OWNER’S MANUAL
Safety, Assembly, Operating, and Maintenance Instructions
and ILLUSTRATED PARTS MANUAL
Model MW - Walk-Behind (15 HP)
™
Please Read and Save These Instructions
For Safety, Read All Safety and Operation
Instructions Prior to Operating Machine
Effective Date: 11-01-03
P/N 9001
Price $5.00
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Table of Contents
Operating Instructions_____________ 21
Owner’s Manual
CONTROL IDENTIFICATION,
General Information ________________ 1
LOCATION, AND FUNCTION _____________ 21
Operating Controls ___________________ 21
Engine Throttle/Choke ________________ 21
Forward Speed Control (FSC) __________ 22
Pistol Grips/Steering Control Levers_____ 22
Blade Clutch (PTO) ___________________ 22
Parking Brake _______________________ 22
Engine Cover Latch___________________ 22
Transaxle Lockout Rods_______________ 22
Hourmeter __________________________ 22
Circuit Breaker_______________________ 22
Ignition Switch _______________________ 23
STARTING THE ENGINE_________________ 23
ADJUSTING GROUND
SPEED AND STEERING _________________ 23
ENGAGING THE MOWER________________ 25
STOPPING THE MACHINE _______________ 25
ADJUSTING CUTTING HEIGHT ___________ 26
TRANSAXLE LOCKOUTS________________ 26
RECOMMENDATIONS FOR MOWING ______ 27
RECOMMENDATIONS FOR
HIGHLIGHTED INFORMATION _____________ 1
GLOSSARY ____________________________ 1
IDENTIFYING NUMBER LOCATIONS________ 1
ENGINE SERIAL NUMBER LOCATION ______ 2
SERVICING OF DRIVETRAIN GEARBOX ____ 2
Specifications _______________________ 3
ENGINE________________________________ 3
ELECTRICAL SYSTEM ___________________ 3
TRANSMISSION_________________________ 3
BLADE DRIVE __________________________ 4
TIRE SIZE ______________________________ 4
TIRE PRESSURE ________________________ 4
DIMENSIONS (Tractor and Mower) _________ 4
MOWER DECK__________________________ 5
CURB WEIGHT__________________________ 5
DRIVE BELTS___________________________ 5
FRAME/BODY CONSTRUCTION ___________ 5
TILT-UP DECK OPERATION/TRANSPORT __ 28
Component Identification___________ 6
Maintenance Instructions__________ 28
Safety Instructions __________________ 9
IMPORTANT TIPS FOR CARE OF THE
BEFORE OPERATING____________________ 9
OPERATING___________________________ 10
MAINTENANCE ________________________ 11
SAFETY, CONTROL,
KAWASAKI ENGINE ____________________ 28
Fuel System _________________________ 28
Starting/Stopping ____________________ 28
Cooling System ______________________ 28
Air Cleaner System ___________________ 28
Oil _________________________________ 28
MAINTENANCE SCHEDULE CHART_______ 29
LUBRICATION _________________________ 30
Engine Oil___________________________ 30
Engine Break-In Oil __________________ 30
Checking Engine Crankcase Oil Level ___ 30
Changing Engine Crankcase Oil/Oil Filter 30
Grease Fitting and Oil Point Lubrication__ 31
Mower Deck Gearbox Lubrication _______ 31
DSD52 Mower Deck Lubrication ________ 32
Tractor PTO Gearbox Lubrication _______ 33
Checking Gearbox Oil Level ___________ 33
Transaxle Lubrication _________________ 33
Steering Linkage and
AND INSTRUCTION DECALS _____________ 13
Assembly Instructions _____________ 14
SETUP INSTRUCTIONS _________________ 14
Tire Installation (Tractor)_______________ 14
Battery Service_______________________ 14
Battery Charging ____________________ 14
Mower Deck Assembly ________________ 15
Deck Caster Wheels Installation ________ 15
Deck Discharge Shield Installation ______ 15
PTO Shaft Guard Installation __________ 16
Tilt-Up Roller Wheel Installation ________ 16
Mower Deck Installation on Tractor ______ 16
Deck Installation ____________________ 16
Deck Leveling ______________________ 18
PREOPERATING CHECKLIST ____________ 19
PTO Linkage Lubrication ______________ 33
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Table of Contents
CLEANING ____________________________ 36
Engine Air Cleaner System _____________ 36
Foam Precleaner Element _____________ 36
Paper Precleaner Element ____________ 36
Engine Cooling System________________ 36
Air Intake Screen ____________________ 36
Engine Cooling Fins _________________ 36
Grass Buildup in Mower Housing________ 36
CHECKING/SERVICING _________________ 37
Battery______________________________ 37
Charging the Battery _________________ 37
Tire Pressure ________________________ 37
Sharpen Mower Blades ________________ 37
Drive Belts __________________________ 38
Mower Deck Gearbox Oil Seals _________ 38
Spark Plugs _________________________ 38
Fuel Lines and Clamps ________________ 38
Blade Brake Action ___________________ 39
REPLACING/REPAIRING ________________ 40
Drive Belts __________________________ 40
PTO Drive Belt _____________________ 40
Ground Drive Belt ___________________ 40
Blade Overload Shear Bolts ____________ 41
PTO Shear Pin _______________________ 41
Mower Blades________________________ 41
Mower Deck Gearbox Replacement ______ 42
ADJUSTMENTS ________________________ 43
Blade Clutch (PTO) ___________________ 43
Clutch Disengagement/Brake Action _____ 43
Transmission Control _________________ 44
FSC Actuator Stop Adjustment _________ 44
Control Arm Rod Adjustment ___________ 45
Neutral Adjustment __________________ 45
Tracking Adjustment _________________ 45
Control Handle (Pistol Grip) Adjustment __ 46
Handlebar Height Adjustment___________ 46
Tilt-Up Deck Adjustable Stop ___________ 46
Carburetor___________________________ 47
Maintenance And Service
Record Sheet_______________________ 61
Operator’s Notes___________________ 62
Warranty___________________________ 63
Illustrated Parts Manual
BODY / CHASSIS ASSEMBLY ____________ 48
MAIN COMPONENT
POWER TRANSMISSION ________________ 50
ENGINE GROUP _______________________ 52
FORWARD SPEED &
STEERING CONTROLS__________________ 54
SULKY ATTACHMENT___________________ 56
ELECTRICAL ASSEMBLY________________ 58
WIRING SCHEMATIC____________________ 60
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General Information
HIGHLIGHTED INFORMATION
•
SIDE DISCHARGE (SD) mows but does not
collect the mowed material.
Walker Manufacturing recommends that any service
requiring special training or tools be performed by
an authorized Walker Mower Dealer. There are sev-
eral general practices to be aware of in the area of
safety. Most accidents associated with the oper-
ation or maintenance of a Walker product are
caused by disregarding basic safety precautions or
specific warnings. Such accidents, in most cases,
can be prevented by being aware of the dangers
present.
•
TRACTOR is the prime mover, including the en-
gine, drive train, and controls to operate the
mower.
IDENTIFYING NUMBER LOCATIONS
The mower serial number is affixed to RH side of the
inside of the unit housing. Model and serial numbers
are helpful when obtaining replacement parts and
maintenance assistance. For ready reference,
please record these numbers in the space provided.
Information of special importance has been high-
lighted in bold type in this manual. Refer to Safety
Instructions for the meanings of DANGER, WARN-
ING, CAUTION, IMPORTANT, and NOTE.
Tractor Model No. _______________________
Tractor Serial No. _______________________
GLOSSARY
There are many terms that are either unique to this
equipment or that are used as acronyms. The fol-
lowing terms and their definitions will help while us-
ing this manual:
Deck Serial No.
_______________________
Engine Model No. _______________________
Engine Serial No. _______________________
Date of Purchase _______________________
•
DECK is the mowing attachment mounted on
the front of the tractor which includes the carrier
frame, deck housing, blade drive gearboxes,
and cutter blades.
Fill In By Purchaser
•
FORWARD
SPEED
CONTROL
(FSC)
SWITCH controls the maximum forward speed
of the tractor; functioning as a cruise control.
•
•
GROUND DRIVE refers to the dual hydrostatic
transmissions which drive the main wheels.
Ref. RH
Drive Wheel
Ref. Engine
Air Cleaner
LEFT HAND (LH) refers to the left-hand side of
the tractor when the operator is seated facing
forward from the operator position.
Serial
Number Plate
•
•
NEUTRAL LOCKOUT releases the hydrostatic
transaxles to permit freewheeling the tractor.
PISTOL GRIPS steer the tractor by controlling
the dual hydrostatic transaxles.
Tractor Serial Number Location
(Top View of Tractor)
•
•
POWER TAKE-OFF (PTO) transmits engine
power to run the cutter blades.
RIGHT HAND (RH) refers to the right-hand side
of the tractor when the operator is facing for-
ward from the operator position.
1
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General Information
SERVICING OF DRIVETRAIN GEARBOX
The detailed servicing and repair of the engine, hy-
drostatic transmission, and gearboxes are not cov-
ered in this manual. Only routine maintenance and
general service instructions are provided. For the
service of these components during the limited war-
ranty period, it is important to find a local, authorized
servicing agent of the component manufacturer.
Any unauthorized work done on these compo-
nents during the warranty period may void the war-
ranty.
If you have any difficulty finding an
authorized outlet or obtaining warranty service,
please contact our Service Department for assis-
tance:
Serial Number
Deck Serial Number Location
Walker Manufacturing Company
5925 E. Harmony Road
Fort Collins, CO 80528
1-970-221-5614
ENGINE SERIAL NUMBER LOCATION
The Kawasaki engine model, type, and code num-
bers are located on the side of the engine opposite
the recoil starter handle (on the aluminum housing).
For the mower model covered by this manual, an en-
gine manual is available to cover the Kawasaki
FH430V.
Service manuals are available for each of these
components from their respective manufacturers as
follows:
Kawasaki Engines Kawasaki Tractor Corp.
P.O. Box 888285
Grand Rapids, MI 49588-8285
Transmissions
HydroGear Corporation
Sullivan, IL
Gearboxes
(Deck & PTO)
Tecumseh Products Co.
900 North Street
Grafton, Wl 53024
Serial Number
Engine Serial Number Location
2
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Specifications
MODEL
MW
ENGINE
Manufacturer/Model
Displacement
Kawasaki, FH430V, OHV, 2 Cyl. V-Twin (Air-Cooled)
431CC (26.3 cu. in.)
15
HP (@ 3600 RPM)
Max. RPM (No Load)
Governed RPM
4000
3600
Max. Torque [ft-lb (N⋅m) @ RPM]
Idle RPM
23.6 (32 N•m) @ 2400
1500
Spark Plug Type
Champion® RCJ8Y
.030 in. (.75 mm)
1.8 qts (1.7 liters)
Spark Plug Gap
Crankcase Capacity
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
Fuel
3 Gallons (11.4 liters)
Automotive Grade Unleaded Gasoline (87 Octane)
ELECTRICAL SYSTEM
Battery
12-Volt, Interstate PC1250
12.5 Amp Alternator
15 Amp DC (Regulated)
Negative Ground
Charging System
Charging Output
System Polarity
Ignition
Electronic Magneto
Recoil Starter
Starter
Interlock Switch
Ignition Lockout by Operator Presence Lever, Transmission Neutral
and Blade Clutch
TRANSMISSION
Manufacturer/Model
Steering
Dual, Independent Hydro-Gear Integrated Transaxles
Handle Pistol Grips
Forward Speed Control
Variable Speed Controlled by Rocker Switch Near RH Thumb, with
Neutral Park Setting
Service Brake
Neutral
Mechanical Lockout for each Transmission (Single Lever Control)
Transmission Release by Manual Dump Valve
3
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Specifications
MODEL
MW
TRANSMISSION (continued)
Transmission Fluid
Factory Service
20W50 Multi-Viscosity Motor Oil
79 fl. oz. (2336 ml.)
Transmission Fluid Capacity
Transmission Cooling
Ground Travel Speed
Cooling Fan Mounted on Drive Pulley
Forward m.p.h. (km/h)
Reverse m.p.h. (km/h)
0-5 (0-8) Infinitely Variable
0-2 (0-3) Infinitely Variable
BLADE DRIVE
PTO Shaft
Quick Disconnect Splined Shaft with Two (2) High-Speed U-Joints
Blade Spindle
Each Blade (2) Mounts Direct on Peerless Right Angle
Gearbox with Tee Gearbox in Center Connected to PTO Shaft
(Complete Geared Drive, Peerless Model 1000 Gearboxes)
Blade Drive Clutch and Brake
Manual Belt Tightener Clutch and Band Brake
(Stops Blades within Five (5) Seconds of Disengagement)
Max. Blade Speed
[25 in. (64 cm) Blade] @ 3600
RPM Engine
2400 RPM
[15700 FPM (4785 m/min)]
(48" Deck)
TIRE SIZE
Deck Caster Wheel
2.80/2.50-4 Pneumatic (4-Ply)
8.25 x 2.75 Foamed Rubber
18 x 8.50-10 (Low-Profile)
2.80/2.50-4 Pneumatic (4-Ply)
8.25 x 2.75 Foamed Rubber
Deck Caster Wheel (Optional)
Drive
Rear
Rear Wheel (Optional)
TIRE PRESSURE
Deck Caster Wheel
20 PSI (137 kPa)
15 PSI (103 kPa)
Drive
Rear
20 PSI (137 kPa)
DIMENSIONS (Tractor and Mower)
80 in. (203 cm)
Length
48-3/4 in. (124 cm)
Width
Height
44-3/4 in. (114 cm)
22 in. (56 cm)
Wheel Base (Tractor)
Tread Width (Tractor)
29-1/4 in. (74 cm)
4
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Specifications
MODEL
MW
MOWER DECK
Width of Cut
36-, 42-, 48-, 52-, or 56-in.(91, 107, 122, 132, or 142 cm)
1 to 4 in. (3 to 10 cm)
Cutting Height
Height Adjustment
7 Positions - 1/2 in. (1 cm) Increment Hitch Pins Installed in
Multi-Position Deck Support
Blade Size
42 in. (107 cm)
22 in. (56 cm) 2 in. (5 cm) Center Overlap
(Two Blades, CW Rotation)
48 in. (122 cm)
48 in. (122 cm) 25 in. (64 cm) 2 in. (5 cm) Center Overlap
(Two Blades, CW Rotation)
Deck Suspension
Torsion-Flex Frame with Caster Wheels and
Counterweight Springs
CURB WEIGHT (Approximate)
Tractor Only
370 lb (168 kg)
520 lb (236 kg)
Tractor and Deck
* Dimensions and weight shown are for 48 in. (122 cm) SD Deck (Typical)
DRIVE BELTS
Engine PTO
Walker P/N 9230
Walker P/N 9248
Ground Drive
FRAME/BODY CONSTRUCTION
Frame/Body
Deck
3/16 Plate Steel
11 Gauge Steel
NOTE: The manufacturer reserves the right to make changes in specifications shown herein at any time
without notice or obligation.
5
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Component Identification
NOTE: Control Identification
shown in Operating
Instructions section.
Throttle/Choke
Control & Cable
Engine
Cover Latch
Engine
Cover
Tilt-Up
Latch
Spring Clip
Fuel Tank
and Cap
Counterweight Spring
and Protective Cover
Deck Support Pins
and Height Adjustment
Hitch Pins
Parking
Brake Handle
Footrests
Tilt-Up
Handle
Fuel Filter
Tail Wheel
Deck
Caster Wheels
Right Hand
Drive Wheel
Deck Support
Arms
Tilt-Up
Hook
Discharge Shield
Deck Lift Handle
(Cutting Height Adjustment)
Front View and Right Side View
6
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Component Identification
Operator Presence Switch Control
PTO Clutch
Lever
Tailpipe
Muffler
Pistol
Grips
Steering Control
Rod (RH)
Steering Control
Rod (LH)
Transaxle (LH)
Transmission
Neutral Lockout
Rods
Left Hand
Drive Wheel
Rear View and Left Side View
7
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Component Identification
Fuel Pickup
Line
FSC
Electric
Actuator
Oil Dipstick/
Oil Fill
Recoil
Starter Handle
Oil Filter
Fuel
Pump
Parking
Brake
Linkage
Transaxle
Pressure
Relief
Valve [(LH)
Not Visible]
Transaxle
Pressure
Relief
Valve (RH)
Counterweight
Dampening Spring
Battery
Counterweight
Dampening Spring
Top View (Cover Removed)
8
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Safety Instructions
Pay particular attention to any information labeled
DANGER, WARNING, CAUTION, IMPORTANT,
and NOTE in this manual.
Walker Manufacturing cannot predict every poten-
tially dangerous situation. Therefore, items labeled
as such in this manual do not cover all conceivable
situations. Any person using procedures, tools, or
control techniques not recommended by Walker
Manufacturing must take full responsibility for safety.
When you see the Safety Alert Symbol (
),
read, understand, and follow the instructions. Fail-
ure to comply with safety instructions may result in
personal injury.
The mower has been designed with many safety
features to protect the operator from personal harm
or injury. However, it is necessary for the operator
to use safe operating procedures at all times. Fail-
ure to follow safety instructions contained in
this manual may result in personal injury or
damage to equipment or property.
The seriousness or degree of importance of each
type of information is defined as follows:
DANGER
An IMMEDIATE hazard that WILL result in
severe personal injury or DEATH, if warn-
ing is ignored and proper safety precau-
tions are not taken.
If you have any questions concerning setup, opera-
tion, maintenance, or safety, please contact your
authorized Walker Mower Dealer or call Walker
Manufacturing Company at (970) 221-5614.
BEFORE OPERATING
1. Read and understand the contents of this
Owner’s Manual before starting and operat-
ing the machine. Become thoroughly familiar
with all machine controls and how to stop the
machine and disengage the controls quickly.
Replacement Owner’s Manuals are available
by sending the Model and Serial Number to:
WARNING
A POTENTIAL hazard that COULD result in
severe personal injury or DEATH, if warn-
ing is ignored and proper safety precau-
tions are not taken.
Walker Manufacturing Company
5925 East Harmony Road
Fort Collins, CO 80528
CAUTION
2. Never allow children to operate the ma-
chine. Do not allow adults to operate without
proper instruction.
Possible hazards or unsafe practices that
MAY result in MODERATE personal injury
or property damage, or machine damage, if
warning is ignored and proper safety pre-
cautions are not taken.
3. Themowershouldbeoperatedbyone(1)person
at a time (do not give rides on the engine cover).
4. Keep everyone, especially children and pets, a
safe distance away from the area being mowed.
Do not operate with bystanders in the area.
IMPORTANT: Identifies mechanical information
demanding special attention, since it deals with the
possibilityof damagingapart orpartsof the machine.
5. Do not operate the machine wearing sneakers,
tennis shoes, or similar lightweight footwear.
Wear substantial protective footwear that
will improve footing on slippery surfaces.
NOTE: Identifies information worthy of special
attention.
6. Ground cover or leaves can sometimes hide ob-
jects that might cause damage to the mower or
make unstable footing for the operator. Clear
the area of objects and mark all sprinkler heads
and/or utility box covers.
9
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Safety Instructions
7. Do not wear loose fitting clothing that could get
caught in moving parts. Always wear ade-
quate protective clothing including long
pants. Wearing safety glasses and safety
shoes is advisable and required by some local
ordinances and insurance regulations.
13. The electrical system battery contains sulfuric
acid. Avoid any contact with skin, eyes, and
clothing. Keep the battery and acid out of reach
of children.
OPERATING
1. Operate the mower only in daylight or in
good artificial light with good visibility of the area
being mowed.
8. Prolonged exposure to loud noise can cause
impairment or loss of hearing. Operator hear-
ing protection is recommended. Wear a suit-
able hearing protective device, such as
earmuffs or earplugs.
2. Keep feet behind the tractor at all times and al-
ways maintain secure footing when the tractor
is moving and/or mower blades are operating.
9. Keep all protective shields and safety de-
vices in place. If a protective shield, safety
device, or decal is damaged, unusable, or miss-
ing, repair or replace it before operating the ma-
chine.
3. Use extreme caution when reversing the ma-
chine towards you.
4. For a beginning operator, learn to steer (ma-
neuver) the tractor with a slow engine speed
before attempting any mowing operation.
Be aware that, with the front mounted mower
configuration, the back of the tractor can raise
off the ground slightly when going into reverse
at high speeds.
10. Be sure interlock switches are functioning
correctly so the engine cannot be started un-
less the Forward Speed Control switch is in the
NEUTRAL-PARK position and the PTO clutch
is in the DISENGAGED position. Also, the en-
gine should stop if the operator lifts their hands
off the operator presence control with the PTO
clutch in the ENGAGED position and/or moving
forward (FSC switch out of neutral).
5. Remember, for an emergency stop, the forward
motion of the tractor can always be stopped by
allowing the operator presence control (on top
of handle bars) to raise up.
11. Never attempt to make any adjustments
while the engine is running, except where
specifically instructed to do so.
6. Disengage the blade clutch and put the FSC in
the NEUTRAL-PARK position before starting
the engine (an ignition interlock switch normally
prevents starting of the machine if these con-
trols are in the OPERATING position).
12. Handle gasoline with care. Gasoline is highly
flammable and its vapors are explosive:
a. Use an approved fuel container.
7. Do not run the engine in a confined area
without adequate ventilation. Exhaust fumes
are hazardous and can be deadly.
b. Never add fuel to a running engine or hot
engine (allow hot engine to cool several
minutes).
8. Watch for holes, rocks, and roots in the terrain
and for other hidden hazards. When mowing
tall grass, mow higher than desired to expose
any hidden obstacles. Then, clean the area and
mow to the desired height.
c. Keep matches, cigarettes, cigars, pipes,
open flames, or sparks away from the fuel
tank and fuel container.
d. Always fill the fuel tank outdoors using
care. Fill to about one inch from the top of
the tank. Use a funnel or spout to prevent
spilling.
9. Avoid sudden starts or stops. Before backing
the machine up, look to the rear to be sure the
area behind you is clear of obstacles. Watch
carefully for traffic when crossing or working
near roadways.
e. Replace the machine fuelcapandcontainer
cap securely and clean up any spilled fuel
before starting the engine.
10
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Safety Instructions
10. Disengage the blade drive when transporting
the machine across drives, sidewalks, etc.
Never raise the mower deck while blades are
rotating.
the mower and repair any damage before re-
starting the engine and operating the mower.
Make sure cutter blades are in good condition
and blade nuts are torqued to 60 ft-lb (81.3
N⋅m).
11. The maximum recommended side slope op-
erating angle is 20 degrees or 33% grade.
When operating the machine on a slope, reduce
ground speed and use caution to start, stop,
and maneuver. To prevent tipping or loss of
control of the machine, avoid sharp turns or
sudden changes in direction.
17. Do not touch the engine, engine cover, or
muffler while the engine is running or imme-
diately after stopping the engine. These areas
may be hot enough to cause serious burns.
18. When leaving the machine unattended, dis-
engage the blade clutch (PTO), stop the en-
gine, and remove the key.
12. Never adjust cutting height with the engine
running. Before adjusting cutting height or
servicing, disengage the blade clutch (PTO),
stop the engine, and remove the ignition key.
Wait for all movement to stop before leaving the
operator position.
MAINTENANCE
1. To prevent accidental starting of the engine
when servicing or adjusting the machine, re-
move the key from the ignition switch and dis-
connect the spark plug wires.
NOTE: A blade brake should normally stop
drive line rotation within five (5) seconds of dis-
engaging the PTO clutch.
2. To reduce fire hazards, keep the engine free of
grass, leaves, excessive grease, and dirt.
13. For side discharge mower decks, do not oper-
ate with the grass deflector chute removed.
Keep the deflector in the lowest possible posi-
tion.
3. Keep all nuts, bolts, and screws tight to ensure
the machine is in a safe, working condition.
Check the blade mounting nuts frequently, mak-
ing sure they are tight.
14. For tractors equipped with tilt-up deck, do not
4. Perform only maintenance instructions de-
scribed in this manual. Unauthorized main-
tenance operations or machine modifications
may result in unsafe operating conditions.
move tractor with deck in tilt-up position.
15. In case of a clogged or plugged mower
deck:
5. If the engine must be running to perform a main-
tenance adjustment, keep hands, feet, and
clothing away from moving parts. Do not wear
jewelry or loose clothing.
a. Disengage the blade clutch (PTO) and
turn the engine off before leaving the
operator position (behind the handles).
b. LOOK to make sure blade drive shaft
movement has stopped before trying to
unclog the deck.
6. Always use the proper engine service man-
ual when working on the engine. Unautho-
rized maintenance operations or modifications
to the engine may result in unsafe operating
conditions.
c. Disconnect the spark plug wires.
d. Never place hands under the deck - use a
stick or similar tool to remove clogged
material.
7. Altering the equipment or engine in any manner
which adversely affects its operation, perfor-
mance, durability, or use will VOID the warran-
ty and may cause hazardous conditions.
16. If the cutting blades strike a solid object or the
machine begins to vibrate abnormally, immedi-
ately disengage the blade clutch (PTO), stop
the engine, and wait for all moving parts to
stop. To prevent accidental starting, discon-
nect the spark plug wires. Thoroughly inspect
8. Never attempt to disconnect any safety devices
or defeat the purpose of these safety devices.
11
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Safety Instructions
9. Do not change the engine governor settings or
overspeed the engine. The governor has been
factory-set for maximum-safe engine operating
speed.
10. Use genuine factory replacement parts.
Substitute parts may result in product malfunc-
tion and possible injury to the operator and/or
others.
11. Use care when charging the battery or per-
forming maintenance on the battery and electri-
cal system:
a. Make sure the battery charger is unplugged
before connecting or disconnecting cables
to the battery.
b. Charge the battery in a well-ventilated
space, so gases produced while charging
can dissipate.
c. Keep sparks, flames, and smoking materi-
als away from the battery at all times. To
avoid sparks, use care when removing bat-
tery cables from posts.
d. Disconnect both battery cables before
unplugging any wiring connectors or mak-
ing repairs on the electrical system.
IMPORTANT: Keep all applicable manuals
immediately accessible to anyone who may
operate or service this machine.
12
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Safety Instructions
SAFETY, CONTROL, AND INSTRUCTION DECALS
Safety, Control, and Instruction Decals are installed on the machine; if any are missing, illegible, or
damaged, a replacement should be ordered and installed before putting the machine into operation. The
Decal Part Number is listed below and in the Parts List.
Control Panel (Walker P/N 9801)
On Body Adjacent
to Parking Brake Lever
(P/N 9802)
On Body Adjacent
to Clutch Control Lever
(P/N 9803)
On Rear of Body Above
Neutral Lockout Arms (2)
(P/N 9804)
13
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Assembly Instructions
SETUP INSTRUCTIONS
Battery Charging
Walker Mowers are shipped partially assembled.
After uncrating the tractor and mower deck, initial
setup is required.
DANGER
BATTERIES PRODUCE EXPLOSIVE GASES
NOTE: During the process of unpacking, any dam-
aged or missing parts should be noted and reported
to the delivering carrier immediately (put in writing
within 15 days). The carrier will provide directions
for proceeding with a claim to receive compensation
for damage.
• Charge the battery in a well-ventilated
area, so that gases produced while charg-
ing can dissipate.
• Keep sparks, flames, and smoking mate-
rials away from the battery at all times.
Tire Installation (Tractor)
• Make sure the battery charger is unplug-
ged before connecting or disconnecting
cables to the battery.
• Install the drive tires using the eight (8) lug bolts
that are supplied with the owner’s packet of materi-
als. Drive tires are 18 x 8.50-10, 4-ply; rear tire is
2.80/2.50-4 Pneumatic (4-Ply).
Limit initial charging current to 1000mA. Charge un-
til battery voltage (under charge) reaches 14.40 to
14.70 volts at 68°F (20°C). Hold at 14.40 to 14.70
volts until current drops to approximately 50mA.
Battery is fully charged under these conditions, and
charger should be disconnected.
• Check and adjust the inflation of the tires. The
tire inflation recommendations are:
Drive = 15 PSI (103 kPa)
Rear = 20 PSI (137 kPa)
NOTE: Due to the self-discharge characteristics of
this type of battery, it is imperative that it be charged
after 6-9 months of storage, otherwise permanent
loss of capacity might occur as a result of sulfation.
Battery Service
The battery is a completely sealed, non-serviceable
battery.
IMPORTANT: Make sure battery is securely
mounted in the frame. A loose battery may cause
damage to the case resulting in acid leakage and se-
vere damage to the machine. A hazard may be cre-
ated by damage to critical working parts and safety
systems.
Front of Mower
Ref. Engine
Battery Location
14
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Assembly Instructions
Mower Deck Assembly
Deck Discharge Shield Installation
(Side Discharge Models Only)
Deck Caster Wheels Installation
Attach the deck side discharge shield by positioning
the shield hinge lug in front of the deck mount and
fastening with two 3/8-16 x 1-1/4 in. bolts, 3/8-16
ESNA nuts, and 3/8 in. wave spring washers. The
wave washers fit between the two hinging surfaces.
Tighten the nuts until the shield moves freely but is
not loose.
1. Remove the bolt, nut, axle spacer tube, and
spacer washers from each deck caster wheel
fork.
NOTE: Spacer washers are used only when
the optional semi-pneumatic deck wheels (8.25
x 2.75) are installed.
WARNING
2. Fit the axle spacer tube through the wheel hub,
position the spacer washer on each side of the
hub (if used), and fit the assembly into the wheel
fork.
DO NOT operate the machine without the
grass deflector chute attached and in the
lowest possible position.
3. Insert the 3/8-16 x 4-1/2 in. bolt through the
wheel fork with the bolt head to the outside and
install the 3/8-16 in. Keps nut.
4. Tighten the bolt and nut until the axle spacer
tube bottoms against the inside of the wheel
fork (will not turn) while the wheel and spacer
washers (if used) spin freely without binding.
Attach Shield
Deck Discharge Shield Installation
Deck Caster Wheel Installation
15
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Assembly Instructions
PTO Shaft Guard Installation
Mower Deck Installation on Tractor
Position the shaft guard as shown and mount with
two 1/4-20 x 1/2 in. bolts.
Deck Installation
1. Lightly grease each deck support arm (2) on the
tractor. Refer to Mower Deck Installation
photo for location of deck support arm.
Attach Guard
2. Engage the deck carrier frame tube sockets on
the tractor support arms. Slide the deck onto
the support arms.
NOTE: When installing the DSD52 Mower
deck, make sure to retract the dolly wheel after
mounting the deck on the tractor.
3. Install the hitch pin through the hole on the end
of each support arm to lock the deck in place
(refer to Counterweight Spring Receptacle
Assembly photos). Two (2) hitch pins are
included in the owner’s packet of materials.
PTO Shaft Guard Installation
Tilt-Up Roller Wheel Installation
NOTE: A 2-1/2" diameter tilt-up roller wheel
(P/N 9772) is required for decks installed on the
walk-behind.
4. Connect the mower deck PTO drive shaft
assembly to the tractor with the splined quick
disconnect coupler. This coupler simplifies
shaft alignment and installation.
Mount the two (2) tilt-up roller wheels on the brack-
ets on the rear skirt of the deck housing using the
P/N 8490 axle bolt, 3/8 in. wave spring washer and
3/8-16 in. Whiz locknut. Tighten the axle bolt until
the wheel rolls freely, but is not loose.
a. Use the arrows on the shaft and tube to
align and slide the PTO quick coupler onto
the deck splined shaft.
Roller Wheels
b. Reaching under the tractor, pull the ring
back on the coupler, slide onto the spline
shaft on the tractor, and release the ring.
IMPORTANT: To prevent damage to the
mower, make sure the PTO shaft assembly is
securely locked on the tractor, with the locking
balls fully seated in the groove and the ring in the
full forward position (refer to the Coupler Ring
“Locked” Position photo). After installation,
pull on the shaft to check for security.
Tilt-Up Roller Wheel Installation
16
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Assembly Instructions
5. Pull out counterweight spring receptacle assist
handle and lift up on locking finger slightly to
unlock the receptacle assembly. Lower this
assembly toward the deck and attach the coun-
terweight springs to the receptacle. Raise the
assist handle until the assembly locks into the
raised position to tension the springs
Grease Deck
Support Arms
1) Install Counterweight
2) Retain Spring Clip
Spring Clip
Using Tab
into Receptacle
PTO
Shaft
Mower Deck Installation
(PTO Shaft Connection)
3) Use Lever to Assist
Raising Assembly to
"Locked" Position
Pull Back Spring-Loaded
Coupler Ring
Counterweight Spring Receptacle Assembly in
"Unlocked" Position
Locking Finger "Snaps"
to Hold Assembly in
"Locked" Position
Lift Up on Locking
Finger to Lower
Assembly
Installing PTO Quick Coupler
Spring-Loaded Coupler Ring
In Fully Forward Position
Counterweight Spring Receptacle Assembly in
"Locked" Position
6. With the counterweight springs connected, the
weight on the deck caster wheels should be
15 to 25 Ib (7 to 11 kg). Check this weight by lift-
ing on the front of the deck carrier frame. If
required, the spring tension can be adjusted by
tightening or loosening the elastic stop nuts
located underneath the lower spring hook.
Coupler Ring “Locked” Position
17
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Assembly Instructions
2. Check the side-to-side level. Rotate each
blade sideways and measure the distance
from blade tip to ground on each side. If mea-
surements vary more than 1/8 in. (3 mm), add a
washer shim under the deck support pins on the
low side to level the deck.
3. Check the front-to-rear level. Rotate the blades
to point forward. Measure the distance from
blade tip to ground on the front and rear. The
rear of the blade should be 1/8 to 1/4 in. (3 to 6
mm) higher than the front of the blade; shim the
rear (or front) deck support pins equally to
achieve at least 1/8 in. (3 mm) difference.
Deck Leveling
1. Position mower on a smooth, level surface. Set
the cutting height to the highest position - 4 in.
(102 mm) - for easy access under the deck to
measure blade height. Refer to ADJUSTING
CUTTING HEIGHT in Operating Instructions.
NOTE: A block of wood cut 4 in. (102 mm) high
is a convenient gauge to measure blade height
above ground during the leveling process.
WARNING
NOTE: The mower deck and support frame are
jig welded; within normal tolerances, very little, if
any, shimming should be required to level the
deck. Tire pressure will influence the levelness
of the deck. Check the tire pressure as a possi-
ble cause of the deck not being level.
The machine must be shut off during this
procedure.
4 in. (102 mm)
Wood Block
Should be 1/8 in. (3 mm)
to 1/4 in. (6 mm) higher
at the rear of the blade
Should not vary more
than 1/8 in. (3 mm)
side-to-side
4 in. (102 mm)
Wood Block
Deck Leveling
18
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Assembly Instructions
PREOPERATING CHECKLIST
IMPORTANT: DO NOT mix oil with gasoline. Al-
ways use fresh, automotive grade gasoline. DO
NOT use premium, white, or high-test gasoline. DO
NOT use additives, such as carburetor cleaners, de-
icers, or moisture removing agents. DO NOT use
gasoline blended with methyl alcohol.
Before operating the mower for the first time, and as
a routine before daily operations, it is important to
make sure the mower is properly prepared and
ready for operation. The following is a list of items to
be checked. (For a mower with frequent operation,
some of these items will not need to be checked ev-
ery day, but the operator should be aware of the con-
dition of each.)
CHECK ENGINE CRANKCASE OIL LEVEL
Check the engine crankcase oil level before use and
after each 5 hours of continuous operation. Refer
to LUBRICATION for Checking Engine Crankcase
Oil Level in Maintenance Instructions.
For proper fuels and lubricants refer to Specifica-
tions.
FILL FUEL TANK
CHECK AND SERVICE ENGINE AIR CLEAN-
ER SYSTEM
Fill the fuel tank using clean, fresh automotive grade
unleaded gasoline (87 octane rating minimum).
• Check condition, cleanliness, and security of
the air cleaner system (clean air filter every
100 hours). For detailed procedures, refer to
CLEANING the Engine Air Cleaner System in
Maintenance Instructions.
DANGER
Handle gasoline with care. Gasoline is
highly flammable and its vapors are ex-
plosive. Use safe refueling procedures:
ADJUST CARBURETOR (Initial Start-up Only)
• DO NOT fill fuel tank with the engine run-
Refer to ADJUSTMENTS of Carburetor in Mainte-
nance Instructions.
ning.
• If the engine is hot, allow to cool before
CHECK ENGINE COOLING SYSTEM
refueling.
Check condition and cleanliness of engine air intake
screen located on top of engine. For detailed proce-
dures, refer to CLEANING the Engine Cooling
System in Maintenance Instructions.
• Use an approved fuel container.
• Fuel the mower outdoors.
• DO NOT smoke while refueling.
• Avoid spilling fuel; use a funnel or spout.
• DO NOT overfill the fuel tank; fill up to
about 1 in. (25 mm) below the top of tank.
IMPORTANT: DO NOT permit dirt or other foreign
matter to enter the fuel tank. Wipe dirt from around
the filler cap before removing. Use a clean fuel stor-
age container and funnel.
19
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Assembly Instructions
INSPECT TWO (2) DRIVE BELTS
PTO Drive and Hydrostatic Ground Drive.
CHECK TIRE PRESSURE
DANGER
With the deck in the tilt-up position, the U-
joint tube and shaft may separate. Check
after lowering deck and before operating.
Deck Caster Wheel = 20 PSI (137 kPa)
Drive
Rear
=
=
15 PSI (103 kPa)
20 PSI (137 kPa)
DANGER
CHECK AND CLEAN GRASS BUILDUP
UNDERNEATH MOWER DECK
Never operate cutter blades with deck in
raised position because it is hazardous.
The tilt-up deck can be secured in the raised position
by unlocking the deck lock levers on each side of the
carrier frame and inserting the deck hook into the tilt-
up latch on the tractor body. Before operating the
tractor, make sure to re-engage the deck lock levers
after lowering the deck to the normal operating po-
sition.
CAUTION
Do not operate machine with deck tilt-up
pivot joint unlocked.
CHECK MOWER BLADE CONDITION, SHARP-
NESS, AND SECURITY OF MOUNTING
The blade mounting nut should be tightened to
60 ft-lb (81.3 N⋅m). If blade sharpening is required,
refer to CHECKING/SERVICING for Sharpen
Mower Blades in Maintenance Instructions.
ADJUST MOWER CUTTING HEIGHT, IF RE-
QUIRED
Deck Secured in TILT-UP Position
Position the hitch pins in the four deck support pins.
Refer to the “Cutting Height Adjustment” decal on
the deck gearbox cover.
DANGER
PERFORM ANY ADDITIONAL PROCEDURES
called for on the MAINTENANCE SCHEDULE
CHART in Maintenance Instructions.
Do not operate the mower with deck in tilt-
up position. Do not move the tractor with
the deck in the tilt-up position.
20
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Operating Instructions
CONTROL IDENTIFICATION, LOCATION, AND
FUNCTION
Engine Throttle/Choke
The throttle/choke control lever (red knob) is located
to the left hand side of the operator’s control panel.
This control is a dual-functioning control (choke and
throttle). The control is equipped with a detent be-
tween the choke position (full forward) and the throt-
tle control range.
Operating Controls
CAUTION
Before operating the mower, become fa-
miliar with the location and function of
all operator controls. Knowing the loca-
tion, function, and operation of these
controls is important for safe and effi-
cient operation of the mower.
To start a cold engine, push the control to the
CHOKE position. After the engine starts, pull the
control back past the detent into the THROTTLE
CONTROL range. A warm engine requires little or
no choke for starting.
Moving the lever forward into the FAST position in-
creases engine speed; moving it backward toward
the IDLE position decreases engine speed.
Blade Clutch
(PTO)
Engine Throttle/
Choke Positions
Parking Brake
Lever
Engine Throttle/
Choke Lever
Operating Controls Not Located on Control Panel (Top View)
10 Amp
Circuit Breaker
Operator Presence
Ignition Switch
Operator Presence
Control
Control
Pistol Grip/
Steering
Pistol Grip/
Steering
Control (RH)
(Not Visible)
Control (LH)
(Not Visible)
Hourmeter
Forward Speed
Control Positions
Forward Speed
Control Switch
Operating Control on Control Panel (Top View)
Operating Controls
21
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Operating Instructions
IMPORTANT: Make sure the choke is in the OFF
position during normal engine operation; running
with the choke in the ON position CAN damage the
engine.
Parking Brake
The parking brake functions by locking a detent arm
into the transaxle outer control gear teeth. Moving
the lever FORWARD engages the parking brake;
moving the lever BACKWARD releases the brake.
Forward Speed Control (FSC)
IMPORTANT: Stop the tractor completely before
engaging the parking brake. The parking brake
uses a positive mechanical lock similar to the PARK
position on an automotive automatic transmission.
If the tractor is moving when the brake is engaged, it
will result in sudden stoppage and possible internal
damage to the transaxle.
The Forward Speed Control (FSC) is a rocker switch
located adjacent to the RH thumb position near the
RH pistol grip.
This rocker switch controls an electric actuator that
has two functions: One is to set forward travel
speed, and the other is to establish the NEUTRAL-
PARK position. When the FSC switch is moved into
the FORWARD position, it sets the forward speed
from 0 to 5 mph (0 to 8 km/h). The ground speed is
proportional to how long the rocker switch is held for-
ward; the longer the switch is held forward, the faster
the tractor moves. It is not necessary to hold the
FSC switch in position since the electric actuator
maintains the selected position. Squeezing the pis-
tol grips/steering control levers overrides the FSC
setting and slows or stops forward travel. Releasing
the pistol grips/steering control levers allows the
tractor to resume forward travel at the speed set by
the FSC switch. To stop and park the machine, the
FSC switch is depressed backward until the NEU-
TRAL-PARK position is achieved.
NOTE: If pressure on the parking brake lever is no-
ticed when engaging the brake, move the mower
gently forward or backward to allow the brake detent
to set into the teeth.
Engine Cover Latch
The engine cover hinges forward for maintenance
access and is latched down in the OPERATING po-
sition. To raise the body, unhook the rubber latch lo-
cated between the fuel tank and engine.
Transaxle Lockout Rods
The transaxle lockout rods disengage the transax-
les. By pulling the rods toward the rear of the mow-
er and locking them into place with the shoulder on
the rod in the body, the transaxles are released to
permit freewheeling. By releasing the rods and
pushing it back into the body, the transaxles are en-
gaged for normal operation. The transaxle rods in
the LOCKOUT position are used to enable moving
the machine without the engine running (e.g., for
service). Refer to TRANSAXLE LOCKOUT in this
section for operating instructions.
Pistol Grips/Steering Control Levers
Each drive wheel is controlled by its own indepen-
dent pistol grip (located below the operators han-
dles), for both steering function and FORWARD/
REVERSE motion. The FSC switch sets the maxi-
mum forward speed, and also sets the forward posi-
tion of the pistol grips. The pistol grips operate only
with a squeezing movement of the grip, which
causes the drive wheel for that lever to first slow
down, stop, and then reverse with a full backward le-
ver stroke. The grips are released to the FOR-
WARD position for “straight-ahead” ground travel.
Reverse is achieved by squeezing the pistol grips
past the NEUTRAL-PARK position. For better con-
trol, it is recommended that this is done in conjunc-
tion with toggling the FSC switch back to the
NEUTRAL-PARK position.
NOTE: The transaxle lockout rods ends should be
completely retracted against the body, otherwise op-
eration of the transaxle may be erratic.
Hourmeter
The hourmeter displays operating time accumulat-
ed while the ignition switch is in the ON position with
the engine running. It also gives service indications
for oil changes and lubrication.
Blade Clutch (PTO)
Circuit Breaker
The blade clutch lever has two positions. Pulling the
lever BACK engages the PTO that drives the mow-
er blades. Pushing the lever FORWARD disengag-
es the PTO and engages the blade brake.
A manual reset circuit breaker is located on the op-
erator panel. It has a button that pops out if the cir-
cuit breaker trips. The circuit breaker protects the
safety switches.
22
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Operating Instructions
Ignition Switch
CAUTION
The ignition switch has two positions: a RUN and an
OFF position. The RUN position should be used
when starting (using the recoil starter) and running
the engine. The OFF position stops the engine.
A safety interlock switch system PRE-
VENTS CRANKING the engine with either
the Forward Speed Control or the blade
clutch (PTO) out of neutral. If the engine
cranks otherwise, the safety system is not
working and should be repaired or ad-
justed before operating the mower. DO
NOT disconnect safety switches; they are
for the operator’s protection.
OFF
ON
2. Turn the ignition key to the RUN position. Move
thethrottle/chokeleverintotheCHOKEposition.
NOTE: The choke may not be required if the
engine is warm.
3. Make sure you have secure footing and pull
the recoil starter handle toward you.
IMPORTANT: If the engine fails to start after
approximately 5 attempts, the engine and safety
switch circuit should be checked before any fur-
ther attempts. Turn the key to the OFF posi-
tion to begin these checks.
Ignition Switch
STARTING THE ENGINE
4. After the engine starts, gradually move the
throttle/choke lever to the THROTTLE position,
keeping enough choke on to allow the engine
to run smoothly as it warms up. As soon as
possible, move the lever past the detent into
the THROTTLE position.
CAUTION
Before operating the mower, read and un-
derstand all Safety Instructions and Operat-
ing Instructions.
IMPORTANT: Make sure the choke is in the
OFF position during normal engine operation;
running with the choke in the ON position CAN
damage the engine.
WARNING
ADJUSTING GROUND SPEED AND STEERING
NEVER run the engine in an enclosed or
poorly ventilated area. Engine exhaust
contains carbon monoxide, an odorless
and deadly gas.
IMPORTANT: If the DSD52 Mower deck is
installed on the tractor, make sure the dolly
wheel is retracted BEFORE moving.
CAUTION
1. Before attempting to start the engine, make
sure the Forward Speed Control (FSC) rocker
switch is in NEUTRAL-PARK position, and the
blade clutch and parking brake are
DISENGAGED.
Learn to START, STOP, and MANEUVER
the mower in a large, open area.
If the operator has not operated a machine
with DUAL TRANSAXLES or PISTOL
GRIPS, steering and ground operation
should be learned and practiced until the
operator is completely comfortable han-
dling the machine BEFORE ATTEMPTING
TO MOW.
23
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Operating Instructions
1. Place both hands on their respective grips and
using your RH thumb, toggle the FSC switch out
of NEUTRAL- PARK position to the desired for-
ward speed. It is not necessary to hold the FSC
switch in position since the electric actuator
holds the selected switch position (and forward
travel speed).
Beginning Recommendations are:
♦ Learn operation of the mower in an open
area away from buildings, fences, and ob-
structions. Learn operation on flat ground
BEFORE operating on slopes.
♦ Start maneuvering the mower with
SLOW engine speed and SLOW Forward
Speed Control setting until familiar with all
operating characteristics.
2. Steer by squeezing the pistol grip on the side of
desired direction of turn, e.g., squeeze the LH
grip to turn left.
3. Reverse direction of the mower by squeezing
both grips.
♦ Remember the forward speed of the
mower is controlled by the FSC toggle
switch (a unique Walker feature); always
squeeze the pistol grips for steering or for
reverse motion of the mower.
NOTE: Smooth action on the pistol grips will
produce smooth mower operation. Remember
to keep the engine and ground speed slow until
learning the control response.
♦ Learn to operate the pistol grips with
smooth action. Jerky movements are hard
on the transaxles and lawn. For sharp
turns, do not allow the inside wheel to stop
and twist on the grass. Squeeze the pistol
grip controlling the inside wheel into re-
verse for a smooth “rolling” turn (one wheel
rolling forward while the other rolls back-
ward).
4. The FSC switch may be adjusted forward for
faster ground speed and backward for slower
ground speed. When mowing, ground speed
should be adjusted to match the load on the cut-
ter blades, i.e., as the engine pulls down in
heavy cutting, toggle back the FSC switch to re-
duce ground speed. Adjusting ground speed
helps maintain a balance between engine power
and blade speed for high-quality cutting action.
♦ Practice maneuvering the mower until
you can make it go exactly where you are
aiming.
5. Stop ground travel by squeezing both pistol
grips to the NEUTRAL position (tractor not
moving) and depressing the FSC switch back to
the NEUTRAL-PARK position.
♦ Remember, for an emergency stop, or in
case of loss of control, the machine is
equipped with an operator presence switch
on the handlebars. Releasing this when the
machine is driving or the PTO is engaged
will make the engine shut down.
NOTE: If the tractor creeps forward or back-
ward with the FSC switch in the NEUTRAL-
PARK position, the transmission control needs
to be adjusted. Refer to ADJUSTMENTS of
Transmission Control in Maintenance In-
structions.
Operator Presence
Controls Depressed
RH Thumb Control
FSC Switch
Correct Operator Hand Position
24
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Operating Instructions
ENGAGING THE MOWER
1. Set the engine throttle at about 1/3 speed. Do
not attempt to engage the blade clutch at
high engine speeds. This will drastically short-
en drive belt life. Use only moderate engine
speed when engaging the blade clutch.
2. Pull the blade clutch lever SLOWLY up to en-
gage the mower blades.
CAUTION
A safety interlock switch (operator pres-
ence on handle grips) will cause the en-
gine to stop if the blade clutch is engaged
and the operator presence control is not
depressed. The function of this switch
should be checked by the operator lifting
off of the control and engaging the blade
Blade Clutch Engaged
clutch; the engine should stop.
If the
switch is not working, it should be re-
paired or replaced before operating the
mower. DO NOT disconnect the safety
switches; they are for the operator’s pro-
tection.
IMPORTANT: DO NOT engage the blade clutch
when transporting the mower across drives, side-
walks, loose materials, etc. DO NOT engage the
blade clutch with the PTO shaft disconnected
(the mower deck removed from tractor).
Blade Clutch Disengaged
CAUTION
STOPPING THE MACHINE
If the cutting blades strike a stationary ob-
ject while mowing, stop the mower imme-
diately, disconnect the spark plug wires,
lift the deck, and inspect the deck and
blades thoroughly for damage. Make sure
that the blade timing has not been dis-
turbed (the blades should be at 90 degrees
to each other on gear-driven decks). Refer
to REPLACING/REPAIRING the Blade
Overload Shear Bolts in Maintenance In-
structions if blades are out of time. Also,
make sure the blade retaining nuts are
torqued to 60 ft-lb (81.3 N⋅m).
1. Slow the engine to a fast idle; put the throttle in
the 1/2 throttle position.
2. Squeeze the pistol grips to the NEUTRAL posi-
tion and toggle the FSC switch back to the
NEUTRAL-PARK position.
3. Disengage the blade clutch.
IMPORTANT: DO NOT disengage the blade
clutch with high engine speed (above 1/2 throt-
tle) since the brake action on the blade drive will
cause premature wear of the brake band.
25
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Operating Instructions
Cutting height is adjusted by positioning the four re-
tainer hitch pins in a series of seven vertical holes on
the deck support pins. Lift handles have been pro-
vided on each end of the deck to assist in raising the
deck while positioning the hitch pins. Cutting heights
range from 1 in. (25 mm) [top holes] to 4 in. (102 mm)
[bottom holes] in 1/2 in. (13 mm) increments.
CAUTION
A brake stops the cutter blades from free-
wheeling within five (5) seconds after dis-
engaging the clutch. If the brake system
malfunctions and the blades do not stop
within five (5) seconds, the brake should
be adjusted or repaired before operating
the mower. Refer to ADJUSTMENTS of
Blade Clutch (PTO) in Maintenance Instruc-
tions.
Lift Handle
Deck Support
Pin
4. Slow the engine to idle, put throttle in IDLE po-
sition; and turn the ignition switch OFF.
WARNING
Hitch Pin
Remove the key from the ignition switch
when leaving the mower unattended. This
will prevent children and inexperienced
operators from starting the engine.
Cutting Height Adjustment
TRANSAXLE LOCKOUTS
5. Engage the parking brake.
IMPORTANT: DO NOT TOW this mower with the
transaxlelockoutsengaged. Towingcanproduceex-
cessive internal pressure and damage the transaxle.
IMPORTANT: The transaxles lock to prevent
the mower from rolling freely with the engine
stopped. However, if the mower is parked on a
slope, it is necessary to ENGAGE the parking
BRAKE to prevent the mower from creeping.
This is due to a small amount of slippage in the
transaxles, especially when transmission fluid is
warm.
To move the mower with the engine NOT running
(will not start, maintenance, etc.), unlock (release)
the transaxles.
1. Locate each lockout rod at the rear of the mow-
er on either side of the tail wheel below the fuel
tank.
ADJUSTING CUTTING HEIGHT
2. Pull each rod out and lock them on the body us-
ing the shouldered part of the rod.
WARNING
3. The mower will “freewheel” with the rods in the
LOCKOUT position. The rods must be shoul-
dered on the body to completely unlock the
transmissions.
The engine must be stopped before ad-
justing cutting height. Disengage the
blade clutch (PTO), stop the engine, and
remove the ignition key. Wait for all move-
ment to stop before leaving the operator
position.
4. After moving the mower, release the rods, plac-
ing them in the normal OPERATING position.
The transmission rod ends should be complete-
ly retracted against the body, otherwise opera-
tion of the transmission may be erratic.
26
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Operating Instructions
• When mowing in adverse conditions (tall and/or
wet grass), mow the grass twice. Raise the mower
to the highest setting - 4 in. (102 mm) - for the first
pass and then make a second pass cutting to the
desired height.
• Use a slow setting on the FSC for trimming
operations.
• Make sure the mower is leveled properly for a
smooth cut. Refer to Deck Leveling in Assembly
Instructions.
Neutral Lockout
Rod (LH)
Freewheel Position
• Use an alternating stripe mowing pattern for
best appearance and vary the direction of the stripe
each time the grass is mowed to avoid wear patterns
in the grass.
• Avoid damage to the grass by slipping and skid-
ding of the drive tires. Use smooth control move-
ments of the pistol grips since the hydrostatic
transmissions are “power boosted controls” and
jerking the levers can easily slip the tires. For sharp
turns, do not allow the inside wheel to stop and twist
on grass; squeeze the inside pistol grip into reverse
for a smooth “rolling” turn (one wheel rolling forward
while the other rolls backward).
Neutral Lockout
Rod (LH)
Operating Position
• When using a side discharge mower deck, the
side discharge shield must not be removed and
must be kept in the lowest possible position to
deflect grass clippings and thrown objects down-
ward. Orient the side discharge away from side-
walks or streets to minimize cleanup of clippings.
When mowing close to obstacles, orient the side dis-
charge away from obstacles to reduce the chance of
damage to property by thrown objects.
RECOMMENDATIONS FOR MOWING
IMPORTANT: Operate the engine at full speed
when mowing, to allow the engine to produce full
horsepower and to increase efficiency of the engine
cooling system.
• Keep the mower deck and discharge chute clean.
• Mow with sharp blades. A dull blade tears the
grass (resulting in poor lawn appearance) and uses
extra power (slowing the mowing speed).
• It is preferable to cut grass when it is dry and not
too tall. Mow frequently and do not cut grass too
short. (For best appearance, cut off 1/3 or less of
existing grass height.)
Discharge
Shield
• When mowing, operate the engine at or near full
throttle for the best cutting action and performance
of the deck. Mowing with a lower engine RPM
causes the mowing blade to not cut clean and tear
the grass. The engine is designed to be operated
at full speed.
Side Discharge Shield in Lowest Position
27
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Operating Instructions
Maintenance Instructions
• When operating on a slope, reduce speed and
use caution to start, stop, and maneuver. Avoid
sharp turns or sudden changes in direction. The
maximum recommended side slope operating
angle is 20 degrees or 33% grade.
IMPORTANT TIPS FOR CARE OF THE
KAWASAKI ENGINE
Fuel System
• Fuel must be clean - free from water, dirt, and
organic material.
• Change fuel filter on a regular basis and when
contamination is suspected or found in the fuel.
Starting/Stopping
• Match crankcase oil viscosity to the ambient tem-
perature, allowing the engine to crank faster and
start easier.
Cooling System
• Operate the engine at full speed when mowing.
This will allow the engine to produce full horsepower
and move more cooling air through the cooling fins.
Air Cleaner System
• Use only Kawasaki air cleaner elements. After-
market elements may not seal in the air cleaner
housing, allowing dirt to enter the engine. Also,
aftermarket filters often skimp on the filtration media
and require more frequent cleaning and replace-
ment (see following instructions).
22 in.
20°
60 in.
• DO NOT overservice or frequently “disturb” the
air filter. A dirty air filter actually cleans better than
a new one. Changing and cleaning the air filter too
often can actually reduce filter efficiency and
increase the opportunity for traces of dust to enter
the engine.
Maximum Recommended Side Slope
RECOMMENDATIONS FOR TILT-UP DECK
OPERATION/TRANSPORT
• When the air filter element is removed or
replaced, make sure all dust is cleaned out of the
air cleaner housing. Use a damp cloth and wipe
the interior of the air cleaner case clean (a little dirt
left here will be sucked into the engine and reduce
engine life). When the filter is installed, make sure
the element is held tight and straight in the hous-
ing for proper seating and sealing.
To avoid potential deck and/or tractor damage while
using the tilt-up deck, the following recommenda-
tions are offered:
• Do not move the tractor with the deck in the tilt-
up position since both the roller wheels (on the back
of the deck) may be damaged by moving the tractor.
The tilt-up configuration should only be used when
the tractor is parked.
Oil
• When transporting a tractor with the deck in the
tilt-up position (on a truck or trailer), the deck
should be secured to the vehicle with a strap or
rope (stop vertical movement). This will prevent the
deck from bouncing on the rear roller wheels (caus-
ing breakage).
• DO NOT screw filler cap into crankcase when
checking oil level.
• Single viscosity or multi-viscosity oils may be
used with the viscosity matching ambient tempera-
tures for the engine operating conditions. This will
aid starting in cold weather and assure proper lubri-
cation in hot weather.
• Use only Kawasaki oil filters. Aftermarket filters
may not seal properly and/or have the incorrect
pressure relief valve for proper lubrication.
28
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Maintenance Instructions
CAUTION
Maintenance procedures requiring special training or
tools should be performed by a trained technician.
MAINTENANCE SCHEDULE CHART - RECOMMENDED SERVICE INTERVALS - MODEL MW
25
Hours
50
Hours
100
Hours
200
Hours
Ref.
Page
Service Item
Daily
Check Engine Crankcase Oil Level
Check/Clean Engine Air Intake Screen*
Check for Loose or Lost Nuts and Screws
Clean Grass Buildup Under Deck
Service Mower Blades
x
x
x
x
x
30
36
N/A
36
37
31
37
38
38
36
36
30
38
36
30
38
39
36
Lubricate Grease Fittings and Oil Points*
Check Tire Pressure
x
x
x
x
x
Check Drive Belts (PTO, Ground Drive)
Check PTO and Deck Gearbox Oil Seals
Clean Air Filter Foam Element*
Inspect Air Filter Paper Element*
Change Engine Crankcase Oil**
Clean and Regap Spark Plugs
Clean Engine Cooling Fins
x
x
x
x
x
x
Change Engine Oil Filter
Check Fuel Lines and Clamps
Check/Adjust Blade/Brake Action
Replace Air Filter Paper Element*
x
x
x
∗
More often in extremely dusty or dirty conditions
(see notes about air cleaner element in IMPORTANT TIPS FOR CARE OF KAWASAKI ENGINE)
∗∗ Change engine oil and filter after first 8 hours of operation of a new engine (break-in period)
29
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Maintenance Instructions
LUBRICATION
LUBRICATION
IMPORTANT: DO NOT operate engine without
a sufficient oil supply in the crankcase. DO NOT
operate with the oil level below the lower mark or
above the upper mark on the dipstick.
WARNING
DO NOT attempt to lubricate the machine
with the engine running. Disengage the
PTO clutch, shut off the machine, and re-
move the ignition key.
5. If additional oil is needed, refer to Specifications
for proper crankcase lubricant. Fill up to, but
not above, the upper mark on the dipstick.
IMPORTANT: DO NOT overfill the crankcase
(oil above “F” mark) as this CAN result in en-
gine overheating, loss of power, and possible
engine damage.
Proper lubrication is an important maintenance pro-
cedure. It reduces wear and makes the machine
quieter and easier to operate.
Changing Engine Crankcase Oil/Oil Filter
Engine Oil
Change the engine crankcase oil after every 100
hours of operation and replace the oil filter every
other oil change (every 200 hours of operation or
more often in extremely dusty or dirty conditions).
Engine Break-In Oil
No special break-in oil is required. The engine is
serviced with 10W-30, Service Class SG oil from the
factory. Change the oil after the initial engine break-
in period of 5 hours. Thereafter, change oil after
every 100 hours of operation or more often in ex-
tremely dusty or dirty conditions.
1. Park the mower on a level surface with the en-
gine stopped. The engine oil should be warm
beforedraining. Ifnotwarm from operation, start
the engine and run a fewminutes to warm the oil.
2. Before removing the dipstick and oil fill cap,
clean the area around them to keep any dirt or
debris out of the engine.
Checking Engine Crankcase Oil Level
Check the engine crankcase oil level before use and
after each 5 hours of continuous operation.
3. Remove the dipstick, oil fill cap, and unscrew
the oil drain plug 4-1/2 revolutions (to prevent
the drain plug from coming out completely, do
not exceed 4-1/2 turns). Drain oil into a suitable
container. Be sure to allow ample time for com-
plete drainage.
IMPORTANT: The importance of checking and
maintaining the proper crankcase oil level can-
not be overemphasized. Check the oil level BE-
FORE EACH USE.
1. Park the mower on a level surface with the en-
gine stopped. Also, make sure the engine is
cool and oil has had time to drain into the sump
[allow at least five (5) minutes after stopping
the engine].
IMPORTANT: NEVER check or add oil with the
engine running.
Oil Fill/
Dipstick
2. Before removing the dipstick, clean the area
around the dipstick to keep any dirt or debris out
of the engine.
3. Remove the dipstick, wipe off with a clean rag,
then reinsert the dipstick into the tube without
screwing it in.
Oil Filter
Oil Drain
4. Remove the dipstick again and check the oil lev-
el on the dipstick. The oil level should be be-
tween the FULL and LOW mark on the dipstick.
Oil Drain, Dipstick (Oil Fill),
and Oil Filter Location
30
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Maintenance Instructions
LUBRICATION
4. Before removing the oil filter, clean the area
around the filter to keep dirt and debris out of
the engine.
Grease Fitting and Oil Point Lubrication
Lubricate the grease fittings and oil points after ev-
ery 25 hours of operation. Lubricate more often
when operating in dusty or dirty conditions. Use
SAE general purpose lithium or molybdenum base
grease for grease fittings and light machine oil (SAE
10) to lubricate oil points. Lubricate the locations
shown in the Chassis and Deck Lubrication
Points illustration.
5. Remove the old oil filter and wipe off the filter
mounting surface on the engine.
6. Apply a thin coating of clean oil to the rubber
gasket on the replacement oil filter.
IMPORTANT: Use ONLY oil filters from the en-
gine manufacturer (Kawasaki 49065-2078). Af-
termarket oil filters may not seal properly and/or
may not have the correct pressure relief valve
for proper lubrication.
NOTE: PTO universal joints (on the deck and trac-
tor) require routine lubrication after every 8 hours
of running time.
Mower Deck Gearbox Lubrication
7. Install the new oil filter on the engine. Turn the
filter clockwise until the rubber gasket contacts
the sealing surface, then tighten an additional
1/2 turn.
NOTE: These instructions apply to all mower
decks with gear-driven blades. Refer to DSD52
Mower Deck Lubrication in this section for the
DSD52 deck with belt-driven blades.
8. Close drain valve.
The mower deck gearboxes (tee gearbox and blade
drive gearboxes) are connected as a unitized as-
sembly, and oil flows freely between them. The
gearboxes are permanently lubricated (oil filled) and
sealed requiring no scheduled lubrication. Howev-
er, the gearbox oil seals should be checked every
25 hours for indication of an oil leak; particularly
the lower seals on the blade drive gearboxes
should be inspected, since they operate in a dirty en-
vironment. If an oil leak is noted, replace the oil seal
and relubricate the gearbox assembly as follows:
9. Fill the crankcase with new, clean oil. Use only
crankcase lubricants recommended by the en-
gine manufacturer. Refer to Specifications in
this manual or the engine owner’s manual. Use
the recommended oil viscosity for the expected
ambient temperature. Oil with the correct vis-
cosity will aid starting in cold weather and as-
sure proper lubrication in hot weather. Fill up
to, but not above, the upper mark on the dip-
stick. Crankcase capacity is 1.6 quarts (1.5 li-
ters) plus 0.2 quart (0.2 liters) for the new oil
filter.
1. Remove gearbox cover (footrest). Deck orien-
tation shouldbeinthenormaloperatingposition.
IMPORTANT: Check the dipstick reading be-
fore adding the last 1/2 pint of oil and fill only to
the upper mark. DO NOT overfill the crankcase
(oil above upper mark) as this CAN result in
engine overheating, loss of power, and possi-
ble engine damage.
Blade Drive
Gearboxes
10. Start the engine and check for oil leaks around
the oil filter. Stop the engine, recheck the oil lev-
el, and add oil if necessary. (When the engine
is first operated with a new oil filter, the oil level
drops slightly as the filter is filled with oil.)
Tee
Gearbox
Mower Deck Gearboxes
(shown with gearbox cover removed for clarity)
31
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Maintenance Instructions
LUBRICATION
2. Clean the area around the individual gearbox
cover plates to prevent contaminants from en-
tering the gearcase.
Blade
Spindles
3. Remove the screws securing the cover plates
on the blade drive gearboxes.
4. Check the level of lubricant in the gearboxes. If
the lubricant is low, add SAE E.P. (Extreme
Pressure) 90W oil until the oil level is up to (sub-
merges) the horizontal shaft in the gearbox
(shaft parallel to cover plate).
NOTE: In case the gearboxes are completely
drained of oil, approximately 5 fl. oz. (15 cl) of oil
per gearbox is required to refill the gear drive
assembly.
Blade Spindle Lubrication (DSD52)
NOTE: Since the gearboxes are connected as
a unit by connector tubes, it is necessary to add
oil slowly. Allow a few minutes after adding oil
for the oil to flow throughout the assembly and
the oil level to stabilize before reassembly.
2. Check the oil level in the belt drive gearbox ev-
ery 100 hours (or sooner if a visible oil leak has
developed). With the deck in the normal oper-
ating position, remove the level plug in the side
of the gearcase. Add SAE E.P. (Extreme Pres-
sure) 90W oil to maintain the oil level to the plug.
If the oil level is low, check the gearbox for any
indication of an oil leak. If an oil leak is noted,
the gearbox will need to be removed and rebuilt.
IMPORTANT: DO NOT overfill the deck gear-
boxes. The gearbox assembly is not vented,
and overfilling with oil will cause excessive pres-
sure and result in oil leaks.
5. Check condition of the cover gasket and replace
if worn or damaged. Reinstall gearbox cover
plates; torque screws to 24 in-lb (2.7 N⋅m).
3. Lubricate the dolly wheel pivot every 25 hours
with general purpose grease.
4. Lubricate the U-Joint in the drive shaft every
8 hours with SAE general purpose lithium or
molybdenum base grease.
DSD52 Mower Deck Lubrication
There are several special lubrication requirements
for the DSD52 mower deck in addition to the require-
ments detailed in the Chassis and Deck Lubrica-
tion illustration. Lubricate the locations shown in
the Blade Spindle Lubrication and Gearbox, Dol-
ly Wheel, and U-Joint Lubrication photos and
check and maintain oil in the belt drive gearbox.
Belt Drive
Gearbox
1. Lubricate the blade spindles every 25 hours
with two (2) shots of SAE general purpose lithi-
um or molybdenum base grease.
Dolly Wheel
Level Plug
Pivot
U-Joint
Gearbox, Dolly Wheel, and U-Joint Lubrication
32
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Maintenance Instructions
LUBRICATION
Tractor PTO Gearbox Lubrication
Transaxle Lubrication
Checking Gearbox Oil Level
• The transaxle oil lubrication is SAE 20W-50 en-
gine oil.
The tractor PTO gearbox is permanently lubricated
(oil filled) and sealed requiring no scheduled lubrica-
tion. However, the gearbox oil seals should be
checked every 25 hours for indication of oil leaks. If
evidence of an oil leak is noted, replace the oil seal
and relubricate the gearbox. The gearbox can be
drained by removing the plug on the gearbox cover.
Replace plug and refill gearbox using 5 fl. oz. (15cl)
of SAE E.P. (Extreme Pressure) 90W oil.
• Inspect both transaxle cases after every 100
hours of operation for visible leaks. If a leak is de-
tected, the oil level should be checked through the
breather port on top of the transaxle. Using a clean
rod, measure the oil level by placing the rod in the fill
port and bottoming out the rod on the bottom of the
case. Remove the rod and measure the oil level on
the rod. It should measure 4 to 4-1/4 in. (10 to 10.75
cm) total depth of oil. DO NOT overfill.
With the deck removed, the tractor unit may need to
be tilted forward (resting on deck support arms) for
positioning purposes, to add oil into the PTO gear-
box.
Steering Linkage and PTO Linkage Lubrication
The steering and PTO linkage are located at the rear
of the tractor below the body. The grease and oil
points should be lubricated every 25 hours.
CAUTION
Do not leave the mower in this position for
an extended period of time to prevent oil
from draining into the heads and causing
possible engine damage.
Rear of Tractor
PTO Linkage
Lubrication Points
PTO Gearbox
Fill Plug
Rear of Tractor
Steering Linkage
Lubrication Points
Steering and PTO Linkage Location
(view from underside of tractor)
PTO Gearbox
Drain Plug
Tractor PTO Gearbox Location
(view from underside of tractor)
33
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Maintenance Instructions
LUBRICATION
Ident
No.
Lubrication
Type
No.
Places
Ident
No.
Lubrication
No.
Places
Location
Location
Type
13 PTO Clutch Lever Pivot
14 Parking Brake Pivot
Grease
Oil
Oil***
Grease
Grease
3
1
1
2
Deck Caster Wheel Fork Pivot Grease
2
2
Deck Caster Wheel Bearing
Grease
15 Engine Oil
1
2
2
3
Tee Gearbox, Deck
Oil*
1
16 Steering Control Linkage
17 Tail Wheel Fork Pivot &
Wheel Bearing (not shown)
18 Clutch Actuator Push Rod
19 Deck Support Pivot Arm
4
5
6
Blade Drive Gearbox
PTO Shaft Guard Hinge
Oil*
Oil
2
1
1
Universal Joint Shaft &
Tube Assembly
Grease**
Grease
Grease
1
2
7
8
9
Pivot Assembly, Tilt-Up Deck
Deck Support Arm Socket
Universal Joint Quick Connect Grease
Spline (Grease Slide Area)
Grease
Grease
4
2
1
*
Gearboxes are permanently lubricated and
sealed requiring no scheduled lubrication.
Oil level should be checked only when an oil
leak is noted. Refer to Mower Deck Gear-
box Lubrication in this section.
10 Tilt-Up Roller Wheel
11 Ground Drive Belt Idler Arm
Oil
Grease
2
1
(not visible - access side of body)
12 Throttle/Choke Control Pivot
(on Control Panel) & Cable End
Oil
1
** Lubricate every eight (8) hours.
*** Refer to Engine Oil in this section.
NOTE: DSD42 Deck is shown for reference. For oth-
er Deck Lubrication Points, Refer to Deck and
Carrier Frame Illustrated Parts Manual.
34
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Maintenance Instructions
LUBRICATION
1
1
2
3
2
4
5
6
8
7
9
4
7
7
10
8
7
10
19
12
19
11
14
16
18
16
13
15
13
13
17
12
Chassis and Deck Lubrication Points
35
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Maintenance Instructions
CLEANING
CLEANING
Engine Cooling Fins
Engine Air Cleaner System
Every 100 hours, check and clean the cooling fins
and inside of engine shrouds to remove grass, chaff
or dirt clogging the cooling system and causing
overheating. When cleaning, remove the recoil
starter and the fan housing.
There are two components in the engine air cleaner
system: a foam prefilter element and a paper ele-
ment. Each component is checked, cleaned and
maintained on a different schedule based on the fil-
tering action required. Each component is serviced
as follows:
Grass Buildup in Mower Housing
DANGER
Paper
Foam
Before raising or removing the mower
deck for cleaning, stop the engine, re-
move the ignition key, and disconnect the
spark plug wires.
Element
Element
1. Raise the deck lock lever handle on each side
of the carrier frame and pull out to release car-
rier frame for tilting action.
2. Using the carrier frame lift handle, raise deck to
the TILT-UP position and insert the deck hook
into the tilt-up latch on the tractor body.
Engine Air Cleaner Foam and Paper Element
Foam Precleaner Element
DANGER
Clean and inspect the foam element after every 25
hours of service and replace the element yearly (or
when dirty or damaged). Wash the element in de-
tergent and water; and dry it thoroughly. More fre-
quent cleaning may be required when operating in
extremely dusty conditions.
Do not operate the mower with deck in tilt-
up position. Do not move the tractor with
the deck in the tilt-up position.
3. Clean grass buildup underneath the deck using
a pressure washer (and scraper if required).
Paper Precleaner Element
Inspect the paper element after every 50 hours of
service and replace the element every 200 hours
(or when dirty or damaged). More frequent replace-
ment may be required when operating in extremely
dusty conditions.
NOTE: While some degree of material buildup
in the mower deck housing can be tolerated, a
point is finally reached where cutting quality
deteriorates and clogging begins to occur
because of too much buildup on the baffling and
housing.
Be careful to reinstall the foam element and the pa-
per element into the air cleaner case. Carefully re-
install the air cleaner cover into the air cleaner body
by putting the hooks on the bottom of the air cleaner
cover into the air cleaner body bottom.
4. Lower the deck to the normal operating position
and reengage the deck lock levers.
CAUTION
Engine Cooling System
Air Intake Screen
NEVER operate the cutter blades with the
deck in the raised position.
Before each use, check that the air intake (rotary)
screen is free from grass and debris and clean if
necessary.
36
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CHECKING/SERVICING
Maintenance Instructions
CHECKING/SERVICING
2. Raise the deck and secure it in the TILT-UP po-
sition. Refer to CLEANING the Grass Buildup
in Mower Housing in this section for deck rais-
ing instructions.
DANGER
To prevent accidental starting of the en-
gine when servicing or adjusting the ma-
chine, remove the key from the ignition
switch and disconnect the spark plug
wires.
DANGER
NEVER operate cutter blades with the
deck in the raised position.
Battery
3. Check the blades for straightness by marking
the blade tip position inside the deck housing,
and then rotating the opposite end of the blade
to the same position and comparing. If the dif-
ference in blade tip track is more than 1/8 in.
(3 mm), the blade is bent and should be re-
placed.
Charging the Battery
Limit initial charging current to 1000mA. Charge un-
til battery voltage (under charge) reaches 14.40 to
14.70 volts at 68°F (20°C). Hold at 14.40 to 14.70
volts until current drops to approximately 50mA.
Battery is fully charged under these conditions, and
charger should be disconnected.
WARNING
NOTE: Due to the self-discharge characteristics of
this type of battery, it is imperative that it be charged
after 6-9 months of storage, otherwise permanent
loss of capacity might occur as a result of sulfation.
DO NOT try to straighten a blade that is
bent. NEVER weld a broken or cracked
blade. ALWAYS replace with a new blade
to assure safety.
Tire Pressure
4. If the blade cutting edge is dull or nicked, it
should be sharpened. Remove blades for
sharpening by grasping the end of the blade us-
ing a rag or a thick, padded glove, while loosen-
ing and removing the nut, lock washer, and flat
washer that mounts the blade.
Inflate tires to pressures shown below:
Deck Caster Wheel = 20 PSI (137 kPa)
Drive = 15 PSI (103 kPa)
Rear = 20 PSI (137 kPa)
5. Grind cutting edge at the same bevel as the
original. Sharpen only the top of the cutting
edge to maintain sharpness.
Sharpen Mower Blades
Check mower blade(s) for straightness, sharp-
ness, condition of the cutting edge, and balance
every 10 hours of operation (or more often when
mowing abrasive type grass or operating on sandy
soils). Replace blades if worn, bent, cracked, or
otherwise damaged (refer to REPLACING/RE-
PAIRING the Mower Blades in this section). Use
the following procedure to check and sharpen
blades:
NOTE: Blades can be sharpened with an elec-
tric blade sharpener, conventional electric grind-
er, or a hand file.
CAUTION
ALWAYS wear eye protection and gloves
when sharpening a blade.
NOTE: Keep blades sharp - cutting with dull
blades not only yields a poor mowing job but
slows the cutting speed of the mower and caus-
es extra wear on the engine and blade drive by
pulling hard.
1. Stop the engine, remove ignition key, and dis-
connect the spark plug wires before raising the
mower deck to service blades.
37
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Maintenance Instructions
CHECKING/SERVICING
Mower Deck Gearbox Oil Seals
Intersection
Wear Area
Sharpen at
Original 30° Angle
The mower deck gearbox seals and gaskets should
be inspected every 25 hours for evidence of oil
leaking; particularly the lower oil seal on the blade
drive gearbox. This seal is protected by the trash
guard on the blade hub and seal protector plate on
the housing, but is still vulnerable to seal damage
due to operating in an adverse environment. The
mower blade must be removed for inspection of the
seal, so it is recommended to inspect the gearbox
seals when blades are removed for sharpening.
If an oil leak is noted, the seal should be replaced
and the gearbox assembly relubricated. Refer to
Mower Deck Gearbox Lubrication in this section.
Spark Plugs
Wing
Tip
30°
Do Not Grind or
Sharpen on Underside
Mower Blade Profile For Sharpening
6. Check blade balance by positioning the blade
horizontally on a blade balancer or use a nail or
shaft through the center hole. If either end of the
blade rotates downward, grind (remove) metal
on that end until the blade will balance. The
blade is properly balanced when neither end
drops. Balance of a blade is generally main-
tained by removing an equal amount of material
from each end of the blade when sharpening.
Every 100 hours, remove the spark plugs, inspect,
clean, and reset the gap (or replace with new
plugs). Clean spark plugs with a wire brush. If the
electrodes are burned short or pitted, replace the
plug (refer to Specifications for the proper type of
replacement plug). Check the spark plug gap with a
wire-type feeler gauge and set the gap to 0.030 in.
(0.75 mm). Reinstall and tighten to 16 ft-lb (22 N·m).
Fuel Lines and Clamps
Every year, inspect the fuel supply line from the tank
to engine for deterioration or damage. Also, inspect
the fuel line clamps for tightness. Good preventive
maintenance calls for complete replacement of fuel
lines and clamps every two (2) years.
Blade Balancer
Blade Balanced on Magnetic
Wall-Mounted Balancer
7. Mount the blade with wing tips pointing up into
the housing. Reinstall the blade, washer, lock
washer, and nut. Tighten the nut to 60 ft-lb
(81.3 N⋅m).
Drive Belts
Look under the body and inspect the condition of the
two (2) belts every 25 hours of operation - engine
PTO drive, and ground drive belt. If the belts show
signs of cracking or deteriorating, the belts
should be replaced. Refer to REPLACING/RE-
PAIRING the Drive Belts in this section.
38
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CHECKING/SERVICING
Maintenance Instructions
Blade Brake Action
WARNING
It is important to check and maintain blade
brake action for safe operation of the ma-
chine.
Check the function of the cutter blade brake by en-
gaging the blade clutch (PTO), operating the engine
at full throttle, then disengaging the clutch and mea-
suring how quickly the blades stop. Watch the rota-
tion of the blade drive shaft as a visual indication that
movement has stopped. If the brake is working
properly, all rotation will stop five (5) seconds af-
ter disengagement of the clutch. If the brake sys-
tem malfunctions - blades do not stop in five (5)
seconds - adjust or repair the brake before operating
the mower. Refer to ADJUSTMENTS of Blade
Clutch (PTO) in this section.
PTO Gearbox
Brake Band Adjustment Nuts
on These Ends Should Be
Adjusted Out Evenly
Brake Band
(View with PTO Geabox Assembly Removed)
39
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REPLACING/REPAIRING
Maintenance Instructions
REPLACING/REPAIRING
PTO Drive Belt
1. Remove the two mounting bolts holding the
PTO belt guide in place and loosen the front
mounting bolts of PTO actuator assembly (as
shown). Remove belt guide. Remove nuts on
the front of brake band and remove.
DANGER
To prevent accidental starting of the en-
gine when replacing parts or repairing the
machine, remove the key from the ignition
switch and disconnect the spark plug
wires.
2. Unhook spring and unbolt actuator clevis at-
tached to the PTO gearbox assembly. Pull
gearbox assembly to the rear and remove belt.
3. Install the PTO drive belt by reversing removal
procedure.
IMPORTANT: ALWAYS use genuine factory re-
placement parts. Substitute parts CAN result in
product malfunction and possible injury to the oper-
ator and/or others.
Ground Drive Belt
NOTE: The PTO drive belt must be removed for re-
moval of the ground drive belt.
Drive Belts
There are two (2) individual belts:
1. Relax the belt by releasing spring tension from
the ground drive belt idler arm.
• Ground Drive Belt
• PTO Drive Belt (3 Groove Power Band)
2. Slide the belt over both transaxle pulleys and
feed it toward the back of the mower.
The belts may be removed and replaced using the
following procedures:
3. Install ground drive belt by reversing removal
procedure.
Ground Drive
Idler Pulley
Ground
Drive Belt
PTO
Drive Belt
Remove Spring and
Linkage
Remove Mounting Bolts and
Loosen Front Bolts
(not shown)
PTO Drive and Ground Drive Belt Removal
(view from underside rear of tractor)
40
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Maintenance Instructions
REPLACING/REPAIRING
Blade Overload Shear Bolts
When the PTO pin has sheared, use the following
procedure to replace it:
NOTE: Shear bolts are not used on the DSD52
1. Loosen the two bolts securing the PTO shaft
guard on the deck; lift the guard off. (Holes in
guard are slotted for easy removal.)
mower deck.
The cutting blade is keyed to the blade hub by two
(2) shear bolts (10-24 x 5/8 in. stainless steel ma-
chine screws). These bolts are designed to shear
and protect the blade drive gearbox from damage if
the blade encounters a shock load.
2. Rotate U-joint on shaft to align the shear pin
hole with the hole (and shear pin fragment) in
the shaft. Use a punch to drive the remaining
portion of the old shear pin out.
3. Install new shear pin and secure with cotter pin.
Shear Pin
Split Spring Pin
Cutting Blade
Shear Bolts
U-Joint
Tube Assembly
U-Joint
Shaft Assembly
Cotter Pin
Cutting Blade Shear Bolts
PTO Shear Pin
NOTE: Tightening the 5/8-18 blade mounting nut
to 60 ft-lb (81.3 N⋅m) is also important for proper
shock load protection. It is important to not over-
tighten the mounting nut since this defeats (over-
rides) the function of the shear bolts.
IMPORTANT: Use only Walker P/N 8067-13
shear pins for replacement to provide proper
shock protection -- these pins are hardened to
shear under a specific amount of load.
If these bolts shear, remove the blade and install new
bolts. Refer to CHECKING/SERVICING in this sec-
tion for Sharpen Mower Blades which describes the
blade removal and installation procedure.
4. Reinstall the PTO shaft guard.
Before operating the deck, inspect the blade over-
load shear bolts and also check blade timing (on
gear driven decks) by moving blades through one (1)
complete revolution. Make sure blade tips pass
clear of each other. If timing is incorrect, refer to
Mower Deck Gearbox Replacement in this section.
After reinstalling the blade, check blade timing by
moving blades through one (1) complete revolu-
tion. Make sure blade tips pass clear of each other.
If timing is incorrect, refer to Mower Deck Gearbox
Replacement in this section.
Mower Blades
PTO Shear Pin
Mower blades are removed and remounted as de-
scribed in Sharpen Mower Blades instructions.
During the course of sharpening and inspecting
mower blades, if there are any of the following
conditions of wear or damage, blades should be
replaced for reasons of safety and performance of
the machine:
The PTO drive shaft connection to the deck gearbox
has a shear pin to provide shock load protection to
the mower deck drive. This system provides prima-
ry shock protection in case of blade impact and will
normally shear before the individual shear bolts on
the blade hub.
41
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Maintenance Instructions
REPLACING/REPAIRING
• An excessive amount of the flat section of the
blade has been ground away (removed) when the
blade is sharpened. Replace the blade when less
than a 3/4 in. (19 mm) flat section remains at the
blade tip.
CAUTION
ALWAYS use genuine factory replacement
parts. Substitute parts CAN result in prod-
uct malfunction and possible injury to the
operator.
• Examine ends of the blade carefully, especially
the intersection where the flat section of the blade
turns up to form the “wing tip” (refer to Mower Blade
Profile for Sharpening illustration in Sharpen
Mower Blades instructions). Since sand and abra-
sive material can wear metal away in this area, the
blade should be replaced when metal thickness
has worn to 1/16 in. (1.6 mm) or less.
Mower Deck Gearbox Replacement
NOTE: Deck gearbox(es) may be changed with
the deck mounted on the tractor. However, the deck
may be removed from the tractor making the overall
job of removing the gearbox assembly easier. Refer
to Deck Installation in Assembly Instructions and re-
verse the procedure to remove the deck.
DANGER
To replace the mower deck gearbox(es), use the fol-
lowing procedure:
When blades are operated over sandy
soil, and if blades are allowed to wear, a
“slot” may be worn into the wing tip of
blade. Eventually a piece of the blade may
break off creating a serious potential for
injury or damage.
1. Remove mower blades. Refer to procedure in
Sharpen Mower Blade instructions.
2. Remove gearbox cover (two machine screws)
and PTO shaft guard (two 1/4-20 bolts).
3. Remove two (2) 3/8-16 mounting bolts from
each blade drive gearbox and lift the entire
gearbox assembly from the deck (including
PTO drive shaft).
• Check the blades for straightness by marking
blade tip position inside the deck housing and then
rotating the opposite end of the blade to the same
position and comparing. If the difference in blade tip
track is more than 1/8 in. (3 mm), the blade is bent
and should be replaced.
4. Remove the screws securing the cover plates
on the gearboxes and remove the covers. Re-
move all covers to be sure oil is completely
drained from all gearboxes.
• Inspect the blade surface, especially in formed
areas, for cracks. Replace the blade if any cracks
are found.
NOTE: With oil flow throughout the unitized
gear drive assembly; if one gearbox has internal
damage or excessive wear, the remaining gear-
boxes and connector tubes should be complete-
ly disassembled and thoroughly flushed out with
solvent before reassembly.
WARNING
DO NOT try to straighten a blade that is
bent. NEVER weld a broken or cracked
blade. ALWAYS replace with a new blade
to assure safety.
5. Drain and properly dispose of oil.
6. Remove the four (4) bolts mounting the gearbox
to the connector tube and slide the gearbox off
the splined drive shaft coupling.
Reinstall the blades following procedure from
Sharpen Mower Blades instructions. If blades are
replaced, always use Walker original equipment
blades to ensure safety and optimum performance.
The quality and performance of replacement
blades offered by other manufacturers cannot be
guaranteed, they could be dangerous.
42
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REPLACING/REPAIRING
ADJUSTMENTS
Maintenance Instructions
7. Install the new gearbox on the spline coupling of
the drive shaft. Establish correct timing of the
blade drive gearboxes by setting flats on the
output shaft at 90 degrees when connecting the
gearbox(es) to the spline coupling. Make sure
the timing is correct before proceeding with as-
sembly.
ADJUSTMENTS
DANGER
If the engine must be running to perform
a maintenance adjustment, keep hands,
feet, and clothing from moving parts. DO
NOT wear jewelry or loose clothing.
8. Reinstall the four (4) bolts mounting the gear-
box to the connector tube but do not tighten
them at this time; leave connector tube bolts fin-
ger-tight.
Blade Clutch (PTO)
Clutch Disengagement/Brake Action
9. Position the gear drive assembly on the deck
and install the 3/8-16 bolts mounting the entire
assembly. Leave the mount bolts finger-tight.
WARNING
10. Torque all the connector tube bolts to 80 in-lb
It is important to check and maintain blade
brake action for safe operation of the ma-
chine.
(9 N⋅m); then tighten the deck mount bolts.
NOTE: This fastener tightening sequence
aligns the gearbox assembly with the deck hous-
ing and eliminates the possibility of mounting the
unitized assembly in a bind.
The blade brake is activated by linkage to the clutch
pulley mechanism. The brake is designed to stop
the blades within five (5) seconds after disengaging
the clutch.
11. Fill gearbox assembly with oil. Refer to Mower
Deck Gearbox Lubrication in this section for
instructions.
Use the following procedure to check and adjust
clutch disengagement and brake action:
12. Reassemble remaining items onto deck to com-
plete installation. After installing blades, check
that the blade timing is correct by moving the
blades through one (1) complete revolution.
Make sure blade tips pass clear of each other.
1. Evenly adjust the nuts on the end of the brake
band to achieve 1/4" of travel of the PTO gear-
box assembly between the engaged and the
disengaged position (refer to PTO Gearbox En-
gagement Photo).
Assembly Should
Move 1/4" Between
Engaged and
Disengaged
Position
Brake Band
Adjustment Nuts
Located at Front
of Assembly
Mower Deck Gearboxes
(Shown with Gearbox Cover Removed for Clarity)
(Not Visible)
PTO Gearbox Engagement
(view from underside of tractor)
43
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Maintenance Instructions
ADJUSTMENTS
2. Use the adjustment nut on the PTO clutch actu-
ator assembly (refer to PTO Clutch Linkage
Adjustment photo) to set the tension applied
by the PTO clutch lever. The adjustment nut is
initially set to achieve an approximate measure-
ment of 2-3/4" between the jam nut and the
knuckle joint. As the belt and pulleys wear, it will
be necessary to tighten the adjustment nut in
order to prevent belt slippage--this adjustment
is the same in the Engaged and Disengaged
positions.
NOTE: It would not be unusual for a new machine,
after initial 5 or 10 hours of operation, to begin to not
travel straight (this is due to the break-in of the trans-
missions). In this case, proceed to Tracking Adjust-
ment - Step 4.
IMPORTANT: The following adjustment proce-
dures are sequential. Check and adjust each func-
tion in the order given.
FSC Actuator Stop Adjustment - Step 1
1. Loosen jam nut and back off the adjustment bolt
located in the steering pivot rod (as shown).
Do not overtighten the adjustment nut. This may
cause damage to the clutch linkage and the PTO
belt.
2. Turn the ignition key to the ON position and tog-
gle the FSC switch to the Neutral position (fully
retracted).
Adjustment Nut
3. Tighten the adjustment bolt until it contacts the
chassis and turn an additional 1/2 turn. Tighten
jam nut.
Transmission Lockout
Rod (RH)
Spring Length
Should be 2-3/4"
Steering Control Rod
PTO Clutch Linkage Adjustment
Transmission Control
Rear of
Tractor
Jam Nut
Adjustment Nut
DANGER
FSC Actuator Stop Adjustment
(View from underside of tractor)
If the engine must be running to perform
a maintenance adjustment, keep hands,
feet, and clothing from moving parts. DO
NOT wear jewelry or loose clothing.
IMPORTANT: The proper adjustment of the trans-
mission control stops is essential for efficient oper-
ation and life of the transmission. These stops are
properly adjusted at the factory and should only re-
quire readjustment if the transmission or related
control linkage is removed or changed.
44
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Maintenance Instructions
ADJUSTMENTS
Control Arm Rod Adjustment - Step 2
NOTE: If the 1/8" to 3/16" gap between speed
control actuator and speed control stop can not
be maintained as neutral adjustments are made,
it will be necessary to adjust the length of the
control rod (Step 2). Increasing the length of the
control rod, decreases the gap. Shortening the
control rod, increases the gap.
1. For both control arm rods, loosen jam nut on
ball joint end of control arm rod and adjust to ob-
tain a 1-1/4" measurement between jam nuts
(4-1/2" measurement between centers of ball
joints). Tighten jam nuts.
1/8" to
3/16" Gap
Adjust Bolt to
Achieve 1/8" to
3/16" Gap
4-1/2"
1-1/4"
Speed Control Actuator Adjustment (LH)
Tracking Adjustment - Step 4
DANGER
If the engine must be running to perform
a maintenance adjustment, keep hands,
feet, and clothing from moving parts. DO
NOT wear jewelry or loose clothing.
Control Arm Rod Adjustment - Both Transaxles
(view from underside of tractor)
1. Start engine and set the FSC switch to a normal
walking speed. Check for equal drive speed for
both wheels.
Neutral Adjustment - Step 3
1. Turn the ignition key to the ON position and tog-
gle the FSC switch to the Neutral position (fully
retracted).
2. Tighten adjustment bolt in speed control actua-
tor to achieve approximately an 1/8" to 3/16"
gap between speed control actuator and speed
control stop.
3. Make identical adjustment to the other side of
tractor.
4. Start engine. If one or both drive wheels creep
forward, turn corresponding adjustment bolt in
(toward rear of mower). If drive wheels creep
backwards, turn corresponding adjustment bolt
out (toward front of mower).
45
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Maintenance Instructions
ADJUSTMENTS
2. If one wheel is moving too fast, bring the mower
back into NEUTRAL (using the FSC switch) and
slightly tighten the adjustment bolt on the speed
control actuator on the side that is moving faster.
2. Reattach handlebar and control arms in corre-
sponding holes.
Handle Bar
Attachment to Body
Tighten Bolt to
Slow Down
Travel Speed
Adjustable Steering
Control Rod
Handlebar Height Adjustment
Tracking Adjustment
Control Handle (Pistol Grip) Adjustment - Step 5
1. Loosen jam nut and adjust upper ball joint on
upper lever linkage to achieve a 1" gap between
control handle and pistol grip.
Jam Nut
2. Make identical adjustment to the other side of
handle. It may be necessary to adjust both
wheels in order to achieve tracking and neutral.
Set Screw
A
c
h
i
e
v
Tilt-Up Deck Adjustable Stop
Tilt-Up Deck Adjustable Stop
e
1
"
G
a
p
H
e
r
e
1
"
When the carrier frame hinge joint is properly adjust-
ed, the deck lock levers should move in and out of
the engaged and disengaged positions freely. All
four hitch pins used for height adjustment should sit
flush on the washers above the deck pin bushing.
On a level surface, if any pin is sticking up (likely the
front pins), tighten the opposite side or loosen the
existing side to lower the pin. Adjustments are made
by loosening the jam nut and tightening or loosening
the set screws on the Deck Mount Pivot Brackets.
Retighten the jam nut when the adjustment is com-
plete.
Use Ball Joint
End to Adjust
Pistol Grip Position Adjustment
Handlebar Height Adjustment
The height of the handlebar position for operators
can be adjusted (taller for taller operators, shorter for
shorter operators) using the following steps:
1. Unbolt the handlebar connection at the body on
both sides. Unbolt the steering control arms.
46
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Maintenance Instructions
ADJUSTMENTS
Carburetor
CAUTION
DO NOT change the engine governor set-
tings or overspeed the engine. The gov-
ernor has been factory set for maximum
safe engine operating speed.
Carburetor adjustments are required to compensate
for differences in altitude, temperature, and fuel.
Once the carburetor has been set, no further adjust-
ments should be required. However, if the engine
exhibits any of the following symptoms, the carbure-
tor adjustment should be checked by an authorized
Kawasaki engine dealer: black, sooty exhaust
smoke, lack of power, engine miss or backfire, hard
to start, rough running or idle.
47
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WALKER MODEL MW
Beginning S/N 2004-68081
RED/YEL
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S1 = START CIRCUIT
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Operator’s Notes
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LIMITED WARRANTY
FOR
WALKER
COMMERCIAL RIDER MOWER
1.
WHAT THIS WARRANTY COVERS, AND FOR HOW LONG:
Walker Manufacturing company will, at its option, repair or replace, without charge, any part covered by this warranty which
is found to be defective in material and/or workmanship within one (1) year after date of sale to the original retail purchaser
unless the product is used for rental purposes, in which case this warranty is limited to ninety (90) days. At Walker’s
request, customer will make the defective part available for inspection by Walker and/or return the defective part to Walker,
transportation charges prepaid. All parts and components of the Walker Mower are covered by this warranty except the
following components which are warranted separately by their respective manufacturers:
Kawasaki Engine
HydroGear Transaxles
Peerless Gearboxes
Battery
Tires
The available 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.
2.
WHAT THIS WARRANTY DOES NOT COVER:
A.
B.
This warranty does not cover defects caused by depreciation or damage caused by normal wear, accidents, improper
maintenance, improper use or abuse of the product, alterations, or failure to follow the instructions contained in the
Owner’s Manual for operation and maintenance.
The customer shall pay any charges for making service calls and/or for transporting the mower to and from the place
where the inspection and/or warranty work is performed.
3.
4.
HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:
Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Walker Man-
ufacturing Company, 5925 East Harmony Road, Ft. Collins, CO 80528. Proof of the date of purchase may be required to
verify warranty coverage.
WARRANTY LIMITATION:
A.
THERE IS NO OTHER EXPRESS WARRANTY. ANY WARRANTY THAT MAY BE IMPLIED FROM THIS
PURCHASE INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY
LIMITED TO THE DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL
IMPLIED WARRANTIES ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty
lasts, so the above limitations may not apply to you.
B.
WALKER WILL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, OR SPECIAL DAMAGES AND/OR
EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not
apply to you.
C. Only the warranty expressed in this limited warranty shall apply and no dealer, distributor, or individual is authorized
to amend, modify, or extend this warranty in any way. Accordingly, additional statements such as dealer advertising
or presentations, whether oral or written, do not constitute warranties by Walker, and should not be relied upon.
D. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
63
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WALKER MFG. CO. • 5925 E. HARMONY ROAD, FORT COLLINS, CO 80528 • (970) 221-5614
FORM NO. 110103
PRINTED IN USA
©2004 WALKER MFG. CO
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