spline Shaft with Two High-Speed U-Joints

Blade Spindle Each Blade (2) Mounts Direct on Peerless Right Angle

Gearbox with Tee Gearbox in Center Connected to PTO Shaft

(Complete Geared Drive, Peerless Model 1000 Gearboxes)

Blade Drive Clutch and Brake Manual Belt Tightener Clutch and Band Brake

(Stops Blades within Five (5) Seconds of Disengagement)

Max. Blade Speed

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

RPM Engine

2900 RPM

[16700 FPM (5090 m/min)]

TIRE SIZE

Deck Caster Wheel 2.80/2.50-4 Pneumatic (4-Ply)

Deck Caster Wheel (Optional) 8.25 x 2.75 Semi-Pneumatic

Drive 18 x 8.50-8 (4-Ply)

Drive (Optional Narrow Tire) 18 x 6.50-8 (4-Ply)

Rear 13 x 6.50-6 (4-Ply)

TIRE PRESSURE

Deck Caster Wheel 20 PSI (137 kPa)

Drive 15 PSI (103 kPa)

Rear 20 PSI (137 kPa)

DIMENSIONS (Tractor and Mower)

Length

36 in. (91 cm) GHS Model 87 in. (221 cm)

42 in. (107 cm) GHS Model 89 in. (226 cm)

Width

36 in. (91 cm) SD Model

(with Deflector) 41-3/4 in. (106 cm)

42 in. (107 cm) SD Model

(with Deflector) 47-3/4 in. (121 cm)

36 in. (91 cm) GHS Model 37 in. (94 cm)

42 in. (107 cm) GHS Model 43 in. (109 cm)

Specifications

5

MODEL MC

DIMENSIONS (continued)

Height

SD Model 37-1/2 in. (95 cm)

GHS Model 44-1/2 in. (112 cm)

Wheel Base (Tractor) 42-1/4 in. (107 cm)

Tread Width (Tractor)

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

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

MOWER DECK

Width of Cut SD/GHS 36 or 42 in. (91 or 107 cm)

Cutting Height 1 to 4 in. (3 to 10 cm)

Height Adjustment 7 Positions - 1/2 in. (1 cm) Increment Hitch Pins Installed in

Multi-Position Deck Support

Blade Size

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

(10 cm) Center Overlap

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

(10 cm) Center Overlap

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

(5 cm) Center Overlap

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

(5 cm) Center Overlap

Deck Suspension Torsion-Flex Frame with Caster Wheels and

Counterweight Springs

CURB WEIGHT (Approximate)

SD Tractor Only 645 lb (293 kg)

GHS Tractor Only 735 lb (334 kg)

SD Tractor and 36 in. SD Deck 775 lb (352 kg)

SD Tractor and 42 in. SD Deck 810 lb (368 kg)

GHS Tractor and 36 in. GHS Deck 860 lb (390 kg)

GHS Tractor and 42 in. GHS Deck 895 lb (406 kg)

DRIVE BELTS

Engine PTO Walker P/N 8230

Jackshaft Drive Gates 3VX395 (or Walker P/N 6251)

Ground Drive, Micro-V Walker P/N 7248

Blower (GHS Model) Walker P/N 7234-1

Specifications

6

MODEL MC

GHS SYSTEM (Optional)

Blower 4 x 10 x 1/4 in. (10 x 25 x 1 cm) Three-Blade Paddle Wheel

(Driven by Mower Engine)

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

Blower within Five (5) Seconds of PTO Disengagement)

Max. Blower Speed 3600 RPM

Grass Catcher Capacity 63 Gallons (238 liters)/6.7 Bushels

Optional Grass Catcher Capacity*89 Gallons (335 liters)/9.5 Bushels

Full Signal Oscillating Vane Switch Mounted on Grass Delivery Spout Triggers

Horn Signal

Powerfil ®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 All Welded Unitized Steel Chassis

Body 14 Gauge Steel

Deck 11 Gauge Steel

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

*Optional (9.5 Bushel) Grass Catcher adds approx. 5 lb (2 kg) and 5 in. (13 cm) in Height

NOTE: The manufacturer reserves the right to make changes in specifications shown herein at any time

without notice or obligation.

Component Identification

7

Front View and Right Side View

NOTE: Control Identification

shown in Operating

Instructions section.

Catcher Door

Safety Latch Turbine

Precleaner

Grass Handling System

9.5 Bushel Catcher

Anti-Scuff

Roller

Catcher Lift /

Dump Handle

Transmission Control

Rod Adjustment Nut

(RH)

Deck Lift Handle

(Cutting Height Adjustment)

Tilt-Up Hook

(Not Visible)

Deck

Caster Wheels

Counterweight Spring

and Protective Cover

Spring Clip

Tilt-Up

Latch

Footrests

Tilt-Up

Deck Handle

Deck Support Pins

and Height Adjustment

Hitch Pins

Transmission Control Rod

Adjustment Nut (LH)

Fuel Tank and Cap

Deck Support Arms

Component Identification

8

Oil

Filter

Oil Drain

Plug

Tailpipe

Muffler

Left Hand

Drive Wheel

Catcher Lift /

Dump Handle

Catcher Door

Gas Spring

Removable Grass

Catcher Screen

(Not Visible)

Catcher

Door

Catcher

Door Handle

Anti-Scuff

Roller

Tailwheel Fork

and Wheel

Catcher Exhaust

Deflector

Catcher Door

Gas Spring

Protective Cover

Rear View and Left Side View

Component Identification

9

Negative (-)

Battery Cable

LH Hydrostatic

Transmission

RH Hydrostatic

Transmission

GHS Blower

Muffler Heat Shield

30 Amp

Circuit Breaker

RH Transmission

Lockout Lever

PTO Gearbox

Dipstick

Precleaner

Tube

Fuel Pump

Donaldson

Air Cleaner Air Cleaner

Cover Rubber Bumper

(Body Support)

Air Restriction

Indicator

(Not Visible)

Rubber Bumper

(Body Support)

Air Intake

Hose

Fuel Tank Cap

Jackshaft

PTO

Clutch Lever

Turbine

Precleaner

Positive (+)

Battery Cable

Muffler

Oil Fill/

Dipstick

Throttle and

Choke Linkage

Neutral Safety

Switch

LH Transmission

Lockout Lever

Battery

Top View (Engine Compartment)

Safety Instructions

10

Pay particular attention to any information labeled

DANGER, WARNING, CAUTION, IMPORTANT,

and NOTE in this manual.

When you see the Safety Alert Symbol ( ),

read, understand, and follow the instructions. Fail-

ure to comply with safety instructions may result in

personal injury.

The seriousness or degree of importance of each

type of information is defined as follows:

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 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

2. Never allow children to operate rider mower.

Do not allow adults to operate without proper

instruction.

3. Clear the area to be mowed of any foreign

objects which may be picked up and thrown by

cutter blades. Pick up all sticks, stones, wire,

and any other debris.

4. Keep everyone, especially children and pets, a

safe distance away from the area being mowed.

Do not mow with bystanders in the area.

5. Do not operate the machine barefoot or wearing

sandals, sneakers, tennis shoes, or similar light-

weight footwear. Wear substantial protective

footwear.

DANGER

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.

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.

CAUTION

Possible hazards or unsafe practices that

MAY result in MODERATE personal injury

or property damage, or machine damage, if

warning is ignored and proper safety pre-

cautions are not taken.

Safety Instructions

11

6. Do not wear loose fitting clothing that could get

caught in moving parts. Do not operate this

machine while wearing shorts; always wear

adequate protective clothing, including long

pants. Wearing safety glasses, safety shoes,

and a helmet is advisable and required by some

local ordinances and insurance regulations.

7. Prolonged exposure to loud noise can cause

impairment or loss of hearing. Operator hear-

ing protection is recommended; particularly

for continuous operation of the GHS Model due

to blower noise level. Wear a suitable hearing

protective device, such as earmuffs or earplugs.

8. Keep all protective shields and safety de-

vices in place. If a protective shield, safety

device, or decal is damaged, unusable, or miss-

ing, repair or replace it before operating the ma-

chine.

9. 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.

10. Handle gasoline with care. Gasoline is highly

flammable and its vapors are explosive:

a. Use an approved fuel container.

b. Never add fuel to a running engine or hot

engine (allow hot engine to cool several

minutes).

c. Keep matches, cigarettes, cigars, pipes,

open flames, or sparks away from the fuel

tank and fuel container.

d. Always fill the fuel tank outdoors using care.

Fill to about one inch from the top of the tank.

Use a funnel or spout to prevent spilling.

e. Replace the machine fuel cap and container

cap securely and clean up any spilled fuel

before starting the engine.

11. Never attempt to make any adjustments

while the engine is running, except where

specifically instructed to do so.

12. The electrical system battery contains sulfuric

acid. Avoid any contact with skin, eyes, and

clothing. Keep the battery and acid out of reach

of children.

OPERATING

1. Operate the mower only in daylight or in

good artificial light with good visibility of the area

being mowed.

2. Sit on the seat when starting the engine and

operating the machine. Keep feet on the deck

footrests at all times when the tractor is moving

and/or mower blades are operating.

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

neuver) the tractor with a slow engine speed

before attempting any mowing operation.

Be aware that, with the front mounted mower

configuration, the back of the tractor swings to

the outside during turns.

4. Remember, for an emergency stop, the forward

motion of the tractor can always be stopped by

pulling the Forward Speed Control (FSC) into

the NEUTRAL-PARK position.

5. In case 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 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).

7. Do not run the engine in a confined area

without adequate ventilation. Exhaust fumes

are hazardous and can be deadly.

8. Do not carry passengers - maximum seating

capacity is one (1) person.

Safety Instructions

12

9. Watch for holes, rocks, and roots in the terrain

and for other hidden hazards. When mowing

tall grass, mow higher than desired to expose

any hidden obstacles. Then, clean the area and

mow to the desired height.

10. Avoid sudden 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.

11. Disengage the blade drive when transporting

the machine across drives, sidewalks, etc. Ne-

ver raise the mower deck while blades are

rotating.

12. The maximum recommended side slope 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 turns or sudden

changes in direction.

13. Never adjust cutting height with the engine

running. Before adjusting cutting height or

servicing, disengage the blade clutch (PTO),

stop the engine, and remove the ignition key.

Wait for all movement to stop before getting off

the seat.

NOTE: A blade/blower brake should normally

stop drive line rotation within five (5) seconds of

disengaging the PTO clutch.

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

ate with the grass deflector chute removed.

Keep the deflector in the lowest possible posi-

tion.

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

the following recommendations:

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

sition.

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

position.

16. For GHS equipped models, do not operate the

machine with the grass catcher in the DUMP

position or with the back door OPEN. Dan-

gerous projectiles may be thrown out of the 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.

18. In case of a clogged or plugged mower deck

or GHS catching system:

a. Disengage the blade clutch (PTO) and turn

the engine off before leaving the seat.

b. LOOK to make sure blade drive shaft and

blower drive pulley movement has stopped

before trying to unclog the system.

c. Disconnect the spark plug wires.

d. Never place hands under the deck or in the

GHS blower - use a stick or similar tool to

remove clogged material.

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

machine begins to vibrate abnormally, immedi-

ately disengage the blade clutch (PTO), stop

the engine, and wait for all moving parts to

stop. 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).

20. Do not touch the engine or muffler while the

engine is running or immediately after stopping

the engine. These areas may be hot enough to

cause serious burns.

21. When leaving the machine unattended, dis-

engage the blade clutch (PTO), stop the 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

13

2. To reduce fire hazards, keep the engine free of

grass, leaves, excessive grease, and dirt.

3. Keep all nuts, bolts, and screws tight to ensure

the machine is in a safe, working condition.

Check the blade mounting nuts frequently, mak-

ing sure they are tight.

4. Perform only maintenance instructions de-

scribed in this manual. Unauthorized main-

tenance operations or machine modifications

may result in unsafe operating conditions.

5. 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.

6. 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.

7. 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.

8. Never attempt to disconnect any safety devices

or defeat the purpose of these safety devices.

9. Do not change the engine governor settings or

overspeed the engine. The governor has been

factory-set for maximum-safe engine operating

speed.

10. Use genuine factory replacement parts.

Substitute parts may result in product malfunc-

tion and possible injury to the operator and/or

others.

11. 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.

b. Charge the battery in a well-ventilated

space, so gases produced while charging

can dissipate. Make sure the battery vents

in the caps are open.

c. Keep sparks, flames, and smoking materi-

als away from the battery at all times. To

avoid sparks, use care when removing bat-

tery cables from posts.

d. Disconnect both battery cables before

unplugging any wiring connectors or mak-

ing repairs on the electrical system.

IMPORTANT: Keep all applicable manuals

immediately accessible to anyone who may

operate or service this machine.

Safety Instructions

14

Adjacent to Blower Discharge Chute

through Body (5804)

SD Deck Discharge Shield (5848) Front Body Adjacent to

RH Steering Lever (6807) Hydrostat Oil

Reservoir (5810-2)

Rear of Grass Catcher Exhaust Screen (5869)

Engine Shroud (5855)

SAFETY, CONTROL, AND INSTRUCTION DECALS

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

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

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

Each End of Mower Deck (5808)

Catcher Safety Latch,

RH Side (5874)

Underside of Body (5861)

Gear Axle (5810-1) LH Side of Body,

Above Muffler (5805)

Safety Instructions

15

Fender, RH Side (7802)

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

Deck Carrier Frame (8653)

Deck Gearbox Cover (5807-3)

On Engine (6810)

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.

Deck Carrier Frame (8647)

Deck Carrier Frame (5865)

Right Side, Below Operator Seat (7809)

Top of Blower Housing (5819)

Fender, LH Side (5802-2)

Jackshaft Support Adjacent

to Dipstick (7827)

Rear Bumper (5815)

Assembly Instructions

16

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 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.

•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 13 mm)

above plates]. If the specific gravity is less than

1.225, the battery needs charging. If the battery

has been shipped dry, or is wet but needs service,

refer to the following instructions.

IMPORTANT: Make sure battery is securely

mounted in the frame. A loose battery may cause

damage to the case resulting in acid leakage and se-

vere damage to the machine. A hazard may be 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.

2. Charge battery. Refer to Battery Charging in

this section.

Dry Battery Service

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.

2. Remove the filler caps and carefully fill each cell

until the electrolyte is just above the plates.

DANGER

Activating a battery can be dangerous.

The battery should be taken to a reliable

service station, battery store, or power

equipment dealer where a trained techni-

cian can activate the battery safely. DO

NOT attempt to activate the battery unless

you are experienced in battery service

work. The following activation and charg-

ing instructions are provided for use by a

trained battery technician.

DANGER

Battery electrolyte is a poisonous and cor-

rosive sulfuric acid solution.

•Avoid spillage and contact with skin,

eyes, and clothing - causes severe burns.

•To prevent accidents, wear safety gog-

gles and rubber gloves when working with

electrolyte.

•Neutralize acid spills with baking soda

and water solution.

Assembly Instructions

17

3. After the battery is filled with electrolyte, replace

the filler caps and charge the battery. Refer to

Battery Charging.

Battery Charging

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 exceed one (1) hour.

2. After charging the battery, adjust the electrolyte

level to the bottom of the vent wells [1/4 to 1/2 in.

(6 to 13 mm) above the plates].

IMPORTANT: DO NOT overfill the battery.

Electrolyte will overflow through the vented caps

onto parts of the machine and WILL result in

severe corrosion.

3. Install battery.

Battery Installation

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.

Battery Installation

Mower Deck Assembly

Deck Caster Wheels Installation

1. Remove the bolt, nut, axle spacer tube, and

spacer washers from each deck caster wheel

fork.

NOTE: Spacer washers are used only when

the optional semi-pneumatic deck wheels (8.25

x 2.75) are installed.

2. Fit the axle spacer tube through the wheel hub,

position the spacer washer on each side of the

hub (if used), and fit the assembly into the wheel

fork.

3. Insert the 3/8-16 x 4-1/2 in. bolt through the

wheel fork with the bolt head to the outside and

install the 3/8-16 in. Keps nut.

4. Tighten the bolt and nut until the axle spacer

tube bottoms against the inside of the wheel

fork (will not turn) while the wheel and spacer

washers (if used) spin freely without binding.

DANGER

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 battery cap vents are open

after the battery is filled with acid (check

manifold vent on each cap).

•Make sure the battery charger is unplug-

ged before connecting or disconnecting

cables to the battery.

WARNING

Make sure the battery cap vents are open.

Improper venting of the battery COULD

cause a battery explosion.

Battery Clamp

Secured by

Wing Nut(s)

(+) Battery Cable

Connection

Assembly Instructions

18

Deck Caster Wheel Installation

NOTE: If semi-pneumatic wheels are installed,

make sure the spacer washers fit over the spacer

tube and are not caught between the fork and the

end of the tube. The washers should move freely

on the axle spacer tube.

5. Grease the caster wheel bearings and caster

pivot bearings - one grease fitting for each wheel

and each pivot.

Deck Discharge 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. Position the

bolt with the head inside of the chute and the nut on

the outside.

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.

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.

Spacer Washer

Axle Spacer Tube

Grease Fitting

Locations

Attach Guard

Attach

Chute

Nut on Top

Carrier Frame

Tube Sockets

WARNING

DO NOT operate the machine without the

grass deflector chute attached and in the

lowest possible position.

Attach Shield

Assembly Instructions

19

Tilt-Up Spring and Roller Wheel

Installation on Rear Discharge Deck

Mower Deck lnstallation on Tractor

Deck Installation

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

tractor. Refer to Mower Deck Installation pho-

to on next page for location of deck support arm.

2. Engage the deck carrier frame tube sockets on

the tractor support arms (refer to Discharge

Chute and PTO Shaft Guard Installation photo

for socket location). 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.

3. If the deck is rear discharge (GHS equipped

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.

NOTE: Raising the mower body may be help-

ful in fitting and guiding the deck chute into the

blower.

4. Install the hitch pin through the hole on the end

of each support arm to lock the deck in place

(refer to Deck Counterweight Spring Installa-

tion photo). Two (2) hitch pins are included in

the owner’s packet of materials.

5. Connect the mower deck PTO drive shaft

assembly to the tractor with the splined quick

disconnect coupler. This coupler simplifies

shaft alignment and installation.

a. Use the arrows on the shaft and tube to

align and slide the PTO quick coupler onto

the deck splined shaft.

b. Reaching under the tractor, pull the ring

back on the coupler, slide onto the spline

shaft on the tractor, and release the ring.

IMPORTANT: To prevent damage to the mower,

make sure the PTO shaft assembly is securely locked

on the tractor, with the locking balls fully seated in the

groove and the ring in the full forward position (refer

to the Coupler Ring “Locked” Position photo). Af-

ter installation, pull on the shaft to check for security.

Installing PTO Quick Coupler

Coupler Ring “Locked” Position

Attach Spring

Roller Wheels

Pull Back Spring-Loaded

Coupler Ring

Spring-Loaded Coupler Ring

In Fully Forward Position

Assembly Instructions

20

6. 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)

7. 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.

Deck Counterweight Spring Installation

Arrows on Shaft and Tube

(used to align when sliding together)

PTO

Connection

Grease Deck

Support Arms

Counterweight Springs

Clip Onto Body

With Body Tilted Up

Hitch Pins

Lock Deck On

Support Arms

Spring Tension Adjustment

Nut Located Under Lower

Spring Hook (Not Visible)

Assembly Instructions

21

Deck Leveling

1. Position mower on a smooth, level surface. Set

the cutting height to the highest position - 4 in.

(102 mm) - for easy access under the deck to

measure blade height. Refer to ADJUSTING

CUTTING HEIGHT in Operating Instructions.

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

is a convenient gauge to measure blade height

above ground during the leveling process.

2. Check the side-to-side level. Rotate each blade

sideways and measure the distance from blade

tip to ground on each side. If measurements

vary more than 1/8 in. (3 mm), add a washer

shim under the deck support pins on the low side

to level the deck.

3. Check the front-to-rear level. Rotate the blades

to point forward. Measure the distance from

blade tip to ground on the front and rear. The

rear of the blade should be 1/8 to 1/4 in. (3 to 6

mm) higher than the front of the blade; shim the

rear (or front) deck support pins equally to

achieve at least 1/8 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.

WARNING

The machine must be shut off during this

procedure.

Deck Leveling

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

4 in. (102 mm)

Wood Block

Should not vary more

than 1/8 in. (3 mm)

side-to-side

Assembly Instructions

22

PREOPERATING CHECKLIST

Before operating the mower for the first time, and as

a routine before daily operations, it is important to

make sure the mower is properly prepared and

ready for operation. The following is a list of items to

be checked. (For a mower with frequent operation,

some of these items will not need to be checked 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).

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.

CHECK ENGINE CRANKCASE OIL LEVEL

Check the engine crankcase oil level before use and

after each 5 hours of continuous operation. Refer

to LUBRICATION for Checking Engine Crankcase

Oil Level in Maintenance Instructions.

CHECK AND SERVICE ENGINE AIR CLEAN-

ER SYSTEM

•Check air restriction gauge to make sure there is

no red indication showing.

•Check condition, cleanliness, and security of the

complete air cleaner system (clean air filter

every 100 hours). For detailed procedures,

refer to CLEANING the Engine Air Cleaner

System in Maintenance Instructions.

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.

DANGER

Handle gasoline with care. Gasoline is

highly flammable and its vapors are ex-

plosive. Use safe refueling procedures:

•DO NOT fill fuel tank with the engine run-

ning.

•If the engine is hot, allow to cool before

refueling.

•Use an approved fuel container.

•Fuel the mower outdoors.

•DO NOT smoke while refueling.

•Avoid spilling fuel; use a funnel or spout.

•DO NOT overfill the fuel tank; fill up to

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

DANGER

Make sure to keep hands clear of exhaust

pipe, muffler, and moving parts when

checking airflow.

Assembly Instructions

23

CHECK GEAR AXLE OIL LEVEL

Refer to Gear Axle Lubrication in Maintenance In-

structions.

INSPECT FOUR (4) DRIVE BELTS

Engine PTO Drive, Jackshaft Drive, Hydrostatic

Ground Drive, and GHS Blower Drive (if equipped).

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 = 15 PSI (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.

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.

Deck Secured in TILT-UP Position

CHECK MOWER BLADE CONDITION, SHARP-

NESS, AND SECURITY OF MOUNTING

The blade mounting nut should be tightened to

60 ft-lb (81.3 N⋅m). If blade sharpening is required,

refer to CHECKING/SERVICING for Sharpen

Mower Blades in Maintenance Instructions.

ADJUST MOWER CUTTING HEIGHT, IF RE-

QUIRED

Position the hitch pins in the four deck support pins.

Refer to the “Cutting Height Adjustment” decal on

the deck gearbox cover.

PERFORM ANY ADDITIONAL PROCEDURES

called for on the MAINTENANCE SCHEDULE

CHART in Maintenance Instructions.

DANGER

Never operate cutter blades with deck in

raised position because it is hazardous.

CAUTION

Do not operate machine with deck tilt-up

pivot joint unlocked.

DANGER

Do not operate the mower with deck in tilt-

up position. Do not move the tractor with

the deck in the tilt-up position.

Tilt-Up Latch

Deck Lock Lever

Tilt-Up Lift Handle

Tilt-Up Latch

Tilt-Up Hook

on Deck

Operating Instructions

24

CONTROL IDENTIFICATION, LOCATION, AND

FUNCTION Ignition Switch

The ignition switch is located on the right front of the

body and is used to start and stop the engine. The

switch has three positions: “O” is the OFF position,

RUN is the position the key returns to after starting,

and “S” is the START position. When starting the

engine, turn the key clockwise to the “S” position.

Do not hold the key in the “S” position longer than 10

seconds. If the engine does not start, return the key

to the “O” position for at least 60 seconds before

making a restart attempt. Prolonged cranking can

damage the starter motor and shorten battery life.

Release the key when the engine starts, and it will

return to the RUN position. To stop the engine, rotate

the key counterclockwise to the “O” position.

CAUTION

Before operating the mower, become fa-

miliar with the location and function of

all operator controls. Knowing the loca-

tion, function, and operation of these

controls is important for safe and effi-

cient operation of the mower.

Operating Controls

Parking

Brake

Blade Clutch

(PTO)

Light Switch

(Optional, Not Shown)

Hourmeter

Forward Speed Control (FSC)

Steering Levers

Oil Pressure

Warning Light

5 Amp

Circuit Breaker

Ignition Switch

Operating Instructions

25

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 NEUTRAL-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 has two positions. Pulling the

lever UP engages the PTO that drives the mower

blades. Pushing the lever DOWN disengages the

PTO and engages the blade brake.

NOTE: On GHS equipped models, the Powerfil ®

motor and Grass-Pak® full signal switch are activat-

ed by engaging the blade clutch. Refer to Using the

GHS Catcher in this section for a complete descrip-

tion of GHS operation.

ON

OFF

START

Throttle Choke

Operating Instructions

26

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: If pressure on the parking brake pin (e.g.,

parked on a hill) makes it impossible to release the

parking brake with the parking brake lever, move the

mower gently forward or backward to release the

pin.

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 the cam

and lowering the lever, the transmissions are en-

gaged for normal operation. The transmission lever

in the LOCKOUT position is used to enable moving

the machine without the engine running (e.g., for ser-

vice). Refer to TRANSMISSION LOCKOUT in this

section for operating instructions.

Lockout Lever Location

NOTE: The transmission plunger on the side of the

transmission case (activated by the LOCKOUT LE-

VER) must be completely released during operation

of the mower, otherwise operation of the 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. If the 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-amp, 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).

Lockout

Levers

Transmission

Plunger

Operating Instructions

27

THROTTLE

BLADE CLUTCH (PTO)

Pull Up to Engage

PARKING

BRAKE

LEFT WHEEL

STEERING LEVER

Forward Position

(No Control Change)

Neutral-Park

Position

Reverse Drive

Wheel Motion

Position

RIGHT WHEEL

STEERING LEVER

The Forward Speed Control also Establishes the Neutral-Park Position of the Steering Levers

FORWARD SPEED

CONTROL LEVER (FSC)

Full Forward

Ground Speed

Position

Intermediate

Ground Speed

Position

Neutral-Park

Position

Disengaged

Position

Idle

Position

ON Position

OFF Position

CHOKE

Engaged

Position

Fast

Throttle

Position

Engaged

Position

Disengaged

Position

Operating Controls (Top View from Drivers Point of View)

Operating Instructions

28

STARTING THE ENGINE

1. Before attempting to start the engine, make

sure the operator is in the seat, the Forward

Speed Control is in NEUTRAL-PARK position,

and the blade clutch and parking brake are

DISENGAGED.

NOTE: Release parking brake to prevent extra

load on the starter if the transmission neutral is

slightly out of adjustment.

2. Move the choke lever to the ON position and

move the throttle 1/4 to 1/2 open (toward

FAST). Turn the ignition switch to the START

position to start the engine. Release the key to

RUN position as soon as the engine starts.

NOTE: The choke may not be required if the

engine is warm.

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.

3. 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.

4. Gradually move the choke to the OFF position,

keeping enough choke on to allow the engine

to run smoothly as it warms up. As soon as

possible, move the choke to the OFF position.

IMPORTANT: Make sure the choke is in the

OFF position during normal engine operation;

running with the choke in the ON position CAN

damage the engine.

ADJUSTING GROUND SPEED AND STEERING

IMPORTANT: If the DSD52 Mower deck is in-

stalled on the tractor, make sure the dolly wheel is

retracted BEFORE moving.

CAUTION

Before operating the mower, read and un-

derstand all Safety Instructions and Operat-

ing Instructions.

WARNING

NEVER run the engine in an enclosed or

poorly ventilated area. Engine exhaust

contains carbon monoxide, an odorless

and deadly gas.

CAUTION

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.

CAUTION

Learn to START, STOP, and MANEUVER

the mower in a large, open area.

If the operator has not operated a ma-

chine with LEVER STEERING OR DUAL

HYDROSTATIC TRANSMISSIONS, steer-

ing and ground operation should be

learned and practiced until the operator is

completely comfortable handling the ma-

chine BEFORE ATTEMPTING TO MOW.

DANGER

Keep feet on footrests at all times when

the machine is moving.

Operating Instructions

29

1. Move the FSC out of NEUTRAL-PARK position

to the desired forward speed. DO NOT hold for-

ward on steering levers. It is not necessary to

hold the FSC lever in position since a friction

lock maintains the selected lever position (and

forward travel speed).

NOTE: This is exactly the same procedure

used to normally stop and park the machine.

NOTE: If the FSC lever will not stay in the

selected position, the friction lock needs to be

adjusted. Refer to ADJUSTMENTS of Forward

Speed Control Friction Lock in Maintenance

Instructions.

2. Steer by pulling the lever on the side of desired

direction of turn, e.g., pull the LH lever to turn

left. To minimize the possibility of overcontrol,

use only one hand on both steering levers.

WARNING

In case either of the transmission drive

belts break during operation, and if the

machine is on a slope, the machine will

freewheel down the slope. To maintain

control, immediately (1) Release the

steering levers and simultaneously (2)

Move the FSC to the NEUTRAL-PARK

position. When the machine is stopped

or moving slowly, engage the parking

brake.

Beginning Recommendations are:

♦Learn operation of the mower in an open

area away from buildings, fences, and 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 inside wheel into reverse

for a smooth “rolling” turn (one wheel roll-

ing forward while the other rolls backward).

♦Practice maneuvering the mower until

you can make it go exactly where you are

aiming.

♦Remember, for an emergency stop, or in

case of loss of control, machine movement

can always be stopped quickly by pulling

the Forward Speed Control into the NEU-

TRAL-PARK position.

Operating Instructions

30

Correct Operator Hand Position

on the Controls

3. Reverse direction of the mower by pulling both

levers backward.

NOTE: Smooth action on the steering levers

will produce smooth mower operation. Remem-

ber to keep the engine and ground speed slow

until learning the control response.

4. The FSC may be adjusted forward for faster

ground speed and 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.

5. 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: If the tractor creeps forward or back-

ward with the FSC 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.

2. Pull the blade clutch lever SLOWLY up to en-

gage the mower blades.

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).

Pull Steering

Levers With

Left Hand

Keep Feet On Footrest

When Moving

Forward Speed Control

(FSC)

CAUTION

A safety interlock switch (seat switch) will

cause the engine to stop if the blade

clutch is engaged and the operator is not

in the seat. The function of this switch

should be checked by the operator 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.

CAUTION

If the cutting blades strike a stationary ob-

ject while mowing, stop the mower imme-

diately, disconnect the spark plug wires,

lift the deck, and inspect the deck and

blades thoroughly for damage. Make sure

that the blade timing has not been dis-

turbed (the blades should be at 90 degrees

to each other). 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

31

Blade Clutch Engaged

Blade Clutch Disengaged

STOPPING THE MACHINE

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

the 1/2 throttle position.

2. Pull the steering levers to the NEUTRAL posi-

tion and then move the FSC lever backward to

the NEUTRAL-PARK position.

3. Disengage the blade clutch.

IMPORTANT: DO NOT disengage the blade

clutch with high engine speed (above 1/2 throt-

tle) since the brake action on the blade drive will

cause premature wear of the brake band.

4. Slow the engine to idle, put throttle in IDLE po-

sition; and turn the ignition switch OFF.

5. Engage the parking brake.

IMPORTANT: The hydrostatic transmissions

lock to prevent the mower from rolling freely with

the engine stopped. However, if the mower is

parked on a slope, it is necessary to ENGAGE

the parking BRAKE to prevent the mower from

creeping. This is due to a small amount of slip-

page in the hydrostatic transmissions, especially

when transmission fluid is warm.

ADJUSTING CUTTING HEIGHT

Engaged

Position

Disengaged

Position

WARNING

A brake stops the cutter blades (and

blower on GHS equipped models) from

freewheeling within five (5) seconds after

disengaging the clutch. If the brake 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

Maintenance Instructions.

WARNING

Remove the key from the ignition switch

when leaving the mower unattended. This

will prevent children and inexperienced

operators from starting the engine.

WARNING

The engine must be stopped before ad-

justing cutting height. Disengage the

blade clutch (PTO), stop the engine, and

remove the ignition key. Wait for all move-

ment to stop before getting off the seat.

Operating Instructions

32

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.

Cutting Height Adjustment

TRANSMISSION LOCKOUT

IMPORTANT: DO NOT TOW this mower with the

transmission lockout engaged. Towing can produce

excessive internal pressure and damage the trans-

mission.

To move the mower with the engine NOT running

(dead battery, maintenance, etc.), the hydrostatic

transmissions are unlocked (released).

1. Raise the body.

2. Lift the transmission lockout lever on both the

RH and LH transmissions and secure into place

with the locking cam.

3. The mower will “freewheel” with the levers in the

LOCKOUT position. The levers must be in the

highest position to completely unlock the trans-

missions.

Lockout Lever - Freewheel Position

4. After moving the mower, release the locking

cam, placing the lever DOWN in the normal OP-

ERATING position. Make sure the transmission

lockout plunger on the side of the transmission

case (activated by the lockout lever) is com-

pletely released, otherwise the transmission

operation will be erratic.

Lockout Lever - Normal Operating Position

Hitch Pin

Deck Support

Pin

Lift Handle

Cam in

LOCKOUT

Position

Plunger

Depressed

Lockout Lever

Cam in

UNLOCKED

Position

Lockout Lever

Plunger

Released

Operating Instructions

33

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).

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

too tall. Mow frequently and do not cut grass too

short. (For best appearance, cut off 1/3 or less of

existing grass height.)

•When mowing, operate the engine at or 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 grass. The engine is designed

to be operated at full speed.

•When mowing in adverse conditions (tall and/or

wet grass), mow the grass twice. Raise the mower to

the highest setting - 4 in. (102 mm) - for the first pass

and then make a second pass cutting to the desired

height.

•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 to property by thrown objects.

Side Discharge Shield in Lowest Position

•When operating on a slope, reduce speed and

use caution to start, stop, and maneuver. Avoid

sharp turns or sudden changes in direction. The

maximum recommended side slope operating

angle is 20 degrees or 33% grade.

Maximum Recommended Side Slope

Maximum Recommended

Side Slope - Do Not Operate

on Steep Slopes

Operating Instructions

34

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.

•The tractor body should never be tilted for-

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

cause the deck to unhook from the tractor and fall

with considerable force, potentially causing deck or

tractor damage and/or bodily injury.

•When transporting a tractor with the deck in the

tilt-up position (on a truck or trailer), the deck

should be secured to the vehicle with a strap or

rope (stop vertical movement). This will prevent the

deck from bouncing on the rear roller wheels (caus-

ing breakage). This will also prevent the deck from

unhooking from the tractor and falling, potentially

causing deck or tractor damage. Damage to other

items parked in front of the deck may also occur.

Operating Instructions

35

GRASS HANDLING SYSTEM (GHS)

GHS Model Only

GHS Flow and Components

PTO and Blade

Gear Drive

PTO

Clutch

Rear Discharge

Mower Deck

Deck

Discharge Chute

Blower

Body Chute

Assembly

Grass Catcher

Catcher

Door Spring

Catcher

Door

Exhaust

Deflector

Exhaust Screen

(Removable)

Catcher Door

Safety Latch

Grass-Pak®

Vane Switch

“Full” Signal

Horn

Actuator

Rod

Powerfil ®

Drive Motor

Dump Handle

Powerfil ®

Delivery Spout

Delivery

Chute

Shear Pin

Shear

Bolt

Operating Instructions

36

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 cleaning required. How-

ever, under certain operating conditions, the inside

of the blower housing may accumulate a deposit of

dirt, causing wear and binding of the blower wheel.

Normally, dirt buildup occurs when mowing a com-

bination of dirty and damp grass, especially in

the springtime. When operating in these condi-

tions, check the blower wheel frequently for

binding and clean the blower housing as required.

Refer to CLEANING the GHS Blower in Mainte-

nance Instructions.

NOTE: In Autumn, when using the GHS mower to

vacuum leaves, it is recommended to raise the

front of the mower deck 2 to 3 notches [1 to 1-1/2

in. (25 to 38 mm)] higher than the rear. This will

avoid “bulldozing” leaves, particularly when the

leaves are piled in a thick layer. To make this ad-

justment, the hitch pins in the two (2) front deck

support pins are repositioned 2 to 3 notches higher

while leaving the rear pins in their original position.

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

DANGER

NEVER operate the GHS catcher with the

back door open. Objects may be thrown

out the back of the catcher with sufficient

force to cause serious injury to bystand-

ers or property damage.

DANGER

ROTATING BLOWER BLADES

NEVER operate the GHS blower with the

blower discharge chute uncovered (grass

catcher in the dump position) since 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.

CAUTION

NEVER leave grass clippings in the grass

catcher after mowing. Damp clippings

generate heat as they decompose. This

MAY cause spontaneous combustion.

Blower

Intake Cover

Operating Instructions

37

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.

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.

•Check to see if the RH and LH mower blades are

installed for the correct rotation - install blades so

the cutting edges move toward each other.

Blade Rotation for GHS Mower Deck

(view from underneath)

•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.

•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.

•Check the deck cutting height setting. When

working in thick, tall grass, lower deck settings

[1 to 2 in. (25 to 51 mm) cutting heights] tend to

restrict airflow from moving into and under the

deck. Raising the deck cutting height will signifi-

cantly increase airflow and reduce clogging when

working in thick, tall grass.

•Check the interior of the chute connecting the

mower deck to the blower for smoothness and

freedom from obstruction.

•Check the blower wheel for bent blades and

excessive clearance between the blade tip and the

blower housing. A clearance greater than 1/8 in.

(3 mm) will cause a significant loss of blower

performance.

•Check the blower discharge chute into the grass

catcher for smoothness and freedom from 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.

•Check that the openings in the removable air

exhaust screen in the grass catcher are not

plugged. If the screen is clogged, refer to Cleaning

the GHS Exhaust Screen in this section.

DANGER

NEVER place hands under the mower deck

or in the GHS blower discharge chute. Use

a stick or similar tool to remove any

clogged material.

FORWARD

Blades Must Operate at

Right Angles (90 Degrees)

Mounting Nut

Torque = 60 ft-lb

(81.3 N⋅m)

Rear Discharge

Chute

Operating Instructions

38

Remember, anything that restricts airflow or material

flow along the entire path from the mower deck to

the grass catcher can cause clogging.

Using the Tilt-Up Deck

Refer to CLEANING of Grass Buildup in Mower

Housing in Maintenance Instructions.

Using the GHS Catcher

Powerfil ®

The GHS catcher has an oscillating grass delivery

spout (POWERFIL®) which is designed to spread

grass clippings throughout the interior of the grass

catcher (even when mowing wet, heavy grass). The

oscillating action may be checked by turning the

ignition switch to the ON position and moving the

blade clutch to the ENGAGED position. The spout

should oscillate approximately 25 cycles per

minute.

NOTE: If the grass spout fails to oscillate, the clutch

switch should be checked for function (the switch

closure is adjustable).

“Full” Signal Horn

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.

The “full” signal horn is designed to operate (sound)

when the grass catcher is almost full. The timing of

the signal is adjustable by changing the position of

the vane on the Grass-Pak® 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 for Cleaning

WARNING

DO NOT test the Grass-Pak® switch with

the engine running. Projectiles may be

thrown out of the grass delivery spout,

and COULD cause serious injury.

Grass Catcher

Screen

Removal

Knobs

Operating Instructions

39

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 move grass clippings from

the catcher to a remote disposal area or container.

Tailgate Dumping

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

NOTE: To prevent accidental door closure, a

safety latch locks the door open in the fully

opened position while the catcher is being

dumped.

2. Tilt the catcher back to dump by lifting on the

catcher lift handle on the lower front corner of

the catcher.

3. Lower the catcher smoothly down to the normal

operating position. DO NOT allow the catcher

to drop down.

4. Close the door by holding the door handle

with the left hand and releasing the safety

latch on the door hinge mechanism with the

right hand. The safety latch is released by

pressing in on the top of the latch. Then,

smoothly close the 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.

2. Orient the dump bag with one of the handle

straps on the bag opening facing up.

Positioning Dump Bag on Catcher

Safety

Latch

Tailgate Door

Handle

Hook Bag

on Bumper

Operating Instructions

40

3. Hook the bottom of the bag over the rear

bumper while lifting on the handle strap.

4. Tilt the catcher back to dump into the bag by lift-

ing on the catcher lift handle on the lower

front corner of the 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.

Dumping Catcher into Dump Bag

5. Lower the catcher smoothly down to the normal

operating position. DO NOT allow the catcher

to drop down.

6. Close the door by holding the door handle with

the left hand and releasing 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 Lift /

Dump Handle

Maintenance Instructions

41

CAUTION

Maintenance procedures requiring special training or

tools should be performed by a trained technician.

MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL MC

Service Item Daily 25

Hours 100

Hours 200

Hours Yearly Every

2Years Ref.

Page

Check Engine Crankcase Oil Level x 43

Check/Clean Engine Air Cooling System* x 52

Check Security of Air Filtration Components x 55

Check Air Filter Restriction Gauge x 51

Clean Grass Buildup Under Deck x 53

Clean GHS Exhaust Screen* x 38

Clean GHS Blower* x 54

Service Mower Blades x 56

Check Function of Oil Pressure Warning Light x 23

Lubricate Grease Fittings and Oil Points* x 44

Check PTO Gearbox Oil Level** x 46

Check Battery Electrolyte Level x 55

Check Hydrostatic Transmission Fluid x 46

Check Tire Pressure x 56

Check Drive Belts (Jackshaft, Engine PTO,

GHS Blower, Ground Drive) x57

Check Gearbox Oil Seals x 58

Check Turbine Precleaner* x 50

Check/Clean Air Filter Element ∆x51

Change Engine Crankcase Oil ∆∆ x43

Check/Adjust Blade Clutch (PTO)/

Brake Action x71

Check Oil Level in Gear Axle x 46

Clean Hydrostatic Transmission Cooling Fins x 55

Clean Engine Cooling Fins x 52

Check/Regap Spark Plugs x 58

Change Engine Oil Filter x 43

Check Fuel Lines and Clamps x 58

Replace Air Filter Element

and Vacuator™ Valve ∆x51

Replace Fuel Filter x65

Service Battery x55

Check/Adjust FSC Friction Lock x 76

Service Solenoid Shift Starter x 58

Check Engine Valve Clearance x 58

Change Gear Axle Oil ∆∆∆ x46

Change Hydrostatic Transmission Fluid ∆∆∆ x47

Replace Fuel Lines and Clamps x58

∗More often in extremely dusty or dirty conditions

(refer to notes about air cleaner element in

IMPORTANT TIPS FOR CARE OF KOHLER ENGINE)

∗∗ Change PTO gearbox oil and filter after first

100 hours of operation (break-in period)

∆Air cleaner is remote mounted Donaldson Radialseal™

unit, replace filter every year or after 6 cleanings

∆∆ Change engine oil and filter after first 5 hours of

operation of a new engine (break-in period)

∆∆∆ Change every 2 years or 1000 hours

CAUTION

When performing maintenance with the

mower body raised, a safety prop should

be installed from back of body to chassis

frame (fail-safe protection in case of fail-

ure of body lift support). For GHS Model,

empty grass catcher before raising body.

Maintenance Instructions KOHLER TIPS

42

IMPORTANT TIPS FOR CARE OF THE KOHLER

ENGINE

Fuel System

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

ganic material.

•Change fuel filter on a regular basis and when

contamination is suspected or found in the fuel.

Starting/Stopping

•Start engine with the throttle advanced off idle (1/

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

cold weather.

•Keep the battery fully charged.

•Match crankcase oil viscosity to the ambient tem-

perature, allowing the engine to crank faster and

start easier.

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

fore stopping engine to avoid run-on or backfiring.

Cooling System

•Keep engine air intake screen and cylinder head

fins free of grass clippings, chaff, and dirt. Inspect

intake screen and cooling fins for cleanliness and no

damage.

•Periodically remove two access panels in the en-

gine shroud to inspect and clean cylinder head cool-

ing fins.

•Check performance of the cooling system by

starting the engine, holding a hand adjacent to the

cylinder head, and feeling the cooling airflow.

•Operate the engine at full speed when mowing.

This allows the engine to produce full horsepower

and move more cooling air through the engine cool-

ing fins.

Air Cleaner System

•Use only Donaldson air cleaner elements. After-

market elements may not seal in the air cleaner

housing, allowing dirt to enter the engine. 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.

•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.

•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

reduce 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.

DANGER

Make sure to keep hands clear of exhaust

pipe, muffler, and moving parts when

checking airflow.

Maintenance Instructions LUBRICATION

43

LUBRICATION

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

overemphasized. Check the oil level BEFORE

EACH USE.

1. Park the mower on a level surface with the en-

gine stopped. Also, make sure the engine is

cool and oil has had time to drain into the sump

[allow at least five (5) minutes after stopping

the engine].

IMPORTANT: NEVER check or add oil with the

engine running.

2. Before removing the dipstick, clean the area

around the dipstick to keep any dirt or debris out

of the engine.

3. Remove the dipstick, wipe off with a clean rag,

then reinsert the dipstick into the tube and press

all the way down.

4. 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.

5. If additional oil is needed, refer to Specifications

for proper crankcase lubricant. Fill up to, but

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

IMPORTANT: DO NOT overfill the crankcase

(oil above “F” mark) as this CAN result in engine

overheating, loss of power, and possible en-

gine damage.

Dipstick Operating Range

Changing Engine Crankcase Oil/Oil Filter

Change the engine crankcase oil after every 100

hours of operation and replace the oil filter every

other oil change (every 200 hours of operation).

WARNING

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.

Full Mark

Low Mark

Maintenance Instructions LUBRICATION

44

1. Park the mower on a level surface with the en-

gine stopped. The engine oil should be warm

before draining. If not warm from operation,

start the engine and run a few minutes to warm

the oil.

2. Before removing the dipstick, clean the area

around it to keep any dirt or debris out of the en-

gine.

3. Remove the dipstick and oil drain plug and drain

the oil into a suitable container. Be sure to allow

ample time for complete drainage.

Oil Drain/Oil Filter Location

4. Before removing the oil filter, clean the area

around the filter to keep dirt and debris out of

the engine.

5. Remove the old oil filter and wipe off the filter

mounting surface on the engine.

6. Apply a thin coating of clean oil to the rubber

gasket on the replacement oil filter.

IMPORTANT: Use ONLY oil filters from the 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.

7. 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.

8. Reinstall the drain plug. Make sure it is tight-

ened to 10 ft-lb (13.6 N·m).

9. Fill the crankcase with new, clean oil. Use only

crankcase lubricants recommended by the en-

gine manufacturer. Refer to Specifications in

this manual or the engine owner’s manual. Use

the recommended oil viscosity for the expected

ambient temperature. Oil with the correct vis-

cosity will aid starting in cold weather and 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.

10. 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.

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.

Drain Plug

Oil Filter

Maintenance Instructions LUBRICATION

45

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 oil leak

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.

Mower Deck Gearboxes

(shown with gearbox cover removed for clarity)

2. Clean the area around the individual gearbox

cover plates to prevent contaminants from en-

tering the gearcase.

3. Remove the screws securing the cover plates

on the blade drive gearboxes.

4. Check the level of lubricant in the gearboxes. If

the lubricant is low, add SAE E.P. (Extreme

Pressure) 90W oil until the oil level is up to (sub-

merges) the horizontal shaft in the gearbox

(shaft parallel to cover plate).

NOTE: In case the gearboxes are completely

drained of oil, approximately 5 fl. oz. (15 cl) of oil

per gearbox is required to refill the gear drive

assembly.

NOTE: Since the gearboxes are connected as

a unit by connector tubes, it is necessary to add

oil slowly. Allow a few minutes after adding oil

for the oil to flow throughout the assembly and

the oil level to stabilize before reassembly.

IMPORTANT: DO NOT overfill the deck gear-

boxes. The gearbox assembly is not vented,

and overfilling with oil will cause excessive pres-

sure and result in oil leaks.

5. Check condition of the cover gasket and replace

if worn or damaged. Reinstall gearbox cover

plates; torque screws to 24 in-lb (2.7 N⋅m).

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 Spindle Lubrication

2. Check the oil level in the belt drive gearbox ev-

ery 100 hours (or sooner if a visible oil leak has

developed). With the deck in the normal oper-

ating position, remove the level plug in the side

of the gearcase. Add SAE E.P. (Extreme Pres-

sure) 90W oil to maintain the oil level to the plug.

If the oil level is low, check the gearbox for any

indication of an oil leak. If an oil leak is noted,

the gearbox will need to be removed and rebuilt.

3. Lubricate the dolly wheel pivot every 25 hours

with general purpose grease.

Blade Drive

Gearboxes

Tee

Gearbox

Blade

Spindles

Maintenance Instructions LUBRICATION

46

4. Lubricate the U-Joint in the drive shaft every

8 hours with SAE general purpose lithium or

molybdenum base grease.

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.

Dipstick Location, Tractor PTO Gearbox

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.

2. Refill the gearbox through the dipstick stand-

pipe using 7 to 8 fl. oz. (21 to 24 cl) of SAE E.P.

(Extreme Pressure) 90W gear lube.

3. Check that the oil level is at the FULL mark on

the dipstick. DO NOT overfill.

Gear Axle Lubrication

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

GL-5) gear lube.

•Check the axle oil level after every 100 hours of

operation by removing the oil level plug. If additional

oil is needed, remove the breather vent on top of 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.

2. Remove the reservoir cap and check the level

of the fluid. The reservoir has a fluid level COLD

mark and HOT mark. The reservoir oil level

should ALWAYS be at or above the COLD

mark and NEVER above the HOT mark.

Dolly Wheel

Pivot

U-Joint

Level Plug

Belt Drive

Gearbox

Dipstick

PTO

Gearbox

Jackshaft

Maintenance Instructions LUBRICATION

47

Transmission Reservoir

and Air Bleed Plug Location

3. 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. If a small amount of fluid leaks from around

the air bleed plug:

* The transmission is full of fluid.

* Tighten the plug and fill the reservoir to

the COLD level mark.

b. If no fluid leaks from around the air bleed

plug:

* Slowly add fluid into the reservoir until

fluid starts to leak from around the plug.

(Transmissions are serviced from the

factory with Mobil 1 (15W50) Synthet-

ic Oil). When it is necessary to add 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.

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

bleed plug before the transmission is considered full.

IMPORTANT: Any attempt to remove or in any way

alter the filtering screen in the transmission reservoir

could cause damage to the transmission and will

VOID any transmission warranty.

Changing Hydrostatic Transmission Fluid

The hydrostatic fluid should be changed every 1000

hours or two (2) years. Also, the fluid should be

changed if the natural color of the fluid has 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. Park the mower on a level surface and stop the

engine.

2. Remove the lower drain plug and the air bleed

plug. Allow the fluid to drain out.

IMPORTANT: Clean any dirt from around the

plugs and reservoir cap before removing them.

3. Reinstall the lower drain plug, making sure the

rubber O-ring on the plug is in place and in

good condition.

4. Refill the transmission through the air bleed

plug hole until it is as full as possible.

IMPORTANT: Avoid fluid contamination when fill-

ing the reservoir. Use clean container, spout, fun-

nel, etc. when pouring the fluid into the reservoir.

5. Rotate the transmission input shaft about five (5)

revolutions to allow any trapped air to escape.

6. Before installing the air bleed plug, fill the reser-

voir with fluid allowing a small amount to leak

out of the air bleed plug hole.

7. Install the air bleed plug and fill the reservoir to

the COLD level line.

Cold Level

Reservoir Cap

Hot Level

Air Bleed Plug

Maintenance Instructions LUBRICATION

48

Ident Lubrication No.

No. Location Type Places Ident Lubrication No.

No. Location Type Places

1 Deck Caster Wheel Fork Pivot Grease 2

2 Deck Caster Wheel Bearing Grease 2

3 Tee Gearbox, Deck Oil*1

4 Blade Drive Gearbox Oil*2

5 PTO Shaft Guard Hinge Oil 1

6 Universal Joint Shaft Assembly Grease** 1

7 Pivot Assembly, Tilt-Up Deck Grease 4

8 Deck Support Arm Socket Grease 2

9 Body Hinge Point Oil 2

10 FSC Actuator Rod Pivot Pins Oil 2

11 FSC Lever Pivot Grease 1

12 FSC Lever Fork Grease 1

(Grease Slide Area)

13 (FSC) Friction Body Pivot Grease 1

14 Steering Lever Pivot Grease 4

15 Deck Roller Wheel Oil 2

16 Deck Support Arm Pivot Grease 2

17 Deck-to-PTO Coupling Grease 1

(Grease Slide Area)

18 Universal Joint Tube Assembly Grease** 1

19 Universal Joint Quick Connect Grease 1

Spline (Grease Slide Area)

20 Parking Brake Lever Grease 1

21 Gear Axle Oil*** 2

22 Belt Tightener Pivot, Grease 1

Jackshaft Drive

23 Clutch Actuator Push Rod Grease 2

24 PTO Clutch Lever Pivot Grease 1

25 Belt Tightener Pivot, Grease 1

PTO Clutch

26 Brake Actuator Rod and Brake Oil 3

Band Pivot Pins (Clevis)

27 Brake Actuator Pivot Grease 1

28 Anti-Scuff Roller Wheel Oil 2

29 Catcher Hinge Point Oil 2

30 Choke Control Cable Ends Oil 2

31 Throttle Control Cable Ends Oil 2

32 Engine Oil Oil*** 1

33 Belt Tightener Pivot, Grease 1

Blower Drive (GHS Model Only)

34 Belt Tightener Pivot, Grease 1

Ground Drive

35 PTO Gearbox Dipstick Oil*** 1

36 Hydrostatic Drive Oil*** 2

37 Choke Control Pivot Oil 1

38 Throttle Control Pivot Oil 1

39 Discharge Chute Hinge Oil 1

40 Tilt-Up Latch Assembly Oil 1

41 Steering Lever Support Oil 1

*Gearboxes are permanently lubricated and

sealed requiring no scheduled lubrication.

Oil level should be checked only when an oil

leak is noted. Refer to Mower Deck Gear-

box Lubrication in this section.

** Grease every eight (8) hours.

*** Refer to Gear Axle Lubrication, Engine

Oil, Tractor PTO Gearbox Lubrication, and

Hydrostatic Transmission Fluid in this sec-

tion.

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

For other Deck Lubrication Points, Refer to

Deck and Carrier Frame Illustrated Parts

Manual.

Maintenance Instructions LUBRICATION

49

2

10

13 11

12

23

25

23 24

27 26

211

4

8

7

7

29 29

32

31

30

28 28

32 & 37

33

21

22

31 & 38

35

36

34

9

41

40

14

39

15

16

21

3

4

5

6

7

7

8

9

15

14

17

18

19

20

16

Chassis and Deck Lubrication Points

Maintenance Instructions CLEANING

50

CLEANING

Engine Air Cleaner System

There are two main components in the engine air

cleaner system: a turbine precleaner 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:

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. Start the engine and watch the fan begin to spin

as the throttle is advanced.

If the fan is not spinning, service or replace the pre-

cleaner as required.

Donaldson

Air Cleaner

Vacuator™

Valve

Donaldson Air

Cleaner Cover

Air Intake

Hose

Turbine Precleaner

Precleaner Tube

Engine

Air Cleaner

Cartridge

Hose

Clamp

Safety

Filter

Air

Restriction

Gauge

Brass

Elbow

Engine Air Cleaner System Components

Maintenance Instructions CLEANING

51

Donaldson Radialseal™ Air Cleaner

A remote mounted Donaldson Radialseal™ air

cleaner provides the air filtering function. The paper

filter element slides over an outlet tube inside the air

cleaner canister with radial sealing action, 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.

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.

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™ 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.

2. Remove the filter element by pulling it out of the

canister. There will be some initial resistance as

the filter seal breaks loose and slides off of the

outlet tube. Gently move the end of the filter up

and down and side to side or twist to loosen the

seal. Use gentle action to minimize the amount

of dust dislodged as the filter is removed.

3. Clean the filter element using low pressure

compressed air [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.

Cover Canister

Vacuator™

Valve

Radialseal™

Filter Element

Cover

Latch

Air Restriction

Gauge

Push Button to Reset

Indicator After Service

Maintenance Instructions CLEANING

52

4. Use a bright light inside the element to inspect

for damage. Check the element very carefully

for pin holes or other damage that will allow

dirt to leak through the paper media. Replace

element if necessary.

5. Check the condition and resilience of the radial

sealing surface (inside of the open end) of the

filter. Replace the filter if any cracks, tears, or

other damage to the sealing surface are noted.

6. Use a clean, damp cloth and wipe the interior of

the air cleaner canister clean. Use special care

to clean both the inside and outside surfaces

of the outlet tube.

IMPORTANT: Any dust left on the inside of the

outlet tube will go into the engine and cause

wear.

7. Check the outside surface of the outlet tube for

smoothness and cleanness (this is the sealing

surface).

8. 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.

Air Filter Element Replacement

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.

Proper Orientation of Air Cleaner Cover

10. Check the air intake hose for cuts, 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.

Radial Sealing

Surface Radialseal™

Filter Element

Outlet Tube

Canister

CAUTION

Operating the engine with a blocked air

intake screen, dirty or plugged cooling

fins, and/or cooling shrouds removed will

cause engine damage from overheating.

Cover Latch

Vacuator™

Valve

Cover Latch Orient to Top

of Canister

Maintenance Instructions CLEANING

53

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.

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 surfaces using compressed air.

Make sure to reinstall the access panels before op-

erating the engine.

Engine Air Intake Screen

and Cooling Fin Access Panels

Cooling System Airflow

Grass Buildup in Mower Housing

1. Raise the deck lock lever handle on each side

of the carrier frame and pull out to release car-

rier frame for tilting action.

2. Using the carrier frame lift handle, raise deck to

the TILT-UP position and insert the deck hook

into the tilt-up latch on the tractor body.

Deck Secured in TILT-UP Position

DANGER

Make sure to keep hands clear of exhaust

pipe, muffler, and moving parts when

checking airflow.

Kohler Engine

Shroud

Engine Air

Intake Screen

Engine Cooling

Fin Access Panels

DANGER

Before raising or removing the mower

deck for cleaning, stop the engine, re-

move the ignition key, and disconnect the

spark plug wires.

Check Airflow

with Hand

Cylinder

Head

Tilt-Up Latch

Deck Lock Lever

Tilt-Up Lift Handle

Tilt-Up Latch Tilt-Up Hook

on Deck

Maintenance Instructions CLEANING

54

3. Clean grass buildup underneath the deck using

a pressure washer (and scraper if required).

NOTE: While some degree of material buildup

in the mower deck housing can be tolerated, a

point is finally reached where cutting quality

deteriorates and clogging begins to occur

because of too much buildup on the baffling and

housing.

4. Lower the deck to the normal operating position

and re-engage the deck lock levers.

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:

1. 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).

2. Use a pressure washer or water spray, and di-

rect the spray inside the blower housing against

the 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.

3. Reinstall the GHS blower drive belt by reversing

the removal procedure.

Collapse Blower Belt Tightener

to Remove GHS Blower Drive Belt

DANGER

Do not operate the mower with deck in tilt-

up position. Do not move the tractor with

the deck in the tilt-up position.

CAUTION

Do not operate machine with deck tilt-up

pivot joint unlocked.

DANGER

Before attempting to wash the blower,

stop the engine, remove the ignition key,

and disconnect the spark plug wires.

GHS Blower

Drive Belt

Blower

Pulley

Blower

Drive Pulley

Belt Tightener

Idler Pulley

55

Maintenance Instructions CLEANING/

CHECKING/SERVICING

GHS Exhaust Screen

Refer to Cleaning the GHS Exhaust Screen in Op-

erating Instructions.

Hydrostatic Transmission Cooling Fins

Keeping the cooling 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 cooling

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

CHECKING/SERVICING

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.

2. 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 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. Check the 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].

3. Replace filler caps.

Cooling Fins

Cooling Fan

DANGER

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.

56

Maintenance Instructions CHECKING/SERVICING

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 exceed one (1) hour.

2. After charging the battery, use drinking water to

adjust the electrolyte level to the bottom of the

vent wells [1/4 to 1/2 in. (6 to 13 mm) above the

plates].

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.

1. Stop the engine, remove ignition key, and dis-

connect the spark plug wires before raising the

mower deck to service blades.

2. 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.

3. Check the blades for straightness by marking

the blade tip position inside the deck housing,

and then rotating the opposite end of the blade

to the same position and comparing. If the dif-

ference in blade tip track is more than 1/8 in.

(3 mm), the blade is bent and should be re-

placed.

DANGER

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 ma-

terials away from the battery at all times.

• Make sure the battery cap vents are open

(check manifold vent on each cap).

• Make sure the battery charger is un-

plugged before connecting or discon-

necting cables to the battery.

DANGER

NEVER operate cutter blades with the

deck in the raised position.

57

Maintenance Instructions CHECKING/SERVICING

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

should be sharpened. Remove blades for

sharpening by grasping the end of the blade us-

ing a rag or a thick, padded glove, while loosen-

ing and removing the nut, lock washer, and flat

washer that mounts the blade.

5. Grind cutting edge at the same bevel as the

original. Sharpen only the top of the cutting

edge to maintain sharpness.

NOTE: Blades can be sharpened with an elec-

tric blade sharpener, conventional electric grind-

er, or a hand file.

Mower Blade Profile For Sharpening

6. Check blade balance by positioning the blade

horizontally on a blade balancer or use a nail or

shaft through the center hole. If either end of the

blade rotates downward, grind (remove) metal

on that end until the blade will balance. The

blade is properly balanced when neither end

drops. Balance of a blade is generally main-

tained by removing an equal amount of material

from each end of the blade when sharpening.

Blade Balanced on Magnetic

Wall-Mounted Balancer

7. Mount the blade with wing tips pointing up into

the housing. Reinstall the blade, washer, lock

washer, and nut. Tighten the nut to 60 ft-lb

(81.3 N⋅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.

WARNING

DO NOT try to straighten a blade that is

bent. NEVER weld a broken or cracked

blade. ALWAYS replace with a new blade

to assure safety.

CAUTION

ALWAYS wear eye protection and gloves

when sharpening a blade.

30°

Do Not Grind or

Sharpen on Underside

Sharpen at

Original 30° Angle

Intersection

Wear Area

Wing

Tip

Blade Balancer

Maintenance Instructions CHECKING/SERVICING

58

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 preventive

maintenance calls for complete replacement of fuel

lines and clamps every two (2) years.

Engine Starter

Yearly or every 500 hours disassemble and clean

the solenoid shift starter. Refer to the Kohler Service

Manual for this procedure or contact an authorized

Kohler engine dealer to perform this service.

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

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.

WARNING

It is important to check and maintain blade

brake action for safe operation of the ma-

chine.

59

Maintenance Instructions REPLACING/REPAIRING

REPLACING/REPAIRING

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:

•Engine PTO Drive Belt (3 Groove Power Band)

•Jackshaft Drive Belt

•GHS Blower Drive Belt (GHS Model Only)

•Hydrostatic Ground Drive Belt

The belts may be removed and replaced using the

procedures described on the following pages.

DANGER

To prevent accidental starting of the en-

gine when replacing parts or repairing the

machine, remove the key from the ignition

switch and disconnect the spark plug

wires.

Maintenance Instructions REPLACING/REPAIRING

60

Jackshaft

Drive Belt

Engine PTO

Belt

GHS Blower Belt

(GHS Model Only)

Hydrostatic Ground

Drive Belt

Belt Locations

Maintenance Instructions REPLACING/REPAIRING

61

Engine PTO Drive Belt (3 Groove Power Band)

1. To remove the engine PTO drive belt:

a. Remove the jackshaft drive belt from its

idler pulley (by pushing down on idler 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).

c. Raise the 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.

2. 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

Engine PTO Drive Belt Removal

Pull UP to Engage

Engine

PTO Belt

Clutch

Linkage PTO Belt

Tightener Arm

Engine

Pulley

Clutch Idler

Pulley

Belt

Guide

Belt Guides

(Bottom Guide Not Visible)

Blade Clutch Lever

in the DOWN Position

PTO Drive

Pulley

Belt

Guide

PTO Belt Tightener

Stop Block

Micro-V

Pulley

Maintenance Instructions REPLACING/REPAIRING

62

Jackshaft Drive Belt

1. To remove the jackshaft drive belt:

a. Remove the engine PTO drive belt, as

described in previous section.

Jackshaft Drive Belt (Engaged)

Jackshaft Drive Belt (Disengaged)

Idler Pulley

Engine

Pulley

Tension Spring

Jackshaft

Jackshaft

Drive Belt

Push Idler Pulley

b. Relax the belt by depressing the spring-

loaded idler arm.

c. Roll the belt off the jackshaft pulley and

remove.

2. Reverse the removal procedure to replace the

jackshaft drive belt.

Idler Arm

Jackshaft

Jackshaft

Drive Belt

Tension Spring

Engine

Pulley

Maintenance Instructions REPLACING/REPAIRING

63

GHS Blower Drive Belt

1. 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

belt off the pulleys.

Blower

Pulley

Belt Tightener

Idler Pulley

(Disengaged)

Blower Drive

Pulley

GHS Blower

Drive Belt

Idler Pulley

(Engaged)

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.

GHS Blower Drive Belt Assembly (Engaged)

Maintenance Instructions REPLACING/REPAIRING

64

Hydrostatic Ground Drive Belt

1. To remove the hydrostatic ground drive belt:

a. Raise the spring-loaded belt tightener arm

and idler pulley to relax belt.

b. Slide belt off pulleys, then release the idler.

Hydrostatic

Ground Drive Belt

Idler Pulley

Belt Tightener Arm Jackshaft

Transmission

Drive Pulley

Spring

Hydrostatic Ground Drive Belt Assembly (Disengaged)

2. Reverse the procedure to install the hydrostatic

ground drive belt.

Belt Tightener Arm

Idler Pulley

Hydrostatic

Ground Drive Belt

Spring

Hydrostatic Ground Drive Belt Assembly (Engaged)

Maintenance Instructions REPLACING/REPAIRING

65

Fuel Filter

Model MC is equipped with an in-line fuel filter. Vi-

sually inspect the filter periodically, and replace the

filter yearly.

Fuel Filter Location

IMPORTANT: Replace the fuel filter only in a clean

area where the fuel line and connections will not be

contaminated by any dust and dirt.

1. Expand and slide clamps on either side of the

filter away from filter and pull fuel lines off filter.

2. Replace filter.

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

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.

DANGER

Gasoline is extremely flammable and can

be highly explosive. To minimize danger:

• Use only an approved fuel container for

gasoline.

• DO NOT allow open flames or sparks

near the machine while performing main-

tenance or refueling; DO NOT smoke

while working with fuel.

• Wipe up spilled gasoline immediately

and completely.

In-Line

Fuel Filter

Cutting Blade

Shear Bolts

Maintenance Instructions REPLACING/REPAIRING

66

After reinstalling the blade, check blade timing by

moving blades through one (1) complete revolu-

tion. Make sure blade tips pass clear of each other.

If timing is incorrect, refer to Mower 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.)

2. Rotate U-joint on shaft to align the shear pin

hole with the hole (and shear pin fragment) in

the shaft. Use a punch to drive the remaining

portion of the old shear pin out.

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

PTO Shear Pin

IMPORTANT: Use only Walker P/N 8067-10

shear pins for replacement to provide proper

shock protection -- these pins are hardened to

shear under a specific amount of load.

4. Reinstall the PTO shaft guard.

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

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.

•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.

•Check the blades for straightness by marking

blade tip position inside the deck housing and then

rotating the opposite end of the blade to the same

position and comparing. If the difference in blade tip

track is more than 1/8 in. (3 mm), the blade is bent

and should be replaced.

•Inspect the blade surface, especially in formed

areas, for cracks. Replace the blade if any cracks

are found.

Cotter Pin

U-Joint

Tube Assembly

Shear Pin

Split Spring Pin

U-Joint

Shaft Assembly

DANGER

When blades are operated over sandy

soil, and if blades are allowed to wear, a

“slot” may be worn into the wing tip of

blade. Eventually a piece of the blade may

break off creating a serious potential for

injury or damage.

Maintenance Instructions REPLACING/REPAIRING

67

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.

Mower Deck Gearbox Replacement

NOTE: Deck gearbox(es) may be changed with

the deck mounted on the tractor. However, the deck

may be removed from the tractor making the overall

job of removing the gearbox assembly easier. Refer

to Deck Installation in Assembly Instructions and re-

verse the procedure to remove the deck.

To replace the mower deck gearbox(es), use the fol-

lowing procedure:

1. Remove mower blades. Refer to procedure in

Sharpen Mower Blade instructions.

2. Remove gearbox cover (two machine screws)

and PTO shaft guard (two 1/4-20 bolts).

3. Remove two (2) 3/8-16 mounting bolts from

each blade drive gearbox and lift the entire

gearbox assembly from the deck (including

PTO drive shaft).

4. Remove the screws securing the cover plates

on the gearboxes and remove the covers. Re-

move all covers to be sure oil is completely

drained from all gearboxes.

NOTE: With oil flow throughout the unitized

gear drive assembly; if one gearbox has internal

damage or excessive wear, the remaining gear-

boxes and connector tubes should be complete-

ly disassembled and thoroughly flushed out with

solvent before reassembly.

5. Drain and properly dispose of oil.

6. Remove the four (4) bolts mounting the gearbox

to the connector tube and slide the gearbox off

the splined drive shaft coupling.

7. 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.

8. 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.

9. 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.

10. 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.

11. Fill gearbox assembly with oil. Refer to Mower

Deck Gearbox Lubrication in this section for

instructions.

12. 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.

WARNING

DO NOT try to straighten a blade that is

bent. NEVER weld a broken or cracked

blade. ALWAYS replace with a new blade

to assure safety.

CAUTION

ALWAYS use genuine factory replacement

parts. Substitute parts CAN result in prod-

uct malfunction and possible injury to the

operator.

Maintenance Instructions REPLACING/REPAIRING

68

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.

Remove Skid Bar for

GHS Blower Removal

2. Remove the blower faceplate by removing six

(6) 1/4-20 nuts.

3. Remove the GHS blower drive belt. Refer to

REPLACING/REPAIRING the Drive Belts in

this section for instructions.

4. 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.

b. Remove the blower belt tightener idler arm

assembly by removing the pivot bolt.

c. Remove two (2) bolts mounting the blower

housing to the frame.

d. Lower the blower assembly straight down

out of the chassis frame and remove.

Blower Wheel Removal

When required, replace the blower wheel using the

following procedure:

1. Loosen blower pulley set screws and remove

the pulley using a wheel puller.

2. 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).

3. 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.

Mower Deck

Gearboxes

Connector Tubes

Skid Bar

Mounting Bolts

Blower Assembly Skid Bar

69

Maintenance Instructions REPLACING/REPAIRING

Pressing Blower Wheel Out of Housing

Blower Wheel Installation

1. 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.

2. 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.

3. Press the rear bearing into place, using Loctite®

on both the outer bearing race and the housing.

4. Install the locking collar on the rear bearing and

install the blower pulley to complete the blower

assembly. Torque the blower pulley set screws

to 250 in-lb (28.3 N⋅m).

GHS Blower Assembly Installation

Reinstall the blower assembly into the mower using

the reverse procedures of GHS Blower Assembly

Removal.

Wheel Puller

Hooked to Lugs

on Bearing Housing

Blower Pulley

5/16-18 x 5/8 SQH

Set Screw

Face Plate

7/16-14 Hex Nut

7/16 Split Lock Washer

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

Blower Wheel

Bearing (3/4)

Bearing (3/4)

Intake Tube

5/16-18 Whiz Locknut

Skid Bar

3/8-16 x 1 Hex Bolt

3/8-16 Keps Nut

5/16-18 x 3/4 Hex Bolt

7/16-14 x 1-1/4 Hex Bolt

GHS Blower Components

70

Maintenance Instructions ADJUSTMENTS

ADJUSTMENTS

Safety Switches

There are three (3) safety interlock switches on the

tractor; Seat Switch, FSC Neutral - Park Switch, and

PTO Switch.

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-

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.

Steering Levers

An adjustment range of approximately 3 inches is

available on the steering levers - the levers can be

adjusted forward or aft depending on the arm length

of the operator. The levers can be adjusted by loos-

ening the locknut at the pivot point and the locknut

holding the lever in position in the adjustment slide.

Adjust levers into most comfortable position and

tighten both locknuts.

Steering Lever Adjustment

DANGER

If the engine must be running to perform

a maintenance adjustment, keep hands,

feet, and clothing from moving parts. DO

NOT wear jewelry or loose clothing.

Locknut

(Position)

Adjustment

Slide

Locknut

(Pivot Point)

Maintenance Instructions ADJUSTMENTS

71

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.

Adjust the bolt head clearance [1/4 in. to 3/8 in.

(6.35 mm to 9.53 mm)] first (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)

Clutch

Actuator Rod

PTO Belt

Tightener Arm Locknut Spring

Compressed

Blade Clutch

Lever Engaged

PTO Clutch Engaged

Maintenance Instructions ADJUSTMENTS

72

Clutch Disengagement/Brake Action 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.

WARNING

It is important to check and maintain

blade brake action for safe operation of

the machine.

PTO Clutch Disengaged

Spring Overall Length

2 in.

(51 mm)

Knuckle

Joint

Adjustment

Nut

Spring

Uncompressed

Blade Clutch

Idler Pulley

Blade Clutch

Lever Disengaged

Maintenance Instructions ADJUSTMENTS

73

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 contact 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).

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.

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

threads on the brake band for adjustment,

lengthen the brake actuator rod.

Blade Brake Band Adjustment

11/16 in.

(17 mm) 9/16 in.

(14 mm)

7/16 in.

(11 mm) 5/16 in.

(8 mm)

Engage

Disengage

Pulley

Travel

1 in. to 1-1/2 in.

(25 mm to 38 mm)

Stop Block

Contacting Frame

Stop

Block

Brake Actuator

Rod

Blade Brake Band

Adjustment Nut

Maintenance Instructions ADJUSTMENTS

74

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).

Brake Actuator Rod Adjustment

2. After adjustments are complete, check blade

brake action as described in CHECKING/SER-

VICING the Blade Brake Action in this section.

If blades do not stop within five (5) seconds,

check the following:

a. Recheck 1/8 in. (3 mm) gap between stop

block and chassis.

b. Make sure clutch and brake linkage are

working freely (no binding).

c. Check the brake band lining.

d. Check the brake drum on the pulley. If

excessive 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 new machine,

after initial 5 or 10 hours of operation, to begin to not

travel straight (this is due to the break-in of the

transmissions). In this case, proceed to Straight

Ground Travel Adjustment - Step 4.

IMPORTANT: The following adjustment procedures

are sequential. Check and adjust each function in

the order given.

Set Forward Travel Limit (Stop) - Step 1

1. Move the Forward Speed Control (FSC) lever to

the most FORWARD position.

2. Check clearance of the RH and LH 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.

3. Tighten the jam nut on the forward travel stop

adjusting bolt.

Blade Clutch

Idler Pulley

1/8 in.

(3 mm)

PTO Belt Tightener Chassis

Stop Block

8-1/4 in.

(209 mm)

Bottom

Clevis

Locknuts

Maintenance Instructions ADJUSTMENTS

75

Forward Speed Control Stop

and Steering Lever Adjustment

Steering Lever End Play Adjustment - Step 2

1. Position the FSC lever to the most FORWARD

position.

2. Loosen the adjustment nut on each steering le-

ver actuator until end play develops between

the lever actuator and the adjustment nut (slid-

ing on transmission control rod).

3. Hold the actuator back as shown (against the

spring pressure) and tighten the nut to the point

where the end play is removed and then tight-

en two additional turns.

IMPORTANT: If the adjustment nut is too loose

(end play exists) excessive loads are placed on

transmission internal control stops. If the adjust-

ment nut is too tight (preferred condition), the 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).

2. Start the engine (operate first at idle and then

normal operating speeds) and check for move-

ment of the drive wheels.

NOTE: If the engine will not start, check and ad-

just the neutral safety switch (see item 4 below).

Neutral Function Adjustment

3. 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.) In this

case, the neutral adjustment should be made for

one wheel stationary and the other moving for-

ward slightly.

4. Check and adjust the 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.

Steering

Adjustment Nut

Steering Lever

Actuator Arms

Forward Travel

Stop Bolt

CAUTION

NEVER attempt to disconnect any safety

devices or defeat the purpose of these

safety devices.

LH Steering Lever

(For Orientation)

FSC Actuator

Clevis

Maintenance Instructions ADJUSTMENTS

76

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.

2. 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.

3. If travel is not straight, tighten the adjustment

nut that is on the same side of the mower as

the wheel that is moving too fast, e.g., the

mower tracks to the right, indicating the LH wheel

is moving too fast, tighten the LH adjustment nut.

Straight Ground Travel Adjustment

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:

Forward Speed Control Friction Lock

1. 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.

2. With the steering levers held back, move the

FSC lever back from the FORWARD position.

With a proper amount of friction adjusted, the

FSC lever should move back with a slight

amount of resistance (friction). If the FSC lever

movement is “stiff”, the friction needs to be de-

creased.

3. 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.

End Wrench on

Adjustment Nut

Friction Washer

Friction

Adjustment Nut

FSC Actuator

Maintenance Instructions ADJUSTMENTS

77

Tilt-Up Deck Adjustable Stop

When the carrier frame hinge joint is properly adjust-

ed, the deck lock levers should move in and out of the

engaged and disengaged positions freely. All four

hitch pins used for height adjustment should sit flush

on the washers above the deck pin bushing. On a

level surface, if any pin is sticking up (likely the front

pins), tighten the opposite side or loosen the 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

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.

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.

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.

2. 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.

CAUTION

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.

Set Screw

Jam Nut

CAUTION

ALWAYS use the proper engine service

manual when working on the engine. Un-

authorized maintenance operations or

modifications to the engine MAY result in

unsafe operating conditions.

Maintenance Instructions ADJUSTMENTS

78

Carburetor Adjustment

3. 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.

4. Move the throttle to the idle position. Adjust idle

speed for 1200 rpm (± 75 rpm) by adjusting the

idle speed screw. Check the idle speed using a

tachometer.

5. With the engine idling, adjust the idle mixture by

turning the idle mixture needle valve in (slowly)

from the preliminary setting until engine speed

decreases and then back out approximately 3/4

to 1 turn to obtain the best low speed perfor-

mance.

6. Recheck idle speed after the final idle mixture

adjustment.

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).

b. Turn the ignition switch ON and move the

blade clutch to the ENGAGED position

(engine not running) to make the horn

sound.

c. If the horn does not sound, the horn is bad

and needs to be replaced.

d. If the horn does sound, proceed to step 2.

2. Check the Grass-Pak® switch.

a. Reconnect the wires to the Grass-Pak®

switch electric connector plug.

b. Turn the ignition switch ON and move the

blade clutch to the ENGAGED position

(engine not running).

c. Open the catcher back door and trigger the

Grass-Pak® vane by hand as it oscillates.

d. 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.

DANGER

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 of the engine,

and moving or rotating parts of the engine.

Low Idle Mixture

Needle Valve

(May be Non-Adjustable)

Fixed Main Jet Under

Shutdown Solenoid

Idle Speed

Screw

WARNING

DO NOT test the Grass-Pak® switch with

the engine running. Projectiles CAN be

thrown out of the grass delivery spout and

CAN cause serious injury to bystanders or

property damage.

79

Maintenance Instructions ADJUSTMENTS/

ELECTRICAL SYSTEM

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.

Circuit Breaker Location

Grass-Pak®

Vane Switch

30 Amp

Circuit Breaker

Circuit Breaker

Mounting Bracket

80

Maintenance Instructions ELECTRICAL SYSTEM

Wiring Diagram - Model MC

B

A

M

S1

S2

G

87

30

8586

30

8685

8586

87A

87A

30

STARTER SOLENOID

STARTER

RECTIFIER/REGULATOR

MAGNETO

OIL PRESSURE SWITCH

ENGINE

CASE GROUND

TO MOTOR MOUNT

POWERFIL

MOTOR

GRASS PAK

SWITCH

R

R

HORN

OPTIONAL

LIGHT

OPTIONAL

LIGHT

30 AMP

CIRCUIT

BREAKER

CHASSIS

GROUND

BATTERY

OIL

PRESSURE

LIGHT

OPTIONAL

LIGHTS

5 AMP

CIRCUIT

BREAKER

PTO

INTERLOCK

SWITCH

HOUR METER

SEAT

SWITCH TIME

DELAY

MODULE

FSC

RELAY - B

RELAY - C

RELAY - A

NEUTRAL

INTERLOCK

SWITCH

OFF

RELAY - A

IGNITION RELAY

START

PTO ON OPEN

30 + 87A

30 + 87A

OFF

RELAY - B

START RELAY

START

PTO ON

OPEN

30 + 87

OPEN

OFF

RELAY - C

DELAY RELAY

START

RUN

OPEN

OPEN

30 + 87A

WALKER MODEL MC

Beginning S/N 2001-49399

S1 = START CIRCUIT

S2 = START/ACCESSORY CIRCUIT

M = MAGNETO GROUND CIRCUIT

B = BATTERY CIRCUIT

A = ACCESSORY CIRCUIT

G = GROUND CIRCUIT

IGNITION SWITCH CIRCUITS

OFF

START

RUN

G + M

B + A / S1 + S2

B + A

ORG

ORG BLK

BLK

BLK

BLK

BLU

ORG

ORG

BRN

BLK

YEL

YEL

RED

PUR

WHT

WHT

BLU

PUR

PUR

PUR

RED

RED

BRN GRA

BLK/WHT

GRN

REDRED

BLU

BLK

BLK

RED

RED RED

RED

RED

YEL

BLK

BLK

WHT

RED

RED

BRN/WHT

GRN

PUR

YEL

WHT

GRN

BLK

WHT

RED

GRAGRA

BRN

BLK

BLK

BRN

GRA GRA

GRN

GRA

ORG

PUR

WHT

WHT

WHT

WHT

RED RED

GRN

BRN

BRN/WHT

WHT

+

-

81

Operator’s Notes

82

Operator’s Notes

83

LIMITED WARRANTY

FOR

WALKER

COMMERCIAL RIDER MOWER

1. WHAT THIS WARRANTY COVERS, AND FOR HOW LONG:

Walker Manufacturing company will, at its option, repair or replace, without charge, any part covered by this warranty which

is found to be defective in material and/or workmanship within one (1) year* after date of sale to the original retail 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 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.

2. WHAT THIS WARRANTY DOES NOT COVER:

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

maintenance, improper use or abuse of the product, alterations, or failure to follow the instructions contained in the

Owner’s Manual for operation and maintenance.

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

where the inspection and/or warranty work is performed.

3. HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:

Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Walker Man-

ufacturing Company, 5925 East Harmony Road, Ft. Collins, CO 80528. Proof of the date of purchase may be required to

verify warranty coverage.

4. WARRANTY LIMITATION:

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

PURCHASE INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY

LIMITED TO THE DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL

IMPLIED WARRANTIES ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty

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

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

EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER. Some states do not allow the

exclusion or limitation of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not

apply to you.

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

to amend, modify, or extend this warranty in any way. Accordingly, additional statements such as dealer advertising

or presentations, whether oral or written, do not constitute warranties by Walker, and should not be relied upon.

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

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

FORM NO. 041503 PRINTED IN USA www.walkermowers.com ©2003 WALKER MFG. CO

Sound - Model MC

Sound Test

Sound test conducted was in accordance

with 79/113/EEC and was performed on

28 January 98 under the conditions listed:

General Condition: Cloudy

Temperature: 32 (F)o0(C)

o

Wind Speed: < 5 mph (< 8 kmh)

Humidity: 58%

Barometric Pressure: 25.0" HG (636 mm Hg)

Lwa

105

OPERATOR

Vibration - Model MC

Vibration Level

Vibration levels at the operators handles

were measured in the vertical, lateral, and

longitudinal directions using calibrated

vibration test equipment.

Tests were performed on 28 January 98 under the

conditions listed:

LpA

92

0.7g

General Condition: Cloudy

Temperature: 32 (F)o0(C)

o

Wind Speed: < 5 mph (< 8 kmh)

Humidity: 58%

Barometric Pressure: 25.0" HG (636 mm Hg)