OWNER’S MANUAL
Safety, Assembly, Operating, and Maintenance Instructions
Model MC (20 HP)
™
Please Read and Save These Instructions
For Safety, Read All Safety and Operation
Instructions Prior to Operating Machine
Effective Date: 03-01-07
P/N 6000-13
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
General Information ________________ 1
Operating Instructions_____________ 24
HIGHLIGHTED INFORMATION _____________ 1
GLOSSARY ____________________________ 1
IDENTIFYING NUMBER LOCATIONS________ 1
ENGINE SERIAL NUMBER LOCATION ______ 2
SERVICING OF ENGINE AND
CONTROL IDENTIFICATION,
LOCATION, AND FUNCTION _____________ 24
Ignition Switch_______________________ 24
Engine Choke________________________ 24
Engine Throttle ______________________ 25
Forward Speed Control (FSC) __________ 25
Steering Levers ______________________ 25
Blade Clutch (PTO) ___________________ 25
Parking Brake _______________________ 25
Transmission Lockout Levers __________ 25
Hourmeter __________________________ 26
Oil Pressure Warning Horn_____________ 26
Circuit Breaker (7 Amp) _______________ 26
Light Switch (For Optional Lights)_______ 26
STARTING THE ENGINE_________________ 28
ADJUSTING GROUND
SPEED AND STEERING _________________ 28
ENGAGING THE MOWER________________ 30
STOPPING THE MACHINE _______________ 31
ADJUSTING CUTTING HEIGHT ___________ 31
TRANSMISSION LOCKOUT ______________ 32
RECOMMENDATIONS FOR MOWING ______ 33
RECOMMENDATIONS FOR TILT-UP DECK
OPERATION/TRANSPORT _______________ 34
GRASS HANDLING SYSTEM (GHS) _______ 35
General Information __________________ 36
Clogging Checklist ___________________ 37
Using the Tilt-Up Deck ________________ 38
DRIVETRAIN COMPONENTS ______________ 2
Specifications________________________ 3
ENGINE________________________________ 3
ELECTRICAL SYSTEM ___________________ 3
TRANSMISSION_________________________ 3
BLADE DRIVE __________________________ 4
TIRE SIZE ______________________________ 4
TIRE PRESSURE ________________________ 4
DIMENSIONS (Tractor and Mower) _________ 4
MOWER DECK__________________________ 5
CURB WEIGHT__________________________ 5
DRIVE BELTS___________________________ 6
GHS SYSTEM (Optional)__________________ 6
SEAT__________________________________ 6
FRAME/BODY CONSTRUCTION ___________ 6
Component Identification___________ 7
Safety Instructions _________________ 10
BEFORE OPERATING___________________ 10
OPERATING___________________________ 11
MAINTENANCE ________________________ 12
SAFETY, CONTROL, AND
Using the GHS Catcher________________ 38
®
Powerfil
_________________________ 38
INSTRUCTION DECALS _________________ 14
“Full” Signal Horn ___________________ 38
Cleaning the GHS Exhaust Screen ______ 38
Dumping the Catcher _________________ 39
Tailgate Dumping ___________________ 39
Using the Dump Bag _________________ 39
Assembly Instructions _____________ 16
SETUP INSTRUCTIONS _________________ 16
Tire Installation (Tractor)_______________ 16
Battery Service_______________________ 16
Wet Battery Service __________________ 16
Dry Battery Service __________________ 16
Battery Charging ____________________ 17
Battery Installation ___________________ 17
Mower Deck Assembly ________________ 17
Deck Caster Wheels Installation ________ 17
Deck Discharge Chute Installation ______ 18
Deck Discharge Shield Installation ______ 18
PTO Shaft Guard Installation __________ 18
Tilt-Up Roller Wheel Installation ________ 18
Mower Deck Installation on Tractor ______ 19
Deck Installation ____________________ 19
Deck Leveling ______________________ 21
PREOPERATING CHECKLIST ____________ 22
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
REPLACING/REPAIRING ________________ 58
Drive Belts __________________________ 58
Engine PTO Drive Belt _______________ 60
Jackshaft Drive Belt _________________ 61
GHS Blower Drive Belt _______________ 62
Hydrostatic Ground Drive Belt _________ 63
Fuel Filter ___________________________ 64
Blade Overload Shear Bolts ____________ 64
PTO Shear Pin _______________________ 65
Mower Blades _______________________ 65
ADJUSTMENTS________________________ 66
Steering Levers ______________________ 66
Tilt-Up Deck Adjustable Stop ___________ 66
Maintenance Instructions__________ 41
MAINTENANCE SCHEDULE CHART _______ 41
IMPORTANT TIPS FOR CARE
OF THE KOHLER ENGINE _______________ 42
Fuel System _________________________ 42
Starting/Stopping_____________________ 42
Cooling System ______________________ 42
Air Cleaner System ___________________ 42
Oil _________________________________ 42
LUBRICATION _________________________ 43
Engine Oil ___________________________ 43
Engine Break-In Oil __________________ 43
Checking Engine Crankcase Oil Level ___ 43
Changing Engine Crankcase Oil/Oil Filter _ 43
Mower Deck Gearbox Lubrication _______ 44
DSD52 Mower Deck Lubrication_________ 45
Tractor PTO Gearbox Lubrication _______ 46
Checking Gearbox Oil Level ___________ 46
Changing Gearbox Oil ________________ 46
Gear Axle Lubrication _________________ 46
Hydrostatic Transmission Fluid _________ 46
Checking Hydrostatic
Warranty___________________________ 67
Transmission Fluid Level ______________ 46
Grease Fitting and Oil Point Lubrication __ 47
CLEANING ____________________________ 50
Engine Air Cleaner System _____________ 50
Turbine Precleaner __________________ 50
Donaldson Radialseal™ Air Cleaner _____ 51
Engine Cooling System________________ 52
Air Intake System ___________________ 52
Cylinder Head Cooling Fins ____________ 53
Grass Buildup in Mower Housing________ 53
GHS Blower _________________________ 54
GHS Exhaust Screen __________________ 55
Hydrostatic Transmission Cooling Fins __ 55
CHECKING/SERVICING _________________ 55
Security of Air Filtration Components ____ 55
Battery______________________________ 55
Electrolyte Level ____________________ 55
Cleaning the Terminals _______________ 56
Charging the Battery _________________ 56
Tire Pressure ________________________ 56
Sharpen Mower Blades ________________ 56
Drive Belts __________________________ 57
Mower Deck Gearbox Oil Seals _________ 58
Spark Plugs _________________________ 58
Fuel Lines and Clamps ________________ 58
Blade Brake Action ___________________ 58
Download from Www.Somanuals.com. All Manuals Search And Download.
General Information
HIGHLIGHTED INFORMATION
•
•
POWER TAKE-OFF (PTO) transmits engine
power to run the cutter blades and GHS blower.
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.
®
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.
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.
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.
GLOSSARY
There are many terms that are either unique to this
equipment or that are used as acronyms. The
following terms and their definitions will help while
using this manual:
•
TRANSMISSION LOCKOUT releases the hy-
drostatic transmissions to permit freewheeling
the tractor.
•
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.
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 LH side of
the LH 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.
•
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.
Tractor Model No. _______________________
Tractor Serial No. _______________________
•
•
GROUND DRIVE refers to the dual hydrostatic
transmissions which drive the main wheels.
Deck Serial No.
_______________________
Engine Model No. _______________________
Engine Serial No. _______________________
Date of Purchase _______________________
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.
Fill In By Purchaser
1
Download from Www.Somanuals.com. All Manuals Search And Download.
General Information
SERVICING OF ENGINE AND DRIVETRAIN
COMPONENTS
Serial Number
The detailed servicing and repair of the engine,
hydrostatic transmission, and gearboxes are not
covered in this manual. Only routine maintenance
and general service instructions are provided. For
the service of these components during the limited
warranty period, it is important to find a local, autho-
rized servicing agent of the component manufactur-
er. Any unauthorized work done on these
components during the warranty period may void
the warranty. If you have any difficulty finding an
authorized outlet or obtaining warranty service,
please contact our Service Department for assis-
tance:
Tractor Serial Number Location
Walker Manufacturing Company
5925 E. Harmony Road
Fort Collins, CO 80528
1-970-221-5614
Serial Number
Service manuals are available for each of these
components from their respective manufacturers as
follows:
Kohler Engines
Kohler Company
Kohler, WI 53044
800-544-2444
Mower Deck Serial Number Location
ENGINE SERIAL NUMBER LOCATION
Hydrostatic
Transmissions
Eaton Corporation
15151 Highway 5
Eden Prairie, MN 55344
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 from Kohler covering the
Kohler Command CH20 gasoline engine.
Gearboxes (Deck)
Tecumseh Power Co.
1555 S. Jackson Street
Salem, IN 47167
812-883-3575
Serial Number
Engine Serial Number Location
2
Download from Www.Somanuals.com. All Manuals Search And Download.
Specifications
MODEL
MC
ENGINE
Manufacturer/Model
Displacement
Kohler Command CH20, 2 Cyl., Gasoline (Air-Cooled)
38.1 cu. in. (624 cc)
20.0
HP (@ 3600 RPM)
Max. RPM (No Load)
Governed RPM
3750
3600
Max. Torque [ft-lb (N·m) @ RPM]
Idle RPM
32 (43) @ 2500
1200 ± 75
®
Spark Plug Type
Champion RC12YC
Spark Plug Gap
.030 in. (.76 mm)
2 qts (1.9 liters)
Crankcase Capacity
Crankcase Lubricant
API SG, SH, SJ or higher Grade Oil Only with 10W-30 Viscosity above
0° F (-18° C), or 5W-20 or 5W-30 Viscosity below 32° F (0° C)
Oil Filter
28-050-01
Fuel Tank Capacity
Fuel
3 Gallons (11.4 liters)
Regular Grade Unleaded Gasoline (87 Octane)
Air Cooled
Cooling System Capacity
ELECTRICAL SYSTEM
Battery
12 Volt, 35 AH, 295 CCA
Charging System
Charging Output
System Polarity
Ignition
Flywheel Alternator
15 Amp DC (Regulated)
Negative Ground
Electronic Capacitive Discharge
12 Volt Electric Ring-Gear Type, Solenoid Shift
IgnitionLockoutbySeatSwitch, TransmissionNeutralandBladeClutch
Auto Reset (30A)
Starter
Interlock Switch
Circuit Breaker
TRANSMISSION
Manufacturer/Model
Steering
Dual Hydrostatic, Eaton Model 7, Each Wheel Independently Driven
Hand Lever Control / Individual Wheel
Forward Speed Control
Precision Friction Lock Lever, Cruise Control, with Neutral-Park
Position
Service Brake
Parking Brake
Dynamic Braking through Hydrostatic Transmission
Mechanical Pin Lock in Transmission Gear
3
Download from Www.Somanuals.com. All Manuals Search And Download.
Specifications
MODEL
MC
TRANSMISSION (continued)
Neutral
Transmission Release by Manual Dump Valve
Gear Drive Axle
Final Drive
Transmission Fluid
Factory Service
Mobil 1 Synthetic Motor Oil (15W-50)
SAE 30W Straight Viscosity Motor Oil
1 qt (1 liter)
Alternate Transmission Fluid
Transmission Fluid Capacity
Transmission Cooling
Ground Travel Speed
Cooling Fan Mounted on Drive Pulley
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
36, 42, 48, 56
52, 62, 74
8 x 3.00-4 Pneumatic (4-Ply)
11 x 4.00-5 Pneumatic
Deck Caster Wheel (Optional)
36, 42, 48, 56
8 x 3.00-4 Foamed Rubber
18 x 8.50-10 (4-Ply Low-Profile)
18 x 7.00-8 (4-Ply)
Drive
Drive (Optional Narrow Tire)
Rear
13 x 6.50-6 (4-Ply)
TIRE PRESSURE
Deck Caster Wheel
20 PSI (137 kPa)
15 PSI (103 kPa)
Drive
Rear
20 PSI (137 kPa)
DIMENSIONS (Tractor and Mower)
Length
36 in. (91 cm) GHS Model
42 in. (107 cm) GHS Model
87 in. (221 cm)
89 in. (226 cm)
4
Download from Www.Somanuals.com. All Manuals Search And Download.
Specifications
MODEL
MC
DIMENSIONS (continued)
Width
36 in. (91 cm) SD Model
(with Deflector)
41-3/4 in. (106 cm)
47-3/4 in. (121 cm)
42 in. (107 cm) SD Model
(with Deflector)
36 in. (91 cm) GHS Model
42 in. (107 cm) GHS Model
37 in. (94 cm)
43 in. (109 cm)
Height
SD Model
37-1/2 in. (95 cm)
49-1/2 in. (112 cm)
42-1/4 in. (107 cm)
GHS Model
Wheel Base (Tractor)
Tread Width (Tractor)
Standard Tires
28-1/4 in. (72 cm)
29-3/4 in. (76 cm)
Optional Tires
MOWER DECK
Width of Cut SD/GHS
Cutting Height
36 or 42 in. (91 or 107 cm)
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
42 in. (107 cm) SD Model
42 in. (107 cm) GHS Model
Deck Suspension
20 in. (51 cm) Two (2) Counter-Rotating Blades with a 4 in.
(10 cm) Center Overlap
22 in. (56 cm) Two (2) Clockwise-Rotating Blades with a 2 in.
(5 cm) Center Overlap
22 in. (56 cm) Two (2) Counter-Rotating Blades with a 2 in.
(5 cm) Center Overlap
Torsion-Flex Frame with Caster Wheels and
Counterweight Springs
CURB WEIGHT (Approximate)
SD Tractor Only
622 lb (282 kg)
753 lb (342 kg)
752 lb (341 kg)
787 lb (357 kg)
878 lb (398 kg)
954 lb (433 kg)
GHS Tractor Only
SD Tractor and 36 in. SD Deck
SD Tractor and 42 in. SD Deck
GHS Tractor and 36 in. GHS Deck
GHS Tractor and 42 in. GHS Deck
5
Download from Www.Somanuals.com. All Manuals Search And Download.
Specifications
MODEL
MC
DRIVE BELTS
Engine PTO
Walker P/N 8230
Jackshaft Drive
Gates 3VX385 (or Walker P/N 6251-1)
Walker P/N 7248
Ground Drive, Micro-V
Blower (GHS Model)
GHS SYSTEM (Optional)
Blower
Walker P/N 7234-1
4-1/2 x 10-1/2 x 1/2 in. (11 x 27 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*
Optional Grass Catcher Capacity
Full Signal
89 Gallons (335 liters)/9.5 Bushels
63 Gallons (238 liters)/6.7 Bushels
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
14 Gauge Steel
Body
Deck
11 Gauge Steel
GHS Catcher and Chutes
Molded Cross-Linked Polyethylene (UV Stabilized)
*Optional (6.7 Bushel) Grass Catcher subtracts approx. 5 lb (2 kg) and 5 in. (13 cm) in Height
NOTE: The manufacturer reserves the right to make changes in specifications shown herein at any time
without notice or obligation.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
Component Identification
NOTE: Control Identification
shown in Operating
Instructions section.
Turbine
Precleaner
Grass Handling System
9.5 Bushel Catcher
Catcher Door
Safety Latch
Tilt-Up
Latch
Spring Clip
Counterweight Spring
and Protective Cover
Transmission Control Rod
Adjustment Nut (LH)
Anti-Scuff
Roller
Deck Support Pins
and Height Adjustment
Hitch Pins
Catcher Lift /
Dump Handle
Fuel Tank and Cap
Transmission Control
Rod Adjustment Nut
(RH)
Deck Support Arms
Footrests
Deck Lift Handle
(Cutting Height Adjustment)
Tilt-Up
Deck Handle
Tilt-Up Hook
(Not Visible)
Deck
Caster Wheels
Front View and Right Side View
7
Download from Www.Somanuals.com. All Manuals Search And Download.
Component Identification
Removable Grass
Catcher Screen
(Not Visible)
Catcher Exhaust
Deflector
Catcher Door
Gas Spring
Catcher Door
Gas Spring
Protective Cover
Catcher Lift /
Dump Handle
Catcher
Door
Catcher
Door Handle
Anti-Scuff
Roller
Muffler
Oil
Filter
Left Hand
Tailpipe
Oil Drain
Plug
Drive Wheel
Tailwheel Fork
and Wheel
Rear View and Left Side View
8
Download from Www.Somanuals.com. All Manuals Search And Download.
Component Identification
Air Restriction
Indicator
(Not Visible)
Air Cleaner
Cover
Donaldson
Air Cleaner
Rubber Bumper
(Body Support)
Rubber Bumper
(Body Support)
Muffler
Fuel Pump
Air Intake
Hose
Muffler Heat Shield
Precleaner
Tube
Throttle and
Choke Linkage
Oil Fill/
Dipstick
Fuel Tank Cap
Jackshaft
PTO Gearbox
Dipstick
GHS Blower
Turbine
Precleaner
RH Hydrostatic
Transmission
RH Transmission
Lockout Lever
Neutral Safety
Switch
PTO
Clutch Lever
LH Hydrostatic
Transmission
Positive (+)
Battery Cable
30 Amp
Circuit Breaker
LH Transmission
Lockout Lever
Negative (-)
Battery Cable
Battery
Top View (Engine Compartment)
9
Download from Www.Somanuals.com. All Manuals Search And Download.
Safety Instructions
Pay particular attention to any information labeled
DANGER, WARNING, CAUTION, IMPORTANT,
and NOTE in this manual.
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.
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 Walker Rider Lawnmower has been designed
withmanysafetyfeaturestoprotecttheoperatorfrom
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.
The seriousness or degree of importance of each
type of information is defined as follows:
DANGER
An IMMEDIATE hazard that WILL result in
severe personal injury or DEATH, if warn-
ing is ignored and proper safety precau-
tions are not taken.
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:
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.
Walker Manufacturing Company
5925 East Harmony Road
Fort Collins, CO 80528
CAUTION
2. Never allow children to operate rider mower.
Do not allow adults to operate without proper
instruction.
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.
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.
IMPORTANT: Identifies mechanical information
demanding special attention, since it deals with the
possibility of damaging a part or parts of the ma-
chine.
4. Keep everyone, especially children and pets, a
safe distance away from the area being mowed.
Do not mow with bystanders in the area.
5. Do not operate the machine barefoot or wearing
sandals, sneakers, tennis shoes, or similar
lightweight footwear. Wear substantial pro-
tective footwear.
NOTE: Identifies information worthy of special
attention.
10
Download from Www.Somanuals.com. All Manuals Search And Download.
Safety Instructions
6. Do not wear loose fitting clothing that could get
caught in moving parts. Do not operate this
machine while wearing shorts; always wear
adequate protective clothing, including long
pants. Wearing safety glasses, safety shoes,
and a helmet is advisable and required by some
local ordinances and insurance regulations.
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.
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.
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.
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.
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.
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.
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.
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).
NOTE: This is exactly the same procedure
used to normally stop and park the machine.
c. Keep matches, cigarettes, cigars, pipes,
open flames, or sparks away from the fuel
tank and fuel container.
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).
d. Always fill the fuel tank outdoors using care.
Filltoaboutoneinchfromthetopofthetank.
Use a funnel or spout to prevent spilling.
7. Do not run the engine in a confined area
without adequate ventilation. Exhaust fumes
are hazardous and can be deadly.
e. Replacethemachinefuelcapandcontainer
cap securely and clean up any spilled fuel
before starting the engine.
8. Do not carry passengers - maximum seating
11. Never attempt to make any adjustments
while the engine is running, except where
specifically instructed to do so.
capacity is one (1) person.
11
Download from Www.Somanuals.com. All Manuals Search And Download.
Safety Instructions
9. Watch for holes, rocks, and roots in the terrain
and for other hidden hazards. When mowing
tall grass, mow higher than desired to expose
any hidden obstacles. Then, clean the area and
mow to the desired height.
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.
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.
18. In case of a clogged or plugged mower deck
or GHS catching system:
11. Disengage the blade drive when transporting
the machine across drives, sidewalks, etc. Ne-
ver raise the mower deck while blades are
rotating.
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.
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.
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
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.
nuts are torqued to 60 ft-lb (81.3 N
·m).
20. Do not touch the engine or muffler while the
engineisrunningorimmediatelyafterstopping
the engine. These areas may be hot enough to
cause serious burns.
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
21. When leaving the machine unattended, dis-
engage the blade clutch (PTO), stop the en-
gine, and remove the key.
the following recommendations:
a. Do not move tractor with deck in tilt-up po-
sition.
MAINTENANCE
b. Never tilt body forward with deck in tilt-up
position.
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.
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.
12
Download from Www.Somanuals.com. All Manuals Search And Download.
Safety Instructions
2. To reduce fire hazards, keep the engine free of
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.
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.
d. Disconnect both battery cables before
unplugging any wiring connectors or mak-
ing repairs on the electrical system.
4. Perform only maintenance instructions de-
scribed in this manual. Unauthorized main-
tenance operations or machine modifications
may result in unsafe operating conditions.
IMPORTANT: Keep all applicable manuals
immediately accessible to anyone who may
operate or service this machine.
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.
13
Download from Www.Somanuals.com. All Manuals Search And Download.
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
Each End of Mower Deck (5808)
Adjacent to Blower Discharge Chute
through Body (5804)
Engine Shroud (5855)
SD Deck Discharge Shield (5848)
Rear of Grass Catcher Exhaust Screen (5869)
Catcher Safety Latch,
RH Side (5874)
Hydrostat Oil
Reservoir (5810-2)
Gear Axle (5810-1)
Underside of Body (5861)
LH Side of Body,
Above Muffler (5805)
Bridge Assembly and
LH Gear Axle (5810-3)
Lower Front Body (6807)
14
Download from Www.Somanuals.com. All Manuals Search And Download.
Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine;
if any are missing, illegible, or damaged, a replacement should be ordered and installed before
putting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.
Top of Blower Housing (5819)
Deck Gearbox Cover (5807-3)
Jackshaft Support Adjacent
to Dipstick (7827)
Deck Carrier Frame (5865)
Right Side of Body (5806)
Deck Carrier Frame (8647)
On Engine (6810)
Right Side, Below Operator Seat (7809)
Catcher Door Hinge Bar, LH and RH Sides (5868)
Deck Carrier Frame (8653)
Rear Bumper (5815)
Fender, RH Side (7802)
Fender, LH Side (5802-2)
15
Download from Www.Somanuals.com. All Manuals Search And Download.
Assembly Instructions
SETUP INSTRUCTIONS
Dry Battery Service
Walker Mowers are shipped partially assembled.
After uncrating the tractor and mower deck, initial
setup is required.
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.
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 materi-
als. Drive tires are 18 x 8.50-10, 4-ply; rear tire is
13 x 6.50-6, 4-ply.
DANGER
• Check and adjust the inflation of the tires. The
tire inflation recommendations are:
Battery electrolyte is a poisonous and cor-
rosive sulfuric acid solution.
Drive = 15 PSI (103 kPa)
Rear = 20 PSI (137 kPa)
• Avoid spillage and contact with skin,
eyes, and clothing - causes severe burns.
Battery Service
• To prevent accidents, wear safety gog-
gles and rubber gloves when working with
electrolyte.
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.
• Neutralize acid spills with baking soda
and water solution.
To fill (activate) battery with electrolyte (if battery has
been shipped dry):
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.
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.
Wet Battery Service
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.
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. Remove the filler caps and carefully fill each cell
until the electrolyte is just above the plates.
2. Charge battery. Refer to Battery Charging in
this section.
16
Download from Www.Somanuals.com. All Manuals Search And Download.
Assembly Instructions
3. After the battery is filled with electrolyte, replace
the filler caps and charge the battery. Refer to
Battery Charging.
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 Charging
DANGER
WARNING
BATTERIES PRODUCE EXPLOSIVE GASES
Make sure the battery cap vents are open.
Improper venting of the battery COULD
cause a battery explosion.
• 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.
Battery Clamp
Secured by
Wing Nut(s)
• 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.
(+) Battery Cable
Connection
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.
Battery Installation
Mower Deck Assembly
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].
Deck Caster Wheels Installation
1. Remove the bolt, nut, axle spacer tube, and
spacer washers from each deck caster wheel
fork.
IMPORTANT: DO NOT overfill the battery.
Electrolyte will overflow through the vented caps
onto parts of the machine and WILL result in
severe corrosion.
NOTE: Spacer washers are used only when
the optional semi-pneumatic deck wheels (8.25
x 2.75) are installed.
3. Install battery.
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.
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.
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.
17
Download from Www.Somanuals.com. All Manuals Search And Download.
Assembly Instructions
Deck Discharge Shield Installation
(Side Discharge Models Only)
Grease Fitting
Locations
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.
Spacer Washer
Axle Spacer Tube
WARNING
Deck Caster Wheel Installation
DO NOT operate the machine without the
grass deflector shield attached and in the
lowest possible position.
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)
Attach Shield
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.
Carrier Frame
Tube Sockets
Attach
Chute
Attach Guard
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
Nut on Top
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.
Discharge Chute and PTO Shaft Guard
Installation on Rear Discharge Deck
18
Download from Www.Somanuals.com. All Manuals Search And Download.
Assembly Instructions
4. Reaching under the tractor, join the PTO tube to
the PTO shaft (align arrow decals). Slide the
PTO tube onto the spline shaft on the tractor
PTO gearbox.
Attach Spring
NOTE: When installing the DSD52 Mower
deck, make sure to retract the dolly wheel after
mounting the deck on the tractor.
Arrows on Shaft and Tube
(used to align when sliding together)
Roller Wheels
PTO
Connection
Tilt-Up Spring and Roller Wheel
Installation on Rear Discharge Deck
Grease Deck
Support Arms
Mower Deck lnstallation on Tractor
Deck Installation
Mower Deck Installation
(PTO Shaft Connection)
1. Lightly grease each deck support arm (2) on the
tractor. Refer to Mower Deck Installation pho-
to for location of deck support arm.
5. Slide the deck the rest of the way on the deck
arms. If the deck is rear discharge (GHS
equipped model), the rear discharge chute will
need to be aligned and connected to the blower
inlet during the last 2 in. (51 mm) of slide action
on the support arms.
2. Engage the deck carrier frame tube sockets on
the tractor support arms (refer to Discharge
Chute and PTO Shaft Guard Installation
photo for socket location), slide the deck onto
the support arms approximately 3 in. (76 mm).
NOTE: Raising the mower body may be help-
ful in fitting and guiding the deck chute into the
blower.
3. Retract spring-loaded coupler ring on the PTO
Tube (provided in Owner’s Packet) and insert
coupler tool. Refer to Quick Coupler Installa-
tion Tool photo.
6. 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.
Quick Coupler
Installation Tool
7. Remove Installation Tool from coupler ring and
make sure the ring has “snapped” securely on
the spline shaft.
PTO Tube
IMPORTANT: DO NOT operate tractor with
Quick-Coupler Installation Tool installed.
Pull Back Spring-Loaded
Coupler Ring
Quick Coupler Installation Tool
19
Download from Www.Somanuals.com. All Manuals Search And Download.
Assembly Instructions
IMPORTANT: To prevent damage to the
mower, make sure the PTO shaft assembly is
securely locked on the tractor, with the locking
balls fully seated in the groove and the ring in the
full forward position (refer to the Coupler Ring
“Locked” Position photo). After installation,
pull on the shaft to check for security.
9. With the counterweight springs connected, the
weight on the deck caster wheels should be
15 to 25 Ib (6.8 to 11.3 kg). Check this weight
by lifting on the front of the deck carrier frame. If
required, the spring tension can be adjusted by
tightening or loosening the elastic stop nuts
located underneath the lower spring hook.
Refer to Deck Counterweight Spring Installa-
tion photo.
Spring-Loaded Coupler Ring
In Fully Forward Position
Spring Tension Adjustment
Nut Located Under Lower
Spring Hook (Not Visible)
Counterweight Springs
Clip Onto Body
With Body Tilted Up
Hitch Pins
Lock Deck On
Support Arms
Coupler Ring “Locked” Position
Deck Counterweight Spring Installation
8. Raise the mower body (instead of lifting the
front of deck) and clip the counterweight springs
to the receptacle on front of body. Lower the
body to tension the springs. (Refer to Deck
Counterweight Spring Installation Photo.)
20
Download from Www.Somanuals.com. All Manuals Search And Download.
Assembly Instructions
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.
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.
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: A block of wood cut 4 in. (102 mm) high
is a convenient gauge to measure blade height
above ground during the leveling process.
WARNING
The machine must be shut off during this
procedure.
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.
4 in. (102 mm)
Wood Block
Should be 1/8 in. (3 mm)
to 1/4 in. (6 mm) higher
at the rear of the blade
Should not vary more
than 1/8 in. (3 mm)
side-to-side
4 in. (102 mm)
Wood Block
Deck Leveling
21
Download from Www.Somanuals.com. All Manuals Search And Download.
Assembly Instructions
PREOPERATING CHECKLIST
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.
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.)
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.
For proper fuels and lubricants refer to Specifica-
tions.
FILL FUEL TANK
CHECK AND SERVICE ENGINE AIR CLEAN-
ER SYSTEM
Fill the fuel tank using clean, fresh automotive grade
unleaded gasoline (87 octane rating minimum).
• Check air restriction gauge to make sure there is
no red indication showing.
DANGER
• 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.
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-
CHECK ENGINE COOLING SYSTEM
ning.
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].
• If the engine is hot, allow to cool before
refueling.
• Use an approved fuel container.
• Fuel the mower outdoors.
INSPECT FOUR (4) DRIVE BELTS
• DO NOT smoke while refueling.
• Avoid spilling fuel; use a funnel or spout.
Engine PTO Drive, Jackshaft Drive, Hydrostatic
Ground Drive, and GHS Blower Drive (if equipped).
• DO NOT overfill the fuel tank; fill up to
CHECK HYDROSTATIC TRANSMISSION OIL
LEVEL
about 1 in. (25 mm) below the top of tank.
Refer to LUBRICATION for Checking Hydrostatic
Transmission Fluid Level in Maintenance Instruc-
tions.
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.
CHECK FUNCTION OF OIL PRESSURE
WARNING HORN
Turn ignition key to the RUN position. The oil pres-
sure horn should signal, indicating normal function.
22
Download from Www.Somanuals.com. All Manuals Search And Download.
Assembly Instructions
CHECK TIRE PRESSURE
DANGER
Deck Caster Wheel = 20 PSI (137 kPa)
Drive
Rear
=
=
15 PSI (103 kPa)
20 PSI (137 kPa)
Do not operate the mower with deck in tilt-
up position. Do not move the tractor with
the deck in the tilt-up position.
CHECK AND CLEAN GRASS BUILDUP
UNDERNEATH MOWER DECK (and inside
GHS blower, if equipped)
CHECK MOWER BLADE CONDITION, SHARP-
NESS, AND SECURITY OF MOUNTING
Refer to CLEANING the GHS Blower in Mainte-
nance Instructions for blower cleaning information.
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.
DANGER
Never operate cutter blades with deck in
raised position because it is hazardous.
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.
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.
CHECK DRIVE WHEEL BOLT TORQUE
The lug bolts mounting the drive tires should be
tightened to 75 to 85 ft-lbs. (101.7-115.2 N·m).
Tilt-Up Lift Handle
Tilt-Up Latch
PERFORM ANY ADDITIONAL PROCEDURES
called for on the MAINTENANCE SCHEDULE
CHART in Maintenance Instructions.
Tilt-Up Latch
Tilt-Up Hook
on Deck
Deck Lock Lever
Deck Secured in TILT-UP Position
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
23
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
CONTROL IDENTIFICATION, LOCATION, AND
FUNCTION
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
Engine Choke
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.
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.
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
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.
OFF
ON
Forward Speed
Control (FSC)
START
Ignition Switch
Key Positions
Steering
Levers
Parking
Brake
Hourmeter
Blade Clutch
(PTO)
5 Amp
Circuit Breaker
Ignition Switch
(See Inset)
Light Switch
(Optional, Not Shown)
Oil Pressure
Warning Horn
Operating Controls
24
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
Engine Throttle
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.
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.
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.
Throttle
Choke
®
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.
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.
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.
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
service). Refer to TRANSMISSION LOCKOUT in
this section for operating instructions.
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.
25
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
*** In normal operating conditions, oil changes in
100-hour intervals are acceptable. Walker and
the engine manufacturers recommend engine
oil changes every 50 hours in extremely dirty
or dusty conditions or for units with less than
100 hours annual use.
Lockout
Levers
NOTE: The blinking hour glass on the display
means that the meter is operating properly.
Transmission
Plunger
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
Oil Pressure Warning Horn
Hourmeter
The oil pressure warning horn indicates that engine
oil pressure is below the safe operating range [below
3to5PSI(21to34kPa)]. Thishornwillcomeonwhen
theignitionisturnedON,butshouldgooffaftertheen-
gine is started. If the horn fails to come on when the
ignition switch is turned ON, it could indicate a faulty
horn. If the horn comes on during engine operation,
stop the engine immediately and correct the source
of the problem before further engine operation.
The hourmeter, which is located on the left front of
the body, displays operating time accumulated
while the ignition switch is in the ON position.
The hourmeter provides maintenance reminders
after certain hours of operation. The hourmeter
screen will start flashing the reminder one hour prior
to the recommended interval and will continue until
one hour after the recommended interval (two
hours). The hourmeter does not have a manual
reset function.
IMPORTANT: Continued operation of the engine
with oil pressure warning horn sounding MAY cause
severe engine damage (if a low oil pressure condi-
tion exists).
Procedure
Interval*
Reminder
C
Oil Change
(Break-In)**
Circuit Breaker (7 Amp)
4-6 Hours
OIL
H
G
A 7-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.
Lubricate
and Check
Levels
24-26 Hours
LUBE
C
Oil Change
49-51 Hours***
OIL
H
G
Light Switch (For Optional Lights)
*
These intervals reflect the actual time that the
reminder will flash (one hour prior to and one
hour after the recommended interval).
Operates headlights (when installed).
** This reminder is only used one time.
26
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
The Forward Speed Control also Establishes the Neutral-Park Position of the Steering Levers
LEFT WHEEL
STEERING LEVER
RIGHT WHEEL
STEERING LEVER
FORWARD SPEED
CONTROL LEVER (FSC)
Full Forward
Ground Speed
Position
Forward Position
(No Control Change)
Intermediate
Ground Speed
Position
Neutral-Park
Position
Reverse Drive
Wheel Motion
Position
Neutral-Park
Position
Engaged
Position
PARKING
BRAKE
Disengaged
Position
Fast
Throttle
Position
Disengaged
Position
Idle
Position
THROTTLE
ON Position
OFF Position
Engaged
Position
BLADE CLUTCH (PTO)
Pull Up to Engage
CHOKE
Operating Controls (Top View from Drivers Point of View)
27
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
STARTING THE ENGINE
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.
CAUTION
Before operating the mower, read and un-
derstand all Safety Instructions and Operat-
ing Instructions.
3. After the engine starts, make sure the oil
pressure horn goes off. If not, stop the engine
immediately and find the cause of the problem.
Make sure the oil pressure horn is off prior to
engaging the mower blades and beginning
operation.
WARNING
NEVER run the engine in an enclosed or
poorly ventilated area. Engine exhaust
contains carbon monoxide, an odorless
and deadly gas.
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.
1. Before attempting to start the engine, make
sure the operator is in the seat, the Forward
Speed Control is in NEUTRAL-PARK position,
and the blade clutch and parking brake are
DISENGAGED.
IMPORTANT: Make sure the choke is in the
OFF position during normal engine operation;
running with the choke in the ON position CAN
damage the engine.
NOTE: Release parking brake to prevent extra
load on the starter if the transmission neutral is
slightly out of adjustment.
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
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.
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.
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.
DANGER
Keep feet on footrests at all times when
the machine is moving.
NOTE: The choke may not be required if the
engine is warm.
28
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
1. Move the FSC out of NEUTRAL-PARK position
to the desired forward speed. DO NOT hold for-
ward on steering levers. It is not necessary to
hold the FSC lever in position since a friction
lock maintains the selected lever position (and
forward travel speed).
Beginning Recommendations are:
♦ Learn operation of the mower in an open
area away from buildings, fences, and 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.
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.
♦ 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).
NOTE: This is exactly the same procedure
used to normally stop and park the machine.
NOTE: If the FSC lever will not stay in the
selected position, the friction lock needs to be
adjusted. Contact your Walker Dealer.
2. Steer by pulling the lever on the side of desired
direction of turn, e.g., pull the LH lever to turn
left. To minimize the possibility of overcontrol,
use only one hand on both steering levers.
♦ Practice maneuvering the mower until
you can make it go exactly where you are
aiming.
♦ Remember, for an emergency stop, or in
case of loss of control, machine movement
can always be stopped quickly by pulling
the Forward Speed Control into the NEU-
TRAL-PARK position.
29
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
ENGAGING THE MOWER
Pull Steering
Levers With
Left Hand
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.
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.
Keep Feet On Footrest
When Moving
Correct Operator Hand Position
on the Controls
3. Reverse direction of the mower by pulling both
levers backward.
NOTE: Smooth action on the steering levers
will produce smooth mower operation. 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.
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).
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).
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. Contact your Walker Dealer.
30
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
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. Contact your Walker
Dealer.
Engaged
Position
4. Slow the engine to idle, put throttle in IDLE po-
sition; and turn the ignition switch OFF.
Blade Clutch Engaged
WARNING
Remove the key from the ignition switch
when leaving the mower unattended. This
will prevent children and inexperienced
operators from starting the engine.
5. Engage the parking brake.
IMPORTANT: The 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.
Disengaged
Position
Blade Clutch Disengaged
STOPPING THE MACHINE
ADJUSTING CUTTING HEIGHT
1. Slow the engine to a fast idle; put the throttle in
the 1/2 throttle position.
WARNING
2. Pull the steering levers to the NEUTRAL posi-
tion and then move the FSC lever backward to
the NEUTRAL-PARK position.
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.
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.
31
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
Cutting height is adjusted by positioning the four re-
tainer hitch pins in a series of seven vertical holes on
the deck support pins. Lift handles have been pro-
vided on each end of the deck to assist in raising the
deck while positioning the hitch pins. Cutting
heights range from 1 in. (25 mm) [top holes] to 4 in.
(102 mm) [bottom holes] in 1/2 in. (13 mm) incre-
ments.
Lockout Lever
Plunger
Depressed
Lift Handle
Cam in
LOCKOUT
Position
Deck Support
Pin
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.
Hitch Pin
Cutting Height Adjustment
TRANSMISSION LOCKOUT
Lockout Lever
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).
Cam in
UNLOCKED
Position
Plunger
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 - Normal Operating Position
32
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
RECOMMENDATIONS FOR MOWING
• 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.
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.
Side Discharge Shield in Lowest Position
• When mowing in adverse conditions (tall and/or
wet grass), mow the grass twice. Raise the mower to
the highest setting - 4 in. (102 mm) - for the first pass
and then make a second pass cutting to the desired
height.
• When operating on a slope, reduce speed and
use caution to start, stop, and maneuver. Avoid
sharp turns or sudden changes in direction. The
maximum recommended side slope operating
angle is 20 degrees or 33% grade.
• Use a slow setting on the FSC for trimming
Maximum Recommended
Side Slope - Do Not Operate
on Steep Slopes
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).
22 in.
20°
60 in.
Maximum Recommended Side Slope
33
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
RECOMMENDATIONS FOR TILT-UP DECK
OPERATION/TRANSPORT
To avoid potential deck and/or tractor damage while
using the tilt-up deck, the following recommenda-
tions are offered:
• Do not move the tractor with the deck in the tilt-
up position since both the roller wheels (on the back
of the deck) and the GHS discharge chute may be
damaged by moving the tractor. The tilt-up configu-
ration should only be used when the tractor is
parked.
• 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.
34
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
GRASS HANDLING SYSTEM (GHS)
GHS Model Only
Exhaust Screen
(Removable)
Catcher Door
Safety Latch
®
Grass-Pak
Vane Switch
®
Powerfil
Exhaust
Deflector
Drive Motor
Actuator
Rod
“Full” Signal
Horn
Delivery
Chute
Catcher
Door
PTO Clutch
Shear Pin
Catcher
Door Spring
PTO and Blade
Gear Drive
Grass Catcher
Dump Handle
Shear
Bolt
®
Powerfil
Delivery Spout
Body Chute
Assembly
Blower
Deck
Discharge Chute
Rear Discharge
Mower Deck
GHS Flow and Components
35
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
NOTE: When a side discharge or mulching mow-
er deck is installed on the GHS model, a blower
intake cover should be installed in the blower 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.
General Information
The Grass Handling System (GHS) consists of a
rear discharge mower deck connected to a 10.5 in.
(27 cm) blower and a rear mounted grass catcher
with 9.5 bushel (335 liters) capacity or optional 6.7
bushel (238 liters) capacity. The GHS blower 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.
Blower
Intake Cover
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.
Blower Intake Cover
NOTE: An alternative to using the blower intake
cover when a side discharge or mulching deck is
installed on a GHS model is the blower lockout kit
(P/N 7541). The blower lockout kit releases ten-
sion on the blower drive belt and does not require
the blower intake cover.
NOTE: In Autumn, when using the GHS mower to
vacuum leaves, it is recommended to raise the
front of the mower deck 2 to 3 notches [1 to 1-1/2
in. (25 to 38 mm)] higher than the rear. This will
avoid “bulldozing” leaves, particularly when the
leaves are piled in a thick layer. To make this ad-
justment, the hitch pins in the two (2) front deck
support pins are repositioned 2 to 3 notches higher
while leaving the rear pins in their original position.
DANGER
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.
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.
CAUTION
NEVER leave grass clippings in the grass
catcher after mowing. Damp clippings
generate heat as they decompose. This
MAY cause spontaneous combustion.
36
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
• 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
oftheflatsectionisremoved,the“airlift”performance
or“shovel”effectofthebladedeterioratestothepoint
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.
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.
• 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.
DANGER
NEVERplacehandsunderthemowerdeck
or intheGHS blowerdischargechute. Use
a stick or similar tool to remove any
clogged material.
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.
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 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 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.
• Check the interior of the chute connecting the
mower deck to the blower for smoothness and
freedom from obstruction.
Blades Must Operate at
Right Angles (90 Degrees)
FORWARD
• 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.
Mounting Nut
Torque = 60 ft-lb
Rear Discharge
(81.3 N·m)
Chute
• 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.
Blade Rotation for GHS Mower Deck
(view from underneath)
37
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
NOTE: An optional exhaust screen with larger
holes (3/4") is available for use when mowing in wet
grass; the screen provides less airflow restriction
and more clog resistance (use standard screen in
dry conditions to avoid excessive material blowing
out of the catcher).
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.
Remember, anything that restricts airflow or material
flow along the entire path from the mower deck to
the grass catcher can cause clogging.
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
Using the Tilt-Up Deck
®
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), contact your Walker Dealer.
Refer to CLEANING of Grass Buildup in Mower
Housing in Maintenance Instructions.
Using the GHS Catcher
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.
®
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.
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.
NOTE: If the grass spout fails to oscillate, the clutch
switch should be checked for function (the switch
closure is adjustable).
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.
“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.
Grass Catcher
Screen
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.
Removal
Knobs
(Not Visible)
Grass Catcher Screen Removal for Cleaning
38
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
Dumping the Catcher
Using the Dump Bag
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.
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 be-
ing dumped.
Tailgate Dumping
2. Orient the dump bag with one of the handle
straps on the bag opening facing up.
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.
Tailgate Door
Handle
2. Tilt the catcher back to dump by lifting on the
catcher lift handle on the lower front corner of
the catcher.
3. Lower the catcher smoothly down to the normal
operating position. DO NOT allow the catcher
to drop down.
Hook Bag
on Bumper
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.
Positioning Dump Bag on Catcher
3. Hook the bottom of the bag over the rear
bumper while lifting on the handle strap.
4. Tilt the catcher back to dump into the bag by
lifting on the catcher lift handle on the lower
front corner of the catcher with the one hand
while continuing to hold up on the bag strap
with the other hand. Refer to photos for posi-
tioning the bag and dumping.
Safety
Latch
Catcher Door Safety Latch
39
Download from Www.Somanuals.com. All Manuals Search And Download.
Operating Instructions
Catcher Lift /
Dump Handle
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.
40
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
CAUTION
Maintenance procedures requiring special training or
tools should be performed by a trained technician.
MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL MC
25
Hours
100
Hours
200
Hours
Every
2Years
Ref.
Page
Service Item
Daily
Yearly
Check Engine Crankcase Oil Level
Check/Clean Engine Air Cooling System*
Check Security of Air Filtration Components
Check Air Filter Restriction Gauge
Clean Grass Buildup Under Deck
Clean GHS Exhaust Screen*
x
x
x
x
x
x
x
x
x
43
52
55
51
53
38
54
56
22
47
46
55
46
56
Clean GHS Blower*
Service Mower Blades
Check Function of Oil Pressure Warning Horn
Lubricate Grease Fittings and Oil Points*
Check PTO Gearbox Oil Level**
Check Battery Electrolyte Level
Check Hydrostatic Transmission Fluid
Check Tire Pressure
x
x
x
x
x
Check Drive Belts (Jackshaft, Engine PTO,
GHS Blower, Ground Drive)
Check Gearbox Oil Seals
x
x
57
58
50
51
43
46
55
53
58
43
58
Check Turbine Precleaner*
x
x
x
x
x
x
Check/Clean Air Filter Element Δ
Change Engine Crankcase Oil ΔΔ
Check Oil Level in Gear Axle
Clean Hydrostatic Transmission Cooling Fins
Clean Engine Cooling Fins
Check/Regap Spark Plugs
Change Engine Oil Filter
Check Fuel Lines and Clamps
x
x
x
x
Replace Air Filter Element
51
and Vacuator™ Valve Δ
Replace Fuel Filter
x
x
64
55
46
58
Service Battery
Change Gear Axle Oil ΔΔΔ
Replace Fuel Lines and Clamps
x
x
∗
More often in extremely dusty or dirty conditions
CAUTION
∗∗ Change PTO gearbox oil after first 100 hours
of operation (break-in period)
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.
Δ
Air cleaner is remote mounted Donaldson Radialseal™
unit, replace filter every year or after 6 cleanings
ΔΔ Change engine oil and filter after first 5 hours of
operation of a new engine (break-in period)
ΔΔΔ Change every 2 years or 1000 hours
41
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
KOHLER TIPS
IMPORTANT TIPS FOR CARE OF THE KOHLER
ENGINE
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).
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.
• Use the air flow restriction gauge to indicate the
need to service the air filter.
Starting/Stopping
• Do frequently check the Turbine Precleaner for
• Start engine with the throttle advanced off idle
(1/4 to 1/2 throttle). This will aid starting, especially
in cold weather.
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.
• 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-
• 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.
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 check the air intake hose for cuts,
• Periodically remove two access panels in the en-
gine shroud to inspect and clean cylinder head cool-
ing fins.
nicks, etc., and the hose clamps for tightness.
Oil
• Check performance of the cooling system by
starting the engine, holding a hand adjacent to the
cylinder head, and feeling the cooling airflow.
• 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.
DANGER
• Use only Kohler oil filters. Aftermarket filters
may not seal properly and/or have the incorrect
pressure relief valve for proper lubrication.
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
• Operate the engine at full speed when mowing.
This allows the engine to produce full horsepower
and move more cooling air through the engine cool-
ing fins.
42
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
LUBRICATION
LUBRICATION
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).
WARNING
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.
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.
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.
Proper lubrication is an important maintenance pro-
cedure. It reduces wear and makes the machine
quieter and easier to operate.
IMPORTANT: DO NOT overfill the crankcase
(oilabove“F”mark) as this CAN result in engine
overheating, loss of power, and possible en-
gine damage.
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.
Full Mark
Low Mark
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.
Dipstick Operating Range
2. Before removing the dipstick, clean the area
around the dipstick to keep any dirt or debris out
of the engine.
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).
3. Remove the dipstick, wipe off with a clean rag,
then reinsert the dipstick into the tube and press
all the way down.
43
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
LUBRICATION
1. Park the mower on a level surface with the en-
gine stopped. The engine oil should be warm
before draining. If not warm from operation,
start the engine and run a few minutes to warm
the oil.
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 startingin 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.
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.
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
level, and add oil if necessary. (When the
engine is first operated with a new oil filter, the oil
level drops slightly as the filter is filled with oil.)
Oil Filter
Mower Deck Gearbox Lubrication
Drain Plug
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.
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.
The mower deck gearboxes (tee gearbox and blade
drive gearboxes) are connected as a unitized as-
sembly, and oil flows freely between them. The gear-
boxes are permanently lubricated (oil filled) and
sealed requiring no scheduled lubrication. Howev-
er, the gearbox oil seals should be checked every
25 hours for indication of an oil leak; particularly
the lower seals on the blade drive gearboxes
should be inspected, since they operate in a dirty en-
vironment. If an oil leak is noted, replace the oil seal
and relubricate the gearbox assembly as follows:
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.
1. Remove gearbox cover (footrest). Deck orien-
tation should be the normal operating position.
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).
44
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
LUBRICATION
DSD52 Mower Deck Lubrication
Blade Drive
Gearboxes
There are several special lubrication requirements
for the DSD52 mower deck in addition to the require-
ments detailed in the Chassis and Deck Lubrica-
tion illustration. Lubricate the locations shown in
the Blade Spindle Lubrication and Gearbox, Dol-
ly Wheel, and U-Joint Lubrication photos and
check and maintain oil in the belt drive gearbox.
1. Lubricate the blade spindles every 25 hours
with two (2) shots of SAE general purpose lithi-
um or molybdenum base grease.
Tee
Gearbox
Blade
Spindles
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) 80W-90 oil until the oil level is up to
(submerges) 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.
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) 80W-90 gear lube to maintain the level to
the plug. If the oil level is low, check the gear-
box for any indication of an oil leak. If an oil leak
is noted, the gearbox will need to be removed
and rebuilt.
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.
3. Lubricate the dolly wheel pivot every 25 hours
with general purpose grease.
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).
4. Lubricate the U-Joint in the drive shaft every
8 hours with SAE general purpose lithium or
molybdenum base grease.
45
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
LUBRICATION
Changing Gearbox Oil
Belt Drive
Gearbox
The tractor PTO gearbox is oil filled. No scheduled
oil change is required. However, changing the oil af-
ter the first 100 hour break-in period will extend
gearbox life and is recommended.
1. Remove the drain plug in the bottom of the
gearcase, drain the oil, and reinstall the plug.
Dolly Wheel
Pivot
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) 80W-90 gear lube. Re-
move plug in top of gearcase to vent air when
refilling.
U-Joint
Gearbox, Dolly Wheel, and U-Joint Lubrication
Tractor PTO Gearbox Lubrication
Checking Gearbox Oil Level
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
Check the gearbox oil level every 25 hours, and if
necessary, add oil [SAE E.P. (Extreme Pressure)
80W-90 gear lube] to maintain oil level to the FULL
mark on the dipstick.
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.
IMPORTANT: DO NOT overfill the PTO gearbox to
avoid oil leakage out of the dipstick standpipe.
• Change axle oil every 1000 hours or two (2)
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.
years.
Hydrostatic Transmission Fluid
Checking Hydrostatic Transmission Fluid Level
Jackshaft
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:
Dipstick
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.
PTO
Gearbox
IMPORTANT: Before removing the reservoir
cap, clean any dirt from around it. Any dirt or
contaminants entering the transmission will ac-
celerate wear and eventually cause loss of pow-
er to the drive wheels.
NOTE: Check oil level of sealed hydrostatic
transmission after first 500 hours using a light
next to the reservoir.
Dipstick Location, Tractor PTO Gearbox
46
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
LUBRICATION
2. Remove the reservoir cap and check the level
of the fluid. The reservoir has a fluid level COLD
mark and HOT mark. The reservoir oil level
should ALWAYS be at or above the COLD
mark and NEVER above the HOT mark.
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.
Reservoir Cap
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.
Hot Level
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.
Cold Level
Air Bleed Plug
Grease Fitting and Oil Point Lubrication
Transmission Reservoir
and Air Bleed Plug Location
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.
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:
NOTE: PTO universal joints (on the deck and trac-
tor) require routine lubrication after every 8 hours
of running time.
*
*
The transmission is full of fluid.
Tighten the plug and fill the reservoir to
the COLD level mark.
NOTE: The best way to lubricate the PTO tube half
of the universal joint assembly is to remove it from
the tractor. See instructions for removing and install-
ing PTO quick coupler, refer to Deck Installation in
Mower Deck Installation on Tractor in the Assem-
bly Instructions.
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.
47
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
LUBRICATION
Ident
No.
Lubrication
Type
No.
Places
Ident
No.
Lubrication
Type
No.
Places
Location
Location
24
Brake Actuator Rod and Brake
Band Pivot Pins (Clevis)
Brake Actuator Pivot
Catcher Hinge Point
Choke Control Cable Ends
Throttle Control Cable Ends
Engine Oil
Belt Tightener Pivot,
Blower Drive (GHS Model Only)
Belt Tightener Pivot,
Ground Drive
Oil
3
1
2
3
4
5
6
7
8
9
Deck Caster Wheel Fork Pivot
Deck Caster Wheel Bearing
Tee Gearbox, Deck
Blade Drive Gearbox
Universal Joint Shaft Assembly Grease**
Pivot Assembly, Tilt-Up Deck
Deck Support Arm Socket
Body Hinge Point
FSC Actuator Rod Pivot Pins
FSC Lever Pivot
Grease
Grease
Oil*
2
2
1
2
1
4
2
2
2
1
1
25
26
27
28
29
30
Grease
Oil
Oil
Oil
Oil***
Grease
1
2
2
2
1
1
Oil*
Grease
Grease
Oil
Oil
Grease
Grease
31
Grease
1
10
11
FSC Lever Fork
(Grease Slide Area)
32
33
34
35
PTO Gearbox Dipstick
Hydrostatic Drive
Choke Control Pivot
Throttle Control Pivot
Oil***
Oil***
Oil
1
2
1
1
12
13
14
15
(FSC) Friction Body Pivot
Steering Lever Pivot
Deck Support Arm Pivot
Deck-to-PTO Coupling
(Grease Slide Area)
Grease
Grease
Grease
Grease
1
4
2
1
Oil
*
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.
16
17
Universal Joint Tube Assembly Grease**
1
1
Universal Joint Quick Connect
Spline (Grease Slide Area)
Parking Brake Lever
Gear Axle
Belt Tightener Pivot,
Jackshaft Drive
Clutch Actuator Push Rod
PTO Clutch Lever Pivot
Belt Tightener Pivot,
PTO Clutch
Grease
18
19
20
Grease
Oil***
Grease
1
2
1
** Grease every eight (8) hours.
*** Refer to Gear Axle Lubrication, Engine
Oil, Tractor PTO Gearbox Lubrication, and
Hydrostatic Transmission Fluid in this sec-
tion.
21
22
23
Grease
Grease
Grease
2
1
1
NOTE: DGHS42 Tilt-Up Deck is shown for reference.
For other Deck Lubrication Points, Refer to
Deck and Carrier Frame Illustrated Parts
Manual.
48
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
LUBRICATION
1
1
2
2
3
4
5
4
6
7
6
6
7
6
8
9
10
12
8
11
13
13
14
15
16
14
19
28 & 35
17
18
27 & 34
33
19
32
31
20
30
29
22
28
27
21
21
25
24
23
26
26
Chassis and Deck Lubrication Points
49
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
CLEANING
CLEANING
Turbine Precleaner
The turbine precleaner is mounted on a remote air
intake tube connected to the Donaldson air cleaner.
A spinning fan driven by the intake airflow separates
dust from the air, giving the initial stage of air clean-
ing. Dust particles are exhausted through a single
small vent in the side of the housing. Since no dust
is trapped, the precleaner operates without clean-
ing. The only maintenance required is to check the
operation of the internal fan every 100 hours. Verify
operation:
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:
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.
Air Intake
Hose
Donaldson
Air Cleaner
Safety
Filter
Air Cleaner
Cartridge
Precleaner Tube
Brass
Elbow
Air
Restriction
Gauge
Donaldson Air
Cleaner Cover
Vacuator™
Valve
Turbine Precleaner
Hose
Clamp
Engine
Engine Air Cleaner System Components
50
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
CLEANING
Donaldson Radialseal™ Air Cleaner
A remote mounted Donaldson Radialseal™ air
cleaner provides the air filtering function. The paper
filter element slides over an outlet tube inside the air
cleaner canister with radial sealing action, 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.
Push Button to Reset
Indicator After Service
Air Restriction
Gauge
Air Restriction Gauge Location
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.
Inspect the paper element after every 100 hours of
service and replace the element yearly (or when
dirty or damaged). More frequent replacement may
be required when operating in extremely dusty con-
ditions as indicated by the air restriction gauge. Ser-
vice the air cleaner as follows:
Canister
Cover
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.
Cover
Latches
Radialseal™
Filter Element
Vacuator™
Valve
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.
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.
3. Replace filter element.
NOTE: Washing the element in water or clean-
ing solution is not recommended. Do not try to
clean the element with compressed air.
51
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
CLEANING
4. Use a bright light inside the element to inspect
for damage. Check the element very carefully
for pin holes or other damage that will allow
dirt to leak through the paper media. Replace
element if necessary.
10. Install the cover with the word “TOP” properly
oriented to the top of the canister. Give the
cover a slight twist as it reaches the canister to
make sure the tab inside the cover goes into a
slot, otherwise the cover will not fit properly.
Make sure both the top and bottom cover
latches are securing the cover in place.
5. Without removing, visually inspect the condition
of the safety filter for damage or holes. The
safety filter should only be removed for yearly
replacement (or when dirty or damaged).
Cover Latch
Orient to Top
of Canister
6. Check the condition and resilience of the radial
sealing surface (inside of the open end) of the
filter. Replace the filter if any cracks, tears, or
other damage to the sealing surface are noted.
7. Use a clean, damp cloth and wipe the interior of
the air cleaner canister clean. Use special care
to clean both the inside and outside surfaces
of the outlet tube.
Vacuator™
Valve
Cover Latch
IMPORTANT: Any dust left on the inside of the
outlet tube will go into the engine and cause
wear.
Proper Orientation of Air Cleaner Cover
11. Check the air intake hose for cuts, nicks, cracks,
etc., and the hose clamps for tightness.
8. Check the outside surface of the outlet tube for
smoothness and cleanness (this is the sealing
surface).
12. Reset the air restriction indicator (press button
on the end of the indicator).
9. Insert and seat the safety filter and Radialseal™
element carefully into the canister, applying
pressure at the outer rim of the filter; not at the
flexible center. Make sure the filter element is
completely in place before installing the cover.
Engine Cooling System
Air Intake System
IMPORTANT: DO NOT use the cover latches
to force the filter into the canister -- the cover
should fit on with no extra force.
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.
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.
CAUTION
Safety Filter
Outlet Tube
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.
Canister
Radialseal™
Filter Element
Radial Sealing
Surface
Air Filter Element Replacement
52
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
CLEANING
Cylinder Head Cooling Fins
It is essential for performance and longevity of the
air-cooled engine to keep the cylinder head cooling
fins clean and free of obstruction. After every 8
hours of operation, check the performance of the
cooling system by starting the engine, holding a
hand adjacent to the cylinder head, and feeling the
cooling airflow. If there is little or no airflow, clean the
cooling fins as described below.
Check Airflow
with Hand
DANGER
Make sure to keep hands clear of exhaust
pipe, muffler, and moving parts when
checking airflow.
Cooling System Airflow
Grass Buildup in Mower Housing
DANGER
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.
Before raising or removing the mower
deck for cleaning, stop the engine, re-
move the ignition key, and disconnect the
spark plug wires.
1. Raise the deck lock lever handle on each side
of the carrier frame and pull out to release car-
rier frame for tilting action.
Engine Cooling
Fin Access Panels
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.
Kohler Engine
Shroud
Tilt-Up Lift Handle
Tilt-Up Latch
Tilt-Up Latch
Engine Air
Intake Screen
Tilt-Up Hook
on Deck
Engine Air Intake Screen
and Cooling Fin Access Panels
Deck Lock Lever
Deck Secured in TILT-UP Position
53
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
CLEANING
1. Remove the GHS blower drive belt tension by
DANGER
depressing the idler pulley on the tightener arm.
Roll the belt off the blower pulley. The belt
should be clear of the blower pulley, allowing
free movement of the blower wheel.
Do not operate the mower with deck in tilt-
up position. Do not move the tractor with
the deck in the tilt-up position.
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).
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.
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 ver-
tically and horizontally to cause rotation in both
directions for thorough washing action. Wash
blower until the blower wheel spins freely in
both directions.
4. Lower the deck to the normal operating position
and re-engage the deck lock levers.
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
3. Reinstall the GHS blower drive belt by reversing
the removal procedure.
GHS Blower
GHS Blower
Drive Belt
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.
Blower
Pulley
Blower
Drive Pulley
NOTE: A visual clue of binding of the blower wheel
is the blower blade tips are polished from rubbing
on dirt.
Depress Idler Pulley
Down to Relax Belt
When a dirt deposit is found, use a high pressure
washer or water spray to clean the inside of the
housing as follows:
Belt Tightener
Idler Pulley
DANGER
Collapse Blower Belt Tightener
to Remove GHS Blower Drive Belt
Before attempting to wash the blower,
stop the engine, remove the ignition key,
and disconnect the spark plug wires.
54
Download from Www.Somanuals.com. All Manuals Search And Download.
CLEANING/
CHECKING/SERVICING
Maintenance Instructions
GHS Exhaust Screen
CHECKING/SERVICING
Refer to Cleaning the GHS Exhaust Screen in Op-
erating Instructions.
DANGER
Hydrostatic Transmission Cooling Fins
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.
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.
Security of Air Filtration Components
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.
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:
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.
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.
An additional procedure in maintaining transmission
cooling is to inspect the cooling fans. Replace the
fan(s) if blades are missing or damaged.
3. Check to make sure the air flow indicator is in
place and tight.
Battery
NOTE: For initial battery service during setup, re-
fer to Battery Service in Assembly Instructions.
Cooling Fins
IMPORTANT: Make sure battery is securely mount-
ed in the frame. A loose battery may cause damage
tothecase resulting in acidleakageandseveredam-
age to the machine. A hazard may be created by
damage to critical working parts and safety systems.
Cooling Fan
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.
Hydrostatic Transmission Cooling Fins
55
Download from Www.Somanuals.com. All Manuals Search And Download.
CHECKING/SERVICING
Maintenance Instructions
IMPORTANT: DO NOT overfill the battery. Electro-
lyte will overflow through the vented caps onto parts
of the machine and WILL result in severe corrosion.
Tire Pressure
Inflate tires to pressures shown below:
Deck Caster Wheel = 20 PSI (137 kPa)
Drive = 15 PSI (103 kPa)
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.
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-
PAIRINGtheMowerBladesinthissection). Usethe
following procedure to check and sharpen blades:
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.
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. 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].
2. Raise the deck and secure it in the TILT-UP po-
sition. Refer to CLEANING the Grass Buildup
in Mower Housing in this section for deck rais-
ing instructions.
DANGER
BATTERIES PRODUCE EXPLOSIVE
GASES
DANGER
• Charge the battery in a well-ventilated
area, so that gases produced while charg-
ing can dissipate.
NEVER operate cutter blades with the
deck in the raised position.
NOTE: PTO shaft must be disconnected be-
fore checking blades for straightness.
• Keep sparks, flames, and smoking ma-
terials away from the battery at all times.
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.
• Makesurethebatterycap ventsareopen
(check manifold vent on each cap).
• Make sure the battery charger is un-
plugged before connecting or discon-
necting cables to the battery.
56
Download from Www.Somanuals.com. All Manuals Search And Download.
CHECKING/SERVICING
Maintenance Instructions
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.
WARNING
DO NOT try to straighten a blade that is
bent. NEVER weld a broken or cracked
blade. ALWAYS replace with a new blade
to assure safety.
4. If the blade cutting edge is dull or nicked, it
should be sharpened. Remove blades for
sharpening by grasping the end of the blade 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.
Blade Balancer
NOTE: Blades can be sharpened with an elec-
tric blade sharpener, conventional electric grind-
er, or a hand file.
Blade Balanced on Magnetic
Wall-Mounted Balancer
CAUTION
ALWAYS wear eye protection and gloves
when sharpening a blade.
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.
Intersection
Wear Area
Sharpen at
Original 30° Angle
Wing
Tip
30°
Drive Belts
Do Not Grind or
Sharpen on Underside
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.
Mower Blade Profile For Sharpening
57
Download from Www.Somanuals.com. All Manuals Search And Download.
CHECKING/SERVICING/
REPLACING/REPAIRING
Maintenance Instructions
Mower Deck Gearbox Oil Seals
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.
The mower deck gearbox seals should be inspected
every 25 hours for evidence of oil leaking; particu-
larlytheloweroil seal onthebladedrive gearbox.
This seal is protected by the trash guard on the blade
hub and seal protector plate on the housing, but is
still vulnerable to seal damage due to operating in an
adverse environment. The mower blade must be re-
moved for inspection of the seal, so it is recommend-
ed to inspect the gearbox seals when blades are
removed for sharpening. If an oil leak is noted, the
seal should be replaced and the gearbox assembly
relubricated. Refer to LUBRICATION for Mower
Deck Gearbox Lubrication in this section.
REPLACING/REPAIRING
DANGER
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,
To prevent accidental starting of the en-
gine when replacing parts or repairing the
machine, remove the key from the ignition
switch and disconnect the spark plug
wires.
®
IMPORTANT: ALWAYS use genuine factory re-
placement parts. Substitute parts CAN result in
product malfunction and possible injury to the oper-
ator and/or others.
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).
Drive Belts
Fuel Lines and Clamps
There are four (4) individual belts on GHS models
or three (3) belts on SD models:
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 PTO Drive Belt (3 Groove Power Band)
• Jackshaft Drive Belt
• GHS Blower Drive Belt (GHS Model Only)
• Hydrostatic Ground Drive Belt
Blade Brake Action
WARNING
The belts may be removed and replaced using the
procedures described on the following pages.
It is important to check and maintain blade
brake action for safe operation of the ma-
chine.
58
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
REPLACING/REPAIRING
Jackshaft
Drive Belt
Engine PTO
Belt
GHS Blower Belt
(GHS Model Only)
Hydrostatic Ground
Drive Belt
Belt Locations
59
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
REPLACING/REPAIRING
Engine PTO Drive Belt (3 Groove Power Band)
c. Raise the clutch lever (engage position) to
lift the clutch idler away from the belt.
1. To remove the engine PTO drive belt:
d. Next remove the belt from the engine pul-
ley and then the PTO drive pulley.
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.
2. Install the PTO drive belt by reversing the re-
moval procedure.
NOTE: Step (a) is not essential to removing
the PTO belt, but it makes more room to work
with the PTO belt.
IMPORTANT: Make sure the belt is installed
inside the four (4) belt guide pins.
Check and make the following adjustments:
a. Clutch engagement for proper belt tension
b. Clutch disengagement and brake action
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).
Clutch
Linkage
PTO Belt
Tightener Arm
PTO Belt Tightener
Pull UP to Engage
Stop Block
Belt
Guide
Engine
PTO Belt
Blade Clutch Lever
in the DOWN Position
Engine
Pulley
Belt Guides
(Bottom Guide Not Visible)
Clutch Idler
Pulley
Belt
Guide
PTO Drive
Pulley
Micro-V
Pulley
Engine PTO Drive Belt Removal
60
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
REPLACING/REPAIRING
Jackshaft Drive Belt
b. Relax the belt by depressing the spring-
loaded idler arm.
1. To remove the jackshaft drive belt:
a. Remove the engine PTO drive belt, as
described in previous section.
c. Roll the belt off the jackshaft pulley and
remove.
Push Idler Pulley Down to Relax Belt
Idler Pulley
Jackshaft
Jackshaft
Drive Belt
Engine
Pulley
Tension Spring
Jackshaft Drive Belt (Disengaged)
2. Reverse the removal procedure to replace the
jackshaft drive belt.
Idler Arm
Jackshaft
Jackshaft
Drive Belt
Engine
Pulley
Tension Spring
Jackshaft Drive Belt (Engaged)
61
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
REPLACING/REPAIRING
GHS Blower Drive Belt
1. Remove the GHS blower drive belt tension by
depressing the idler pulley on the tightener arm.
Roll the belt off the blower pulley. The belt
should be clear of the blower pulley, allowing
free movement of the blower wheel.
GHS Blower
Drive Belt
Blower Drive
Pulley
Blower
Pulley
Depress Idler Pulley
Down to Relax Belt
Belt Tightener
Idler Pulley
(Disengaged)
GHS Blower Drive Belt Assembly (Disengaged)
Blower Drive Belt Spring Removal
2. Reverse the procedure to install the GHS blow-
er drive belt and spring.
Idler Pulley
(Engaged)
GHS Blower Drive Belt Assembly (Engaged)
62
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
REPLACING/REPAIRING
Hydrostatic Ground Drive Belt
b. Slide belt off pulleys, then release the idler.
1. To remove the hydrostatic ground drive belt:
a. Raise the spring-loaded belt tightener arm
and idler pulley to relax belt.
Belt Tightener Arm
Idler Pulley
Jackshaft
Transmission
Drive Pulley
Spring
Hydrostatic
Ground Drive Belt
Hydrostatic Ground Drive Belt Assembly (Disengaged)
2. Reverse the procedure to install the hydrostatic
ground drive belt.
Belt Tightener Arm
Idler Pulley
Spring
Hydrostatic
Ground Drive Belt
Hydrostatic Ground Drive Belt Assembly (Engaged)
63
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
REPLACING/REPAIRING
Fuel Filter
Blade Overload Shear Bolts
Model MC is equipped with an in-line fuel filter. Vi-
sually inspect the filter periodically, and replace the
filter yearly.
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
In-Line
Fuel Filter
Fuel Filter Location
IMPORTANT: Replace the fuel filter only in a clean
area where the fuel line and connections will not be
contaminated by any dust and dirt.
Cutting Blade Shear Bolts
DANGER
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.
Gasoline is extremely flammable and can
be highly explosive. To minimize danger:
• Use only an approved fuel container for
gasoline.
If these bolts shear, remove the blade and install
new bolts. Refer to CHECKING/SERVICING in this
section for Sharpen Mower Blades which de-
scribes the blade removal and installation proce-
dure.
• 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
After reinstalling the blade, check blade timing by
moving blades through one (1) complete revolu-
tion. Make sure blade tips pass clear of each other.
If timing is incorrect, contact your Walker Dealer.
and completely.
1. Expand and slide clamps on either side of the
filter away from filter and pull fuel lines off filter.
2. Replace filter.
64
Download from Www.Somanuals.com. All Manuals Search And Download.
Maintenance Instructions
REPLACING/REPAIRING
PTO Shear Pin
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:
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:
• 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.
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.)
• 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.
2. Rotate U-joint on shaft to align the shear pin
hole with the hole (and shear pin fragment) in
the shaft. Use a punch to drive the remaining
portion of the old shear pin out.
3. Install new shear pin and secure with cotter pin.
Shear Pin
DANGER
Split Spring Pin
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.
U-Joint
Tube Assembly
U-Joint
Shaft Assembly
Cotter Pin
• 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.
PTO Shear Pin
IMPORTANT: Use only Walker P/N 8067-13
shear pins for replacement to provide proper
shock protection -- these pins are hardened to
shear under a specific amount of load.
• Inspect the blade surface, especially in formed
areas, for cracks. Replace the blade if any cracks
are found.
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, contact your
Walker Dealer.
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.
NOTE: Use Walker P/N 8067-10 for heavy duty
gearboxes.
65
Download from Www.Somanuals.com. All Manuals Search And Download.
REPLACING/REPAIRING/
ADJUSTMENTS
Maintenance Instructions
ReinstallthebladesfollowingprocedurefromSharp-
en Mower Blades instructions. If blades are re-
placed, always use Walker original equipment
blades to ensure safety and optimum performance.
Thequalityandperformanceofreplacementblades
offered by other manufacturers cannot be guar-
anteed, they could be dangerous.
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. Ad-
justments are made by loosening the jam nut and
tightening or loosening the set screws on the Deck
Mount Pivot Brackets. Retighten the jam nut when
the adjustment is complete.
CAUTION
ALWAYS use genuine factory replacement
parts. Substitute parts CAN result in prod-
uct malfunction and possible injury to the
operator.
Jam Nut
ADJUSTMENTS
Steering Levers
Set Screw
An adjustment range of approximately 3 inches is
available on the steering levers - the levers can be
adjusted forward or aft depending on the arm length
of the operator. The levers can be adjusted by loos-
ening the locknut at the pivot point and the locknut
holding the lever in position in the adjustment slide.
Adjust levers into most comfortable position and
tighten both locknuts.
Tilt-Up Deck Adjustable Stop
Adjustment
Slide
Locknut
(Position)
Locknut
(Pivot Point)
Steering Lever Adjustment
66
Download from Www.Somanuals.com. All Manuals Search And Download.
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 6200-9 Gear Axle Assembly.
2.
WHAT THIS WARRANTY DOES NOT COVER:
A. This warranty does not cover defects caused by depreciation or damage caused by normal wear, accidents, improper
maintenance, improper use or abuse of the product, alterations, or failure to follow the instructions contained in the
Owner’s Manual for operation and maintenance.
B. The customer shall pay any charges for making service calls and/or for transporting the mower to and from the place
where the inspection and/or warranty work is performed.
3.
4.
HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:
Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Walker Man-
ufacturing Company, 5925 East Harmony Road, Ft. Collins, CO 80528. Proof of the date of purchase may be required to
verify warranty coverage.
WARRANTY LIMITATION:
A. THERE IS NO OTHER EXPRESS WARRANTY. ANY WARRANTY THAT MAY BE IMPLIED FROM THIS
PURCHASE INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY
LIMITED TO THE DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL
IMPLIED WARRANTIES ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty
lasts, so the above limitations may not apply 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.
67
Download from Www.Somanuals.com. All Manuals Search And Download.
Sound - Model MC
Vibration - Model MC
Sound Test
Vibration Level
Vibration levels at the operators handles
were measured in the vertical, lateral, and
longitudinal directions using calibrated
vibration test equipment.
Sound test conducted was in accordance
with 79/113/EEC and was performed on
28 January 98 under the conditions listed:
Lwa
105
0.7g
Tests were performed on 28 January 98 under the
conditions listed:
General Condition:
Temperature:
Wind Speed:
Humidity:
Cloudy
LpA
o
o
General Condition:
Temperature:
Wind Speed:
Humidity:
Cloudy
32 (F) 0 (C)
92
o
o
32 (F) 0 (C)
< 5 mph (< 8 kmh)
58%
OPERATOR
< 5 mph (< 8 kmh)
58%
Barometric Pressure: 25.0" HG (636 mm Hg)
Barometric Pressure: 25.0" HG (636 mm Hg)
TM
WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, CO 80528 • (970) 221-5614
FORM NO. 030107
PRINTED IN USA
©2007 WALKER MFG. CO
Download from Www.Somanuals.com. All Manuals Search And Download.
|