OWNER’S MANUAL - Walker

™

OWNER’S MANUALSafety, Assembly, Operating, and Maintenance Instructions

Model MS (13 HP)

Please Read and Save These Instructions Effective Date: 10-01-03For Safety, Read All Safety and Operation P/N 5000-11Instructions Prior to Operating Machine Price $5.00

Foreword

Thank you. . .for purchasing a Walker mower. Every effort has been made to provide you with themost reliable mower on the market, and we are sure you will be among our many satisfied custom-ers. If for any reason this product does not perform to your expectations, please contact us at (970)221-5614. Every customer is important to us. Your satisfaction is our goal.

Please. . .read this manual thoroughly! This manual is to be used in conjunction with the enginemanufacturer’s manual for the specific engine on the mower model you have purchased. Before youoperate your new mower, please read this entire manual. Some of the information is crucial for prop-er operation and maintenance of this mower - it will help protect your investment and ensure that themower performs to your satisfaction. Some of the information is important to your safety, and mustbe read and understood to help prevent possible injury to the operator or others. If anything in thismanual is confusing or hard to understand, please call our service department, at (970) 221-5614,for clarification before operating or servicing this mower.

This manual covers Model MS with the Kawasaki FE400 13 HP gasoline engine.

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

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

Walker Mfg. Co. is continually striving to improve the design and performance of its products. Wereserve the right to make changes in specifications and design without thereby incurring any obli-gation relative to previously manufactured products.

Sincerely, WALKER MANUFACTURING COMPANY

Bob Walker, President

Table of Contents

General Information ________________ 1

HIGHLIGHTED INFORMATION _____________ 1GLOSSARY ____________________________ 1IDENTIFYING NUMBER LOCATIONS________ 1ENGINE SERIAL NUMBER LOCATION ______ 2SERVICING OF ENGINEAND DRIVETRAIN COMPONENTS__________ 2

Specifications________________________ 3

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

Component Identification___________ 7

Safety Instructions _________________ 10

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

Assembly Instructions _____________ 16

SETUP INSTRUCTIONS _________________ 16Tire Installation (Tractor)_______________ 16Battery Service_______________________ 16

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

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

Mower Deck lnstallation on Tractor ______ 19Deck Installation ____________________ 19Deck Leveling ______________________ 21

PREOPERATING CHECKLIST ____________ 22

Operating Instructions_____________ 24

CONTROL IDENTIFICATION,LOCATION, AND FUNCTION _____________ 24

Ignition Switch _______________________ 24Engine Choke________________________ 25Engine Throttle ______________________ 25Forward Speed Control (FSC) __________ 25Steering Levers ______________________ 25Blade Clutch (PTO) ___________________ 25Parking Brake _______________________ 26Transmission Lockout Levers __________ 26Hourmeter __________________________ 26Light Switch (For Optional Lights)_______ 26

STARTING THE ENGINE_________________ 28ADJUSTING GROUND SPEEDAND STEERING________________________ 28ENGAGING THE MOWER________________ 30STOPPING THE MACHINE _______________ 31ADJUSTING CUTTING HEIGHT ___________ 31TRANSMISSION LOCKOUT ______________ 32RECOMMENDATIONS FOR MOWING ______ 32RECOMMENDATIONS FOR TILT-UP DECKOPERATION/TRANSPORT _______________ 33

General Information __________________ 35Clogging Checklist ___________________ 36Using the Tilt-Up Deck ________________ 37Using the GHS Catcher ________________ 37

Powerfil® __________________________ 37“Full” Signal Horn ___________________ 37

Cleaning the GHS Exhaust Screen ______ 37Dumping the Catcher _________________ 38

Tailgate Dumping ___________________ 38Using the Dump Bag _________________ 38

Table of Contents

Maintenance Instructions __________ 40

MAINTENANCE SCHEDULE CHART _______ 40IMPORTANT TIPS FOR CARE OF THEKAWASAKI ENGINE ____________________ 41

Fuel System _________________________ 41Starting _____________________________ 41Cooling System ______________________ 41Air Cleaner __________________________ 41Oil _________________________________ 41

LUBRICATION _________________________ 42Engine Oil ___________________________ 42

Engine Break-In Oil __________________ 42Checking Engine Crankcase Oil Level ___ 42Changing Engine Crankcase Oil/Oil Filter _ 43

Grease Fitting and Oil Point Lubrication __ 43Mower Deck Gearbox Lubrication _______ 46Tractor PTO Gearbox Lubrication _______ 46Gear Axle Lubrication _________________ 47Hydrostatic Transmission Fluid _________ 47

Checking HydrostaticTransmission Fluid Level ______________ 47Changing Hydrostatic Transmission Fluid _ 48

CLEANING ____________________________ 48Engine Air Cleaner System _____________ 48

Donaldson Radialseal™ Air Cleaner _____ 48Fuel Filter ___________________________ 50Engine Cooling System________________ 50

Air Intake Screen ____________________ 50Cylinder Head Cooling Fins ____________ 51

Grass Buildup in Mower Housing________ 52GHS Blower _________________________ 52GHS Exhaust Screen __________________ 53Hydrostatic Transmission Cooling Fins __ 53

CHECKING/SERVICING _________________ 54Security of Air Filtration Components ____ 54Battery______________________________ 54

Electrolyte Level ____________________ 54Cleaning the Terminals _______________ 54Charging the Battery _________________ 54

Tire Pressure ________________________ 55Sharpen Mower Blades ________________ 55Drive Belts __________________________ 56Mower Deck Gearbox Oil Seals _________ 56Spark Plug __________________________ 56Breaker Points _______________________ 56Fuel Lines and Clamps ________________ 56Blade Brake Action ___________________ 57

REPLACING/REPAIRING ________________ 57Drive Belts __________________________ 57

Engine Belt ________________________ 58PTO Drive Belt _____________________ 59Ground Drive Belt ___________________ 60

Blade Overload Shear Bolts ____________ 61PTO Shear Pin _______________________ 61Mower Blades _______________________ 61Mower Deck Gearbox Replacement______ 62GHS Blower Assembly ________________ 63

GHS Blower Assembly Removal _______ 63Blower Wheel Removal ______________ 63Blower Wheel Installation _____________ 64GHS Blower Assembly Installation ______ 64

ADJUSTMENTS________________________ 64Safety Switches ______________________ 64

Seat Switch ________________________ 64FSC Neutral-Park Switch _____________ 65PTO Switch(es) _____________________ 65

Steering Levers ______________________ 65Blade Brake _________________________ 65Transmission Control _________________ 66

Set Forward Travel Limit (Stop) ________ 66Steering Lever End Play Adjustment ____ 67Neutral Function Adjustment __________ 67Straight Ground Travel Adjustment _____ 67

Forward Speed Control Friction Lock ____ 68Tilt-Up Deck Adjustable Stop ___________ 68Carburetor __________________________ 69GHS “Full” Signal Hornwith Grass-Pak® Switch _______________ 70

Troubleshooting(When Horn Fails to Operate) __________ 70

ELECTRICAL SYSTEM ________________ 70Wiring Diagram ______________________ 71

Maintenance and ServiceRecord Sheet _______________________ 72

Operator’s Notes___________________ 73

Warranty___________________________ 75

General Information

1

HIGHLIGHTED INFORMATION

Walker Manufacturing recommends that any ser-vice requiring special training or tools be performedby an authorized Walker Mower Dealer. There areseveral general practices to be aware of in the areaof safety. Most accidents associated with the oper-ation or maintenance of a Walker Mower arecaused by disregarding basic safety precautions orspecific warnings. Such accidents, in most cases,can be prevented by being aware of the dangerspresent.

Information of special importance has been high-lighted in bold type in this manual. Refer to SafetyInstructions for the meanings of DANGER, WARN-ING, CAUTION, IMPORTANT, and NOTE.

GLOSSARY

There are many terms that are either unique to thisequipment or that are used as acronyms. The fol-lowing terms and their definitions will help whileusing this manual:

• DECK is the mowing attachment mounted onthe front of the tractor which includes the carrierframe, deck housing, blade drive gearboxes,and cutter blades.

• FORWARD SPEED CONTROL (FSC) controlsthe maximum forward speed of the tractor;functioning as a cruise control.

• GRASS HANDLING SYSTEM (GHS ) collectsmowed material and deposits it in the catcher.

• GRASS-PAK SWITCH is mounted on thegrass delivery spout (in the catcher) and acti-vates the “full” signal horn when the grasscatcher is full.

• GROUND DRIVE refers to the dual hydrostatictransmissions which drive the main wheels.

• HYDROSTATIC TRANSMISSION transmitsand controls power from the ground drive belt tothe main drive wheel.

• LEFT HAND (LH) refers to the left-hand side ofthe tractor when the operator is seated facingforward in the tractor seat.

• POWER TAKE-OFF (PTO) transmits enginepower to run the cutter blades and GHS blower.

• POWERFIL spreads the mowed materialthroughout the interior of the grass catcher byan oscillating delivery spout.

• RIGHT HAND (RH) refers to the right-hand sideof the tractor when the operator is seated facingforward in the tractor seat.

• SIDE DISCHARGE (SD) mows but does notcollect the mowed material.

• STEERING LEVERS steer the tractor by con-trolling the dual hydrostatic transmissions.

• TRACTOR is the prime mover, including the en-gine, drive train, operator seat, and controls tooperate the mower.

• TRANSMISSION LOCKOUT releases the hy-drostatic transmissions to permit freewheelingthe tractor.

IDENTIFYING NUMBER LOCATIONS

The tractor serial number plate is affixed to the trac-tor body just below the left rear corner of the seat.The mower deck serial number plate is affixedalongside the angle iron framing on the RH side ofthe RH mower blade drive. Model and serial num-bers are helpful when obtaining replacement partsand maintenance assistance. For ready reference,please record these numbers in the space provided.

Fill In By Purchaser

Tractor Model No. _______________________

Tractor Serial No. _______________________

Deck Serial No. _______________________

Engine Model No. _______________________

Engine Serial No. _______________________

Date of Purchase _______________________

General Information

2

Tractor Serial Number Location

Mower Deck Serial Number Location

ENGINE SERIAL NUMBER LOCATION

The Kawasaki engine model, type, and code num-bers are located on the starter side of the engineshroud. For the mower model covered by this man-ual, an engine manual is available to cover theKawasaki FE400.

Engine Serial Number Location(view from right side of tractor)

SERVICING OF ENGINE AND DRIVETRAINCOMPONENTS

The detailed servicing and repair of the engine,hydrostatic transmission and gearboxes are not cov-ered in this manual. Only routine maintenance andgeneral service instructions are provided. For theservice of these components during the limited war-ranty period, it is important to find a local, authorizedservicing agent of the component manufacturer. Anyunauthorized work done on these components dur-ing the warranty period may void the warranty. Ifyou have any difficulty finding an authorized outlet orobtaining warranty service, please contact our Ser-vice Department for assistance:

Walker Manufacturing Company5925 E. Harmony RoadFort Collins, CO 80528

1-970-221-5614

Service manuals are available for each of thesecomponents from their respective manufacturers asfollows:

Kawasaki Engine Kawasaki Engine DivisionP.O. Box 888285Grand Rapids, MI 49588-8285

Hydrostatic Eaton CorporationTransmissions 15151 Highway 5

Eden Prairie, MN 55344

Gearboxes (Deck) Tecumseh Products Co.900 North StreetGrafton, Wl 53024

Serial Number

Serial Number

Serial Number

Specifications

3

MODEL MSENGINE

Manufacturer/Model Kawasaki, FE 400D, 1 Cyl. OHV (Air-Cooled)

Displacement 24.5 cu. in. (401 cc)

HP (@ 3600 RPM) 13.0

Max. RPM (No Load) 4000

Governed RPM 3600

Max. Torque [ft-lb (N⋅m) @ RPM] 19.5 (26.4) @ 2500

Idle RPM 1300

Spark Plug Type NGK BPR5ES

Spark Plug Gap .030 in. (.75 mm)

Crankcase Capacity 1.35 qts (1.3 liters)

Crankcase Lubricant API SC/SD/SE/SF/SG/SH Grade Oil Only with 10W-30/10W-40 Viscosity or 40W Above 68° F (20° C) Only

Fuel Tank Capacity 1.7 Gallons (6.4 liters)

Fuel Automotive Grade Unleaded Gasoline (87 Octane)

Cooling System Air Cooled

ELECTRICAL SYSTEM

Battery 12 Volt, 230 CCA (Interstate SP-30)

Charging System Flywheel Alternator

Charging Output 13 Amp DC (Regulated)

System Polarity Negative Ground

Ignition Transistorized Electronic Magneto

Starter 12 Volt Electric Key and Solenoid Operated

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

TRANSMISSION

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

Steering Hand Lever Control / Individual Wheel

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

Service Brake Dynamic Braking through Hydrostatic Transmission

Parking Brake Mechanical Pin Lock in Transmission Gear

Neutral Transmission Release by Manual Dump Valve

Final Drive Gear Drive Axle

Specifications

4

MODEL MSTRANSMISSION (continued)

Transmission Fluid

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

Transmission Fluid Capacity 1 qt (1 liter)

Transmission Cooling Cooling Fan Mounted on Drive Pulley

Ground Travel Speed

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

0-5 (0-8) Infinitely Variable 0-5 (0-8) Infinitely Variable

BLADE DRIVE

PTO Shaft Sliding Spline Shaft with Two (2) High-Speed U-Joints

Blade Spindle Each Blade (2) Mounts Direct on Peerless Right AngleGearbox 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 Scrubber Brake(Stops Blades within Five (5) Seconds of Disengagement)

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

2900 RPM [16700 FPM (5090 m/min)]

TIRE SIZE

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

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

Drive 18 x 6.50-8 (4-Ply)

Drive (Optional Wide Tire) 18 x 8.50-8 (4-Ply)

Rear 13 x 6.50-6 (4-Ply)

TIRE PRESSURE

Deck Caster Wheel 20 PSI (137 kPa)

Drive 15 PSI (103 kPa)

Rear 20 PSI (137 kPa)

DIMENSIONS (Tractor and Mower)

Length

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


Width

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

41-3/4 in. (106 cm)

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

47-3/4 in. (121 cm)



Specifications

5

MODEL MS

DIMENSIONS (continued)

Height

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

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

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

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

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

MOWER DECK

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

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

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

Blade Size

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

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

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

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

Deck Suspension Torsion-Flex Frame with Caster Wheels andCounterweight Springs

CURB WEIGHT (Approximate)

SD Tractor Only 490 lb (224 kg)

GHS Tractor Only 565 lb (256 kg)

SD Tractor and 36 in. SD Deck 635 lb (288 kg)

SD Tractor and 42 in. SD Deck 670 lb (304 kg)

GHS Tractor and 36 in. GHS Deck 715 lb (324 kg)

GHS Tractor and 42 in. GHS Deck 735 lb (340 kg)

DRIVE BELTS

Engine PTO Walker P/N 5230-2Gates BX30

Ground Drive Walker P/N 5232Gates 6847

PTO DriveSD Model

Walker P/N 5234-1Gates 6935

PTO DriveGHS Drive

Walker P/N 5234-2Gates 6944

Specifications

6

MODEL MSGHS SYSTEM (Optional)

Blower 3 1/2 x 9 x 1/4 in. (9 x 23 x 1 cm) Three-Blade Paddle Wheel(Driven by Mower Engine)

Blower Brake Belt Scrubber Brake (Works in Combination with PTO Clutch, Stops Blower within Five (5) Seconds of PTO Disengagement)

Max. Blower Speed 3600 RPM

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

Full Signal Oscillating Vane Switch Mounted on Grass Delivery Spout Triggers Horn Signal

Powerfil ® Oscillating Delivery Spout Driven by 12 Volt Electric Gearmotor Spreads Material throughout Interior of Catcher @ 25 Cycles/Minute

SEAT Contour-Molded, with Nylon Backed Vinyl Cover and Integral Foam Cushion

FRAME/BODY CONSTRUCTION

Frame All Welded Unitized Steel Chassis

Body 14 Gauge Steel

Deck 11 Gauge Steel

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

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

Component Identification

7

Front View and Right Side View

Footrests

DeckCaster Wheels

Deck Lift Handle(Cutting Height Adjustment)

Transmission Control RodAdjustment Nut (RH)

Tilt-Up Latch

Grass Handling System6.7 Bushel Catcher

Catcher DoorSafety Latch

Anti-ScuffRoller

CounterweightSpring and

Protective Cover

NOTE: Control Identificationshown in OperatingInstructions section.

Deck Support Pinand Height Adjustment

Hitch Pins

Deck Support Arms

Catcher Lift/Dump Handle

Transmission Control RodAdjustment Nut (LH)

Tilt-UpHook

Tilt-UpDeck Handle


8

Rear View and Left Side View

Left HandDrive Wheel

Catcher Lift/Dump Handle

Catcher Door

Tailwheel Forkand Wheel

Fuel Filter

Muffler ExhaustOpening

Oil Filter

Rotating EngineScreen

Anti-ScuffRollers

CatcherExhaustDeflector

Removable Grass Catcher Screen

(Not Visible)

Catcher DoorHandle

Catcher DoorGas Spring

Catcher DoorGas Spring

Protective Cover

Fuel Shut-off Valve


9

Top View (Body Raised)

LH HydrostaticTransmission

Positive (+)Battery Cable

Fuel TankCap

Air CleanerDust Cup

StarterSolenoid

Rubber BumperBody Support

Muffler

Tractor PTOGearbox

RH HydrostaticTransmission

RH TransmissionLockout Lever

Air Cleaner

Air RestrictionIndicator

Air Intake HoseFuel Tank

Fuel LevelIndicator

Carburetor

GHS Blower

LH TransmissionLockout Lever Negative (-)

Battery CableBattery Neutral Safety

Switch

Safety Instructions

10

Pay particular attention to any information labeledDANGER, WARNING, CAUTION, IMPORTANT,and NOTE in this manual.

When you see the Safety Alert Symbol ( ),read, understand, and follow the instructions. Fail-ure to comply with safety instructions may result inpersonal injury.

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

IMPORTANT: Identifies mechanical informationdemanding special attention, since it deals with thepossibility of damaging a part or parts of themachine.

NOTE: Identifies information worthy of specialattention.

Walker Manufacturing cannot predict every poten-tially dangerous situation. Therefore, items labeledas such in this manual do not cover all conceivablesituations. Any person using procedures, tools, orcontrol techniques not recommended by WalkerManufacturing must take full responsibility for safety.

The Walker Rider Lawnmower has been designedwith many safety features to protect the operatorfrom personal harm or injury. However, it is necessaryfor the operator to use safe operating procedures atall times. Failure to follow safety instructionscontained in this manual may result in personalinjury or damage to equipment or property.

If you have any questions concerning setup, opera-tion, maintenance, or safety, please contact yourauthorized Walker Mower Dealer or call WalkerManufacturing Company at (970) 221-5614.

BEFORE OPERATING

1. Read and understand the contents of thisOwner’s Manual before starting and operat-ing the machine. Become thoroughly familiarwith all machine controls and how to stop themachine and disengage the controls quickly.Replacement Owner’s Manuals are available bysending the Model and Serial Number to:

Walker Manufacturing Company5925 East Harmony Road

Fort Collins, CO 80528

2. Never allow children to operate rider mower.Do not allow adults to operate without properinstruction.

3. Clear the area to be mowed of any foreignobjects which may be picked up and thrown bycutter blades. Pick up all sticks, stones, wire,and any other debris.

4. Keep everyone, especially children and pets, asafe distance away from the area being mowed.Do not mow with bystanders in the area.

5. Do not operate the machine barefoot or wearingsandals, sneakers, tennis shoes, or similar light-weight footwear. Wear substantial protectivefootwear.

DANGER

An IMMEDIATE hazard that WILL result insevere personal injury or DEATH, if warn-ing is ignored and proper safety precau-tions are not taken.

WARNING

A POTENTIAL hazard that COULD result insevere personal injury or DEATH, if warn-ing is ignored and proper safety precau-tions are not taken.

CAUTION

Possible hazards or unsafe practices thatMAY result in MODERATE personal injuryor property damage, or machine damage, ifwarning is ignored and proper safety pre-cautions are not taken.

Safety Instructions

11

6. Do not wear loose fitting clothing that could getcaught in moving parts. Do not operate thismachine while wearing shorts; always wearadequate protective clothing, including longpants. Wearing safety glasses, safety shoes,and a helmet is advisable and required by somelocal ordinances and insurance regulations.

7. Prolonged exposure to loud noise can causeimpairment or loss of hearing. Operator hear-ing protection is recommended; particularlyfor continuous operation of the GHS Model dueto blower noise level. Wear a suitable hearingprotective device, such as earmuffs or earplugs.

8. Keep all protective shields and safety de-vices in place. If a protective shield, safetydevice, or decal is damaged, unusable, or miss-ing, repair or replace it before operating themachine.

9. Be sure interlock switches are functioningcorrectly, so the engine cannot be started un-less the Forward Speed Control lever is in theNEUTRAL-PARK position, and the PTO clutchis in the DISENGAGED position. Also, theengine should stop if the operator lifts off theseat with the PTO clutch in the ENGAGEDposition.

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

a. Use an approved fuel container.

b. Never add fuel to a running engine or hotengine (allow hot engine to cool severalminutes).

c. Keep matches, cigarettes, cigars, pipes,open flames, or sparks away from the fueltank and fuel container.

d. Always fill the fuel tank outdoors using care.Fill to about one inch from the top of the tank.Use a funnel or spout to prevent spilling.

e. Replace the machine fuel cap and containercap securely and clean up any spilled fuelbefore starting the engine.

11. Never attempt to make any adjustmentswhile the engine is running, except where spe-cifically instructed to do so.

12. The electrical system battery contains sulfuricacid. Avoid any contact with skin, eyes, andclothing. Keep the battery and acid out of reachof children.

OPERATING

1. Operate the mower only in daylight or in goodartificial light with good visibility of the area beingmowed.

2. Sit on the seat when starting the engine andoperating the machine. Keep feet on the deckfootrests at all times when the tractor is movingand/or mower blades are operating.

3. For a beginning operator, learn to steer(maneuver) the tractor with a slow enginespeed before attempting any mowing oper-ation. Be aware that, with the front mountedmower configuration, the back of the tractorswings to the outside during turns.

4. Remember, for an emergency stop, the forwardmotion of the tractor can always be stopped bypulling the Forward Speed Control (FSC) intothe NEUTRAL-PARK position.

5. In case either of the transmission drive beltsbreak during operation, and if the machine is ona slope, the machine will freewheel down theslope. 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 movingslowly, engage the parking brake.

NOTE: This is exactly the same procedure used tonormally stop and park the machine.

6. Disengage the blade clutch and put the FSC inthe NEUTRAL-PARK position before startingthe engine (an ignition interlock switch normallyprevents starting of the machine if these controlsare in the OPERATING position).

7. Do not run the engine in a confined areawithout adequate ventilation. Exhaust fumesare hazardous and can be deadly.

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

Safety Instructions

12

9. Watch for holes, rocks, and roots in the terrainand for other hidden hazards. When mowingtall grass, mow higher than desired to exposeany hidden obstacles. Then, clean the area andmow to the desired height.

10. Avoid sudden starts or stops. Before backingthe machine up, look to the rear to be sure noone is behind the machine. Watch carefully fortraffic when crossing or working near roadways.

11. Disengage the blade drive when transportingthe machine across drives, sidewalks, etc. Neverraise the mower deck while blades arerotating.

12. The maximum recommended side slopeoperating angle is 20 degrees or 33% grade.When operating the machine on a slope, reducespeed and use caution to start, stop, andmaneuver. To prevent tipping or loss of controlof the machine, avoid sharp turns or suddenchanges in direction.

13. Never adjust cutting height with the enginerunning. Before adjusting cutting height orservicing, disengage the blade clutch (PTO),stop the engine, and remove the ignition key.Wait for all movement to stop before getting offthe seat.

NOTE: A blade/blower brake should normallystop drive line rotation within five (5) seconds ofdisengaging the PTO clutch.

14. For side discharge mower decks, do not oper-ate with the grass deflector chute removed.Keep the deflector in the lowest possibleposition.

15. For tractors equipped with tilt-up deck, observethe following recommendations:

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

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

16. For GHS equipped models, do not operate themachine with the grass catcher in the DUMPposition or with the back door OPEN. Dan-gerous projectiles may be thrown out of thedischarge chute or the back of the grass catcher.

17. For GHS equipped models, use care whenclosing the grass catcher door. Keep fingersand hands away from the hinge and pinch pointswhen the door is being closed. Also, keep fin-gers and hands clear of the door frame. Thedoor is held closed with springs and the doormay slam shut with considerable force.

18. In case of a clogged or plugged mower deckor GHS catching system:

a. Disengage the blade clutch (PTO) and turnthe engine off before leaving the seat.

b. LOOK to make sure blade drive shaft andblower drive pulley movement has stoppedbefore trying to unclog the system.

c. Disconnect the spark plug wire.

d. Never place hands under the deck or in theGHS blower - use a stick or similar tool to re-move clogged material.

19. If the cutting blades strike a solid object or themachine begins to vibrate abnormally, immedi-ately disengage the blade clutch (PTO), stopthe engine, and wait for all moving parts tostop. To prevent accidental starting, discon-nect the spark plug wire. Thoroughly inspect themower and repair any damage before restartingthe engine and operating the mower. Make surecutter blades are in good condition and bladenuts are torqued to 60 ft-lb (81.3 N⋅ m).

20. Do not touch the engine or muffler while theengine is running or immediately after stop-ping the engine. These areas may be hotenough to cause serious burns.

21. When leaving the machine unattended, dis-engage the blade clutch (PTO), stop theengine, and remove the key.

MAINTENANCE

1. To prevent accidental starting of the enginewhen servicing or adjusting the machine, re-move the key from the ignition switch and dis-connect the spark plug wire.

2. To reduce fire hazards, keep the engine free ofgrass, leaves, excessive grease, and dirt.

Safety Instructions

13

3. Keep all nuts, bolts, and screws tight to ensurethe machine is in a safe, working condition.Check the blade mounting nuts frequently, mak-ing sure they are tight.

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

5. If the engine must be running to perform a main-tenance adjustment, keep hands, feet, andclothing away from moving parts. Do not wearjewelry or loose clothing.

6. Always use the proper engine servicemanual when working on the engine.Unauthorized maintenance operations ormodifications to the engine may result inunsafe operating conditions.

7. Altering the equipment or engine in any mannerwhich adversely affects its operation, perfor-mance, durability, or use will VOID the warrantyand may cause hazardous conditions.

8. Never attempt to disconnect any safety devicesor defeat the purpose of these safety devices.

9. Do not change the engine governor settings oroverspeed the engine. The governor has beenfactory-set for maximum-safe engine operatingspeed.

10. Use genuine factory replacement parts. Sub-stitute parts may result in product malfunctionand possible injury to the operator and/orothers.

11. Use care when charging the battery or per-forming maintenance on the battery andelectrical system:

a. Make sure the battery charger is unpluggedbefore connecting or disconnecting cablesto the battery.

b. Charge the battery in a well-ventilatedspace, so gases produced while chargingcan dissipate. Make sure the battery ventsin the caps are open.

c. Keep sparks, flames, and smoking materi-als away from the battery at all times. Toavoid sparks, use care when removing bat-tery cables from posts.

d. Disconnect both battery cables before un-plugging any wiring connectors or makingrepairs on the electrical system.

IMPORTANT: Keep all applicable manualsimmediately accessible to anyone who mayoperate or service this machine.

Safety Instructions

14

Gear Axle (5810-1)

SAFETY, CONTROL, AND INSTRUCTION DECALSSafety, Control, and Instruction Decals are installed on the machine;

if any are missing, illegible, or damaged, a replacement should be ordered and installed beforeputting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.

Hydrostat OilReservoir (5810)

Deck Gearbox Cover (5807-3)

Underside of Body (5861)

Top Rear of Fuel Tank (5855)

Rear Crossbreed of Body (5815)

On Body Adjacent to ClutchControl Lever (5806)

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

Deck Carrier Frame (5865)

Parking Brake (7809)

Top of Blower Housing (5819)

Top of Fuel Tank (6810)

Safety Instructions

15

Each End of Mower Deck (5808)

SD Deck Discharge Shield (5848)

Adjacent to Blower Discharge ChuteThrough Body (5804)

RH Fender (5802-1)LH Fender (5802-2)

SAFETY, CONTROL, AND INSTRUCTION DECALSSafety, Control, and Instruction Decals are installed on the machine;

if any are missing, illegible, or damaged, a replacement should be ordered and installed beforeputting the machine into operation. The Decal Part Number is listed below and in the Parts Manual.

Assembly Instructions

16

SETUP INSTRUCTIONS

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

NOTE: During the process of unpacking, any dam-aged or missing parts should be noted and reportedto the delivering carrier immediately (put in writingwithin 15 days). The carrier will provide directions forproceeding with a claim to receive compensation fordamage.

Tire Installation (Tractor)

• Install the drive tires using the eight (8) lug boltsthat are supplied with the owner’s packet of materials.Drive tires are 18 x 6.50-8, 4-ply; rear tire is 13 x 6.50-6, 4-ply.

• Check and adjust the inflation of the tires. The tireinflation recommendations are:

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

Battery Service

Tilt mower body up (lift on rear of body) for batteryaccess. Check the battery for electrolyte level andcharge. The electrolyte level should be at the bottomof the vent wells [1/4 to 1/2 in. (6 to 13 mm) aboveplates]. If the specific gravity is less than 1.225, thebattery needs charging. If the battery has beenshipped dry, or is wet but needs service, refer to thefollowing instructions.

IMPORTANT: Make sure battery is securelymounted in the frame. A loose battery may causedamage 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 safetysystems.

Wet Battery Service

If the battery has been shipped wet, but the electro-lyte level is low or the battery needs to be chargedthen:

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

2. Charge battery. Refer to Battery Charging in thissection.

Dry Battery Service

To fill (activate) battery with electrolyte (if battery hasbeen shipped dry):

1. Remove the battery hold down bar, disconnectthe battery cables and lift the battery out of thetray.

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

IMPORTANT: Obtain and use only batterygrade sulfuric acid electrolyte with a 1.265 spe-cific gravity to activate the battery. DO NOT usewater or any other liquid during initial activation.

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

3. After the battery is filled with electrolyte, replacethe filler caps and charge the battery. Refer toBattery Charging.

DANGER

Activating a battery can be dangerous.The battery should be taken to a reliableservice station, battery store, or powerequipment dealer where a trained techni-cian can activate the battery safely. DONOT attempt to activate the battery unlessyou are experienced in battery servicework. The following activation and charg-ing instructions are provided for use by atrained battery technician.

DANGER

Battery electrolyte is a poisonous and cor-rosive sulfuric acid solution.

• Avoid spillage and contact with skin,eyes, and clothing - causes severe burns.

• To prevent accidents, wear safety gog-gles and rubber gloves when working withelectrolyte.

• Neutralize acid spills with baking sodaand water solution.


17

Battery Charging

1. Charge the battery at 15 amps for 10 minutes.DO NOT exceed 20 amps maximum recom-mended charging rate. Charge until specificgravity is at least 1.250. Total charging timeshould not exceed one (1) hour.

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

IMPORTANT: DO NOT overfill the battery.Electrolyte will overflow through the vented capsonto parts of the machine and WILL result insevere corrosion.

3. Install battery.

Battery Installation

IMPORTANT: Make sure battery is securelymounted in the frame. A loose battery may causedamage to the case resulting in acid leakage andsevere damage to the machine. A hazard may becreated by damage to critical working parts andsafety systems.

Install the battery in the mower as shown in BatteryInstallation photo. Connect the positive and neg-ative cables to the proper battery terminal [red cableand boot connects to the positive (+) terminal].Slide the rubber boot up and over the battery post,making sure it covers the post completely to preventan electrical short.

Battery Installation

Mower Deck Assembly

Deck Caster Wheels Installation

1. Remove the bolt, nut, axle spacer tube, andspacer washers from each deck caster wheelfork.

NOTE: Spacer washers are used only whenthe optional semi-pneumatic deck wheels (8.25x 2.75) are installed.

2. Fit the axle spacer tube through the wheel hub,position the spacer washer on each side of thehub (if used), and fit the assembly into the wheelfork.

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

4. Tighten the bolt and nut until the axle spacer tubebottoms against the inside of the wheel fork (willnot turn) while the wheel and spacer washers (ifused) spin freely without binding.

DANGER

BATTERIES PRODUCE EXPLOSIVE GASES

• Charge the battery in a well-ventilatedarea, so that gases produced while charg-ing can dissipate.

• Keep sparks, flames, and smoking mate-rials away from the battery at all times.

• Make sure the battery cap vents are openafter the battery is filled with acid (checkmanifold vent on each cap).

• Make sure the battery charger is unplug-ged before connecting or disconnectingcables to the battery.

RH Drive Wheel

(+) Battery CableConnection

Battery ClampSecured byWing Nuts


18

Deck Caster Wheel Installation

NOTE: If semi-pneumatic wheels are installed,make sure the spacer washers fit over thespacer tube and are not caught between the forkand the end of the tube. The washers shouldmove freely on the axle spacer tube.

5. Grease the caster wheel bearings and casterpivot bearings - one grease fitting for each wheeland each pivot.

Deck Discharge Chute Installation(GHS Rear Discharge Models Only)

Mount the discharge chute hinge on top of the deckdischarge opening using the 1/4-20 x 1/2 in. socketbutton head bolt and 1/4-20 ESNA nut. Position thebolt with the head inside of the chute and the nut onthe outside.

Discharge Chute and PTO Shaft GuardInstallation on Rear Discharge Deck

Deck Discharge Shield Installation(Side Discharge Models Only)

Attach the deck side discharge shield by positioningthe shield hinge lug in front of the deck mount andfastening with two (2) 3/8-16 x 1-1/4 in. bolts, 3/8-16ESNA nuts, and 3/8 in. wave spring washers. Thewave washers fit between the two hinging surfaces.Tighten the nuts until the shield moves freely but isnot loose.

Discharge Shield Installationon Side Discharge Deck

PTO Shaft Guard Installation

Position the shaft guard as shown and mount with two1/4-20 x 1/2 in. bolts.

Tilt-Up Roller Wheel Installation

Mount the two (2) tilt-up roller wheels on the bracketson the rear skirt of the deck housing using the P/N 8490 axle bolt, 3/8 in. wave spring washer and3/8-16 in. Whiz locknut. Tighten the axle bolt until thewheel rolls freely, but is not loose.

Spacer Washer

Axle Spacer Tube

Grease FittingLocations

Attach GuardAttachChute

Nut on Top

Carrier FrameTube Sockets

WARNING

DO NOT operate the machine without thegrass deflector chute attached and in thelowest possible position.

Attach Shield


19

Tilt-Up Spring and Roller WheelInstallation on Rear Discharge Deck

Mower Deck lnstallation on Tractor

Deck Installation

1. Lightly grease each deck support arm (2) on thetractor. Refer to Mower Deck Installation photofor location of deck support arm.

2. Engage the deck carrier frame tube sockets onthe tractor support arms (refer to DischargeChute and PTO Shaft Guard Installation photofor socket location). Slide the deck onto the sup-port arms approximately 3 in. (76 mm).

3. Align and connect the splined PTO shaft andsocket halves, as shown in Mower Deck Instal-lation photo. The PTO shaft has a pilot end toease alignment of shaft; fit shaft end into socketand rotate shaft until the splines line up as indi-cated by arrows, then slide together.

4. If the deck is rear discharge (GHS equippedmodel), the rear discharge chute will need to bealigned and connected to the blower inlet duringthe last 2 in. (51 mm) of slide action on the sup-port arms.

NOTE: Raising the mower body may be help-ful in fitting and guiding the deck chute into theblower.

Mower Deck Installation/PTO Shaft Connection

5. Install the hitch pin through the hole on the endof each support arm to lock the deck in place (re-fer to Deck Counterweight Spring Installationphoto). Two (2) hitch pins are included in theowner’s packet of materials.

Attach Spring

Roller Wheels

Grease DeckSupport Arms

PTO Connection

Arrows on Shaft and Tube(used to align when sliding together)


20

Deck Counterweight Spring Installation

6. Raise mower body (instead of lifting the front ofdeck) and clip the counterweight springs to thereceptacle on front of body. Lower the body totension the springs. (Refer to Deck Counter-weight Spring Installation photo.)

7. With the counterweight springs connected, theweight on the deck caster wheels should be 15to 25 Ib (6.8 to 11.3 kg). Check this weight by lift-ing on the front of the deck carrier frame. Ifrequired, the spring tension can be adjusted bytightening or loosening the elastic stop nuts lo-cated underneath the lower spring hook. Referto Deck Counterweight Spring Installationphoto.

Counterweight SpringsClip Onto Body

With Body Tilted Up

Hitch PinsLock Deck OnSupport Arms

Spring Tension Adjustment NutLocated Under Lower

Spring Hook (not visible)


21

Deck Leveling

1. Position mower on a smooth, level surface. Setthe cutting height to the highest position - 4 in.(102 mm) - for easy access under the deck tomeasure blade height. Refer to ADJUSTINGCUTTING HEIGHT in Operating Instructions.

NOTE: A block of wood cut 4 in. (102 mm) highis a convenient gauge to measure blade heightabove ground during the leveling process.

2. Check the side-to-side level. Rotate each bladesideways and measure the distance from bladetip to ground on each side. If measurementsvary more than 1/8 in. (3 mm), add a washershim under the deck support pins on the low sideto level the deck.

3. Check the front-to-rear level. Rotate the bladesto point forward. Measure the distance fromblade tip to ground on the front and rear. Therear of the blade should be 1/8 to 1/4 in. (3 to 6mm) higher than the front of the blade; shim therear (or front) deck support pins equally toachieve at least 1/8 in. (3 mm) difference.

NOTE: The mower deck and support frameare jig welded; within normal tolerances, very lit-tle, if any, shimming should be required to levelthe deck. Tire pressure will influence the level-ness of the deck. Check the tire pressure as apossible cause of the deck not being level.

WARNING

The machine must be shut off during this procedure.

4 in. (102 mm)Wood Block

Should not vary more than 1/8 in. (3 mm)

side-to-side

Should be 1/8 in. (3 mm) to 1/4 in. (6 mm) higher at the rear of the blade

4 in. (102 mm)Wood Block

Deck Leveling


22

PREOPERATING CHECKLIST

Before operating the mower for the first time, and asa routine before daily operations, it is important tomake sure the mower is properly prepared and readyfor operation. The following is a list of items to bechecked. (For a mower with frequent operation,some of these items will not need to be checked everyday, but the operator should be aware of the conditionof each.)

For proper fuel and lubricants refer to Specifications.

FILL FUEL TANK

Raise the mower body and locate the fuel tank on topof the engine, between the muffler and the air cleanerassembly.

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

IMPORTANT: DO NOT permit dirt or other foreignmatter to enter the fuel tank. Wipe dirt from aroundthe filler cap before removing. Use a clean fuel stor-age container and funnel.

IMPORTANT: DO NOT mix oil with gasoline.Always use fresh, automotive grade unleaded gas-oline. DO NOT use premium, white, or high-testgasoline. DO NOT use additives, such as carburetorcleaners, deicers, or moisture removing agents. DONOT use gasoline blended with methyl alcohol.

CHECK ENGINE CRANKCASE OIL LEVEL

Check the engine crankcase oil level before use andafter each 5 hours of continuous operation. Referto LUBRICATION for Checking Engine CrankcaseOil Level in Maintenance Instructions.

CHECK AND SERVICE ENGINE AIR CLEAN-ER SYSTEM

• Check air restriction gauge to make sure there isno red indication showing.

• Check condition, cleanliness, and security of thecomplete air filter element (clean air filter every100 hours). For detailed procedures, refer toCLEANING the Engine Air Cleaner System inMaintenance Instructions.

ADJUST CARBURETOR (Initial Start-up Only)

Refer to ADJUSTMENTS of Carburetor in Mainte-nance Instructions.

CHECK ENGINE COOLING SYSTEM

Check that the engine cooling air intake screen is freeof obstruction by grass clippings or debris and cleanif required. Also, cylinder head cooling fins should beinspected and cleaned if any build-up of debris isnoted (remove cylinder head shroud to clean).

Check performance of the cooling system by startingthe engine, holding a hand adjacent to the cylinderhead, and feeling the cooling airflow.

DANGER

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

• DO NOT fill fuel tank with the engine run-ning.

• If the engine is hot, allow to cool beforerefueling.

• Use an approved fuel container.

• Fuel the mower outdoors.

• DO NOT smoke while refueling.

• Avoid spilling fuel; use a funnel or spout.

• DO NOT overfill the fuel tank; fill up toabout 1 in. (25 mm) below the top of tank. DANGER

Make sure to keep hands clear of exhaustpipe, muffler, and moving parts whenchecking airflow.


23

CHECK GEAR AXLE OIL LEVEL (if equipped)

Refer to Gear Axle Lubrication in MaintenanceInstructions.

INSPECT THREE (3) DRIVE BELTS

Engine, PTO, and Hydrostatic Ground Drive.

CHECK HYDROSTATIC TRANSMISSION OILLEVEL

Refer to LUBRICATION for Checking HydrostaticTransmission Fluid Level in Maintenance Instruc-tions.

CHECK BATTERY ELECTROLYTE LEVEL

Refer to CHECKING/SERVICING the Battery inMaintenance Instructions.

CHECK TIRE PRESSURE

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

CHECK AND CLEAN GRASS BUILDUPUNDERNEATH MOWER DECK (and insideGHS blower, if equipped)

Refer to CLEANING the GHS Blower in Mainte-nance Instructions for blower cleaning information.

The tilt-up deck can be secured in the raised positionby unlocking the deck lock levers on each side of thecarrier frame and inserting the deck hook into the tilt-up latch on the tractor body. Before operating thetractor, make sure to re-engage the deck lock leversafter lowering the deck to the normal operating posi-tion.

Deck Secured in Tilt-Up Position

CHECK MOWER BLADE CONDITION, SHARP-NESS, AND SECURITY OF MOUNTING

The blade mounting nut should be tightened to 60 ft-lb (81.3 N⋅m). If blade sharpening is required, referto CHECKING/SERVICING for Sharpen MowerBlades in Maintenance Instructions.

ADJUST MOWER CUTTING HEIGHT, IF RE-QUIRED

Position the hitch pins in the four deck support pins.Refer to the “Cutting Height Adjustment” decal on thedeck gearbox cover.

PERFORM ANY ADDITIONAL PROCEDUREScalled for on the MAINTENANCE SCHEDULECHART in Maintenance Instructions.

DANGER

Never operate cutter blades with deck inraised position because it is hazardous.

CAUTION

Do not operate machine with deck tilt-uppivot joint unlocked.

DANGER

Do not operate the mower with deck in tilt-up position. Do not move the tractor withthe deck in the tilt-up position.

Tilt-Up Latch

Operating Instructions

24

CONTROL IDENTIFICATION, LOCATION, AND FUNCTION

Ignition Switch

The ignition switch is located on the right front of thebody and is used to start and stop the engine. Theswitch 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 theengine, turn the key clockwise to the “S” position. Donot hold the key in the “S” position longer than 10

seconds. If the engine does not start, return the keyto the “O” position for at least 60 seconds beforemaking a restart attempt. Prolonged cranking candamage the starter motor and shorten battery life.Release the key when the engine starts, and it willreturn to the RUN position. To stop the engine, rotatethe key counterclockwise to the “O” position.

Ignition Switch

CAUTION

Before operating the mower, become fa-miliar with the location and function of alloperator controls. Knowing the location,function, and operation of these controlsis important for safe and efficient opera-tion of the mower.

ON

START

OFF

Operating Controls

Steering Levers

Throttle

Choke(not visible)

Hourmeter

Forward SpeedControl (FSC)Blade Clutch

(PTO)

Parking Brake

Ignition Switch


25

Engine Choke

The choke control lever (black knob) is located onthe left side of the seat. To start a cold engine, movethe choke control forward to the ON position. Afterengine starts, move choke control toward the OFFposition, keeping enough choke to allow the engineto run smoothly as it warms up. As soon as possible,move the choke to the OFF position. A warm enginerequires little or no choke for starting.

IMPORTANT: Make sure the choke is in the OFFposition during normal engine operation; runningwith the choke in the ON position CAN damage theengine.

Engine Throttle

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

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 isto establish the NEUTRAL-PARK position. Whenthe FSC lever is moved into the FORWARD position,a friction lock holds any forward speed setting from0 to 5 mph (0 to 8 km/h). The ground speed is pro-portional to the lever position; the further the lever isadvanced forward, the faster the tractor moves. It isnot necessary to hold the FSC in position since thefriction lock maintains the selected lever position.Pulling back on the steering levers overrides theFSC setting and slows or stops forward travel.Releasing the steering levers allows the tractor toresume forward travel at the speed set by the FSClever. To stop and park the machine, the FSC leveris moved backward to the NEUTRAL-PARKposition.

Steering Levers

Each drive wheel is controlled by its own indepen-dent steering lever, for both steering function andFORWARD/REVERSE motion. The FSC lever setsthe maximum forward speed, and also sets the for-ward position of the steering levers. The steeringlevers operate only with a backward pulling move-ment of the lever, which causes the drive wheel forthat lever to first slow down, stop, and then reversewith a full backward lever stroke. The levers arereleased to the FORWARD position for “straight-ahead” ground travel.

NOTE: Pushing forward on the steering levers willnot cause any change in tractor motion - there will beno steering lever reaction and there will be nomachine damage.

Blade Clutch (PTO)

The blade clutch lever is located on the right side ofthe seat behind the right fender and is used toengage and disengage the mower blades. The bladeclutch has two positions. Pushing the lever BACK-WARD engages the PTO that drives the mowerblades. Pulling the lever FORWARD disengagesthe PTO and engages the blade brake.

NOTE: On GHS equipped models, the Powerfil

motor and Grass-Pak full signal switch are acti-vated by engaging the blade clutch. Refer to Usingthe GHS Catcher in this section for a completedescription of GHS operation.

Throttle Choke


26

Parking Brake

The parking brake functions by locking a pin into thehydrostatic transmission pinion gear teeth. Movingthe lever FORWARD engages the parking brake;moving the lever BACKWARD releases the brake.

IMPORTANT: Stop the tractor completely beforeengaging the parking brake. The parking brake usesa positive mechanical lock similar to the PARK posi-tion on an automotive automatic transmission. If thetractor is moving when the brake is engaged, it willresult in sudden stoppage and possible internaldamage to the axle drive.

NOTE: If pressure on the parking brake pin (e.g.parked on a hill) makes it impossible to release theparking brake with the parking brake lever, move themower gently forward or backward to release the pin.

Transmission Lockout Levers

The transmission lockout levers disengage thehydrostatic transmissons. By lifting the lever on topof the transmission and locking it into place with thelockout cam, the hydrostatic transmissions arereleased to permit freewheeling. By releasing thecam and lowering the lever, the transmissions areengaged for normal operation. The transmissionlever in the LOCKOUT position is used to enablemoving the machine without the engine running(e.g., for service). Refer to TRANSMISSION LOCK-OUT in this section for operating instructions.

NOTE: The transmission plunger on the side of thetransmission case (activated by the LOCKOUTLEVER) must be completely released during opera-tion of the mower, otherwise operation of thetransmission will be erratic.

Lockout Lever Location

Hourmeter

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

Light Switch (For Optional Lights)

Operates headlights (when installed).

LockoutLevers


27

Operating Controls (Top View from Drivers Point of View)

THROTTLE

BLADE CLUTCH(PTO)

PARKINGBRAKE

LEFT WHEELSTEERING LEVER

Forward Position(No Control Change)

Neutral-ParkPosition

Reverse DriveWheel Motion

Position

RIGHT WHEELSTEERING LEVER

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

FORWARD SPEEDCONTROL LEVER (FSC)

Full ForwardGround Speed

Position

IntermediateGround Speed

Position

Neutral-ParkPosition

IdlePosition

ON Position

OFF Position

CHOKE

EngagedPosition

FastThrottlePosition

EngagedPosition

DisengagedPosition

DisengagedPosition


28

STARTING THE ENGINE

1. Before attempting to start the engine, makesure the operator is in the seat, the ForwardSpeed Control is in NEUTRAL-PARK position,and the blade clutch and parking brake areDISENGAGED.

NOTE: Release parking brake to prevent extraload on the starter if the transmission neutral isslightly out of adjustment.

2. Move the choke lever to the ON position and

move the throttle 1/4 to 1/2 open (toward FAST).Turn the ignition switch to the START position tostart the engine. Release the key to RUN posi-tion as soon as the engine starts.

NOTE: The choke may not be required if theengine is warm.

IMPORTANT: DO NOT crank the engine con-tinuously for more than 10 seconds at a time. Ifthe engine does not start, turn the key to theOFF position and allow a 60 second cool-downperiod between starting attempts. Failure to fol-low these guidelines can damage the startermotor and shorten battery life.

3. After the engine starts, gradually move thechoke to the OFF position, keeping enoughchoke on to allow the engine to run smoothly asit warms up. As soon as possible, move thechoke to the OFF position.

IMPORTANT: Make sure the choke is in theOFF position during normal engine operation;running with the choke in the ON position CANdamage the engine.

ADJUSTING GROUND SPEED AND STEERING

CAUTION

Before operating the mower, read and un-derstand all Safety Instructions and Operat-ing Instructions.

WARNING

NEVER run the engine in an enclosed orpoorly ventilated area. Engine exhaustcontains carbon monoxide, an odorlessand deadly gas.

CAUTION

A safety interlock switch system PRE-VENTS CRANKING the engine with eitherthe Forward Speed Control or the bladeclutch (PTO) out of neutral. If the enginecranks otherwise, the safety system is notworking and should be repaired or adjust-ed before operating the mower. DO NOTdisconnect safety switches; they are forthe operator’s protection.

CAUTION

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

If the operator has not operated a machinewith LEVER STEERING OR DUAL HYDRO-STATIC TRANSMISSIONS, steering andground operation should be learned andpracticed until the operator is completelycomfortable handling the machine BE-FORE ATTEMPTING TO MOW.

DANGER

Keep feet on footrest at all times when themachine is moving.


29

1. Move the FSC out of NEUTRAL-PARK positionto the desired forward speed. DO NOT hold for-ward on steering levers. It is not necessary tohold the FSC lever in position since a frictionlock maintains the selected lever position (andforward travel speed).

NOTE: This is exactly the same procedureused to normally stop and park the machine.

NOTE: If the FSC lever will not stay in theselected position, the friction lock needs to beadjusted. Refer to ADJUSTMENTS of ForwardSpeed Control Friction Lock in MaintenanceInstructions.

2. Steer by pulling the lever on the side of desireddirection of turn, e.g., pull the LH lever to turnleft. To minimize the possibility of overcontrol,use only one hand on both steering levers.

Correct Operator Hand Position on the Controls

3. Reverse direction of the mower by pulling bothlevers backward.

Beginning Recommendations are:

♦ Learn operation of the mower in an openarea away from buildings, fences, and ob-structions. Learn operation on flat groundBEFORE operating on slopes.

♦ Start maneuvering the mower with SLOWengine speed and SLOW Forward SpeedControl setting until familiar with all operat-ing characteristics.

♦ Remember it is not necessary to hold thesteering levers forward (a unique Walkerfeature); always PULL on the levers forsteering or for reverse motion of the mower.

♦ Learn to operate the mower with your lefthand on the steering levers and right hand onForward Speed Control. The use of twohands on the steering levers tends to causeovercontrol.

♦ Learn to operate the steering levers withsmooth action. Jerky movements are hardon the transmission and lawn. For sharpturns, do not allow the inside wheel to stopand twist on the grass. Pull the steering le-ver controlling the inside wheel into reversefor a smooth “rolling” turn (one wheel roll-ing forward while the other rolls backward).

♦ Practice maneuvering the mower untilyou can make it go exactly where you areaiming.

♦ Remember, for an emergency stop, or incase of loss of control, machine movementcan always be stopped quickly by pullingthe Forward Speed Control into the NEU-TRAL-PARK position.

WARNING

In case either of the transmission drivebelts break during operation, and if themachine is on a slope, the machine willfreewheel down the slope. To maintaincontrol, immediately (1) Release thesteering levers and simultaneously (2)Move the FSC to the NEUTRAL-PARKposition. When the machine is stoppedor moving slowly, engage the parkingbrake.

Pull SteeringLevers withLeft Hand

Keep Feet on Footrestwhen Moving

Forward Speed Control(FSC)


30

NOTE: Smooth action on the steering leverswill produce smooth mower operation. Remem-ber to keep the engine and ground speed slowuntil learning the control response.

4. The FSC may be adjusted forward for fasterground speed and backward for slower groundspeed. When mowing, ground speed should beadjusted 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 groundspeed. Adjusting ground speed helps maintaina balance between engine power and bladespeed for high-quality cutting action.

5. Stop ground travel by pulling both steeringlevers backward to the NEUTRAL-PARK posi-tion (tractor not moving) and then moving theFSC lever to the NEUTRAL-PARK position.

NOTE: If the tractor creeps forward or back-ward with the FSC lever in the NEUTRAL-PARKposition, the transmission control needs to beadjusted. Refer to ADJUSTMENTS of Trans-mission Control in Maintenance Instructions.

ENGAGING THE MOWER

1. Set the engine throttle at about 1/2 speed. DONOT attempt to engage the blade clutch athigh engine speeds. This will drastically short-en drive belt life. Use only moderate enginespeed when engaging the blade clutch.

2. Push the blade clutch lever SLOWLY back toengage the mower blades.

IMPORTANT: DO NOT engage the blade clutchwhen transporting the mower across drives, side-walks, loose materials, etc. DO NOT engage theblade clutch with the PTO shaft disconnected(the mower deck removed from tractor).

Blade Clutch Engaged

Blade Clutch Disengaged

CAUTION

A safety interlock switch (seat switch) willcause the engine to stop if the bladeclutch is engaged and the operator is notin the seat. The function of this switchshould be checked by the operator rais-ing off the seat and engaging the bladeclutch; the engine should stop. If theswitch is not working, it should be re-paired or replaced before operating themower. DO NOT disconnect the safetyswitches; they are for the operator’s pro-tection.

CAUTION

If the cutting blades strike a stationaryobject while mowing, stop the mower im-mediately, disconnect the spark plug wire,lift the deck, and inspect the deck andblades thoroughly for damage. Make surethat the blade timing has not been dis-turbed (the blades should be at 90 degreesto each other). Refer to REPLACING/RE-PAIRING the Blade Overload Shear Boltsin Maintenance Instructions if blades are outof time. Also, make sure the blade retain-ing nuts are torqued to 60 ft-lb (81.3 N⋅m).

EngagedPosition

DisengagedPosition


31

STOPPING THE MACHINE

1. Slow the engine to idle; put the throttle in theIDLE position.

2. Pull the steering levers to the NEUTRAL-PARKposition and then move the FSC lever backwardto the NEUTRAL-PARK position.

3. Disengage the blade clutch.

IMPORTANT: DO NOT disengage the bladeclutch with high engine speed (above 1/2throttle) since the brake action on the blade drivewill cause premature wear of the PTO Drive Belt.

4. Turn the ignition switch OFF.

5. Engage the parking brake.

IMPORTANT: The hydrostatic transmissionslock to prevent the mower from rolling freelywith the engine stopped. However, if the moweris parked on a slope, it is necessary toENGAGE the parking BRAKE to prevent themower from creeping. This is due to a smallamount of slippage in the hydrostatic trans-missions, especially when transmission fluid iswarm.

ADJUSTING CUTTING HEIGHT

Cutting height is adjusted by positioning the fourretainer hitch pins in a series of seven verticalholes on the deck support pins. Lift handles havebeen provided on each end of the deck to assist inraising the deck while positioning the hitch pins. Cut-ting heights range from 1 in. (25 mm) [top holes] to4 in. (102 mm) [bottom holes] in 1/2 in. (13 mm)increments.

Cutting Height Adjustment

WARNING

A brake stops the cutter blades (and blow-er on GHS equipped models) from free-wheeling within five (5) seconds afterdisengaging the clutch. If the brake sys-tem malfunctions and the blades do notstop within five (5) seconds, the brakeshould be adjusted or repaired beforeoperating the mower. Refer to ADJUST-MENTS of Blade Clutch (PTO) in Mainte-nance Instructions.

WARNING

Remove the key from the ignition switchwhen leaving the mower unattended. Thiswill prevent children and inexperiencedoperators from starting the engine.

WARNING

The engine must be stopped before ad-justing cutting height. Disengage theblade clutch (PTO), stop the engine, andremove the ignition key. Wait for all move-ment to stop before getting off the seat.

Lift Handle

Deck Support Pin

Hitch Pin


32

TRANSMISSION LOCKOUT

IMPORTANT: DO NOT TOW this mower with thetransmission lockout engaged. Towing can produceexcessive internal pressure and damage thetransmission.

To move the mower with the engine NOT running(dead battery, maintenance, etc.), the hydrostatictransmissions are unlocked (released).

1. Raise the body.

2. Lift the transmission lockout lever on both theRH and LH transmissions and secure into placewith the locking cam.

3. The mower will “freewheel” with the levers in theLOCKOUT position. The levers must be in thehighest position to completely unlock thetransmissions.

Lockout Lever - Freewheel Position

4. After moving the mower, release the lockingcam, placing the lever DOWN in the normalOPERATING position. Make sure the trans-mission lockout plunger on the side of the trans-mission case (activated by the lockout lever) iscompletely released, otherwise the transmis-sion operation will be erratic.

Lockout Lever - Normal Operating Position

RECOMMENDATIONS FOR MOWING

IMPORTANT: Operate the engine at full speedwhen mowing, to allow the engine to produce fullhorsepower and to increase efficiency of the enginecooling system.

• Keep the mower deck and discharge chute clean.

• Mow with sharp blades. A dull blade tears thegrass (resulting in poor lawn appearance) and usesextra power (slowing the mowing speed).

• It is preferable to cut grass when it is dry and nottoo tall. Mow frequently and do not cut grass tooshort. (For best appearance, cut off 1/3 or less ofexisting grass height.)

• When mowing, operate the engine at or near fullthrottle for the best cutting action and performanceof the grass handling system (GHS). Mowing with alower engine RPM causes the mowing blade to notcut clean and tear the grass. The engine isdesigned to be operated at full speed.

• When mowing in adverse conditions (tall and/orwet grass), mow the grass twice. Raise the mower tothe highest setting - 4 in. (102 mm) - for the first passand then make a second pass cutting to the desiredheight.

• Use a slow setting on the FSC for trimmingoperations.

Cam inLOCKOUT

Position

PlungerDepressed

Lockout Lever

Cam inUNLOCKED

Position

Lockout Lever

PlungerReleased


33

• Make sure the mower is leveled properly for asmooth cut. Refer to Deck Leveling in AssemblyInstructions.

• Use an alternating stripe mowing pattern forbest appearance and vary the direction of the stripeeach time the grass is mowed to avoid wear patternsin 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 hydrostatictransmissions are “power boosted controls” andjerking the levers can easily slip the tires. For sharpturns, do not allow the inside wheel to stop and twiston grass; pull inside steering lever into reverse for asmooth “rolling” turn (one wheel rolling forward whilethe other rolls backward).

• When using a side discharge mower deck, theside discharge shield must not be removed andmust be kept in the lowest possible position todeflect 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 ofdamage to property by thrown objects.

Side Discharge Shield in Lowest Position

• When operating on a slope, reduce speed anduse caution to start, stop, and maneuver. Avoidsharp turns or sudden changes in direction. Themaximum recommended side slope operatingangle is 20 degrees or 33% grade.

Maximum Recommended Side Slope

RECOMMENDATIONS FOR TILT-UP DECK OPERATION/TRANSPORT

To avoid potential deck and/or tractor damage whileusing 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 backof the deck) and the GHS discharge chute may bedamaged by moving the tractor. The tilt-up configu-ration should only be used when the tractor isparked.

• The tractor body should never be tilted for-ward with the deck in the tilt-up position. This cancause the deck to unhook from the tractor and fallwith considerable force, potentially causing deck ortractor damage and/or bodily injury.

• When transporting a tractor with the deck in thetilt-up position (on a truck or trailer), the deckshould be secured to the vehicle with a strap orrope (stop vertical movement). This will prevent thedeck from bouncing on the rear roller wheels (caus-ing breakage). This will also prevent the deck fromunhooking from the tractor and falling, potentiallycausing deck or tractor damage. Damage to otheritems parked in front of the deck may also occur.

DischargeShield

Maximum RecommendedSide Slope - Do Not Operate

on Steep Slopes


34

PTO and BladeGear Drive

Rear DischargeMower Deck

DeckDischarge Chute

Blower

Body ChuteAssembly

Grass Catcher

CatcherDoor Spring

CatcherDoor

ExhaustDeflector

Exhaust Screen(Removable)

Catcher DoorSafety Latch

Grass-Pak®

Vane Switch

“Full” SignalHorn

ActuatorRod

Powerfil ®

Drive Motor

Dump Handle

Powerfil ®

Delivery Spout

DeliveryChute

Shear Pin

ShearBolt

PTOClutch

GHS Flow and Components

GRASS HANDLING SYSTEM (GHS)GHS Model Only


35

General Information

The Grass Handling System (GHS) consists of a reardischarge mower deck connected to a 9 in. (23 cm)blower and a rear mounted grass catcher with 6.7bushel (238 liters) capacity. The GHS blower oper-ates any time the mower blade clutch is engaged andmoves grass through the rear discharge deck chuteinto the grass catcher. Blower airflow is exhaustedout the back of the grass catcher, through a filteringscreen. When the grass catcher is full and needs tobe emptied, a “full” signal horn alerts the opera-tor. When the “full” signal horn sounds, it is importantto stop mowing to prevent overfilling and clogging ofthe blower system.

IMPORTANT: Normally, the GHS blower operateswith no maintenance or cleaning required. However,under certain operating conditions, the inside of theblower housing may accumulate a deposit of dirt,causing wear and binding of the blower wheel. Nor-mally, dirt buildup occurs when mowing acombination of dirty and damp grass, especiallyin the springtime. When operating in these condi-tions, check the blower wheel frequently forbinding and clean the blower housing as required.Refer to CLEANING the GHS Blower in Mainte-nance Instructions.

NOTE: In Autumn, when using the GHS mower tovacuum leaves, it is recommended to raise the frontof the mower deck 2 to 3 notches [1 to 1-1/2 in. (25to 38 mm)] higher than the rear. This will avoid“bulldozing” leaves, particularly when the leavesare piled in a thick layer. To make this adjustment,the hitch pins in the two (2) front deck support pinsare repositioned 2 to 3 notches higher while leavingthe rear pins in their original position.

NOTE: When a side discharge or mulching mowerdeck is installed on the GHS model, a blower intakecover should be installed in the blower intake tube.This cover “unloads” the blower and seals the intaketo effectively eliminate power loss and blower noisewhen the blower is not being used.

Blower Intake Cover

DANGER

NEVER operate the GHS catcher with theback door open. Objects may be thrownout the back of the catcher with sufficientforce to cause serious injury to bystandersor to damage property.

DANGER

ROTATING BLOWER BLADES

NEVER operate the GHS blower with theblower discharge chute uncovered (grasscatcher in the dump position) since dan-gerous projectiles may be thrown. NEVERput hands into the blower discharge chutefor any reason. Use a stick or similar in-strument to remove any material if clog-ging has occurred.

CAUTION

NEVER leave grass clippings in the grasscatcher after mowing. Damp clippingsgenerate heat as they decompose. ThisMAY cause spontaneous combustion.

BlowerIntake Cover


36

Clogging Checklist

In case of clogging, there will be a distinct changein the sound of the blower, i.e., the blower sound willstop. Also, the mower deck will begin to leave a trailof grass clippings. When this occurs, stop theengine, disconnect the spark plug wire, and makesure all movement has stopped before attempt-ing to unclog.

Normally, any clogging will first develop at the backof the mower deck in the discharge opening into theblower chute. Clogging at this point does not indi-cate a particular problem in this part of thesystem, but is a symptom of something restrict-ing the flow of material throughout the entiresystem. The following list of items should bechecked if a pattern of clogging begins to develop.All of these items are capable of causing clogging atthe back of the deck.

• Check to see if the RH and LH mower blades areinstalled for the correct rotation - install the bladesso the cutting edges move toward each other.

Blade Rotation for GHS Mower Deck(View from Underneath)

• Check the amount of flat section remaining atblade tip. This is the area that is ground away(removed) when the blades are sharpened. If toomuch of the flat section is removed, the “air lift” per-formance or “shovel” effect of the blade deterioratesto the point that discharge of grass clippings into theblower chute is marginal. Replace cutter blades ifless than 3/4 in. (19 mm) flat section remains at theblade tip.

• Check that the interior of the deck housing andbaffling is reasonably clean and free of grass anddirt buildup. While some degree of material buildupcan be tolerated, a point is finally reached where theflow of air and grass clippings is restricted.

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

• Check the deck cutting height setting. Whenworking in thick, tall grass, lower deck settings [1to 2 in. (25 to 51 mm) cutting heights] tend torestrict airflow from moving into and under thedeck. Raising the deck cutting height will signifi-cantly increase airflow and reduce clogging whenworking in thick, tall grass.

• Check the interior of the chute connecting themower deck to the blower for smoothness and free-dom from obstruction.

• Check the blower wheel for bent blades andexcessive clearance between the blade tip and theblower housing. A clearance greater than 1/8 in.(3 mm) will cause a significant loss of blowerperformance.

• Check the blower discharge chute into the grasscatcher for smoothness and freedom fromobstruction.

• Check the elbow inside the grass catcher for abuildup of material in the radius of the elbow. Incertain conditions (damp/dirty grass) a considerable“clump” of material can accumulate at this point,greatly restricting material and airflow.

DANGER

NEVER place hands under the mower deckor in the GHS blower discharge chute. Usea stick or similar tool to remove anyclogged material.

FORWARD

Blades Must Operate atRight Angles (90 Degrees)

Mounting NutTorque = 60 ft-lb

(81.3 N⋅m)Rear DischargeChute


37

• Check that the openings in the air exhaustscreen in the grass catcher are not plugged. If thescreen is clogged, refer to Cleaning the GHSExhaust Screen in this section.

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

Using the Tilt-Up Deck

Refer to CLEANING of Grass Buildup in MowerHousing in Maintenance Instructions.

Using the GHS Catcher

Powerfil

The GHS catcher has an oscillating grass deliveryspout (POWERFIL ) which is designed to spreadgrass clippings throughout the interior of the grasscatcher (even when mowing wet, heavy grass). Theoscillating action may be checked by turning theignition switch to the ON position and moving theblade clutch to the ENGAGED position. The spoutshould oscillate approximately 25 cycles per minute.

NOTE: If the grass spout fails to oscillate, the clutchswitch should be checked for function (the switchclosure is adjustable).

“Full” Signal Horn

The GHS catcher has a “full” signal horn to alertthe operator to dump the catcher when it is full (toprevent overfilling and clogging). The “full” signalhorn 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 asgrass begins to fill in around the spout when thecatcher is almost full.

The “full” signal function may be checked by turningthe ignition switch ON, engaging the blade clutch(engine not running), opening the catcher back door,and triggering the Grass-Pak vane by hand as itoscillates. The horn should sound as the switch ismoved in both directions.

The “full” signal horn is designed to operate (sound)when the grass catcher is almost full. The timing ofthe signal is adjustable by changing the position ofthe vane on the Grass-Pak switch. If the signal iscoming on too soon (catcher not completely full) ortoo late (grass clogging in catcher spout and deliv-ery chute), refer to ADJUSTMENTS of GHS “Full”Signal Horn in Maintenance Instructions.

NOTE: The horn signal should be adjusted tosound BEFORE the catcher is completely full togive the operator time to react and stop mowing. Anindication the horn signal is coming on too late(delayed too much) is if grass clippings are falling outof the grass catcher delivery chute when the catcheris dumped.

Cleaning the GHS Exhaust Screen

To remove the grass catcher screen for cleaning,open the catcher door, push forward and pull downon the grass catcher screen knobs (on either side ofthe screen), and slide the screen out. Use a highpressure washer or water spray and brush to cleanthe screen.

Keeping the catcher exhaust screen clean and openis essential to good performance of the catching sys-tem. In some mowing conditions, e.g., wet and dirty,it will be necessary to clean the screen frequently toavoid clogging the mower deck, blower, and chutesdue to airflow restriction.

Grass Catcher ScreenRemoval for Cleaning

WARNING

DO NOT test the Grass-Pak switch withthe engine running. Projectiles may bethrown out of the grass delivery spout, andCOULD cause serious injury.

Grass CatcherScreen

RemovalKnobs


38

Dumping the Catcher

For dumping, the catcher either tailgate dumps intoa disposal area or dumps into the optional dump bag.The dump bag is a reusable nylon fabric bagdesigned to conveniently move grass clippings fromthe catcher to a remote disposal area or container.

Tailgate Dumping

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

NOTE: To prevent accidental door closure,a safety latch locks the door open in thefully opened position while the catcher is be-ing dumped.

2. Tilt the catcher back to dump by lifting on thehandle on the front of the catcher.

3. Lower the catcher smoothly down to the normaloperating position. DO NOT allow the catcherto drop down.

4. Close the door by holding the door handlewith the left hand and releasing the safetylatch on the door hinge mechanism with theright hand. The safety latch is released bypressing in on the top of the latch. Then, thedoor should close smoothly with the assis-tance of the gas springs.

Catcher Door Safety Latch

Using the Dump Bag

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

NOTE: To prevent accidental door closure,a safety latch locks the door open in thefully opened position while the catcher is be-ing dumped.

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

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

4. Tilt the catcher back to dump into the bag bylifting on the handle on the front of the catcherwith one hand while continuing to hold up onthe bag strap with the other hand. Refer tophotos for positioning the bag and dumping.

5. Lower the catcher smoothly down to the normaloperating position. DO NOT allow the catcherto drop down.

SafetyLatch


39

Positioning Dump Bag on Catcher

6. Close the door by holding the door handlewith the left hand and releasing the safetylatch on the door hinge mechanism with theright hand. The safety latch is released bypressing in on the top of the latch. Then, thedoor should close smoothly with the assis-tance of the gas springs.

Dumping Catcher into Dump Bag

Tailgate DoorHandle

Hook Bagon Bumper

CatcherDump Handle

Maintenance Instructions

40

MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL MS

Service Item Daily25

Hours50

Hours100

Hours YearlyEvery 2Years

Ref.Page

Check Engine Crankcase Oil Level x 42

Check/Clean Engine Air Cooling System* x 50

Clean Grass Buildup Under Deck x 52

Clean GHS Exhaust Screen* x 37

Clean GHS Blower* x 52

Service Mower Blades x 55

Check Security of Air Filtration Components x 54

Check Air Filter Restriction Gauge x 49

Lubricate Grease Fittings and Oil Points* x 43

Check Battery Electrolyte Level x 54

Check Hydrostatic Transmission Fluid x 47

Check Tire Pressure x 55

Check Drive Belts (Engine, PTO, Ground Drive) x 56

Check PTO and Deck Gearbox Oil Seals x 56

Change Engine Crankcase Oil** x 43

Clean Fuel Filter x 50

Change Engine Oil Filter x 43

Clean Air Filter Element* x 48

Check Gear Axle Oil Level x 47

Clean Hydrostatic Transmission Cooling Fins x 53

Clean and Regap Spark Plug x 56

Clean Engine Cooling Fins x 51

Check Fuel Lines and Clamps x 56

Replace Air Filter Element and Vacuator Valve*** x 48

Service Battery x 54

Check/Adjust Blade/Brake Action x 57

Check/Adjust FSC Friction Lock x 68

Change Gear Axle Oil ∆ x 47

Change Hydrostatic Transmission Fluid ∆ x 48

Replace Fuel Lines and Clamps x 56

∗ More often in extremely dusty or dirty conditions(see notes about air cleaner element under IMPORTANT TIPS FOR CARE OF KAWASAKI ENGINE)

∗∗ Change engine oil and filter after first 8 hours of operation of a new engine (break-in period)

∗∗∗ Replace every year or after 6 cleanings∆ Change every 2 years or 1000 hours

CAUTION

When performing maintenance with themower body raised, a safety prop shouldbe installed from back of body to chassisframe (fail-safe protection in case of fail-ure of body lift support). For GHS Model,empty grass catcher before raising body.

CAUTION

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

Maintenance Instructions KAWASAKI TIPS

41

IMPORTANT TIPS FOR CARE OF THE KAWASAKI ENGINE

Fuel System

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

• Clean the fuel filter on a regular basis and whencontamination is suspected or found in the fuel.

Starting

• Start engine with the throttle advanced off idle(1/4 to 1/2 throttle). This will aid starting, especiallyin cold weather.

• Keep the battery fully charged.

• Match crankcase oil viscosity to the ambient tem-perature, allowing the engine to crank faster andstart easier.

• Allow engine to run at idle for a few seconds be-fore stopping engine to avoid run-on or backfiring.

Cooling System

• Keep engine air intake screen and cylinder headfins free of grass clippings, chaff, and dirt. Inspectintake screen and cooling fins for cleanliness anddamage.

• Check performance of the cooling system bystarting the engine, holding a hand adjacent to thecylinder head, and feeling the cooling airflow.

• Operate the engine at full speed when mowing.This will allow the engine to produce full horsepowerand move more cooling air through the engine cool-ing fins.

Air Cleaner

• Use only Donaldson air cleaner elements. After-market elements may not seal in the air cleanerhousing, allowing dirt to enter the engine. Also, af-termarket filters often skimp on the filtration mediaand require more frequent cleaning and replace-ment (see instructions below).

• Use the air flow restriction gauge to indicate theneed to service the air filter.

• DO NOT overservice or frequently “disturb” theair filter. A dirty air filter actually cleans better thana new one. Changing and cleaning the filter too of-ten can actually reduce filter efficiency and increasethe opportunity for traces of dust to enter the engine.Wait until the element really needs servicing as indi-cated by the loss of engine power.

• When the air filter element is removed or re-placed, make sure all dust is cleaned out of the aircleaner housing and hose. Use a damp cloth andwipe the interior of the canister and hose clean (alittle dirt left here will be sucked into the engine andreduce engine life). When the filter is reinstalled,make sure the element is held tight and straightin the canister for proper seating and sealing.

• Periodically check the air intake hose for cuts,nicks, etc., and the hose clamps for tightness.

Oil

• DO NOT screw filler cap into crankcase whenchecking oil level.

• Single viscosity or multi-viscosity oils may beused with the viscosity matching ambient tempera-tures for the engine operating conditions. This willaid starting in cold weather and assure proper lu-brication in hot weather.

• Use only Kawasaki oil filters. Aftermarket filtersmay not seal properly and/or have the incorrectpressure relief valve for proper lubrication.

DANGER


Maintenance Instructions LUBRICATION

42

LUBRICATION

Proper lubrication is an important maintenance pro-cedure. It reduces wear and makes the machinequieter and easier to operate.

Engine Oil

Engine Break-In Oil

No special break-in oil is required. The engine is ser-viced with 10W-30, Service Class SG oil from thefactory. The oil should be changed after the initialengine break-in period of 8 hours. Thereafter,change oil after every 50 hours of operation.

Checking Engine Crankcase Oil Level

Check the engine crankcase oil level before use andafter each 5 hours of continuous operation.

IMPORTANT: The importance of checking andmaintaining the proper crankcase oil level cannot beoveremphasized. Check the oil level BEFOREEACH USE.

1. Park the mower on a level surface with theengine stopped. Also, make sure the engine iscool and oil has had time to drain into the sump[allow at least five (5) minutes after stoppingthe engine].

IMPORTANT: NEVER check or add oil with theengine running.

2. Before removing the dipstick, clean the areaaround the dipstick opening in the engine blockto keep any dirt or debris out of the engine.

3. Unscrew and remove the filler plug/dipstick andwipe off with a clean rag. Insert dipstick into fillerhole but DO NOT screw it in to check the oillevel. Remove the dipstick and check the level.The oil level should be within the safe range(between the H and L marks on the dipstick).

IMPORTANT: DO NOT operate engine withoutsufficient oil supply in the crankcase. DO NOToperate with oil level below the LOW (L) mark orabove the FULL (H) mark on the dipstick.

Dipstick Positionfor Checking Oil Level

Dipstick Operating Range

4. If additional oil is needed, refer to Specificationsfor proper crankcase lubricant. Fill to the FULL(H) mark.

IMPORTANT: DO NOT overfill crankcase [oilabove FULL (H) level] as this CAN result inengine overheating, loss of power, and possi-ble engine damage.

WARNING

DO NOT attempt to lubricate the machinewith the engine running. Disengage thePTO clutch, shut off the machine, and re-move the ignition key.

Filler Plug

FULL (H) Mark

LOW (L) Mark

NOT SCREWED IN

FULL (H)Mark

LOW (L)Mark


43

Changing Engine Crankcase Oil/Oil Filter

Change the engine crankcase oil after every 50hours of operation and the oil filter after every 100hours of operation as follows:

1. Park the mower on a level surface with theengine stopped. The engine oil should bewarm before draining. If not warm from opera-tion, start the engine and run a few minutes towarm the oil.

2. Before removing the dipstick, clean the areaaround it to keep any dirt or debris out of theengine.

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

4. Before removing the oil filter, clean the areaaround the filter to keep dirt and debris out of theengine.

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

Oil Drain, Dipstick (Oil Fill),and Oil Filter Locations

(view from lower left side of tractor)

6. Apply a thin coating of new oil to the rubber gas-ket on the replacement oil filter.

IMPORTANT: Use ONLY oil filters from theengine manufacturer. Aftermarket oil filters maynot seal properly and/or may not have the cor-rect pressure relief valve for proper lubrication.

7. Install the new oil filter on the engine. Turn theoil filter clockwise until the rubber gasket con-tacts the sealing surface, then tighten the filteran additional 3/4 turn.

8. Reinstall the drain plug. Make sure it is tight-ened to 16.5 ft-lb (23 N·m).

9. Fill the crankcase (through the dipstick opening)with oil using only crankcase lubricants suppliedby the engine manufacturer. Refer to Specifica-tions in this manual or the engine owner’smanual. Use the recommended oil viscosity forthe expected ambient temperature. Oil with thecorrect viscosity will aid starting in cold weatherand assure proper lubrication in hot weather.Fill to FULL (H) mark on the dipstick; crankcasecapacity is 2.7 pints (1.3 liters).

IMPORTANT: Check the dipstick reading be-fore pouring in the last 1/2 pint of oil and fill onlyto the FULL (H) mark. The oil level shouldnever be over the FULL (H) mark on the dipstick;overfilling can result in engine overheating andloss of power.

10. Start the engine and check for oil leaks aroundthe oil filter. Stop the engine, recheck the oil lev-el, and add oil if necessary. (When the engineis first operated with a new oil filter, the oil levelwill drop slightly as the filter is filled with oil.)

Grease Fitting and Oil Point Lubrication

Lubricate the grease fittings and oil points afterevery 25 hours of operation. Lubricate more oftenwhen operating in dusty or dirty conditions. UseSAE general purpose lithium or molybdenum basegrease for grease fittings and light machine oil (SAE10) to lubricate oil points. Lubricate the locationsshown in the Chassis and Deck LubricationPoints illustration.

NOTE: PTO universal joints (on the deck and trac-tor) require routine lubrication after every 8 hours ofrunning time.

NOTE: The pillowblock bearings on the PTO driveshaft are a sealed, relubricatable-type bearing.Grease lightly once per year using care to notover-lubricate and damage the seals.

Oil Filter

Dipstick(Oil Fill)

Oil Drain


44

Ident Lubrication No.No. Location Type Places

Ident Lubrication No.No. Location Type Places

� �� ! ��" �#��$��%�� & '��(��" �#�)�*��+ �� , ��)�*��+��-'.�� / ��"$..��)�*�"�� 0 "�� 1�� 2 ��+�%�� "��)�$��3�� 4��".��1�� 4��".��1��

5��"��)��6�� 5�"�6��+�� ! ��3�� & ��-�-��$.�� , ��"$..��)�*�� / �"��1�� 0 '��(��$��)�*��+ �� 2 �"��1��

5��"��)��6�� 4�� " �# �� $� ��1�� $� �� "��$��1�� !

5�%"�7��+6�! ��8��$��+ �� & 3��$*.��3�� , �� %�� / � ��9�� 0 � ��9�� 2 9� ��8��$��+ �� 9� ��.��:��

�� 9� �� )�*��+ �� 3� �)� �� $��8��$��+ �� ! %+�� & 5�"�6��+�� , � �� / � �� 0 �� $��%�� 2 �"��)�$��3��

* Gearboxes are permanently lubricated andsealed requiring no scheduled lubrication.Oil level should be checked only when an oilleak is noted. Refer to Mower Deck Gear-box Lubrication in this section.

** Grease every eight (8) hours.

*** Refer to Gear Axle Lubrication, EngineOil, Tractor PTO Gearbox Lubrication, andHydrostatic Transmission Fluid in this sec-tion.


45

2 31

4

40

7

879

35

36

29 & 37

28 & 38

173515

3910

26

28

29

30

31

32

34

33

27 27

26

2223

25

10

1617

18

20

2121

19

15

6787

9

5

4

2 1

11

11

12

1314

24

24

Chassis and Deck Lubrication Points


46

Mower Deck Gearbox Lubrication

The mower deck gearboxes (tee gearbox and bladedrive gearboxes) are connected as a unitizedassembly, and oil flows freely between them. Thegearboxes are permanently lubricated (oil filled) andsealed requiring no scheduled lubrication. However,the gearbox oil seals should be checked every 25hours for indication of an oil leak; particularly thelower seals on the blade drive gearboxes should beinspected, since they operate in a dirty environment.If an oil leak is noted, replace the oil seal and relu-bricate the gearbox assembly as follows:

1. Remove gearbox cover (footrest). Deck orien-tation should be the normal operating position.

Mower Deck Gearboxes(shown with gearbox cover removed for clarity)

2. Clean the area around the individual gearboxcover plates to prevent contaminants fromentering the gearcase.

3. Remove the screws securing the cover plateson the blade drive gearboxes.

4. Check the level of lubricant in the gearboxes. Ifthe lubricant is low, add SAE E.P. (ExtremePressure) 90W oil until the oil level is up to (sub-merges) the horizontal shaft in the gearbox(shaft parallel to cover plate).

NOTE: In case the gearboxes are completelydrained of oil, approximately 5 fl. oz. (15 cl) of oilper gearbox is required to refill the gear driveassembly.

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

IMPORTANT: DO NOT overfill the deck gear-boxes. The gearbox assembly is not vented,and overfilling with oil will cause excessive pres-sure and result in oil leaks.

5. Check condition of the cover gasket and replaceif worn or damaged. Reinstall gearbox coverplates; torque screws to 24 in-lb (2.7 N·m).

Tractor PTO Gearbox Lubrication

The tractor PTO gearbox is permanently lubricated(oil filled) and sealed requiring no scheduled lubrica-tion. However, the gearbox oil seals should bechecked every 25 hours for indication of oil leaks. Ifevidence of an oil leak is noted, replace the oil sealand relubricate the gearbox. The gearbox will needto be removed from the tractor to be serviced. Refillwith SAE E.P. (extreme pressure) 90W oil until oillevel is up to (submerges) horizontal shaft of gearbox(shaft parallel to cover). DO NOT overfill.

NOTE: In case the gearboxes are completelydrained of oil, approximately 5 fl. oz. (15 cl) of oilper gearbox is required to refill the gear driveassembly.

Tractor PTO Gearbox

Blade DriveGearboxes

TeeGearbox

PTOGearbox


47

Gear Axle Lubrication

• The gear axle oil lubrication is SAE 80W-90 (APIGL-5) gear lube.

• Check the axle oil level after every 100 hours ofoperation by removing the oil level plug. If additionaloil is needed, remove the breather vent on top of ax-le and fill until oil is at the level plug.

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

Hydrostatic Transmission Fluid

Checking Hydrostatic Transmission Fluid Level

Hydrostatic transmission fluid level should bechecked every 25 hours of machine operation. It ispreferable to check the fluid level when fluid iscold. Check fluid level as follows:

1. Park the mower on a level surface. Stop theengine and wipe dirt and contaminants fromaround the reservoir cap and air bleed plug.

IMPORTANT: Before removing the reservoircap, clean any dirt from around it. Any dirt orcontaminants entering the transmission willaccelerate wear and eventually cause loss ofpower to the drive wheels.

2. Remove the reservoir cap and check the level ofthe fluid. The reservoir has a fluid level COLDmark and HOT mark. The reservoir oil levelshould ALWAYS be at or above the COLDmark and NEVER above the HOT mark.

3. If the fluid is below the COLD mark (or the trans-mission is not performing properly), loosen theair bleed plug (located on the top of transmis-sion case next to the plastic reservoir).

a. If a small amount of fluid leaks from aroundthe air bleed plug:

* The transmission is full of fluid.

* Tighten the plug and fill the reservoir tothe COLD level mark.

b. If no fluid leaks from around the air bleedplug:

* Slowly add fluid into the reservoir untilfluid starts to leak from around the plug.(Transmissions are serviced from thefactory with Mobil DTE 18M hydraulicoil. When it is necessary to add fluid,refer to Specifications for the proper flu-id. Use any of the fluids listed.)

* As soon as there is fluid leaking fromaround the air bleed plug, tighten theplug and fill the reservoir to the COLDlevel mark. Wipe any excess oil off ofthe transmission housing.

Transmission Reservoirand Air Bleed Plug Location

IMPORTANT: DO NOT overfill the transmissionreservoir. This will result in oil leaking out of the res-ervoir cap vent when the transmission warms up. Itis preferable to add fluid to the transmission when itis cold and make sure the oil is not above or be-low the COLD level mark.

IMPORTANT: The transmission reservoir has a finemesh screen in the bottom to trap dirt and foreignparticles from entering the transmission. When fillingthe reservoir, fluid will flow quite slowly through thisscreen; so it is essential that there is fluid at the bleedplug before the transmission is considered full.

IMPORTANT: Any attempt to remove or in any wayalter the filtering screen in the transmission reservoircould cause damage to the transmission and willVOID any transmission warranty.

Reservoir Cap

Hot Level

Cold Level

Air BleedPlug

Maintenance Instructions LUBRICATION/CLEANING

48

Changing Hydrostatic Transmission Fluid

The hydrostatic fluid should be changed every 1000hours or two (2) years. Also, the fluid should bechanged if the natural color of the fluid has becomeblack or milky (indicating possible overheatingor water contamination of fluid). The transmissionmay be refilled using any of the fluids listed inSpecifications. The fluid is changed as follows:

1. Park the mower on a level surface and stop theengine.

2. Remove the lower drain plug and the air bleedplug. Allow the fluid to drain out.

IMPORTANT: Clean any dirt from around theplugs and reservoir cap before removing them.

3. Reinstall the lower drain plug, making sure therubber O-ring on the plug is in place and in goodcondition.

4. Refill the transmission through the air bleed plughole until it is as full as possible.

IMPORTANT: Avoid fluid contamination whenfilling the transmission. Use clean container,spout, funnel, etc. when pouring the fluid into theair bleed opening and reservoir.

5. Rotate the transmission input shaft about five (5)revolutions to allow any trapped air to escape.

6. Before installing the air bleed plug, fill the reser-voir with fluid allowing a small amount to leak outof the air bleed plug hole.

7. Install the air bleed plug and fill the reservoir tothe COLD level line.

CLEANING

Engine Air Cleaner System

Donaldson Radialseal™ Air Cleaner

A remote mounted Donaldson Radialseal™ aircleaner provides the air filtering function. The paperfilter element slides over an outlet tube inside the aircleaner canister with radial sealing action, eliminatingthe possibility of dust leaks due to improper filter instal-lation. Intake design, internal baffling, and aVacuator™ valve provide dust separation and auto-matic precleaning action. Daily or frequent servicingof the air cleaner is not required. Use the air restrictiongauge on the air cleaner outlet to indicate when theair filter needs servicing -- a red flag will appear whenthe filter is overly restricting airflow into the engine.IMPORTANT: Use only Donaldson air filter ele-ments for replacement (Donaldson P822686 orWalker 5090-1). Aftermarket filters may not sealproperly or filter efficiently.

Air Cleaner Components(shown with cover being removed)

IMPORTANT: The Donaldson air cleaner uses a drypaper-type air filter element. NEVER apply oil to thepaper element.

Vacuator™Valve

CoverCanister

Radialseal™Filter Element

Cover Latch

Maintenance Instructions LUBRICATION/CLEANING

49

Air Restriction Gauge Location

Clean and inspect the paper element after every100 hours of service and replace the elementyearly or after six (6) cleanings (or when dirty ordamaged). More frequent cleaning may be requiredwhen operating in extremely dusty conditions asindicated by a loss of engine power. Service the aircleaner as follows:

1. Release the top and bottom cover latches andremove the air cleaner cover. Wash the coverand Vacuator™ valve. Check that these com-ponents are in good condition. The Vacuator™valve is subject to wear and deterioration andshould be replaced yearly or when damaged.The lips of the valve should close and fittogether; any cracks, deformation, or wear in thevalve is cause for replacement.

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

3. Clean the filter element using low pressurecompressed air [less than 100 PSI (689 kPa)].Blow out the filter from the interior of the elementwhile turning the element.

NOTE: Washing the element in water or clean-ing solution is not recommended. Replace theelement if it does not clean up with compressedair.

4. Use a bright light inside the element to inspectfor damage. Check the element very carefullyfor pin holes or other damage that will allowdirt to leak through the paper media. Replaceelement if necessary.

5. Check the condition and resilience of the radialsealing surface (inside of the open end) of the fil-ter. Replace the filter if any cracks, tears, orother damage to the sealing surface are noted.

6. Use a clean, damp cloth and wipe the interior ofthe air cleaner canister clean. Use special careto clean both the inside and outside surfacesof the outlet tube.

IMPORTANT: Any dust left on the inside of theoutlet tube will go into the engine and causewear.

7. Check the outside surface of the outlet tube forsmoothness and cleanness (this is the sealingsurface).

8. Insert and seat the filter element carefully intothe canister, applying pressure at the outer rimof the filter; not at the flexible center. Make surethe filter element is completely in place beforeinstalling the cover.

IMPORTANT: DO NOT use the cover latchesto force the filter into the canister -- the covershould fit on with no extra force.

NOTE: DO NOT use petroleum based lubri-cants on the sealing surfaces of the filter; use tal-cum powder or dry silicone lubricants if requiredfor filter installation.

Air Filter Element Replacement

Air RestrictionGauge

Push Button to ResetIndicator After Service

Radial SealingSurface

Radialseal™Filter Element

Outlet Tube

Canister

Maintenance Instructions CLEANING

50

9. Install the cover with the word "TOP" properlyoriented to the top of the canister. Give thecover a slight twist as it reaches the canister tomake sure the tab inside the cover goes into aslot, otherwise the cover will not fit properly.Make sure both the top and bottom coverlatches are securing the cover in place.

Proper Orientation of Air Cleaner Cover

10. Check the air intake hose for cuts, nicks, etc.,and the hose clamps for tightness.

11. Reset the air restriction indicator (press buttonon bottom).

Fuel Filter

Clean and inspect the fuel filter screen after every50 hours of service. Replace if damaged. Servicethe fuel filter as follows:

Fuel Filter and Fuel Shut-off Valve Location

IMPORTANT: Service the fuel filter screen only in aclean area where the fuel filter components will notbe contaminated by any dust and dirt.

1. Close the fuel shut-off valve.

2. Loosen sediment bowl and remove filter screenand gasket. Replace filter screen, if damaged(use only Kawasaki replacement filter #49019-2095).

3. Remove any sediment, wipe clean and reinstallassembly.

4. Open the fuel shut-off valve.

Engine Cooling System

Air Intake Screen

To prevent engine overheating and possible enginedamage, clean grass clippings, chaff, and dirt fromthe rotating engine air intake screen after every 8hours of operation. In certain mowing conditions(dry grass, leaves, tree “cotton”, etc.) it may be nec-essary to check and clean this area several timeseach day to prevent engine overheating.

Cover LatchVacuator™

Valve

Cover Latch Orient to Topof Canister

Fuel Shut-OffValve

Fuel Filter andSediment Bowl

DANGER

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

• Use an approved fuel container for gas-oline.

• DO NOT allow open flames or sparkswhile performing maintenance or refuel-ing; DO NOT smoke while working withfuel.

• Wipe up spilled gasoline immediatelyand completely.

CAUTION

Operating the engine with a blocked airintake screen, dirty or plugged coolingfins, and/or cooling shrouds removed willcause engine damage from overheating.


51

Engine Air Intake Screen

Cylinder Head Cooling Fins

It is essential for performance and longevity of theair-cooled engine to keep the cylinder head coolingfins clean and free of obstruction. After every 8hours of operation, check the performance of thecooling system by starting the engine, holding ahand adjacent to the cylinder head, and feeling thecooling airflow. If there is little or no airflow, clean thecooling fins as follows:

NOTE: The planned maintenance schedule callsfor cleaning the cylinder head cooling fins yearly orevery 300 hours as a minimum.

Cooling System Airflow

1. Remove the exhaust shroud by removing thetwo (2) bolts and one (1) nut as shown in theInspect and Clean Cylinder Head CoolingFins photo on the following page. Clean theaccessible cooling fins by blowing with com-pressed air. If the buildup is excessive, refer tostep 2; if the buildup is not excessive, reinstallthe exhaust shroud.

2. Remove the spark plug wire and disconnect thebreather tube on the valve cover. Do not dis-connect the breather tube from the carburetorside. Remove the cylinder head shroud byremoving the four (4) bolts, as shown in theInspect and Clean Cylinder Head CoolingFins photo. Cover the breather tube end andspark plug boot before cleaning out the coolingfins. Clean the cooling fins by blowing with com-pressed air. If the buildup is excessive, use apiece of wire to probe into the fins for cleaning.

3. Reinstall the shrouds by reversing the precedingsteps. Start the engine and confirm the coolingairflow.

Inspect and CleanCylinder Head Cooling Fins

(viewed from left side of tractor)

DANGER


RotatingEngine Air

Intake Screen

Exhaust Shroud

Check for Airflow

Cylinder Head ShroudBolts (not visible) Breather Tube

Exhaust ShroudNut (not visible)

and Bolts

Spark PlugWire

Cylinder HeadShroud Bolts


52

Grass Buildup in Mower Housing

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

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

Deck Secured in Tilt-Up Position

3. Clean grass buildup underneath the deck usinga pressure washer (and scraper if required).

NOTE: If the buildup is severe, it may be easierto clean the deck by removing the deck assem-bly from the tractor and standing the deskassembly on its “nose”.

NOTE: While some degree of material buildupin the mower deck housing can be tolerated, apoint is finally reached where cutting qualitydeteriorates and clogging begins to occurbecause of too much buildup on the baffling andhousing.

4. Lower the deck to the normal operating positionand re-engage the deck lock levers.

GHS Blower

Normally, the GHS blower operates with no mainte-nance or cleaning. However, when mowing grassthat is dirty and damp (especially springtime mow-ing), a deposit of dirt may accumulate inside theblower housing, causing wear and binding of theblower wheel. When operating in these conditions,inspect the blower frequently for dirt buildup.

NOTE: A visual clue of binding of the blower wheelis the blower blade tips are polished from rubbingon dirt.

When a dirt deposit is found, use a high pressurewasher or water spray to clean the inside of the hous-ing as follows:

1. Remove the PTO drive belt from the GHSblower pulley as follows: Move the blade clutch(in direction of engagement) far enough to relaxthe belt scrubber brake without tightening thePTO drive belt. Roll the belt off of the blower pul-ley, then move blade clutch to full “engagement”position. Both the drive belt and scrubber brakebar should be clear of blower pulley, allowingfree movement of the blower wheel.

IMPORTANT: With the belt removed, the blowerwheel must spin freely. Any binding or drag-ging of the wheel is an indication of dirt buildup.This buildup must be cleaned to avoid abra-sive wear of the blower blades, excessivepower loss and eventual loss of blower perfor-mance (clogging).

DANGER

Before raising or removing the mowerdeck for cleaning, stop the engine, removethe ignition key, and disconnect the sparkplug wire.

Body Bracket

CAUTION

Do not operate machine with deck tilt-uppivot joint unlocked.

DANGER

Before attempting to wash the blower,stop the engine, remove the ignition key,and disconnect the spark plug wire.


53

2. Use a pressure washer or water spray, anddirect the spray inside the blower housingagainst the blower blades. Water pressure willcause the blower wheel to begin to spin, and thecombination of spinning action and water willeffectively wash the inside of the housing. Spraymay be directed against the blower blades ver-tically and horizontally to cause rotation in bothdirections for thorough washing action. Washblower until the blower wheel spins freely inboth directions.

PTO Drive Belt Removalfor Cleaning GHS Blower

3. Reinstall the PTO drive belt by reversing theremoval procedure.

GHS Exhaust Screen

Refer to Cleaning the GHS Exhaust Screen inOperating Instructions.

Hydrostatic Transmission Cooling Fins

Keeping the cooling fins on the hydrostatic transmis-sions clean and free of obstruction is essential toavoid overheating the transmission fluid and short-ening transmission life. The cooling fins should bechecked every 100 hours; and cleaned ifnecessary.

To clean the fins, use compressed air and/or a pres-sure washer. The cooling fins extend all the wayaround the housing -- the fins underneath need to beclean as well as the more visible fins above. Also,pay close attention to the area under the drive pulley.

IMPORTANT: In case an oil leak develops on theinput shaft, the cooling fan blowing dusty air and oilon the transmission will quickly pack the cooling finswith oily dirt. If this condition occurs, replace theseal immediately to avoid overheating and damag-ing the transmission. The input shaft assembly andseal are easily replaced without removing the trans-mission from the machine.

An additional procedure in maintaining transmissioncooling is to inspect the cooling fans. Replace thefan(s) if blades are missing or damaged.

Hydrostatic Transmission Cooling Fins

CompoundPulley

Blade ClutchLever

Belt TightenerIdler Pulley

PTODrive Belt

GHSBlowerPulley

Belt Scrubber Brake(Relax to Remove PTO Drive Belt)

PTO Drive Pulley

CoolingFans

Cooling Fins

Maintenance Instructions

54

CHECKING/SERVICING

CHECKING/SERVICING

Security of Air Filtration Components

NOTE: The following inspection is only an externalinspection and should be done without “disturb-ing” the filtration components.

On a daily basis, visually inspect the external condi-tion of the complete air cleaner system. Thefollowing items should be inspected:

1. Check the Donaldson Radialseal™ air cleanercanister for damage. Make sure the cover is inplace and the cover latches are secure - do notrun the engine without the air cleaner cover inplace and secure.

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

Battery

NOTE: For initial battery service during setup, referto Battery Service in Assembly Instructions.

IMPORTANT: Make sure battery is securelymounted in the frame. A loose battery may causedamage to the case resulting in acid leakage andsevere damage to the machine. A hazard may becreated by damage to critical working parts andsafety systems.

Electrolyte Level

The battery electrolyte level should be checked afterevery 25 hours of operation. To check electrolytelevel:

1. Remove battery cell filler caps.

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

3. Replace filler caps.

IMPORTANT: DO NOT overfill the battery. Electro-lyte will overflow through the vent tube onto parts ofthe machine and WILL result in severe corrosion.

Cleaning the Terminals

If battery terminals are corroded, remove batteryfrom the mower. Using a wire brush, remove corro-sion with a solution of one part baking soda andfour parts water. Rinse with clean water. Coat theterminals with petroleum jelly or terminal protectorspray to retard further corrosion.

Charging the Battery

DANGER

To prevent accidental starting of the en-gine when servicing or adjusting the ma-chine, remove the key from the ignitionswitch and disconnect the spark plug wire.

DANGER

BATTERIES PRODUCE EXPLOSIVE GASES

• Charge the battery in a well-ventilatedarea, so that gases produced while charg-ing can dissipate.

• Keep sparks, flames, and smoking ma-terials away from the battery at all times.

• Make sure the battery cap vents are open(check manifold vent on each cap).

• Make sure the battery charger is un-plugged before connecting or discon-necting cables to the battery.

Maintenance Instructions CHECKING/SERVICING

55

Check the battery charge by measuring the specificgravity of electrolyte; if specific gravity is less than1.225, 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 specificgravity is at least 1.250. Total charging timeshould not exceed one (1) hour.

2. After charging the battery, use drinking water toadjust the electrolyte level to the bottom of thevent wells [1/4 to 1/2 in. (6 to 13 mm) above theplates].

Tire Pressure

Inflate tires to pressures shown below:

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

Sharpen Mower Blades

Check mower blade(s) for straightness, sharp-ness, condition of the cutting edge, and balanceevery 10 hours of operation (or more often whenmowing abrasive type grass or operating on sandysoils). Replace blades if worn, bent, cracked, orotherwise damaged (refer to REPLACING/REPAIRING the Mower Blades in this section).Use the following procedure to check and sharpenblades:

NOTE: Keep blades sharp - cutting with dullblades not only yields a poor mowing job but slowsthe cutting speed of the mower and causes extrawear on the engine and blade drive by pulling hard.

1. Stop the engine, remove ignition key, and dis-connect the spark plug wire before raising themower deck to service blades.

2. Raise the deck and secure it in the tilt-up posi-tion (refer to Deck Secured in Tilt-Up Positionphoto in CLEANING of Grass Buildup inMower Housing in this section).

3. Check the blades for straightness by markingthe blade tip position inside the deck housing,and then rotating the opposite end of the bladeto 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.

4. If the blade cutting edge is dull or nicked, itshould be sharpened. Remove blades forsharpening by grasping the end of the bladeusing a rag or a thick, padded glove, while loos-ening and removing the nut, lock washer, andflat washer that mounts the blade.

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

NOTE: Blades can be sharpened with an elec-tric blade sharpener, conventional electricgrinder, or a hand file.

6. Check blade balance by positioning the bladehorizontally on a blade balancer or use a nail orshaft through the center hole. If either end of theblade rotates downward, grind (remove) metalon that end until the blade will balance. Theblade is properly balanced when neither enddrops. Balance of a blade is generally main-tained by removing an equal amount of materialfrom each end of the blade when sharpening.

DANGER

NEVER operate cutter blades with thedeck in the raised position.

WARNING

DO NOT try to straighten a blade that isbent. NEVER weld a broken or crackedblade. ALWAYS replace with a new bladeto assure safety.

CAUTION

ALWAYS wear eye protection and gloveswhen sharpening a blade.

Maintenance Instructions CHECKING/SERVICING

56

Mower Blade Profile For Sharpening

Blade Balanced on MagneticWall-Mounted Balancer

7. Mount the blade with wing tips pointing up intothe housing. Reinstall the blade, washer, lockwasher, 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 beswitched. Check for proper blade rotation beforeinstalling blades on the deck. Refer to Blade Rota-tion for GHS Mower Deck illustration shown inClogging Checklist in Operating Instructions forcorrect blade rotation.

Drive Belts

Raise the body and inspect the condition of the three(3) drive belts after every 25 hours of operation --engine, PTO drive, and ground drive. If the beltsshow signs of cracking or deteriorating, the beltsshould be replaced. Refer to REPLACING/REPAIR-ING the Drive Belts in this section.

Mower Deck Gearbox Oil Seals

The mower deck gearbox seals should be inspectedevery 25 hours for evidence of oil leaking; particu-larly the lower oil seal on the blade drive gear-box. This seal is protected by the trash guard on theblade hub and seal protector plate on the housing,but is still vulnerable to seal damage due to operatingin an adverse environment. The mower blade mustbe removed for inspection of the seal, so it is recom-mended to inspect the gearbox seals whenblades are removed for sharpening. If an oil leakis noted, the seal should be replaced and the gear-box assembly relubricated. Refer to Mower DeckGearbox Lubrication in this section.

Spark Plug

Every 100 hours, remove the spark plug, inspect,clean, and reset the gap (or replace with a newplug). Clean spark plug with a wire brush. If theelectrodes are burned short or pitted, replace theplug (refer to Specifications for the proper type ofreplacement plug). Check the spark plug gap with awire-type feeler gauge and set the gap between0.028 and 0.032 in. (0.7 and 0.8 mm). Reinstall andtighten to 17 ft-lb (23 N·m).

Breaker Points

The Kawasaki engine is equipped with electronicignition. No breaker points, maintenance, or adjust-ments are necessary with this system. Contact anauthorized Kawasaki engine dealer in case of igni-tion failure.

Fuel Lines and Clamps

Every year, inspect the fuel line from the tank toengine for deterioration or damage. Also, inspect thefuel line clamps for tightness. Good preventivemaintenance calls for complete replacement of fuellines and clamps every two (2) years.

Wing Tip

Do Not Grind orSharpen on Underside

30°

Sharpen at Original30° Angle

IntersectionWear Area

Blade Balancer

57

Maintenance Instructions CHECKING/SERVICING/REPLACING/REPAIRING

Blade Brake Action

Check the function of the cutter blade brake (andblower brake on GHS models) by engaging the bladeclutch (PTO), operating the engine at full throttle,then disengaging the clutch and measuring howquickly the blades stop. Watch the rotation of theblade drive shaft and blower pulley as a visual indi-cation that movement has stopped. If the brake isworking properly, all rotation will stop five (5)seconds after disengagement of the clutch. If thebrake system malfunctions -- blades do not stop infive (5) seconds -- adjust or repair the brake beforeoperating the mower. Refer to ADJUSTMENTS ofBlade Clutch (PTO) in this section.

REPLACING/REPAIRING

IMPORTANT: ALWAYS use genuine factory re-placement parts. Substitute parts CAN result inproduct malfunction and possible injury to the oper-ator and/or others.

Drive Belts

There are three (3) individual belts on the machine:

• Engine Belt

• PTO Drive Belt

• Ground Drive Belt

The belts may be removed and replaced using theprocedures described on the following pages.

WARNING

It is important to check and maintain bladebrake action for safe operation of the ma-chine.

DANGER

To prevent accidental starting of the en-gine when replacing parts or repairing themachine, remove the key from the ignitionswitch and disconnect the spark plug wire.

PTO Drive Belt

Ground Drive Belt

Engine Belt

Belt Locations

Maintenance Instructions REPLACING/REPAIRING

58

Engine Belt

1. To remove the engine belt:

a. Relax the belt by depressing the spring-loaded idler arm.

b. Roll the belt off the compound pulley andremove the belt.

Engine Belt (Engaged)

Engine Belt (Disengaged)

CompoundPulley

Idler Pulley

Belt TightenerArm

Push Idler Pulleyto Relax Belt

Engine Pulley

Tension Spring

Engine Belt

2. Reverse the removal procedure to replace theengine belt.

CompoundPulley

Idler Pulley

Belt TightenerArm

Engine Belt

Engine Pulley

Tension Spring


59

PTO Drive Belt

1. To remove the PTO drive belt:

a. Remove the engine belt, as described inprevious section.

b. Remove 1/4-20 x 3/4 bolt locating beltguide on gearbox pulley and rotate guideto clear belt.

c. Move blade clutch (in direction of engage-ment) far enough to relax belt scrubberbrake without tightening the PTO drive belt.Roll belt off PTO drive pulley and GHSblower pulley (GHS model only).

2. Install the PTO drive belt by reversing the re-moval procedure. Refer to ADJUSTMENTS ofBlade Brake (PTO) in this section to checkscrubber brake adjustment and brake action.

PTO Drive Belt Removal

Engage Clutch

Remove Bolt and Rotate Belt Guide to Clear Belt

Compound Pulley

Belt Guide

PTO DrivePulley

Belt Scrubber Brake(Relax Brake to Remove Belt)

GHSBlowerPulley

PTODrive Belt

Clutch Idler Pulley

Blade ClutchLever

PTO Belt TightenerLinkage

ClutchActuator Assembly


60

Ground Drive Belt

1. To remove the ground drive belt:

a. Raise the spring-loaded idler to relax belt.

b. Slide belt off pulleys, then release theidler.

Raise Idler Pulley to Relax Belt

TransmissionDrive Pulley

Ground DriveBelt

Tension Spring

Idler Pulley

Belt Tightener Arm

HydrostaticDrive Pulley


Ground Drive Belt Assembly (Disengaged)

2. Reverse the procedure to install the grounddrive belt.

TransmissionDrive Pulley

Ground DriveBelt

Tension Spring

Idler Pulley

Belt Tightener Arm



Ground Drive Belt Assembly (Engaged)


61

Blade Overload Shear Bolts

The cutting blade is keyed to the blade hub by two(2) shear bolts (10-24 x 5/8 in. stainless steel ma-chine screws). These bolts are designed to shearand protect the blade drive gearbox from damage ifthe blade encounters a shock load.

Cutting Blade Shear Bolts

NOTE: Tightening the 5/8-18 blade mounting nutto 60 ft-lb (81.3 N·m) is also important for propershock load protection. It is important to not over-tighten the mounting nut since this defeats (over-rides) the function of the shear bolts.

If these bolts shear, remove the blade and installnew bolts. Refer to CHECKING/SERVICING in thissection for Sharpen Mower Blades which describesthe blade removal and installation procedure.

After reinstalling the blade, check blade timing bymoving blades through one (1) complete revolu-tion. Make sure blade tips pass clear of each other.If timing is incorrect, refer to Mower Deck GearboxReplacement in this section.

PTO Shear Pin

The PTO drive shaft connection to the deck gearboxhas a shear pin to provide shock load protection to themower deck drive. This system provides primaryshock protection in case of blade impact and willnormally shear before the individual shear bolts onthe blade hub.

When the PTO pin has sheared, use the followingprocedure to replace it:

1. Loosen the two bolts securing the PTO shaftguard on the deck; lift the guard off. (Holes inguard are slotted for easy removal.)

2. Rotate U-joint on shaft to align the shear pin holewith the hole (and shear pin fragment) in theshaft. Use a punch to drive the remaining portionof the old shear pin out.

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

PTO Shear Pin

IMPORTANT: Use only Walker P/N 8067-13shear pins for replacement to provide propershock protection -- these pins are hardened toshear under a specific amount of load.

4. Reinstall the PTO shaft guard.

Before operating the deck, inspect the blade over-load shear bolts and also check blade timing (on geardriven decks) by moving blades through one (1)complete revolution. Make sure blade tips passclear of each other. If timing is incorrect, refer toMower Deck Gearbox Replacement in this section.

Mower Blades

Mower blades are removed and remounted as de-scribed in the Sharpen Mower Blades instructions.During the course of sharpening and inspectingmower 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 themachine:

• An excessive amount of the flat section of theblade has been ground away (removed) when theblade is sharpened. Replace the blade when lessthan a 3/4 in. (19 mm) flat section remains at theblade tip.

Cutting Blade Shear Bolts

Cotter Pin

U-JointTube Assembly

Shear Pin

Split Spring Pin

U-JointShaft Assembly

Set Screw


62

• Examine ends of the blade carefully, especially theintersection where the flat section of the blade turnsup to form the “wing tip” (refer to Mower Blade Pro-file for Sharpening illustration in Sharpen MowerBlades instructions). Since sand and abrasive ma-terial can wear metal away in this area, the bladeshould be replaced when metal thickness hasworn to 1/16 in. (1.6 mm) or less.

• Check the blades for straightness by markingblade tip position inside the deck housing and then ro-tating the opposite end of the blade to the same po-sition and comparing. If the difference in blade tiptrack is more than 1/8 in. (3 mm), the blade is bentand should be replaced.

• Inspect the blade surface, especially in formed ar-eas, for cracks. Replace the blade if any cracks arefound.

Reinstall the blades following procedure from Sharp-en Mower Blades instructions. If blades are re-placed, always use Walker original equipmentblades to ensure safety and optimum performance.The quality and performance of replacement bladesoffered by other manufacturers cannot be guar-anteed, they could be dangerous.

Mower Deck Gearbox Replacement

NOTE: Deck gearbox(es) may be changed with thedeck mounted on the tractor. However, the deck maybe removed from the tractor making the overall job ofremoving the gearbox assembly easier. Refer toDeck Installation in Assembly Instructions and re-verse the procedure to remove the deck.

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

1. Remove mower blades. Refer to procedure inSharpen Mower Blades instructions.

2. Remove gearbox cover (two machine screws)and PTO shaft guard (two 1/4-20 bolts).

3. Remove two (2) 3/8-16 mounting bolts from eachblade drive gearbox and lift the entire gearboxassembly from the deck (including PTO driveshaft).

4. Remove the screws securing the cover plates onthe gearboxes and remove the covers. Removeall covers to be sure oil is completely drainedfrom all gearboxes.

NOTE: With oil flow throughout the unitized geardrive assembly; if one gearbox has internal dam-age or excessive wear, the remaining gearboxesand connector tubes should be completely dis-assembled and thoroughly flushed out with sol-vent before reassembly.

5. Drain and properly dispose of oil.

6. Remove the four (4) bolts mounting the gearboxto the connector tube and slide the gearbox offthe splined drive shaft coupling.

7. Install the new gearbox on the spline coupling ofthe drive shaft. Establish correct timing of theblade drive gearboxes by setting flats on the out-put shaft at 90 degrees when connecting thegearbox(es) to the spline coupling. Make surethe timing is correct before proceeding with as-sembly.

8. Reinstall the four (4) bolts mounting the gearboxto the connector tube but do not tighten themat this time; leave connector tube bolts finger-tight.

DANGER

When blades are operated over sandy soil,and if blades are allowed to wear, a “slot”may be worn into the wing tip of blade.Eventually a piece of the blade may breakoff creating a serious potential for injury ordamage.

WARNING

DO NOT try to straighten a blade that isbent. NEVER weld a broken or crackedblade. ALWAYS replace with a new bladeto assure safety.

CAUTION

ALWAYS use genuine factory replacementparts. Substitute parts CAN result in prod-uct malfunction and possible injury to theoperator.


63

9. Position the gear drive assembly on the deckand install the 3/8-16 bolts mounting the entireassembly. Leave the mount bolts finger-tight.

10. Torque all the connector tube bolts to 80 in-lb(9 N⋅m); then tighten the deck mount bolts.

NOTE: This fastener tightening sequence alignsthe gearbox assembly with the deck housing andeliminates the possibility of mounting the unitizedassembly in a bind.

11. Fill gearbox assembly with oil. Refer to MowerDeck Gearbox Lubrication in this section for in-structions.

12. Reassemble remaining items onto deck to com-plete installation. After installing the blades,check that the blade timing is correct by movingthe blades through one (1) complete revolu-tion. Make sure blade tips pass clear of eachother.

Mower Deck Gearboxes(shown with gearbox cover removed for clarity)

GHS Blower Assembly (and/or Blower Wheel)

GHS Blower Assembly Removal

1. Remove the mower deck. Refer to Deck Instal-lation in Assembly Instructions and reverse theprocedure to remove the deck.

2. Remove the blower faceplate by removing six (6)1/4-20 nuts.

Remove Skid Bar and Scrubber Brakefor GHS Blower Removal

3. Remove the blower assembly from the chassisas follows:

a. Remove the blower skid bar by removingfront and rear mounting bolts from the skidbar (underneath the blower) and removingthe bolt connecting the blower housing tothe skid bar.

b. Remove two (2) bolts mounting the blowerhousing to the frame and the bolt mountingthe scrubber brake assembly on the blowerhousing.

c. Remove scrubber brake assembly, and rollthe blower drive belt off of blower pulley.

d. Lower the blower assembly straight downout of the chassis frame and remove.

Blower Wheel Removal

When required, replace the blower wheel using thefollowing procedure:

1. Loosen blower pulley set screws and remove thepulley using a wheel puller.

2. Remove the locking collar from the back bear-ing (closest to the pulley) by loosening the setscrew and rotating the collar counterclockwise(use punch to drive).

Blade DriveGearboxes

TeeGearbox

Skid BarBlower Assembly

Skid BarMounting

Bolts

Scrubber Brake and

Mount Assembly

Scrubber BrakeMounting Bolts


64

3. Press blower wheel out of the housing using awheel puller hooked to lugs on the bearing hous-ing. The bearings have been secured in thehousing with a retaining compound - Loctite®

RC/680, and considerable force will be re-quired to break this bond. After the bearingshave “broken loose” from the housing, only lightpressure should be required to remove thewheel assembly out of the housing.

NOTE: It may or may not be possible to removethe front bearing from the blower wheel withoutdamaging it. If the bearing is damaged, it willneed to be replaced along with the wheel.

Pressing Blower Wheel Out of Housing

Blower Wheel Installation

1. To install the blower wheel, reverse the removalprocedures. The front bearing is mounted onthe blower wheel shaft, secured by a lockingcollar. Drive the locking collar clockwise with apunch, and tighten the set screw.

2. Press blower wheel and front bearing into theblower housing. Use Loctite® RC/680 retainingcompound on the outer bearing race and insidethe bearing housing.

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

on both the outer bearing race and the housing.

4. Install the locking collar on the rear bearing andinstall the blower pulley to complete the blowerassembly. Torque the blower pulley set screwsto 250 in-lb (28.3 N⋅m).

GHS Blower Assembly Installation

Reinstall the blower assembly into the mower using the reverse procedures of GHS Blower Assembly Removal.

ADJUSTMENTS

Safety Switches

There are four (4) safety interlock switches (and onecontrol switch if GHS equipped) on the tractor. Usethe panel nuts on the switch body to position eachswitch for proper activation of the switch. The ad-justment procedure for each switch is:

Seat Switch

Adjust switch position in body panel to achieve a1/32 to 1/16 in. (.79 mm to 1.59 mm) air gap betweenthe switch plunger and seat frame with no weight onthe seat. Test for proper operation.

Wheel Puller Hooked to Lugs on Bearing Housing

DANGER

If the engine must be running to performa maintenance adjustment, keep hands,feet, and clothing from moving parts. DONOT wear jewelry or loose clothing.

Maintenance Instructions ADJUSTMENTS

65

FSC Neutral-Park Switch

1. Place the FSC in NEUTRAL-PARK position.

2. Adjust switch to the point where the starter en-gages when the ignition switch is turned to thestart position.

3. Adjust switch position forward an additional 1/2to 1 turn of the panel nuts.

NOTE: If the switch cannot be adjusted forwardenough to achieve proper function, it may be nec-essary to bend the switch mounting bracketslightly.

PTO Switch(es)

With the PTO engaged, adjust two (2) switches [three(3) if GHS equipped] to the point of activation plus 1or two 2 turns of the panel nuts. Normally 1/8 to 3/16in. (3 mm to 5 mm) of plunger travel will activate theseswitches. Make sure the switches are adjusted so theactuator plate is not bottoming out the plunger andstriking the switch body.

Steering Levers

An adjustment range of approximately 3 inches isavailable on the steering levers - the levers can be ad-justed forward or aft depending on the arm length ofthe operator. The levers can be adjusted by loosen-ing the locknut at the pivot point and the locknut hold-ing the lever in position in the adjustment slide.Adjust levers into most comfortable position andtighten both locknuts.

Steering Lever Adjustment

Blade Brake

The mower blade drive (and blower on GHS models)is equipped with a brake system to stop blades withinfive (5) seconds after disengaging the clutch. A beltscrubber brake acting on the PTO drive belt providesbraking action. The brake action is adjusted byspringing or bending the scrubber mount on GHSmodels and bending the scrubber on SD models.If the brake system malfunctions - blades do not stopwithin five (5) seconds - adjust or repair the brake asfollows:

Braking Action Adjustment

WARNING

It is important to check and maintainblade brake action for safe operation ofthe machine.

Desired BrakeAction

GHS ModelDirection ofMount Bend

SD ModelDirection of

Scrubber Bend

Stronger (Quicker) Bend Down Bend Up

Weaker (Slower) Bend Up Bend Down

Locknut(Position)

AdjustmentSlide

Locknut(Pivot Point)


66

Scrubber Brake Adjustment - GHS

Scrubber Brake Adjustment - SD

Use “trial and error” to adjust scrubber braking actionand achieve a stopping time of approximately 4 to 5seconds after disengaging clutch with full throttle. Donot exceed five (5) seconds. Avoid having thebrake stop too quickly, as this will reduce PTO drivebelt life (burns belt).

Also check for alignment of the brake bar (scrubber)on the belt and make sure bar is only contacting theback of belt and not the edges of the pulley(s). ForGHS models, it may be necessary to spring the brakemount bar to shift (align) the brake bar on the belt;likewise, the scrubber on SD models is bent for align-ment with the belt.

Transmission Control

IMPORTANT: The proper adjustment of the trans-mission control stops is essential for efficient oper-ation and life of the transmission. These stops areproperly adjusted at the factory and should only re-quire readjustment if the transmission or related con-trol linkage is removed or changed.

NOTE: It would not be unusual for a new machine,after initial 5 or 10 hours of operation, to begin to nottravel straight (this is due to the break-in of thetransmissions). In this case, proceed to StraightGround Travel Adjustment - Step 4.

IMPORTANT: The following adjustment proceduresare sequential. Check and adjust each function inthe order given.

Set Forward Travel Limit (Stop) - Step 1

1. Move the Forward Speed Control (FSC) lever tothe most FORWARD position.

2. Check clearance of the RH and LH steering leveractuator arms with the frame and adjust for-ward stop bolt so each lever clears the frameby at least 1/16 in. (1.6 mm). Clearance of thearm to the frame should be checked while ap-plying pressure back on the arm to remove anyslack in the linkage.

3. Tighten the jam nut on the forward travel stop ad-justing bolt.

Forward Speed Control Stop and Steering Lever Adjustment

Brake Mount Bar

Scrubber Brake Bar Contacting Belt

Quicker

Slower

Scrubber Brake BarContacting Belt

Steering LeverActuator Arms

Forward TravelStop Bolt Steering

Adjustment Nut


67

Steering Lever End Play Adjustment - Step 2

1. Position the FSC lever to the most FORWARDposition.

2. Loosen the adjustment nut on each steering le-ver actuator until end play develops between thelever actuator and the adjustment nut (sliding ontransmission control rod).

3. Hold the actuator back as shown (against thespring pressure) and tighten the nut to the pointwhere the end play is removed and then tightentwo additional turns.

IMPORTANT: If the adjustment nut is too loose(end play exists), excessive loads are placed ontransmission internal control stops. If the adjust-ment nut is too tight (preferred condition), the max-imum forward travel speed is reduced.

Neutral Function Adjustment - Step 3

1. Move the FSC lever to the NEUTRAL-PARK po-sition (rear travel limit).

2. Start the engine (operate first at idle and thennormal operating speeds) and check for move-ment of the drive wheels.

NOTE: If the engine will not start, check and ad-just the neutral safety switch (see item 4 below).

Neutral Function Adjustment

3. If drive wheels are moving, stop the engine andadjust the FSC neutral stop by adjusting theFSC actuator clevis (refer to Neutral Function Ad-justment photo for clevis location). If the drivewheels are moving backward, remove the cotterpin and clevis pin and screw the clevis forward.If the drive wheels are moving forward, screw theclevis backward. Restart the engine and checkfor wheel movement (several “trial and error” ad-justments may be required). At this point it maynot be possible to adjust both wheels station-ary since the differential adjustment has notbeen made. (This is covered by the StraightGround Travel Adjustment - Step 4.) In this case,the neutral adjustment should be made for onewheel stationary and the other moving forwardslightly.

4. Check and adjust the neutral safety switch forclosure and function with the FSC in neutral (theengine will not start when the switch is open).Use the panel nuts on the switch body to adjustswitch position for closure in neutral. Refer to ad-justment description for Safety Switches in thissection.

Straight Ground Travel Adjustment - Step 4

1. Sit in the seat, start the engine (operate at normalspeed), and with the FSC in the NEUTRAL-PARK position check for forward movement ofeither drive wheel (if either wheel moves back-ward, refer back to Neutral Function Adjustment- Step 3 and readjust). Tighten the steering le-ver adjustment nut on the side of the mowerwith the wheel moving forward until wheelmovement stops.

2. Check for straight ground track on a level sur-face (with hands off the steering levers). Setthe FSC at several different speeds and observeif the mower moves in a straight line (use cementjoint or other line on ground for reference).

NOTE: The final tracking adjustment is madewith the mower moving, since the adjustment isquite sensitive and is more easily “fine tuned”when moving.

3. If travel is not straight, tighten the adjustmentnut that is on the same side of the mower asthe wheel that is moving too fast, e.g., the mow-er tracks to the right, indicating the LH wheel ismoving too fast, tighten the LH adjustment nut.

CAUTION

NEVER attempt to disconnect any safetydevices or defeat the purpose of thesesafety devices.

NeutralSafety Switch

FSC Actuator Clevis


68

Straight Ground Travel Adjustment

Forward Speed Control Friction Lock

The FSC friction lock is adjusted to hold the selectedforward speed when the steering levers are movedand yet the friction is not too heavy to make movingthe control difficult (too much friction). The proce-dure for checking and adjusting the FSC friction lockis as follows:

Forward Speed Control Friction Lock

1. Place the FSC in the full FORWARD position andpull both steering levers back; the FSC levershould not move. If the FSC lever moves backwhen the steering levers are pulled back, thefriction needs to be increased.

2. With the steering levers held back, move theFSC lever back from the FORWARD position.With a proper amount of friction adjusted, theFSC lever should move back with a slightamount of resistance (friction). If the FSC levermovement is “stiff”, the friction needs to be de-creased.

3. The FSC friction is increased or decreased bytightening or loosening the friction adjust-ment nut. Loosen or tighten the nut and checkthe control function until conditions of bothsteps 1 and 2 (above) are met.

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 theengaged and disengaged positions freely. All fourhitch pins used for height adjustment should sit flushon the washers above the deck pin bushing. On a lev-el surface, if any pin is sticking up (likely the frontpins), tighten the opposite side or loosen the sameside to lower the pin. Adjustments are made by loos-ening the jam nut and tightening or loosening the setscrews on the Deck Mount Pivot Brackets. Retightenthe jam nut when the adjustment is complete.

Tilt-Up Deck Adjustable Stop

End Wrench onAdjustment Nut

Friction Washer

Friction Adjustment Nut

FSC Actuator

Set Screw

Jam Nut


69

Carburetor

Carburetor adjustments are required to compensatefor differences in altitude, temperature, and fuel.Once the carburetor has been set, no further adjust-ments should be required. However, if the engineexhibits any of the following symptoms, the carbure-tor adjustment should be checked: black, sooty ex-haust smoke, lack of power, engine miss or backfire,hard to start, rough running or idle.

NOTE: Also refer to the Kawasaki Service Manualfor detailed carburetor adjustment information.

NOTE: The air cleaner and air intake hose must beconnected to the carburetor when adjusting the car-buretion.

The carburetor main jet is fixed (non-adjustable). Foroperation above 5,000 ft (1,524 m) above sea level,the carburetor main jet should be changed for best fu-el economy and power. Contact an authorized Ka-wasaki engine dealer to change the carburetor mainjet.

To adjust the carburetor for engine idle, use the fol-lowing procedure:

1. Gently close the idle mixture needle valve byturning it clockwise until it bottoms lightly.

IMPORTANT: The needle valve and carburetorseat may be damaged by turning the adjustmentscrew too tight.

Carburetor Adjustment

2. Preliminary Setting: Turn the idle mixture needlevalve out (counterclockwise) 2 turns from theclosed position. This initial adjustment will al-low the engine to be started and warmed up priorto the final adjustment.

3. Start the engine and allow it to warm up for ap-proximately five (5) minutes.

4. Move throttle to the IDLE position. Adjust idlespeed for 1300 RPM by adjusting the idle speedscrew. Check the idle speed using a tachometer.

5. With the engine idling, adjust the idle mixture byturning the needle valve until the engine slows(clockwise - lean mixture). Then turn the needlevalve out past the smooth operating point untilthe engine slows again (counterclockwise - richmixture). Now turn the needle valve to the mid-point between rich and lean mixture. Check en-gine acceleration from the idle. If the engine willnot accelerate properly, readjust the idle mixture,usually to a slightly richer mixture (open thevalve).

CAUTION

DO NOT change the engine governor set-tings or overspeed the engine. The gov-ernor has been factory-set for maximumsafe engine operating speed.

CAUTION

ALWAYS use the proper engine servicemanual when working on the engine. Un-authorized maintenance operations ormodifications to the engine MAY result inunsafe operating conditions.

DANGER

The engine must be running to adjustthe carburetor for engine idle. To guardagainst injury, keep hands, feet, face, andother parts of body away from the muffler/exhaust pipe, other hot parts of the engine,and moving or rotating parts of the engine.

Idle SpeedScrew

Idle MixtureNeedle Valve


70

6. Recheck idle speed after the final idle mixtureadjustment.

GHS “Full” Signal Horn with Grass-Pak Switch

If the GHS “full” signal horn is not sounding or is notadjusted to sound when the catcher is full, the fol-lowing troubleshooting and adjustment instructionsapply:

Troubleshooting (When Horn Fails to Operate)

1. Check the horn.

a. Disconnect the two wires from the Grass-Pak switch electric connector plug andmake a jumper wire connection betweenthese wires (bypassing switch).

b. Turn the ignition switch ON and move theblade clutch to the ENGAGED position (en-gine not running) to make the horn sound.

c. If the horn does not sound, the horn is badand needs to be replaced.

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

2. Check the Grass-Pak switch.

a. Reconnect the wires to the Grass-Pak

switch electric connector plug.

b. Turn the ignition switch ON and move theblade clutch to the ENGAGED position (en-gine not running).

c. Open the catcher back door and trigger theGrass-Pak vane by hand as it oscillates.

d. The horn should sound as the switch ismoved in both directions. If the horn doesnot sound, the switch is bad and needs to bereplaced.

Checking the Grass-Pak Switch

ELECTRICAL SYSTEM

For troubleshooting, refer to the Wiring Diagram.

IMPORTANT: Disconnect both battery cables be-fore unplugging any wiring connectors or making re-pairs on the electrical system.

WARNING

DO NOT test the Grass-Pak switch withthe engine running. Projectiles CAN bethrown out of the grass delivery spout andCAN cause serious injury to bystanders orproperty damage.

Grass-Pak

Vane Switch

Maintenance Instructions ELECTRICAL SYSTEM

71

Wiring Diagram

G M

S

B

STARTER SOLENOID

STARTER

FUEL SOLENOID

VOLTAGEREGULATOR

ALTERNATOR

MAGNETO

20 AMP FUSE

ENGINE

POWERFILMOTOR

GRASS PAKSWITCH

R

R

HORN

OPTIONALLIGHT

CHASSISGROUND

BATTERY

OPTIONALLIGHTS

PTOINTERLOCKSWITCHES

HOUR METER

SEATSWITCH

FSCNEUTRAL

INTERLOCKSWITCH

L

OPTIONALLIGHT

BLK

ORG/WHT

RED

RED

RED

RED

BLU

BLU

BLU

BLU

BLK

GRN/WHT

GRN/WHT

BLK

BLK

GRN

GRN

RED

GRN

BLK

RED

GRA

BRN

+

-

BRN

BRN

RED

BLK

BLKORG

BLK

YEL

YEL

YEL

YEL

GRA

RED GRN

GRA

ORG

ORG/WHT

ORG

IGNITION SWITCH CIRCUITS

S = START CIRCUITM = MAGNETO GROUND CIRCUITB = BATTERY CIRCUITL = ACCESSORY CIRCUITG = CASE GROUND

LOAD REQUIREMENT - LIGHTS 65.5 WATTS PF MOTOR 18.0 WATTS TOTAL 83.5 WATTS

OFF G + M

START B + S

RUN B + L

ORG

72

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73

Operator’s Notes

74

Operator’s Notes

75

LIMITED WARRANTYFOR

WALKERCOMMERCIAL 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 whichis 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. AtWalker’s request, customer will make the defective part available for inspection by Walker and/or return the defective partto Walker, transportation charges prepaid. All parts and components of the Walker Mower are covered by this warrantyexcept the following components which are warranted separately by their respective manufacturers:

Kohler EngineKubota EngineKawasaki EngineEaton Hydraulic TransmissionPeerless GearboxesBatteryTires

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, impropermaintenance, improper use or abuse of the product, alterations, or failure to follow the instructions contained in theOwner’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 placewhere the inspection and/or warranty work is performed.

3. HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:

Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Walker Man-ufacturing Company, 5925 East Harmony Road, Ft. Collins, CO 80525. Proof of the date of purchase may be required toverify warranty coverage.

4. WARRANTY LIMITATION:

A. THERE IS NO OTHER EXPRESS WARRANTY. ANY WARRANTY THAT MAY BE IMPLIED FROM THISPURCHASE INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBYLIMITED TO THE DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALLIMPLIED WARRANTIES ARE EXCLUDED. Some states do not allow limitations on how long an implied warrantylasts, so the above limitations may not apply to you.

B. WALKER WILL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, OR SPECIAL DAMAGES AND/OREXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER. Some states do not allow theexclusion or limitation of incidental or consequential damages, so the above limitation(s) or exclusion(s) may notapply to you.

C. Only the warranty expressed in this limited warranty shall apply and no dealer, distributor, or individual is authorizedto amend, modify, or extend this warranty in any way. Accordingly, additional statements such as dealer advertisingor presentations, whether oral or written, do not constitute warranties by Walker, and should not be relied upon.

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

WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, CO 80528 • (970) 221-5614FORM NO. 100103 PRINTED IN USA www.walkermowers.com ©2004 WALKER MFG. CO

Sound - Model MS

Sound Test

Sound test conducted was in accordance with 79/113/EEC and was performed on 22 March 96 under the conditions listed:

General Condition: Clear

Temperature: 50 (F)o10 (C)o

Wind Speed: < 5 mph (< 8 kmh)

Humidity: 52%

Barometric Pressure: 24.9" HG (759 mm Hg)

Lwa99

OPERATOR

Vibration - Model MS

Vibration Level

Vibration levels at the operators handles were measured in the vertical, lateral, and longitudinal directions using calibrated vibration test equipment.

Tests were performed on 22 March 96 under the conditions listed:

LpA93

0.4g

General Condition: Clear

Temperature: 50 (F)o10 (C)o

Wind Speed: < 5 mph (< 8 kmh)

Humidity: 52%

Barometric Pressure: 24.9" HG (759 mm Hg)

OWNER’S MANUAL - Walker

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