Walker R21 Operator's Manual

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Walker R21 Operator's Manual | Manualzz

Operator’s Manual

Safety, Assembly, Operating, and Maintenance Instructions

Please Read and Save These Instructions

For Safety, Read All Safety and Operation

Instructions Prior to Operating Machine

Beginning S/N: 178455

P/N: 1000-8

Foreword

Thank you . . .for purchasing a Walker mower. Every effort has been made to provide you with the most reliable mower on the market, and we are sure you will be among our many satisfied customers. If for any reason this product does not perform to your expectations, please contact your local dealer. Every customer is important to us. Your satisfaction is our goal.

Please . . .read this manual thoroughly! This manual is to be used in conjunction with the engine manufacturer’s manual for the specific engine on the mower model you have purchased. Be fore you operate your new mower, please read this entire manual. Some of the information is crucial for proper operation and maintenance of this mower - it will help protect your investment and ensure that the mower performs to your satisfaction. Some of the information is important to your safety, and must be read and understood to help prevent possible injury to the opera tor or others. If anything in this manual is confusing or hard to understand, please contact your local authorized dealer or call our service department, at (970) 221-5614, for clarification before operating or servicing this mower.

This manual covers Model R with the Kohler KT620 (21 HP) Gasoline Engine.

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

Where they are shown removed in this manual, it is for illustration purposes only. Do not operate this machine unless all shields and guards are in place.

Specifications given are based on the latest information available at the time this manual was produced for a tractor with standard equipment. Optional equipment is available and may affect the standard specifications listed.

Walker Mfg. Co. is continually striving to improve the design and performance of its products.

We reserve the right to make changes in specifications and design without thereby incurring any obligation relative to previously manufactured products.

Sincerely,

WALKER MANUFACTURING COMPANY

Bob Walker, Chairman

R21

General Information 1

Highlighted Information ..........................................

1

Glossary ................................................................

2

Servicing of Engine and Transaxle Components ...

2

Identifying Number Locations ................................3

Tractor and Deck Identifiers ...........................................3

Specifications ........................................................

4

Component Identification .......................................

7

Safety Instructions 10

Safety Before Operating ......................................

10

Safety During Operation ......................................

11

Safety During Maintenance .................................

13

Safety, Control, and Instruction Decals ...............

14

Operating Instructions 19

Operator Controls ................................................

19

Ignition Switch ..............................................................

19

Engine Throttle .............................................................

20

Steering Levers ............................................................

20

Forward Speed Control (FSC) ......................................

22

Blade Clutch Switch (PTO) ...........................................

22

Parking Brake ...............................................................

22

Circuit Breaker ..............................................................

22

Seat Panel Latch ..........................................................

23

Hourmeter .....................................................................

23

Transaxle Lockout Arms ...............................................

23

Pre-Operation Checklist ......................................

24

Starting the Engine ..............................................

25

Adjusting Ground Speed and Steering ................

25

Recommendations for Getting Started ................

27

Engaging the Blades ...........................................

27

Stopping the Machine ..........................................

28

Adjusting the Cutting Height ................................

29

Deck Tilt-Up Position ...........................................

29

Recommendations for Mowing ............................

30

Transaxle Lockout ...............................................

32

Recommendations for Towing .............................33

Recommendations for Tilt-up Deck Operation and

Transport .............................................................33

Maintenance 34

R21 Maintenance Schedule Chart .......................

34

Table of Contents

Check Engine Crankcase Oil ...............................

35

Check/Clean Engine Air Cooling System ............

36

Clean Grass Buildup Under Deck ........................

37

Inspect/Service Mower Blades ............................

37

Check Security of Air Filtration Components .......

39

Check Discharge Shield ......................................

39

Lubricate Grease Fittings and Oil Points .............

39

Check Tire Pressure ............................................

41

Check Drive Belts (Ground Drive, Blade) ............

41

Check Safety Switch System ...............................

41

Clean/Replace Engine Precleaner Air Filter ........

42

Replace Engine Air Filter .....................................

43

Change Engine Crankcase Oil and Filter ............

44

Clean Engine Cooling System .............................

45

Replace Fuel Filter ..............................................

46

Clean Transaxle Housing and Fans ....................

46

Check Drive Tire Mounting Nuts ..........................

47

Check Blade Brake Function ...............................

47

Replace Spark Plugs and Set Gap ......................

47

Check/Adjust Engine Valve Lash .........................

47

Check FSC Friction Lock .....................................

48

Check Transmission Control Settings ..................

48

Check Neutral-Park Position ........................................

48

Check Straight Ground Tracking ..................................

48

Check Fuel Lines and Clamps .............................

48

Clean Battery Terminals ......................................

49

Charge Battery ....................................................

49

Long-Term Storage Preparation ..........................

50

Mower Preparation for Storage ....................................

50

Engine Preparation for Storage ....................................

50

Restarting the Mower After Storage .............................

50

Service and Adjustments 51

Belt Replacement ................................................

51

Replacing the Blade Drive Belt (PTO) ..........................

52

Replacing the Ground Drive Belt ..................................

54

Deck Leveling ......................................................

57

Steering Handle Adjustment ................................

58

Forward Speed Control Friction Adjustment ........

58

Neutral Function Adjustment ...............................

59

Straight Tracking Adjustment ...............................

60

Maximum Forward Speed Adjustment .................

60

Table of Contents

Appendix: Assembly Instructions 61

Assembling the Tractor ........................................

61

Assembling the Deck ...........................................

62

Deck Caster Wheel Installation ....................................

62

Tilt-Up Roller Wheel Installation ...................................

62

Installing the Deck ...............................................

63

R21

General Information

In this section...

Highlighted Information ......................................................................

1

Glossary .............................................................................................

2

Identifying Number Locations .............................................................3

Specifications .....................................................................................

4

Component Identification ....................................................................

7

Highlighted Information

Throughout this guide you will find important infor mation labeled DANGER, WARNING, CAUTION,

IMPORTANT, and NOTE. Pay particular attention to the information provided for your safety and the safety and longevity of your equipment.

When you see the Safety Alert Symbol ( ), read, understand, and follow the instructions. Failure to comply with safety instructions may result in personal injury.

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

DANGER

An IMMEDIATE hazard that WILL result in se vere personal injury or DEATH, if warning is ignored and proper safety precautions are not taken.

WARNING

A POTENTIAL hazard that COULD result in severe personal injury or DEATH, if warning is ignored and proper safety precautions are not taken.

CAUTION

Possible hazards or unsafe practices that MAY result in MODERATE personal injury or prop erty damage, or machine damage, if warning is ignored and proper safety precautions are not taken.

IMPORTANT: Identifies mechanical information demanding special attention, since it deals with the possibility of damaging a part or parts of the machine.

NOTE: Identifies information worthy of special attention.

Walker Manufacturing cannot predict every po tentially dangerous situation. Therefore, items labeled as such in this manual do not cover all conceivable situations. Most accidents associated with the operation or maintenance of a Walker

Mower are caused by disregarding basic safety precautions or specific warnings. Such accidents, in most cases, can be prevented by being aware of the dangers present. Any person using pro cedures, tools, or control techniques not recom mended by Walker Manufacturing must take full responsibility for safety.

Walker Manufacturing recommends that any service requiring special training or tools be per formed by an authorized Walker Mower dealer.

1

General Information

Glossary

There are many terms that are either unique to this equipment or that are used as acronyms. The following terms and their definitions will help while using this manual:

● DECK is the mowing attachment mounted on the front of the tractor which includes the carrier frame, deck housing, belt or gear drive components, and cutter blades.

● FORWARD SPEED CONTROL (FSC) controls the maximum forward speed of the tractor, functions as a cruise control, and provides a

NEUTRAL-PARK function to stop the mower.

● GROUND DRIVE refers to the dual transaxles which drive the main wheels.

● LEFT HAND (LH) refers to the left-hand side of the tractor when the operator is seated fac ing forward in the tractor seat.

● 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 seated facing forward in the tractor seat.

● SIDE DISCHARGE (SD) discharges mowed material from the right side of the mower deck.

● STEERING LEVERS steer the tractor by con trolling the two transaxles.

● TRACTOR is the prime mover, including the engine, drivetrain, operator seat, and controls to operate the mower.

● TRANSAXLE transmits and controls power from the ground drive belt to the main drive wheel.

● TRANSAXLE LOCKOUT ARMS release the transaxles to permit freewheeling the tractor.

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The detailed servicing and repair of the engine and transaxles are not covered in this manual.

Only routine maintenance and general service instructions are provided. For the service of these components during the limited warranty period, it is important to find a local, authorized servicing agent of the component manufacturer. Any unauthorized work done on these components during the warranty period may void the warranty.

If you have any difficulty finding an authorized outlet or obtaining warranty service, please contact our

Service Department for assistance:

Walker Manufacturing Company

5925 E. Harmony Road

Fort Collins, CO 80528

1-970-221-5614 www.walker.com

Service manuals are available for each of these components from their respective manufacturers as follows:

Kohler Engines

Transaxles

Kohler Company

Kohler, WI 53044

800-544-2444 www.kohlerengines.com

Hydro-Gear

1411 South Hamilton St.

Sullivan, IL 61951

877-728-7410 www.hydro-gear.com

2

R21

Identifying Number Locations

The tractor serial number plate is affixed to the tractor chassis behind the seat. The mower deck serial number plate is affixed alongside the angle iron framing on the left beside the belt cover. The engine serial number is on right side of the engine.

Model and serial numbers are helpful when obtain ing replacement parts and maintenance assis tance. For ready reference, please record these numbers in the space provided.

Serial Number

Tractor Serial Number Location

Serial Number

General Information

Serial Number

Engine Serial Number Location

Tractor and Deck Identifiers

Tractor Model No. ______________________

Tractor Serial No. ______________________

Deck Serial No. ______________________

Engine Model No. ______________________

Engine Serial No. ______________________

Date of Purchase ______________________

Mower Deck Serial Number Location

3

General Information

Specifications

DIMENSIONS

Length in. (cm)

Tractor Wheel Base

Tractor with Tilted 42" Deck

Tractor with 42" Deck

Tractor with 48" Deck

Tractor with 54" Deck

Width in. (cm)

Tractor Only (Outside Tire)

Tractor with 42" Deck (with Dis charge Shield Raised)

Tractor with 48" Deck (with Dis charge Shield Raised)

Tractor with 54" Deck (with Dis charge Shield Raised)

Height in. (cm)

Tractor

Weight lb (kg)

Tractor Only

Tractor with 42" Deck

Tractor with 48" Deck

Tractor with 54" Deck

39 (99)

74 (188)

88 (224)

91 (231)

90 (229)

39 (99)

43 (109)

49 (124)

55 (140)

42 (107)

404 (183)

575 (261)

593 (269)

622 (282)

MOWER DECK

Available Cut Width

Cutting Height

Deck Suspension

42 to 54 in. (107 to 137 cm)

1.5 to 4 in. (4 to 10 cm) in 1/2 in. (1 cm) Increments

Independent Torsion-Flex Frame with Caster Wheels and

Counterweight Springs

FRAME/BODY CONSTRUCTION

Frame and Body

Deck

Seat

All Welded Unitized Steel Chassis, 14 Gauge Steel

11 Gauge Steel

Contour-Molded, with Nylon Backed Vinyl Cover and Integral

Foam Cushion

TIRE SIZE

Deck Caster Wheel

Drive

8 x 3.00-4 (Semi-Pneumatic)

18 x 8.50-10 (Pneumatic 4-Ply, Low-Profile)

4

R21

R21 General Information

Specifications

TIRE SIZE (Continued)

Tailwheel

TIRE PRESSURE PSI (KPA)

Drive

Tailwheel

ENGINE

Manufacturer/Model

Displacement cu. in. (cc)

Max. Power HP (kW)

Governed RPM

Max. Torque lb

·

ft (N

·

m)

Idle RPM

Spark Plug Type

Spark Plug Gap in. (mm)

Crankcase Capacity qt (L)

Crankcase Lubricant

(From Factory)

Oil Filter (From Factory)

Conventional Crankcase Lubricant

(Alternative Option)

Oil Filter (Alternative Option)

Fuel Tank Capacity gal (L)

Fuel

Cooling System

Air Cleaner

13 x 6.50-6 (Pneumatic 4-Ply)

15 (103)

20 (137)

Kohler KT620

40.3 (660)

21 (15.7) @ 3600 RPM

3600

35.9 (48.7)

1750

Champion ® type RC12YC (or equivalent)

.030 (0.76)

2.0 (1.9)

300 Hour, Kohler PRO ® Synthetic 10W-50 Kohler P/N 25 357 72-S

300 Hour, Kohler PRO ® Filter P/N 25 050 53-S

100 Hour, API SJ or Higher Grade Oil Only with 10W-30 Viscosity

Above 0° F (-18° C), or 5W-30 Viscosity Below 32° F (0° C)

200 Hour, Kohler Filter P/N 12-050-01-S

3 (11.4)

Regular Grade Unleaded Gasoline

(87 Octane Minimum, 10% Ethanol Maximum)

Air-Cooled

Engine Mounted (Kohler)

Kohler P/N 16 083 04-S (Filter), 16 083 05-S (Precleaner)

ELECTRICAL SYSTEM

Battery

Charging System

Charging Output

System Polarity

Ignition

12 Volt, 300 CCA (Interstate SP-35)

Flywheel Alternator

18 Amp DC (Regulated)

Negative Ground

Electronic Capacitive Discharge

5

General Information

Specifications

ELECTRICAL SYSTEM (Continued)

Starter

Interlock Switches

Circuit Breaker(s)

12 Volt Electric, Key and Solenoid Operated

Ignition Lockout by Seat Switch, Transmission Neutral,

Blade Clutch, Parking Brake, and Deck Arm Lock

Two Fuses (5A)

Auto Reset (30A)

BLADE DRIVE

PTO

Blade Drive Clutch and Brake

Single belt

Electric Clutch [Stops Blades within Five (5) Seconds of Disengage ment]

DRIVE BELTS

Ground Drive Belt

Blade Drive Belt

Walker P/N 1250

Walker P/N 1731 (48" Deck)

Walker P/N 1731-1 (42" Deck)

Walker P/N 1731-2 (54" Deck)

TRANSMISSION

Manufacturer/Model

Steering

Forward Speed Control

Service Brake

Parking Brake

Neutral

Final Drive

Transmission Cooling

Transmission Fluid

GROUND TRAVEL SPEED

Forward MPH (km/h)

Reverse MPH (km/h)

TOWING

Towing Capacity lb (kg)

Dual, Independent Hydro-Gear ® ZT-2200 EZT Integrated Transax les

Hand Lever Control / Individual Wheel

Precision Friction Lock Lever, Cruise Control, with

Neutral-Park Position

Dynamic Braking Through Transaxles

Mechanical Cog Lock for each Transaxle (Single Lever Control)

Transmission Release by Manual Dump Valve

Transaxle Direct to Drive Wheel

Cooling Fan Mounted on Drive Pulley

Factory Serviced and Sealed (No Maintenance)

0-6 (0-10) Infinitely Variable

0-6 (0-10) Infinitely Variable

250 (113) if equipped with a factory authorized tow hitch

NOTE: The manufacturer reserves the right to make changes in specifications shown herein at any time without notice or obligation. The specifications listed are for a standard configuration tractor, and may change with the addition of optional equipment.

R21

6

R21 General Information

Component Identification

This section identifies the main features of the R21. Control features are identified and explained in the sec tion “Operator Controls” on page 19.

Oil Dipstick and Fill

Muffler

Guard

Drive Belt Cover

Counterweight

Spring

Carrier

Frame

Footrest Lift

Latch

Deck Tilt Bar

Tilt Bar

Socket

FSC

Friction

Adjustment

Counterweight

Spring

Tilt-Up

Lock Hole

Side

Discharge

Shield Deck Lift

Handle

Tilt-Up

Link

Deck Belt

Cover

Deck

Caster Wheels

Front View and Right Side View

7

General Information

8

Deck Support

Pins

Footrests

Tilt-Up Link

LH Step /

Foot Guard

Tilt-Up Lock

Hole

Left Hand

Drive Wheel

LH

Transaxle

Tailpipe

Spark Plug

Access Hole

Tailwheel Fork and Wheel

Rear View and Left Side View

R21

R21 General Information

Negative (-)

Battery

Cable

PTO Belt

Tensioner Lever

Positive (+)

Battery

Cable

Ground Drive

Belt

30 Amp Circuit

Breaker (Not Visible)

Spark Plug

(Not Visible)

Muffler Brace

Engine Air

Cleaner

Muffler Guard

Seat Panel

5 Amp Fuses

(Two)

PTO Blade

Drive Belt

RH

Transaxle

Maximum Forward

Speed Adjustment

Screw

RH

Transaxle

Fan

Fuel Tank and Cap

Fuel Gauge

In-line

Fuel Filter

Spark Plug

(Not Visible)

Fuel Pump

Muffler Brace

Heat Shield /

Fender

Top View (Engine Compartment)

9

10

Safety Instructions

In This Section...

Safety Before Operating ...................................................................

10

Safety During Operation ...................................................................

11

Safety During Maintenance ..............................................................

13

Safety, Control, and Instruction Decals ............................................

14

The Walker Rider Lawnmower has been designed with many safety features to protect the opera tor from personal harm or injury. However, it is necessary for the operator to use safe operating procedures at all times.

If you have any questions concerning setup, oper ation, maintenance, or safety, please contact your authorized Walker Mower dealer or call Walker

Manufacturing Company at (970) 221-5614.

CAUTION

Failure to follow safety instructions contained in this manual may result in personal injury or damage to equipment or property.

Safety Before Operating

● Read and understand the contents of this

Operator’s Manual and the machines safety decals before starting and operating the machine.

Become thoroughly familiar with all machine controls and how to stop the machine and disengage the controls quickly. Replace ment Operator’s Manuals are available for download at https://www.walker.com.

● Never allow children to operate rider mower.

Do not allow adults to operate without proper instruction.

● Clear the area to be mowed of any foreign objects which may be picked up and thrown by cutter blades. Pick up all sticks, stones, wire, and any other debris.

● Do not mow with bystanders in the area.

Keep everyone, especially children and pets, a safe distance away from the area being mowed.

● Always wear substantial protective footwear. Do not operate the machine barefoot or wearing sandals, sneakers, tennis shoes, or similar lightweight footwear.

● Always wear adequate protective clothing and safety gear. Do not wear loose fitting clothing that could get caught in moving parts.

Do not operate this machine while wearing shorts; always wear long pants. Always wear safety goggles or safety glasses when operat ing this mower. Wearing safety shoes and a helmet is advisable and required by some local ordinances and insurance regulations.

● Operator hearing protection is recommended. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device, such as earmuffs or earplugs.

● Do not wear headphones or listen to music while mowing. Safe operation of the mower requires you to give full attention and to be able to hear clearly.

● Keep all protective shields and safety devices in place.

If a protective shield, safety device, or decal is damaged, unusable, or missing, repair or replace it before operating the machine.

● Do not operate the mower if you are fatigued, sick or under the influence of alcohol or drugs.

R21

● Operators of advanced age are more likely to be involved in a mowing related accident.

Please evaluate the abilities of each operator to make sure they can safely perform the duties required with running this machine.

● Do not operate the machine without the safety switches functioning properly.

These switches are designed to keep the operator safe. Regularly check to ensure the switches are operating as designed. This information is provided in the Maintenance section “Check Safety Switch System” on page 41. If a safety switch is not function ing properly, do not use the mower until it can be repaired by a Walker Dealer.

DANGER

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

● DO NOT fill fuel tank with the engine run ning.

● If the engine is hot, allow to cool before refueling.

● Use an approved fuel container.

● Fuel the mower outdoors.

● DO NOT smoke while refueling. Keep matches, cigarettes, cigars, pipes, open flames, or sparks away from the fuel tank and fuel container.

● Avoid spilling fuel; use a funnel or spout.

● DO NOT overfill the fuel tank; fill up to the bottom of the fill tube.

● 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.

Safety Instructions

WARNING

This product can expose you to chemicals in cluding Di-(2-ethylhexyl) phthalate which is known to the State of California to cause can cer, and Di-(2-ethylhexyl) phthalate, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

Safety During Operation

● Operate the mower only in daylight or in good artificial light with good visibility of the area being mowed.

● Sit on the seat when starting the engine and operating the machine.

Keep feet on the deck footrests at all times when the tractor is moving and/or mower blades are operating.

● Never operate the tractor without a deck or imple ment installed.

● For a beginning operator, learn to steer

(maneuver) the tractor with a slow engine speed before attempting any mowing operation. Be aware that, with the front mounted mower configuration, the back of the tractor swings to the outside during turns.

● For an emergency stop: remember the forward motion of the tractor can always be stopped by pulling the Forward Speed Control

(FSC) into the NEUTRAL-PARK position.

NOTE: The emergency stop procedure is ex actly the same procedure as used to normally stop and park the machine.

● In the event that you lose control of the machine (such as the transmission drive belt breaks during operation, and the machine starts to freewheel down a slope), you can maintain control by immediately (1) Releas ing the steering levers and simultaneously (2)

Moving the FSC to the NEUTRAL-PARK position. When the machine is stopped or moving slowly, engage the parking brake.

11

Safety Instructions

● Never attempt to disable or mow without the safety switches functioning properly.

These switches are designed to keep the operator safe. Regularly check to ensure the switches are operating as designed. This information is provided in the Maintenance section “Check Safety Switch System” on page 41. If a safety switch is not functioning properly, do not use the mower until it can be repaired by a Walker Dealer.

● Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and can be deadly.

● Do not carry passengers - maximum seating capacity is one (1) person.

● Watch for holes, rocks, and roots in the terrain and for other hidden hazards.

When mowing tall grass, mow higher than desired to expose any hidden obstacles. Then, clean the area and mow to the desired height.

● Avoid sudden starts or stops.

● Before backing the machine up, look to the rear to be sure no one is behind the machine.

Watch carefully for traffic when cross ing or working near roadways.

● When moving forward, do not suddenly put the tractor in reverse by rapidly pulling on the steering levers , especially when going downhill, as this can lift the tractor tail wheel off the ground and set up a bucking motion due to operator overcontrol. If bucking does occur, immediately stop the bucking action by pulling the Forward Speed Control (FSC) lever into the NEUTRAL-PARK position.

● Disengage the blade drive when transporting the machine across drives, sidewalks, etc.

● Never attempt to make any adjustments while the engine is running, except where specifically instructed to do so.

● Never raise the mower deck while blades are rotating.

R21

DANGER

Do not mow or dump grass within 5 feet (1.5 meters) of an embankment, retaining wall with drop off, drainage ditch, water, or other hazard.

● The maximum recommended slope operating angle is 15 degrees or 27% grade.

When operating the machine on a slope:

□ Reduce speed and use caution to start, stop, and maneuver.

□ Avoid sharp turns or sudden changes in direction to prevent tipping or loss of con trol of the machine.

□ Do not operate the machine on a slope greater than 15 degrees.

DANGER

Do not mow around overhanging tree branch es or bushes at the same height as the opera tor’s torso and head where inadvertent contact may cause injury.

● Never adjust cutting height with the engine running.

Before adjusting cutting height or servicing, disengage the blade clutch (PTO), engage parking brake, stop the engine, and remove the ignition key. Wait for all move ment to stop before getting off the seat.

NOTE: A blade brake should normally stop drive line rotation within five (5) seconds of disengaging the PTO clutch.

● Do not operate the mower with the grass deflector shield removed from the deck.

Keep the deflector shield in the lowest pos sible position when mowing.

● Do not move tractor with the deck in tilt-up position.

12

R21

● In case of a clogged or plugged mower deck:

1. Disengage the blade clutch (PTO), engage the parking brake, and turn the engine off and remove the ignition key before leaving the seat.

2. Listen to make sure all moving parts have stopped before attempting to lift and visu ally inspect the deck.

3. Never place hands under the deck. Use a stick or similar tool to remove clogged material.

● If the cutting blades strike a solid object or the machine begins to vibrate abnormally, immediately disengage the blade clutch

(PTO), stop the engine, and wait for all moving parts to stop. To prevent accidental starting, disconnect the spark plug wires. Thoroughly inspect the mower and repair any damage before restarting the engine and operating the mower. Make sure cutter blades are in good condition and blade bolts are torqued to 70 lb·ft (95 N·m).

● Do not touch the engine or muffler while the engine is running or immediately after stop ping the engine. These areas may be hot enough to cause serious burns.

● Do not stop or park in or near dry grasses or bushes when operating the mower.

The heat from the engine or muffler could ignite the dry material.

● When leaving the machine unattended, disen gage the blade clutch (PTO), engage parking brake, stop the engine, and remove the ignition key.

● When using a ramp to load or unload the mower, use extreme caution. Avoid sudden acceleration and do not exceed a 15 degree angle incline.

● Only use a full-width ramp which helps prevent the mower from tipping and reduces the risk of a wheel going off the ramp. Do not use an individual ramps for each side of the mower.

Safety Instructions

● When equipped with a factory authorized hitch kit, do not exceed recommended tow capacities. Do not tow with the PTO clutch or mower blades engaged, and do not allow people to ride in or on towed trailers.

● Use caution when towing on slopes, rough ter rain or when conditions limit traction.

Do not tow on slopes greater than 5 degrees (9%).

Safety During Maintenance

● To prevent accidental starting of the engine when servicing or adjusting the machine, remove the key from the ignition switch and disconnect the spark plug wires.

● Keep the engine free of grass, leaves, excessive grease, and dirt to reduce fire hazards.

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

● Perform only maintenance instructions described in this manual. Unauthorized main tenance operations or machine modifications may result in unsafe operating conditions.

● If the engine must be running to perform a main tenance adjustment, keep hands, feet, and clothing away from moving parts. Do not wear jewelry or loose clothing.

● Always use the proper engine service manual when working on the engine. Unauthor ized maintenance operations or modifications to the engine may result in unsafe operating conditions.

IMPORTANT: Altering the equipment or en gine in any manner which adversely affects its operation, perfor mance, durability, or use will

VOID the warranty and may cause hazardous conditions.

● Never attempt to disconnect any safety devices or defeat the purpose of these safety devices.

13

Safety Instructions

● Do not change the engine governor settings or overspeed the engine.

The gover nor has been factory-set for maximum-safe engine operating speed.

● Use genuine factory replacement parts.

Sub stitute parts may result in product malfunc tion and possible injury to the operator and/or others.

● Use care when charging the battery or per forming maintenance on the battery and electrical system:

□ Make sure the battery charger is un plugged before connecting or disconnect ing cables to the battery.

□ Charge the battery in a well-ventilated space, so gases produced while charging can dissipate.

□ Keep sparks, flames, and smoking materials away from the battery at all times. To avoid sparks, use care when removing bat tery cables from posts.

□ Disconnect both battery cables before un plugging any wiring connectors or making repairs on the electrical system.

IMPORTANT: Keep all applicable manuals immediately accessible to anyone who may operate or service this machine.

R21

Safety, control, and instruction decals are installed on the machine. They provide key information to assist the operator with safely using the machine.

WARNING

If any decals are missing, illegible, or dam aged, a replacement should be ordered and installed before operating the machine. The decal part numbers are provided below and in the Parts Manual.

Location: Between Steering Levers

Part Number: 1600-2

Pull Steering Levers back to control direction of tractor movement.

14

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1.

2.

Safety Instructions

Part Number: 8600-53 (Continued)

1. Warning – read Operator’s Manual before servicing or performing maintenance.

□ Engage parking brake.

□ Remove ignition key.

2. Warning – Crushing/dismemberment hazard of bystanders.

□ Do not carry passengers. Always stop machine if someone enters the area.

□ Always be aware of what is behind the machine before backing up. Do not mow in reverse unless absolutely necessary.

Always look down and behind before and while backing up.

3. Parking Brake –

Must be engaged to start the engine. Move the lever forward and to the right to engage.

Location: LH Fender

Part Number: 8600-53

3.

Location: Solenoid Guard

Part Number: 6895-103

Change engine oil and oil filter every 300 hours.

15

Safety Instructions

1.

2.

3.

4.

5.

Part Number: 8600-52 (Continued)

1. Warning – read Operator’s Manual before operating the machine.

2. Warning – wear eye and ear protection when operating the machine.

3. Warning – thrown object hazard.

Keep bystanders away from the machine when operating.

4. Warning – entanglement hazard.

Keep all guards in place while engine is running.

5. Forward Speed Control

Move lever forward to increase speed; back to stop.

6. Warning – roll-over hazard.

Do not operate on slopes greater than 15 degrees. Mow a safe distance of 5 feet (1.5 m) away from drop-offs or other hazards.

7. Throttle

Move lever forward to increase engine speed; back to idle.

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6.

Location: RH Fender

Part Number: 8600-52

7.

Location: Belt Tensioner Mount Assembly

Part Number 8600-66

Warning – pinch point under lever. Move lock right to disengage and release tensioner lever; lift tensioner lever to re-engage lock.

16

R21 Safety Instructions

Location: Deck Carrier Frame

Part Number: 8600-14

8600-14

Warning – do not operate the machine with the deck tilted up .

Location: Deck Discharge Shield

Part Number: 5848-3

Warning – thrown object hazard.

□ Always keep the discharge shield in the lowest position when operating.

□ Do not remove the discharge shield.

Location: Drive Belt Guard of Mower Deck

Part Number: 8600-55

Warning – entanglement and cutting/dis memberment hazards.

Keep away from pulleys, belts, and other components.

Location: Deck Carrier Frame

Warning

Part Number: 1600-3

– lock deck tilt-up hinge before operating the machine.

Location: Deck Carrier Frame

Part Number 8600-57

Warning – pinch point under the lever.

Location: Deck Belt Cover

Part Number: 1600-4

Warning – stop engine and remove ignition key before adjusting deck cutting height.

95

Location: Carrier Frame

Part Number: 8600-56

Tighten blade mounting bolt to 70 lb·ft

(95 N·m).

8600-5

Location: Rear Body Near Muffler Tailpipe

Part Number: 8600-5

Warning – hot surface, do not touch.

17

Safety Instructions

1.

2.

8600-28

Location: Each End of Mower Deck

Part Number: 8600-28

1. Warning – thrown object hazard.

□ Keep bystanders away from the ma chine when operating.

□ Clear lawn of debris before operating.

□ Keep any discharge deflector in place and in the lowest position.

2. Warning – rotating mower blades are a cut ting/dismemberment hazard to hands and feet.

□ Keep all body parts away from rotating mower blades.

□ Do not step on end of deck.

1.

2.

Location: Seat Panel (Underside)

Part Number: 1600-5

1. Blade Drive Belt routing

2. Ground Drive Belt routing

8600-5

4

8600-12

Location: Side of Engine

Part Number: 8600-12

Warning – carbon monoxide (CO) poisoning hazard.

□ CO emitted by a running engine can be deadly.

□ Do not operate indoors or in other en closed areas.

Location: Ignition Switch

Part Number: 8600-54

Ignition switch positions: “O” for OFF, “I” for

ON (RUN), and for START

Location: Chassis Crossmember

in Front of Engine

Part Number: 5855

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18

Operating Instructions

In This Section...

Operator Controls .............................................................................

19

Pre-Operation Checklist ...................................................................

24

Starting the Engine ...........................................................................

25

Adjusting Ground Speed and Steering .............................................

25

Engaging the Blades ........................................................................

27

Stopping the Machine .......................................................................

28

Adjusting the Cutting Height .............................................................

29

Deck Tilt-Up Position ........................................................................

29

Recommendations for Mowing .........................................................

30

Transaxle Lockout ............................................................................

32

Recommendations for Towing ..........................................................33

Recommendations for Tilt-up Deck Operation and Transport ..........33

Operator Controls

This section covers the location and function of the following operator controls.

● “Ignition Switch” on this page

● “Engine Throttle” on page 20

● “Steering Levers” on page 20

● “Forward Speed Control (FSC)” on page 22

● “Blade Clutch Switch (PTO)” on page 22

● “Parking Brake” on page 22

● “Circuit Breaker” on page 22

● “Seat Panel Latch” on page 23

● “Hourmeter” on page 23

● “Transaxle Lockout Arms” on page 23

CAUTION

Before operating the mower, become familiar with the location and function of all operator controls. Knowing the location, function, and operation of these controls is important for safe and efficient operation of the mower.

Ignition Switch

The ignition switch is located on the right front of the body and is used to start and stop the engine.

The switch has three positions:

● “O” is the OFF position

● “I” is the ON (RUN) position

● is the START position

When starting the engine, turn the key clockwise to the START position. Do not hold the key in this position longer than 10 seconds. If the engine does not start, return the key to the OFF position for at least 60 seconds before making a restart attempt.

19

Operating Instructions

Forward Speed

Control (FSC)

Seat Panel Latch

Throttle

Blade Clutch

Switch

Parking

Brake

Steering

Levers

Ignition

Switch

Hourmeter

20

Ignition Switch

IMPORTANT: Prolonged cranking can damage the starter motor and shorten battery life.

Release the key when the engine starts, and it will return to the ON (RUN) position. To stop the engine, rotate the key counterclockwise to the

OFF position.

Engine Throttle

The throttle control lever (red knob) is located on the right side of the seat behind the FSC lever and is used to control engine speed. Moving the lever forward toward the FAST position increases en -

Operator Controls gine speed; moving it backward toward the IDLE position decreases engine speed.

Steering Levers

Each drive wheel is controlled by its own indepen dent steering lever, for both steering function and for forward or reverse motion.

Steering Lever Decal

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The Forward Speed Control (FSC) lever sets the maximum forward speed, and also sets the for ward position of the steering levers.

The steering levers operate only with a backward pulling movement of the lever, which causes the drive wheel for that lever to first slow down, stop, and then reverse with a full backward lever stroke. The levers are released to the FOR-

WARD position for “straight-ahead” ground travel.

Operating Instructions

NOTE: Pushing forward on the steering levers will not cause any change in tractor motion - there will be no steering lever reaction and there will be no machine damage.

The Forward Speed Control also establishes the NEUTRAL-PARK position of the steering levers.

LEFT WHEEL

STEERING LEVER

Forward Position

(No Control Change)

Neutral-Park

Position

Reverse Drive

Wheel Motion

Position

RIGHT WHEEL

STEERING LEVER

BLADE CLUTCH (PTO) FORWARD SPEED

CONTROL LEVER (FSC

Full Forward

Ground Speed

Position

)

Intermediate

Ground Speed

Position

Neutral-Park

Position

Engaged

Position

Disengaged

Position

PARKING

BRAKE

ENGINE

THROTTLE

Fast

Throttle

Position

Idle

Position

Operating Controls (Top View from Drivers Point of View)

21

Operating Instructions

Forward Speed Control (FSC)

Forward Speed Control (FSC) has two functions:

One is to set forward travel speed, and the other is to establish the NEUTRAL-PARK position.

When the FSC lever is moved into the FORWARD position, a friction lock holds any forward speed setting from 0 to 6 mph (0 to 10 km/h).

FORWARD

IMPORTANT: Stop the tractor completely be fore engaging the parking brake. If the tractor is moving when the brake is engaged, it will result in sudden stoppage and possible internal damage to the transaxle.

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

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22

NEUTRAL-PARK

Forward Speed Control FSC

The ground speed is proportional to the lever position; the further the lever is advanced forward, the faster the tractor moves. It is not necessary to hold the FSC in position since the friction lock maintains the selected lever position.

Pulling back on the steering levers overrides the

FSC setting and slows or stops forward travel.

Releasing the steering levers allows the tractor to resume forward travel at the speed set by the FSC lever. To stop and park the machine, the FSC lever is moved backward to the NEUTRAL-PARK position.

Blade Clutch Switch (PTO)

The blade clutch switch (red button) is located be side the steering levers. It is used to engage and disengage the mower blades. The blade clutch switch has two positions. Pull out the switch to engage the PTO that drives the blades and push down the switch to disengage the PTO and en gage the blade brake.

Parking Brake

The parking brake uses a positive mechanical lock similar to the Park position on an automotive auto matic transmission. The brake rests in a forward notch in the body panel when it is engaged. Push the lever to the left and then back to release the brake.

Engaged

Position

Parking Brake Engaged

Disengaged

Position

Parking Brake Disengaged

Circuit Breaker

The auto reset 30 amp master circuit breaker is located in the rear left of the chassis and protects the electrical system. In addition, there are two (2)

5-amp fuses located on the chassis to the right of the PTO belt tensioner lever that provide protec tion to the safety circuits.

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Seat Panel Latch

The seat hinges forward for maintenance access and is latched down in the normal operating posi tion. To raise the seat panel, disengage the latch and lift the seat.

Seat Panel

Latch

Operating Instructions mation about this feature is covered in “Transaxle

Lockout” on page 32.

LH Trans axle

Lockout

Arm Tab

Seat Panel Latch

Hourmeter

The hourmeter, which is located on the right front of the body, displays operating time accumulated when the PTO (blade drive) clutch is engaged.

The hourmeter does not have a manual reset function.

NOTE: The blinking hour glass on the display means that the meter is operating properly.

LH Transaxle Lockout Arm Tab

NOTE: The transaxle lockout arm tabs should be completely retracted against the chassis during normal use, otherwise operation of the transaxle may be erratic.

IMPORTANT: DO NOT TOW this mower faster than 2 mph (3.2 km/h) with the transaxle lockout engaged. Towing can produce excessive internal pressure and damage the transaxle(s).

Hourmeter

Transaxle Lockout Arms

The transaxle lockout arms disengage the transax les to permit freewheeling the tractor. This is used to enable moving the machine without the engine running (e.g., for service). There are two lockout arm tabs, one for each transaxle, used to engaged and disengaged the lockout feature. More infor -

23

Operating Instructions

Pre-Operation Checklist

WARNING

It is critical to follow the steps provided for setup and assembly of the tractor and deck to ensure the safety of the operator and the equipment.

Before operating the mower for the first time, and as a routine before daily operations, it is impor tant 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 every day, but the operator should be aware of the condition of each.)

PERFORM ‘EVERY USE’ MAINTENANCE

ITEMS

These items are covered in detail in the Mainte nance section that starts on page 34.

‘Every Use’ Maintenance Items include:

□ Check Engine Crankcase Oil

□ Check/Clean Engine Air Cooling System

□ Clean Grass Buildup Under Deck

□ Inspect/Service Mower Blades

□ Check Security of Air Filtration Compo nents

□ Check Deck Side Discharge Deflector

Shield in Lowest Position

PERFORM REQUIRED SCHEDULED MAIN-

TENANCE PROCEDURES

See the “R21 Maintenance Schedule Chart” on page 34 for a complete list of periodic mainte nance.

FILL FUEL TANK

Fill the fuel tank using clean, fresh automotive grade unleaded gasoline (87 octane minimum,

10% ethanol maximum).

24

R21

IMPORTANT: DO NOT permit dirt or other for eign matter to enter the fuel tank. Wipe dirt from around the filler cap before removing. Use a clean fuel storage container and funnel.

IMPORTANT: DO NOT mix oil with gasoline.

Always use fresh, automotive grade unleaded gasoline. DO NOT use gasoline containing greater than 10% ethanol. DO NOT use additives, such as carburetor cleaners, deicers, or moisture removing agents. DO NOT use gasoline blended with methyl alcohol.

DANGER

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

● DO NOT fill fuel tank with the engine run ning.

● If the engine is hot, allow to cool before refueling.

● Use an approved fuel container.

● Fuel the mower outdoors.

● DO NOT smoke while refueling. Keep matches, cigarettes, cigars, pipes, open flames, or sparks away from the fuel tank and fuel container.

● Avoid spilling fuel; use a funnel or spout.

● DO NOT overfill the fuel tank; fill up to the bottom of the fill tube.

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Starting the Engine

CAUTION

Before operating the mower, read and understand all Safety Instructions and Operat ing

Instructions.

WARNING

NEVER run the engine in an enclosed or poor ly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

1. Before attempting to start the engine, make sure:

□ The operator is seated.

□ The Forward Speed Control (FSC) is in

NEUTRAL-PARK position.

□ The parking brake is ENGAGED.

□ The blade clutch (PTO) is DISENGAGED.

□ The deck hinges are LOCKED.

2. Move the throttle 1/4 to 1/2 open (toward

FAST ).

3. Turn the ignition switch to the START position to start the engine. Release the key to “I”

(RUN) position as soon as the engine starts.

IMPORTANT: DO NOT crank the engine con tinuously for more than 10 seconds at a time.

If the engine does not start, turn the key to the

OFF position and allow a 60 second cooldown period between starting attempts. Fail ure to follow these guidelines can damage the starter motor and shorten battery life. Consult your Walker dealer or authorized Kohler dealer for additional help.

Operating Instructions

CAUTION

A safety interlock switch system PRE VENTS

CRANKING the engine with any one of these three controls in the OPERATING position: (1)

Forward Speed Control out of neutral, (2) blade clutch (PTO) engaged, or (3) parking brake disengaged. If the engine cranks other wise, the safety system is not working and should be repaired or ad justed before operat ing the mower. The deck hinge lock switch will allow the engine to crank but not start. DO

NOT disconnect safety switches; they are for the operator’s protection.

CAUTION

Learn to START, STOP, and MANEUVER the mower in a large, open area. If the opera tor has not operated a ma chine with lever steering or dual hydrostatic transmissions, steer ing and ground operation should be learned and practiced until the operator is completely comfortable handling the ma chine

BEFORE ATTEMPTING TO MOW.

DANGER

Keep feet on footrests at all times when the machine is moving. Never operate the tractor without a deck or implement installed.

1. Sitting on the mower with the engine started, move the FSC out of NEUTRAL-PARK position to the desired forward speed. DO NOT hold for ward on steering levers. It is not nec essary to hold the FSC lever in position since a friction lock maintains the selected lever position (and forward travel speed).

25

Operating Instructions

Pull Steering

Levers with

Left Hand

Keep Feet on

Footrest When

Moving

Right Hand on the

Forward Speed Control

(FSC)

Correct Operator Hand Position

NOTE: If the FSC lever will not stay in the selected position, the friction lock needs to be adjusted. See “Forward Speed Control Fric tion Adjustment” on page 58 for details.

2. Steer by pulling the lever on the side of de sired direction of turn, e.g., pull the LH lever to turn left.

To minimize the possibility of overcontrol, use only one hand on both steer ing levers.

3. Reverse direction of the mower by pulling back on both levers.

NOTE: Smooth action on the steering le vers will produce smooth mower operation.

Remem ber to keep the engine and ground speed slow until learning the control response.

4. The FSC may be adjusted forward for faster ground speed and backward for slower ground speed. When mowing, ground speed should be adjusted to match the load on the cutter blades, i.e., as the engine pulls down in heavy cutting, pull back on the FSC lever to reduce ground speed. Adjusting ground speed helps maintain a balance between engine power and blade speed for high-quality cutting action.

5. Stop ground travel by pulling both steering le vers backward to the NEUTRAL position

(trac tor not moving) and then moving the FSC lever to the NEUTRAL-PARK position.

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NOTE: If the tractor creeps forward or back ward with the FSC lever in the NEUTRAL-

PARK position, the transmission control needs to be adjusted. See “Neutral Function Adjust ment” on page 59 for details.

CAUTION

An operator presence switch (seat switch) will cause the engine to stop if the parking brake is in the DISENGAGED position and/or the FSC is out of the NEUTRAL-PARK position (tractor stationary or moving forward) and the operator is not in the seat. The function of this switch should be checked by the op erator raising off the seat, first with the parking brake DISEN-

GAGED, and then with the tractor moving for ward; the engine should stop. In each case, if the safety sys tem is not working, it should be repaired or replaced before operating the mower. DO NOT disconnect the safety switches; they are for the operator’s protection.

WARNING

When moving forward, DO NOT suddenly put the tractor in reverse by rapidly pulling on the steering levers, especially when going down hill, as this can lift the tractor tail wheel off the ground and set up a bucking motion due to operator overcontrol. If bucking does occur, immediately stop the bucking action by pulling the Forward Speed Control (FSC) lever into the NEUTRAL-PARK position.

26

R21

Recommendations for Getting Started:

● Learn operation of the mower in an open area away from buildings, fences, and obstructions. 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.

NOTE: Once you are familiar with the operating characteristics, the engine should not be run at slow speeds. The mower is designed to be operated at full throttle for maximum cutting power and component longevity.

● Remember it is not necessary to hold the steering levers forward (a unique Walker feature); always PULL on the levers for steering or for reverse motion of the mow er.

● Learn to operate the mower with your left hand on the steering levers and right hand on Forward Speed Control. The use of two hands on the steering levers tends to cause overcontrol.

● Learn to operate the steering levers with smooth action. Jerky movements are hard on the transmission and lawn. For sharp turns, do not allow the inside wheel to stop and twist on the grass. Pull the steering le ver controlling the inside wheel into re verse for a smooth “rolling” turn (one wheel roll ing forward while the other rolls back ward).

● Practice maneuvering the mower until you can make it go exactly where you are aim ing.

● Remember, for an emergency stop, or in case of loss of control, machine move ment can always be stopped quickly by pulling the Forward Speed Control into the

NEU TRAL-PARK position.

Operating Instructions

WARNING

If the transmission drive belt breaks during op eration, and if the machine is on a slope, the machine will freewheel down the slope. To maintain control, immediately:

1. Release the steering levers and simultaneously

2. Move the FSC to the NEUTRAL-

PARK position.

When the machine is stopped or moving slow ly, engage the parking brake.

NOTE: The emergency stop procedure is ex actly the same procedure as used to normally stop and park the machine.

Engaging the Blades

1. Set the engine throttle fast enough to pre vent the engine from stalling which should be 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. Engage the blade clutch by pulling out on the blade clutch switch.

Blade Clutch Engaged

3. To disengage the blades, reduce the throttle to half speed or less and push in the blade clutch switch.

IMPORTANT: DO NOT engage the blade clutch when transporting the mower across drives, sidewalks, loose materials, etc.

27

Operating Instructions

IMPORTANT: DO NOT engage the blade clutch if the deck is not installed on the tractor.

CAUTION

An operator presence switch (seat switch) will cause the engine to stop if the blade clutch is engaged and the operator is not in the seat.

The function of this safety switch should be checked by the operator raising off the seat and engaging the blade clutch; the engine should stop. If the switch is not working, it should be repaired or replaced before operat ing the mower. DO NOT disconnect the safety switches; they are for the operator’s protec tion.

CAUTION

If the cutting blades strike a stationary ob ject while mowing, stop the mower imme diately, remove the key, lift the deck, and inspect the deck and blades thoroughly for damage. Also, make sure the blade retain ing bolts are still torqued to 70 lb·ft (95 N·m).

WARNING

A brake stops the cutter blades from free wheeling within five (5) seconds after disen gaging the clutch. If the brake sys tem mal functions and the blades do not stop within five

(5) seconds, the brake should be repaired or replaced before further operation of the mow er. Contact your Walker dealer for service.

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Stopping the Machine

1. Pull the steering levers to the NEUTRAL position and then move the FSC lever to the

NEUTRAL-PARK position.

2. Slow the engine to a fast idle; put the throttle in the 1/2 throttle 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 element.

4. Turn the ignition switch to OFF.

When stop ping the engine, do not reduce the throttle be low 1/2 speed. Since the engine is equipped with a fuel shutoff solenoid, stopping at low idle may cause engine run-on or backfiring.

5. Engage the parking brake by moving the lever forward and to the right.

IMPORTANT: It is recommended to always engage the parking brake when turning off the mower. The mower should not roll freely when the engine is stopped, but if the mower is parked on a slope, it is possible it will creep especially if the transmission is warm from operation.

WARNING

Remove the key from the ignition switch when leaving the mower unattended. This will pre vent children and inexperienced operators from starting the engine.

28

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Adjusting the Cutting Height

Cutting height is adjusted by positioning the four

(4) re tainer hitch pins in a series of six 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 1.5 in. (38 mm) [top holes] to 4 in. (102 mm) [bottom holes] in 1/2 in.

(13 mm) incre ments.

Lift Handle

Deck

Support

Pin

Washer

Hitch Pin

Cutting Height Adjustment

WARNING

The engine must be stopped before ad justing cutting height. Disengage the blade clutch

(PTO), engage the parking brake, stop the en gine, and remove the ignition key. Wait for all move ment to stop before getting off the seat.

Deck Tilt-Up Position

Tilting up the deck is useful to clean under the deck, inspect and replace the blades, and lubri cate spindle grease fittings.

DANGER

Before raising the mower deck, always stop the engine and re move the key from the igni tion.

1. Stop the engine, and remove the key from the ignition.

Operating Instructions

2. On each side, push down the deck lock lever to unlock the carrier frame pivot joint. With the lever depressed, push down on the carrier frame, and then release the deck lock lever.

Push Down

Tilt Bar

Stowed Position

Deck Lock Lever

3. Remove the deck tilt bar from its locked stor age position along the front of the footrest, and install it in the socket on the front of the deck housing. Secure the bar in position with the hitch pin.

Hitch Pin

Tilt Bar Socket

Tilt Bar Installed

4. Using the deck tilt bar, raise deck to the tilt-up position and insert the two (2) tilt-up links into the lock holes on each side of the tractor body.

DANGER

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

29

Operating Instructions

LH Lock Hole

Insert RH and LH Tilt-Up Links into the

Lock Holes

Tilt-Up Links

Deck Locked in Tilt-Up Position

5. Reverse procedure to lower the deck back to the operating position. One side at a time, hold the lock lever in the down position and simultaneously raise the carrier frame at the pivot joint to re-engage the deck hinge lock.

CAUTION

Do not operate the mower with the carrier frame unlocked.

The frame must be locked before operating the mower. A safety switch prevents the engine from starting with the RH pivot unlocked.

R21

Recommendations for Mowing

● Keep the mower deck and discharge shield clean.

● Mow with sharp blades. A dull blade tears the grass (resulting in poor lawn appearance) and uses extra power (slowing the mowing speed).

● It is preferable to cut grass when it is dry and not too tall. Mow frequently and do not cut grass too short. (For best appearance, cut off

1/3 or less of existing grass height.)

● When mowing, operate the engine at full throttle for the best cutting action. Mowing with a lower engine RPM causes the mowing blade to not cut clean and tear the grass. The engine is designed to be operated at full speed.

● When mowing in adverse conditions (tall and/ or wet grass), mow the grass twice. Raise the mower to the highest setting, 4 in. (10 cm), for the first pass and then make a second pass cutting to the desired height.

IMPORTANT: Operate the engine at full throttle when mowing, to allow the engine to produce full horsepower and to increase ef ficiency of the engine cooling system.

● Use a slow setting on the FSC for trimming operations.

● 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.

● Make sure the mower is leveled properly for a smooth cut. Refer to “Deck Leveling” on page 57.

● The side discharge deflector 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.

30

R21

Discharge

Shield

No Gap in

Lowest Position

Side Discharge Shield in Lowest Position

● Avoid damage to the grass by slipping and skid ding of the drive tires. Use smooth control move ments of the steering levers since the transaxles are “power boosted controls” and jerk ing the levers can easily slip the tires.

For sharp turns, do not allow the inside wheel to stop and twist on grass; pull inside steering lever into reverse for a smooth “rolling” turn

(one wheel rolling forward while the other rolls backward).

DANGER

Do not mow or drive the tractor within 5 feet

(1.5 meters) of an embankment or retaining wall with drop off.

● When operating on a slope, reduce speed and use caution to start, stop, and maneu ver. Avoid sharp turns or sudden changes in direction. The maximum recommended slope operating angle is 15 degrees or 27% grade.

DANGER

Do not mow around overhanging tree branch es or bushes at the same height as the opera tor’s torso and head where inadvertent contact may cause injury.

Operating Instructions

Maximum

Recommended

Slope -

Do Not Operate on Steep Slopes

860014

15°

52 in.

Maximum Recommended Slope

14 in.

Avoid Low Hanging Branches

31

Operating Instructions R21

5 FT

MINIMUM

No Driving Zone

Transaxle Lockout

IMPORTANT: DO NOT TOW this mower faster than 2 mph (3.2 km/h) with the transaxle lockout engaged. Towing can produce excessive internal pressure and damage the transaxle(s).

Lockout the transaxles to permit freewheeling and to move the tractor with the engine NOT running

(dead battery, maintenance, etc.).

1. Turn off the engine and remove the key from the ignition.

2. Reach below the chassis behind the seat.

Slide the transaxle lockout arm tab back and toward the middle of the machine to catch the step that holds the arm in the LOCKOUT position. Repeat on the other side.

Slide arm back and toward the center to engage the tab and enable freewheeling

Engage Transaxle LOCKOUT (LH shown)

The mower will “freewheel” with the arms in the LOCKOUT position.

3. After moving the mower, release the lockout arms and return them to normal OPERATING position. They should be completely retracted against the chassis, otherwise operation of the transaxle may be erratic.

LH Transaxle

Lockout Arm

Tab

32

LH Transaxle Lockout Tab

Shown in Normal OPERATING Position

R21

Recommendations for Towing

When equipped with a factory authorized hitch kit, the maximum towing capacity on flat ground is

250 lbs (113 kg) gross trailer weight. The maxi mum tongue weight is 50 lbs (23 kg). Use caution when towing on slopes, rough terrain or when conditions limit traction.

● Do not operate on slopes greater than 5 de grees (9%).

● Do not tow with PTO clutch or mower blades engaged.

● Do not allow people to ride in or on towed trailers.

Operating Instructions

To avoid potential deck and/or tractor damage while using the tilt-up deck, the following recom mendations 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 configura tion should only be used when the tractor is parked.

● 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 (causing breakage). This will also prevent the deck from unhooking from the tractor and falling, potentially causing deck or tractor damage. Damage to other items parked in front of the deck may also occur.

33

34

Maintenance

R21 Maintenance Schedule Chart

This section provides the recommended service items and intervals. Regular maintenance is required to keep the mower operating at optimal levels and to prevent damage. Information about each of these tasks is provid ed in this section, and many of them can be performed by the owner-operator unless otherwise noted. Contact your Walker Dealer if you have questions or need assistance.

Service Item

Each

Use

25

Hours

75

Hours

100

Hours

300

Hours

500

Hours Yearly Page

Check Engine Crankcase Oil Level

Check/Clean Engine Air Cooling System x x

35

36

Clean Grass Buildup Under Deck

Inspect/Service Mower Blades

Check Security of Air Filtration

Components

Check Discharge Shield x x x

37

37

39

Lubricate Grease Fittings and Oil Points

Check Tire Pressure

Check Drive Belts (Ground Drive, Blade)

Check Safety Switch System

Clean/Replace Engine Precleaner Air

Filter*

Replace Engine Air Filter *

Clean Engine Cooling System

Replace Fuel Filter

* x x x x x x x x x

39

39

41

41

41

42

43

45

46

Clean Transaxle Housing and Fans

Check Drive Tire Mounting Nuts x x

46

47

Check Blade Brake Function

Change Engine Crankcase Oil **

Change Engine Oil Filter ***

Replace Spark Plugs and Set Gap

Check/Adjust Engine Valve Lash r

Check FSC Friction Lock

Check Transmission Control Settings

Check Fuel Lines and Clamps

Clean Battery Terminals

Charge Battery (As Required)

Long-Term Storage Preparation

(As Required) x x x x x x x x x x x

47

44

44

47

47

48

48

48

49

49

50

* More often in extremely dusty or dirty conditions

** Factory service uses Kohler PRO ® oil. If conventional oil is used for oil changes instead of the Kohler

PRO ® , the oil must be changed every 100 hours.

*** Factory service uses a Kohler PRO ® filter. If a conventional Kohler filter is used for oil changes instead of the Kohler PRO ® version, the filter must be changed every 200 hours.

r Must be performed by an authorized Kohler Dealer.

R21 Maintenance

Check Engine Crankcase Oil

Frequency: Each use or after 8 hours of continu ous operation

The engine is serviced with Kohler PRO ® 10W-50 synthetic oil from the factory. Kohler PRO ® oil is not required, but recommended. See “Specifica tions” for details.

IMPORTANT: The importance of checking and maintaining the proper crankcase oil level cannot be overemphasized. Check the oil level BEFORE

EACH USE.

1. Park the mower on a level surface with the en gine stopped.

Also, make sure the engine is cool and oil has had time to drain into the sump [allow at least five (5) minutes after stopping the engine].

IMPORTANT: NEVER check or add oil with the engine running.

2. Before removing the dipstick, clean the area around the dipstick to keep any dirt or debris out of the engine.

Oil Dipstick

IMPORTANT: DO NOT operate engine with out a sufficient oil supply in the crankcase.

DO NOT operate with the oil level below the

“L” mark or above the “F” mark on the dipstick.

5. If additional oil is needed, refer to “Specifica tions” on page 4 for proper crankcase lubricant. Fill up to, but not above, the “F” mark on the dipstick.

IMPORTANT: DO NOT overfill the crankcase

(oil above “F” mark) as this CAN result in en gine overheating, loss of power, and possible en gine damage.

Full Mark

}

Operating

Range

Low Mark

Dipstick Operating Range

Oil Dipstick Location

3. Remove the dipstick, wipe off with a clean rag, then reinsert the dipstick into the tube and push it all the way down.

4. Remove the dipstick again and check the oil lev el on the dipstick. The oil level should be within the “Operating Range” on the dipstick

(between the “L” mark and the “F” mark).

35

Maintenance R21 system cleaned. See your authorized Walker

Dealer for this service.

Frequency: Each use or after 8 hours of continu ous operation

To prevent engine overheating and possible en gine damage, clean grass clippings, chaff, and dirt from the engine cooling air intake screen guard and the rotating screen below it each time you mow or after every 8 hours of operation. In certain mowing conditions (dry grass, leaves, tree

“cotton”, etc.) it may be necessary to check and clean the screen several times each day to prevent engine overheating.

1. With the engine stopped, clean all the debris off the air intake stationary screen guard and the rotating air intake screen below the guard.

The best way to clean the screens is to use compressed air to blow the screens clean, but do not use a pressure washer. This can cause damage to the engine.

NOTE: For better access to the rotating screen and a more thorough cleaning, remove the screen guard. The guard is secured with a single screw along the front edge of the engine.

Screen Guard

Attachment

Engine Cooling Air

Intake Screen

Checking Engine Air Flow

CAUTION

Operating the engine with a blocked air intake screen, dirty or plugged cooling fins, and/or cooling shrouds removed will cause engine damage from overheating.

CAUTION

DO NOT use a pressure washer to clean the cooling system on an air-cooled engine. Mud may form under the cooling shroud on the cyl inder head and cooling fan and block cooling airflow.

36

Remove the Stationary Screen Guard

2. Start the engine. With the engine running at full throttle, hold a hand above the engine air intake screen to feel for airflow. If there is little or no airflow, the cooling fan and cylinder head cooling fins are clogged. The engine shroud needs to be removed and the air cooling

R21 Maintenance

Clean Grass Buildup Under Deck

Frequency: Each Use

DANGER

Before raising the mower deck for cleaning, stop the engine, and re move the ignition key.

1. Place the deck in the tilt-up position. For details on this procedure, see “Deck Tilt-Up

Position” on page 29.

DANGER

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

2. Clean grass buildup underneath the deck using a pressure washer (and scraper if re quired).

NOTE: While some degree of material build up in the mower deck housing can be toler ated, a point is finally reached where cutting quality deteriorates and clogging begins to occur because of too much buildup on the baffling and housing.

NOTE: While the deck is in the tilt-up posi tion, it is recommended to visually inspect the blades. For more information, see “Inspect/

Service Mower Blades” on this page.

3. Lower the deck to the normal operating posi tion and re-engage the deck lock levers.

CAUTION

Do not operate machine with deck tilt-up pivot joint unlocked.

Inspect/Service Mower Blades

Frequency: Each use or after 10 hours of opera tion

Check mower blade(s) for straightness, sharpness, and condition of the cutting edge. Replace blades if worn, bent, cracked, or otherwise dam aged.

Sharpen the blades after every 10 hours of opera tion (or more often when mowing abrasive type grass or operating on sandy soils).

NOTE: Keep blades sharp.

Cutting with dull blades not only yields a poor mowing job but slows the cutting speed of the mower and causes extra wear on the engine and blade drive by pull ing hard.

DANGER

Before raising the mower deck for service, stop the engine, and re move the ignition key.

1. Place the deck in the tilt-up position. For details on this procedure, see “Deck Tilt-Up

Position” on page 29.

DANGER

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

2. Check the blades for straightness by marking the blade tip position inside the deck hous ing, and then rotating the opposite end of the blade to the same position and comparing. If the diff erence in blade tip track is more than

1/8 in. (3 mm), the blade is bent and should be re placed.

37

Maintenance R21

WARNING

DO NOT try to straighten a blade that is bent.

NEVER weld a broken or cracked blade. AL -

WAYS replace with a new blade to assure safety.

3. Visually inspect the cutting edge. If the cutting edge is dull or nicked, it should be sharp ened using the following procedure:

NOTE: If you are not comfortable performing the following steps, contact your authorized

Walker Dealer for assistance.

To Sharpen the Blades:

A. Remove blades for sharpening by grasp ing the end of the blade using a rag or a thick, padded glove, while loosening and removing the bolt and flat washer that mount the blade.

B. Grind cutting edge at the same bevel as the original. Sharpen only the top of the cutting edge to maintain sharpness.

NOTE: Blades can be sharpened with an electric blade sharpener, conventional electric grinder, or a hand file.

CAUTION

ALWAYS wear eye protection and gloves when sharpening a blade.

C. 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 down ward, 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 maintained by removing an equal amount of material from each end of the blade when sharpening.

Blade Balancer

Blade Balanced on Magnetic Wall-Mounted

Balancer

D. Mount the blade with wing tips pointing up into the housing. Reinstall the blade, washer, and bolt. Tighten the bolt to 70 lb·ft (95 N·m).

Sharpen at

Original 30° Angle

Intersection

Wear Area

30°

Do Not Grind or

Sharpen on Underside

Mower Blade Profile for Sharpening

Wing

Tip

38

R21 Maintenance

Discharge

Shield

Frequency: Each Use

Inspect the engine air cleaner system to make sure it is securely in place and without damage.

The levers on the cover should be rotated inward to maintain a locked position.

NOTE: Operating the engine with a loose or dam aged air filter could cause premature wear to and failure of the engine.

No Gap in

Lowest Position

Discharge Shield Lowered

Tabs Locked and

Cover Secure

Air Filtration Installed

Check Discharge Shield

Frequency: Each Use

Never operate the mower without the discharge shield in place. It prevents objects from being thrown when the blades are engaged. Inspect the discharge shield to make sure it is securely installed and not damaged. Lower it into the down position once it has been inspected.

Frequency: Every 25 hours or more often in extremely dusty or dirty conditions

When lubricating the tractor or deck, use SAE general purpose lithium or molybdenum base grease for grease points and light machine oil

(SAE 10) for oil points.

ID

#

1

2

3

4

5

6

7

8

Location Type

# of

Places

Deck Caster Wheel

Fork Pivot

Deck Caster Wheel

Bearing

Idler Arm Pivot

Blade Spindle

Grease

Grease

2

2

Grease 1

Grease 2*

Steering Lever

Pivot

Throttle Cable

Grease

Oil

2

2

Engine Dipstick and Oil Fill

Oil** 1

Belt Tensioner Arm Grease 1

* Three (3) spindles and grease points on DS54-R

** Refer to “Change Engine Crankcase Oil and

Filter” on page 44 for details on changing the engine oil and filter.

NOTE: The Blade Spindle grease points are ac cessed by lifting the deck, and the Steering Lever

Pivot grease points are accessed by lifting the seat panel.

39

Maintenance R21

1

1

2

3

2

4

5

4

5

6

7

3 4

DS54-R DECK

8

6

Lubrication Points

40

R21 Maintenance

Check Tire Pressure

Frequency: Every 25 hours

Inflate tires to the pressures shown below:

Drive Tires = 15 PSI (103 kPa)

Tailwheel = 20 PSI (137 kPa)

Frequency: Every 25 hours

There are two belts used for the R21: the blade drive belt and the ground drive belt. They need to regularly be inspected for wear.

Blade Drive

Belt

Ground Drive Belt

R21 Belts

1. With the engine turned off, raise the seat pan el for access to the ground drive belt. Visually inspect the belt.

2. If the belt shows signs of cracking or deterio rating, the belt must be replaced. See “Belt

Replacement” on page 51 for details.

3. Raise the footrest on the deck.

4. Remove the four (4) wing nuts on the deck belt cover and slide the cover out. Visually inspect the Blade Drive Belt.

5. If the belt shows signs of cracking or deterio rating, the belt must be replaced. See “Belt

Replacement” on page 51 for details.

Check Safety Switch System

Frequency: Every 25 hours

WARNING

It is important to check and maintain the safety switch system for safe operation of the ma chine.

There are five (5) safety interlock switches on the tractor: seat switch, FSC Neutral-Park switch, PTO switch, parking brake switch, and deck hinge lock switch. These safety switches work together to ensure that the mower engine can only be started when all the following criteria is met:

● The Forward Speed Control (FSC) is disengaged in NEUTRAL-PARK.

● The blade clutch (PTO) is disengaged.

● The parking brake is engaged.

● The deck hinge is locked.

The operator does not need to be seated to start the engine. The operator does need to be seated before the Forward Speed Control (FSC) can be engaged, the blade clutch (PTO) can be engaged, or the parking brake can be disengaged.

The following combinations should be tested to ensure all the safety switches are functioning properly:

● With or without an operator in the seat and with the engine running (with the PTO disen gaged for safety reasons), disengage the deck hinge lock located on the RH hinge and the engine should immediately stop.

41

Maintenance R21

● Without an operator in the seat and the with engine running, any of the following changes should cause the engine to immediately stop:

□ Disengaging the parking brake

□ Moving FSC out of NEUTRAL-PARK

□ Engaging the blade clutch (PTO)

□ Disengaging the deck hinge lock

● With or without an operator in the seat, when the FSC is not in NEUTRAL-PARK but all remaining start conditions are met, the engine should not start.

● With or without an operator in the seat, if the parking brake is disengaged but all remaining start conditions are met, the engine should not start.

● With or without an operator in the seat, if the blade clutch (PTO) is engaged but all remain ing start conditions are met, the engine should not start.

If any of these safety switch checks fail, contact your Walker Dealer for service.

In addition, if you experience the engine stopping during what should be normal operation, it could be caused by a failure of a safety switch. For example:

● An operator is in the seat, the engine is run ning, the parking brake is disengaged, and the engine stalls when the FSC is moved out of

NEUTRAL-PARK.

● An operator is in the seat, the engine is run ning, the parking brake is disengaged, and the engine stalls when the blade clutch (PTO) is engaged.

Contact your Walker Dealer for troubleshooting and/or service if you experience failure-to-operate conditions such as these.

Frequency: Every 25 hours or more often in extremely dusty or dirty conditions

The precleaner can be washed or replaced de pending on its condition.

1. With the engine stopped, clean off the area around the air filter cover to prevent debris from falling in. Rotate the levers on the engine air cleaner cover outward to unlock the cover. Remove the cover.

Foam

Precleaner

Rotate Levers

Unlock Air Filter Cover

Engine Precleaner Filter

2. Slide the precleaner foam filter off the paper filter element.

3. Inspect the precleaner to determine if it can be washed or if it needs to be replaced. If there is damage to the precleaner, replace it using the recommended Kohler replacement pre cleaner. (Kohler P/N 16 083 05-S)

42

R21 Maintenance

4. Wash precleaner in warm water with deter gent. Rinse and allow to air dry. (Do not wring dry.)

5. Lightly oil precleaner with new engine oil; squeeze foam to distribute oil and remove excess oil.

6. Reinstall the precleaner over the paper filter element.

7. Position the air cleaner cover with the levers facing outward over the air cleaner. Rotate the levers inward to lock the cover into place.

Replace Engine Air Filter

Frequency: Every 75 hours or more often in extremely dusty or dirty conditions

NOTE: This filter cannot be blown off with com pressed air. It must be replaced if dirty or dam aged.

1. With the engine stopped, rotate the levers on the engine air cleaner cover outward to unlock the cover. Remove the cover.

2. Slide the precleaner off of the paper filter element and service the precleaner using the steps provided in the section “Clean/Replace

Engine Precleaner Air Filter” on page 42.

3. Remove the paper filter element from the base and discard it.

4. Install the serviced precleaner over the new paper filter element, and install them together on the base. Use ONLY the recommended

Kohler replacement filter. (Kohler P/N 16 083

04-S)

5. Position the air cleaner cover with the levers facing outward over the air cleaner. Rotate the levers inward to lock the cover into place.

Paper

Air Filter

Engine Air Filter

43

Maintenance R21

Oil Dipstick &

Oil Fill

Frequency: Every 300 hours if the recommended

Kohler PRO ® oil and filter are used or every 100 hours for conventional oil and 200 hours for con ventional filter

The engine is serviced with Kohler PRO ® 10W-50 synthetic oil and a Kohler PRO ® filter from the fac tory. Both are rated for 300 hour oil change inter vals. Kohler PRO ® oil and filter are not required, but recommended. If conventional oil and filters are used in the tractor, the oil must be changed after every 100 hours of operation, and the filter must be changed after every 200 hours.

See the

“Specifications” section for details on which oil and filters are recommended. A break-in oil change is not required.

1. Run the engine for at least 10 minutes in a well-ventilated area. The engine oil should be warm before draining.

WARNING

NEVER run the engine in an enclosed or poor ly ventilated area. Engine exhaust contains carbon monoxide, an odorless and deadly gas.

2. Park the mower on a level surface with the en gine stopped and the key removed from the ignition.

3. Before removing the dipstick, clean the area around the dipstick to keep any dirt or debris out of the en gine.

4. Remove the dipstick and oil drain plug, and drain the oil into a suitable container. The oil drain is located behind the left drive tire. Be sure to allow ample time for complete drain age.

Oil Dipstick and Oil Fill Location

Oil Drain

Plug

Oil Drain Location (on LH Side of Engine)

WARNING

Use caution when draining the oil because it may be very hot. Wear appropriate protective gear to avoid being burned or exposed to the engine oil.

5. Before removing the oil filter, clean the area around the filter to keep dirt and debris out of the engine.

44

R21 Maintenance

Oil Filter

Oil Filter Location

(Beneath the Fuel Filter)

6. Remove the old oil filter and wipe off the filter mounting surface on the engine.

7. Apply a thin coating of clean oil to the rubber gasket on the replacement oil filter.

IMPORTANT: Use ONLY Kohler oil filters.

See the “Specifications” section for a list of recommended filters. After market oil filters may not seal properly and/or may not have the correct pressure relief valve for proper lubrica tion.

8. Install the new oil filter on the engine. Turn the filter clockwise until the rubber gasket con tacts the sealing surface, then tighten an ad ditional 3/4 to 1 turn.

9. Reinstall the drain plug and torque to 10 lb·ft

(13.6 N·m). Do not overtighten.

10. Fill the crankcase with new, clean oil. Use only crankcase lubricants recommended by the en gine manufacturer. Refer to “Specifi cations” on page 4 in this manual or the

Kohler Owner’s Manual. Use the recom mended oil viscosity for the expected ambient temperature. Oil with the correct vis cosity will aid starting in cold weather and assure proper lubrication in hot weather. Fill up to, but not above, the “F” mark on the dipstick. Crank case capacity is 2 quarts (1.9 liters) plus 1/2 pint (0.24 liters) for the new oil filter.

IMPORTANT: Check the dipstick reading before adding the last 1/2 pint of oil and fill only to the “F” mark. DO NOT overfill the crank case (oil above “F” mark) as this CAN result in en gine overheating, loss of power, and pos sible engine damage.

11. Start the engine and check for oil leaks around the oil filter and the drain plug. Stop the engine, recheck the oil level, and add oil if necessary. (When the engine is first oper ated with a new oil filter, the oil level will drop slightly as the filter is filled with oil.)

12. Dispose of the used oil and filter in accor dance with local ordinances.

Clean Engine Cooling System

Frequency: Every 100 hours

It is essential for performance and longevity of the air-cooled engine to keep the cooling fan and the cylinder head cooling fins clean and free of ob struction. Even with regular cleaning as detailed in “Check/Clean Engine Air Cooling System” on page 36, the fan and the fins can become dirty or clogged. Kohler recommends removing the engine cooling shroud and cleaning the cooling system every 100 hours. This procedure requires removing the engine from the chassis. See your authorized Walker Dealer for this service.

CAUTION

DO NOT use a pressure washer to clean the cooling system on an air-cooled engine. Mud may form under the cooling shroud on the cyl inder head and cooling fan and block cooling airflow resulting in engine overheating.

45

Maintenance R21

Replace Fuel Filter

Frequency: Every 100 hours

A 10 micron in-line fuel filter is installed between the fuel tank and the fuel pump. Replacement of this filter is recommended every 100 hours of operation or when contamination is suspected or found in the fuel.

In-Line

Fuel Filter

Fuel Filter Location

IMPORTANT: Replace the fuel filter only in a clean area where the fuel line and connections will not be contaminated by dust and dirt.

1. Expand and slide clamps on either side of the filter away from filter and pull fuel lines off filter.

2. Replace the filter using Walker Service Parts

(Walker P/N 5020-3), making sure that the arrow on the filter is aligned with the fuel flow through the filter.

3. Verify that the fuel lines and clamps are securely attached, and that no fuel leaks are present.

Frequency: Every 100 hours

Keeping the housing on the transaxles clean and free of obstruction is essential to avoid overheating the transaxle fluid and short ening transaxle life.

1. With the engine turned off and key removed from the ignition, raise the seat panel for access to the transaxles.

2. Use compressed air and/or a pressure washer to clean the transaxle housing. Pay close attention to any oily dirt buildup. This may be the result of an oil leak. If an oil leak is noted, contact your local Walker Dealer.

IMPORTANT: In case an oil leak develops, the cooling fan blowing dusty air and oil on the transaxle will quickly cover the housing and pack the cooling fins with oily dirt.

If this condition occurs, contact your dealer immedi ately to avoid overheating and dam aging the transaxle.

3. Inspect the cooling fans, and replace the fan(s) if blades are missing or damaged.

Cooling

Fans

Transaxle Housing and Cooling Fans

NOTE: The transaxle is filled with oil at the fac tory and sealed. It does not require oil mainte nance. In the event of oil loss or performance degradation, contact an authorized Walker Dealer.

46

R21 Maintenance

Check Drive Tire Mounting Nuts

Frequency: Every 100 hours

There are four (4) mounting nuts on each drive tire. Check the mounting nuts to ensure they re main secure. They should each be torqued to 75 to 85 lb·ft (102 to 115 N·m).

Check Blade Brake Function

Frequency: Every 100 hours

WARNING

It is important to check and maintain blade brake action for safe operation of the machine.

This mower is designed with a blade brake that should stop all rotation within five (5) seconds of disengaging the clutch. This is a safety feature that should be checked to confirm it is working properly.

1. With the operator seated and the engine run ning, engage the blade clutch (PTO).

2. Operate the engine at full throttle and then disengage the blade clutch. Listening for the blades to stop moving, measure how long it takes.

□ If the brake is working properly, all rotation will stop five (5) seconds after disengage ment of the clutch.

□ If the brake system malfunctions [the blades do not stop within five (5) sec onds], the brake needs to be repaired or replaced before operating the mower.

Contact your local Walker Dealer.

Replace Spark Plugs and Set Gap

Frequency: Every 500 hours

NOTE: If you are not experienced with engine maintenance or comfortable performing the steps outlined below, contact your Walker Dealer for as sistance.

1. With the engine turned off and the ignition key removed, use compressed air to clean the areas around the base of the spark plug and the spark plug covers to keep dirt and debris out of the engine. There are access holes in the chassis for the spark plugs. See “Rear

View and Left Side View” on page 8 for location.

2. Remove the spark plugs. Replace the spark plugs with Champion ® type RC12YC (or equivalent).

3. Check the gap for each plug using a wire

-type feeler gauge, and set the gap at 0.030 in. (0.76 mm).

4. Reinstall each plug and torque to 20 lb·ft (27

N·m).

Check/Adjust Engine Valve Lash

Frequency: Every 500 hours

This maintenance must be performed by an autho rized Kohler Dealer. Contact your Walker Dealer for assistance (if they are a Kohler Dealer) or to help you locate a Kohler Dealer in your area.

47

Maintenance R21

Check FSC Friction Lock

Frequency: Yearly

The Forward Speed Control (FSC) is designed to have enough friction to hold the selected forward travel speed when the steering levers are moved and yet not so much as to make moving the FSC control difficult.

1. With the engine off, place the FSC in the full

FORWARD position and pull both steering levers back. The FSC lever should not move.

If the FSC lever moves back when the steer ing levers are pulled back, the friction needs to be increased.

Pull Steering

Levers Back To

Check Friction

Lock

FSC in Full

Forward Position

FSC Friction Adjustment Test

2. With the steering levers pulled back, move the

FSC lever back from the FORWARD position.

With a proper amount of friction adjusted, the

FSC lever should move back with a slight amount of resistance (friction). If the FSC lever movement is “stiff”, the friction needs to be decreased.

If the FSC friction lock needs to be adjusted, refer to “Forward Speed Control Friction Adjustment” on page 58 or contact your Walker Dealer.

Frequency: Yearly (or when an out-of-adjustment condition is observed)

Check Neutral-Park Position

With the mower parked on level ground, start and run the engine, first at idle and then normal operating speeds. With the FSC in the NEUTRAL-

PARK position, there should be no movement of either drive tire. If the tire(s) are “creeping” forward or reverse, refer to “Neutral Function Adjustment” on page 59.

Check Straight Ground Tracking

Check for straight ground track by driving on a smooth, level surface with hands off the steer ing levers. Set the FSC at different speeds and observe if the mower moves in a straight line (use a cement joint or other line on the ground for refer ence). If the machine is drifting to the right or left, refer to “Straight Tracking Adjustment” and “Maxi mum Forward Speed Adjustment” on page 60.

Check Fuel Lines and Clamps

Frequency: Yearly

Inspect the fuel supply line from the tank to engine for deterioration or damage. Also, inspect the fuel line clamps for tightness. Good preventive main tenance calls for complete replacement of fuel lines and clamps every two (2) years. If your lines need to be replaced, contact your local Walker

Dealer.

48

R21 Maintenance

Clean Battery Terminals

Frequency: Yearly

The battery comes sealed and is maintenance free, so the electrolyte level will not need to be checked or filled. Annually the battery terminals need to be inspected and cleaned.

1. With the engine turned off and the key removed from the ignition, raise the seat panel for access to the battery.

2. Inspect the battery terminals. If the terminals are corroded, remove the battery from the mower by disconnecting the negative (black) terminal first.

3. Using a wire brush, remove the corro sion with a solution of one part baking soda and four parts water. Rinse with clean water. Coat the terminals with petroleum jelly or terminal protector spray to retard further corrosion.

4. Reinstall the battery and make sure it is se curely installed in place. Reconnect the termi nal starting with the positive (red) terminal first.

If the mower will not be used for an extended time, see the section “Long-Term Storage Preparation” for tips to protect the battery.

IMPORTANT: Make sure battery is securely mount ed in the frame. A loose battery may cause damage to the case resulting in acid leakage and severe dam age to the machine.

A hazard may be created by damage to critical working parts and safety systems.

Charge Battery

Frequency: Yearly (or as required)

DANGER

BATTERIES PRODUCE EXPLOSIVE GASES

● Charge the battery in a well-ventilated area, so that gases produced while charging can dissipate.

● Keep sparks, flames, and smoking materials away from the battery at all times.

● Make sure the battery charger is unplugged before connecting or disconnect ing cables to the battery.

Charge the battery at 15 amps for 10 minutes.

DO NOT exceed 20 amps (maximum recommended charging rate). Total charging time should not exceed one (1) hour.

49

Maintenance R21

Long-Term Storage Preparation

Frequency: For storage of longer than two (2) months

At the end of the mowing season, the mower should be serviced and prepped for storage to protect the equipment from damage.

Mower Preparation for Storage

1. Thoroughly clean the mower and deck by removing all grass and dirt. Use a blower or a low pressure wash to perform this step.

IMPORTANT If using water to clean your machine, avoid using excessive water. It can damage the electronics or the engine. Only use a pressure washer to clean the under side of the deck.

2. Perform any yearly maintenance tasks that have not already been completed.

3. Check for any worn or damaged parts and order replacements from your dealer.

4. Lubricate the grease fittings and oil points us ing the details provided in the section “Lubri cate Grease Fittings and Oil Points” on page

39.

5. Disconnect the battery starting with the nega tive (black) battery terminal and remove it from the mower. Store the battery in a cool, dry location where it won’t be exposed to freez ing temperatures. If your mower is stored in a climate controlled environment, you can leave the battery installed but disconnected.

IMPORTANT: Always keep the battery fully charged to prevent damage especially if it may be exposed to freezing temperatures. For instructions, see “Charge Battery” on page

49.

6. Complete the following “Engine Preparation for Storage” on this page.

7. Store the mower in a clean, dry environment.

Engine Preparation for Storage

If the mower is to be stored for more than two

(2) months, complete the following procedure to prepare the engine.

DANGER

Refer to the section “Safety Before Operating” on page 10 that covers the safe handling of fuel before completing this procedure.

1. Add Kohler PRO ® Series fuel treatment or equivalent to the fuel tank. Run the engine for three (3) minutes to get stabilized fuel into the fuel system.

2. Fill the fuel tank with fresh fuel.

3. Change the oil and replace the filter following the steps provided in the section “Change En gine Crankcase Oil and Filter” on page 44.

4. Remove spark plugs and pour 1 oz of engine oil into the cylinders. Replace spark plugs and crank engine slowly to distribute the oil.

Restarting the Mower After Storage

After long-term storage, complete this procedure to make sure your mower is ready to perform.

1. Check the tire pressure and add air if neces sary. See page 41 for details.

2. Check the engine oil level and add fresh oil if necessary. See the section “Check Engine

Crankcase Oil” on page 35.

3. Install a fully charged battery and attach the battery cables.

4. If not done prior to storage, fill the fuel tank with fresh fuel. Run the machine at half speed for at least five minutes. After this time, check for oil leaks, loosing fittings, and such.

5. Check the operation of the steering levers.

6. Tighten any bolts that have loosened and make sure all cotter and clevis pins are in place.

50

Service and Adjustments

In This Section...

Belt Replacement .............................................................................

51

Deck Leveling ...................................................................................

57

Steering Handle Adjustment .............................................................

58

Forward Speed Control Friction Adjustment ....................................

58

Neutral Function Adjustment ............................................................

59

Straight Tracking Adjustment ............................................................

60

Maximum Forward Speed Adjustment .............................................

60

The information covered in this section can be performed by qualified owner/operators or by a

Authorized Walker Dealer.

DANGER

To prevent accidental starting of the engine when servicing the machine, remove the key from the ignition switch and disconnect the spark plug wires.

Belt Replacement

There are two (2) belts on the R21: the blade drive belt (PTO) and the ground drive belt. If either belt shows wear or damage during a regular inspec tion, the belt should be replaced.

NOTE: Only use Walker replacement belts on this machine.

Ground Drive

Idler Arm

Ground Drive Belt

1/4 Twist

1/4 Twist

Deck Idler

Arm

Blade Belt

R21 Belts

51

Service R21

Replacing the Blade Drive Belt (PTO)

1. With the engine off and the key removed from the ignition, lift the seat panel. Unlock and lift the belt tensioner lever to disengage.

Belt Tensioner

Lever

For a 54" deck: Pull back on the RH Vgroove idler to rotate the deck idler arm and reduce tension. Once the belt is broken-in, you should be able to rotate this by hand, but a wrench is helpful for newer belts. Remove the extension spring, and remove the belt from the RH spindle pulley.

52

Unlocked

Position

Unlock and Disengage Belt Tensioner Lever

2. Raise the footrest. Remove the four (4) wing nuts on the deck belt cover and slide the cover out.

3. For a 42", 48" deck: Push back on the tensioned idler, and remove the belt from the fixed LH idler.

Tension Idler

RH Spindle

Pulley

Extension

Spring

54" Deck: Removing Belt from

RH Spindle Pulley

4. Remove the belt from around the remaining pulleys.

5. Remove the belt from the idler pulleys and clutch pulley below the engine, and discard it.

6. Slide a new belt [Walker P/N 1731-1 (42"),

1731 (48"), or 1731-2 (54")] under the tractor, and route it through the middle sets of idler pulleys. Unlock the carrier frame pivot joint on each side of the deck to lower the deck and give clearance to lift the drive belt cover.

Lifting this cover provides access to the idler pulleys on the deck side.

Drive Belt

Cover

Fixed Idler

42", 48" Deck: Removing Belt from

LH Idler Pulley

Lift Drive Belt Cover to Route the Belt

R21 Service

NOTE: The Belt Routing decal located under the seat panel shows correct belt placement.

10. Check and adjust the effective belt length.

With the drive belt in place, check the position of the front idler on the tensioning arm. The top of the idler should be even with to 1/2" below the edge of the chassis. If the idler is too high, adjust the positions of the deck idlers to effectively lengthen the belt. If the idler is too low, adjust the positions of the deck idlers to effectively shorten the belt.

Idler even with to 1/2" below chassis edge

Idler

Pulley

Belt Routing Decal

7. On the engine side, position the belt between the rear idler pulleys and around the clutch pulley. Be sure to add the 1/4 twist on each side forward of the rear idler pulleys. See the

Belt Routing Decal for details.

8. On the deck side, position the belt around the pulleys. Use the Belt Routing decal as a guide. Be sure to have the correct 1/4 twist on each side as it enters the deck area.

For a 42", 48" deck: Ignore the LH spindle during initial belt placement. Once the belt is placed, push back on the tensioned idler and reinstall the belt around the LH spindle.

For a 54" deck: Pull back on the RH Vgroove idler to rotate the deck idler arm and reinstall the extension spring.

9. Re-engage the belt tensioner lever in the tractor by pushing down on it. The lock will automatically engage.

NOTE: The pulley beside the tensioner ex tension spring may need to be pushed down to increase clearance for the tensioner arm before the lever can be engaged.

Belt Tensioner

Lever (Ref)

Check Position of Front Idler o n Tensioning Arm

For a 42", 48" deck: To adjust for varia tions in belt length, the idler stop has two (2) mounting positions; it can be mounted forward to effectively shorten the drive belt or back to lengthen the belt. It comes from the factory mounted in the back position. The LH fixed idler has three (3) mount holes to effectively shorten or lengthen the belt and it comes from the factory mounted in the middle hole. Use any combination of mounting the idler stop and LH idler pulley to adjust for the correct

Position of Front Idler on Tensioning Arm

(as shown in illustration).

RH Tensioning Idler

RH Idler Stop

LH Fixed

Idler

Lengthens

Belt

Shortens

Belt

Adjust Effective Belt Length (42", 48")

53

Service R21

For a 54" deck: The RH and LH fixed idlers can be moved forward (one or both) to effec tively shorten the belt. They come mounted in the rear holes from the factory.

RH Fixed

Idler

LH Fixed

Idler

1. With the engine off and the key removed from the ignition, lift the seat panel. Unlock and lift the belt tensioner lever to disengage.

Belt Tensioner

Lever

54

Unlocked

Position

Shortens

Belt Shortens

Belt

Adjust Effective Belt Length (54")

Tension Idler LH Fixed Idler

Idler Pulleys (42" Shown)

11. Lower the seat panel, raise and lock the car rier frame, and reinstall the deck belt cover.

Tighten the four (4) wing nuts to secure the cover.

Replacing the Ground Drive Belt

NOTE: The first part of this procedure involves loosening the blade drive belt and disconnecting the clutch wire to allow for the ground drive belt to be removed.

Unlock and Disengage Belt Tensioner Lever

2. Raise the footrest. Remove the four (4) wing nuts on the deck belt cover and slide the cover out.

3. For a 42", 48" deck: Push back on the tensioned idler, and remove the belt from the fixed LH idler.

Tension Idler

Fixed Idler

42", 48" Deck: Removing Belt from

LH Idler Pulley

R21 Service

For a 54" deck: Pull back on the RH Vgroove idler to rotate the deck idler arm and reduce tension. Once the belt is broken-in, you should be able to rotate this by hand, but a wrench is helpful for newer belts. Remove the extension spring, and remove the belt from the RH spindle pulley.

Clutch Wire -

Brown to Green Connector

RH Spindle

Pulley

Extension

Spring

54" Deck: Removing Belt from

RH Spindle Pulley

4. Remove the loosened blade drive belt from the clutch pulley directly below the engine.

5. Remove the solenoid guard by removing three (3) screws and nuts as identified in the

Remove Solenoid Guard for Clutch Wire

Access photo.

Mounting Screws

Solenoid

Guard

Disconnect Clutch Wire

7. Using a 9/16 in. (14 mm) wrench from the bot tom of the ground drive idler arm pulley, push back to create slack in the belt. Lift the belt up off of the idler pulley.

Push Back to

Create Slack in the Belt

Ground Drive

Idler Pulley

Rotate Ground Drive Idler Arm to Loosen Belt

8. Place belt between two blades of the transaxle fan and rotate fan to remove the belt as shown in the Ground Drive Belt Between Transaxle

Fan Blades photo. Repeat on the other side.

9. Remove belt from the engine clutch pulley and slide the belt out.

Mounting Screw Below

Remove Solenoid Guard for Clutch Wire Access

6. Disconnect the clutch wire as shown in the

Disconnect Clutch Wire photo. Remove the mounting tie below the engine to free the wire for belt removal.

55

Service R21

18. Re-engage the belt tensioner lever in the tractor by pushing down on it. The lock will automatically engage. Lower the seat panel.

NOTE: The pulley beside the tensioner ex tension spring may need to be pushed down to increase clearance for the tensioner arm before the lever can be engaged.

Ground Drive Belt Between

Transaxle Fan Blades

10. Slide in the replacement ground drive belt

(Walker P/N 1250), and position the belt on clutch pulley.

NOTE: The Belt Routing decal located under the seat panel shows correct belt placement.

11. Position the belt around the transaxle fans using the same technique that was used to remove it.

12. Using the 9/16 in. (14 mm) wrench, rotate the ground drive idler arm to install the new belt around the idler pulley. Release the idler pul ley to tension the belt.

13. Reconnect the clutch wire, replace the mount ing tie for the clutch wire, and reinstall the solenoid guard.

14. On the engine side, position the belt between the rear idler pulleys and around the clutch pulley. Be sure to add the 1/4 twist on each side forward of the rear idler pulleys. See the

Belt Routing Decal for details.

15. Re-tension the blade drive belt in the deck.

For a 42", 48" deck: Push back on the ten sioned idler, and reinstall the belt around the

LH spindle.

For a 54" deck: Pull back on the RH Vgroove idler to rotate the deck idler arm and reinstall the extension spring.

16. Reinstall the belt cover on the deck.

17. Lower the footrest.

56

R21 Service

Deck Leveling

The mower deck and support frame are jig weld ed; 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 of all pneumatic tires as a possible cause of the deck not being level.

1. Position mower on a smooth, level surface.

Turn off the engine and remove the ignition key.

2. Set the cutting height to the highest position at 4 in. (102 mm) - for easy access under the deck to measure blade height. Refer to “Ad justing the Cutting Height” on page 29.

NOTE: A block of wood cut 4 in. (102 mm) high is a convenient gauge to measure blade height above ground during the leveling pro cess.

3. 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.

4. 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.

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

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

4 in. (102 mm)

Wood Block

Deck Leveling

4 in. (102 mm)

Wood Block

57

Service R21

Steering Handle Adjustment

An adjustment range of approximately 3 in. (76 mm) is available on the steering handles which allows the han dles to be adjusted forward or aft depending on the arm length of the operator. The handles are adjusted by loosening the locknut at the pivot point and the locknut holding the handle in position in the adjustment slide. Adjust han dles into most comfortable position and tighten both locknuts.

Pull Steering

Levers Back To

Check Friction

Lock

Locknut

(Position)

Locknut

(Pivot Point)

Steering Handle Adjustment

FSC in Full

Forward Position

FSC Friction Adjustment Test

1. Place the FSC lever in the full FORWARD position, and pull both steering levers fully back; the FSC lever should not move. If the

FSC lever moves back, the friction needs to be increased.

2. With the steering levers held back, move the

FSC lever back from the FORWARD position.

With a proper amount of friction adjusted, the

FSC le ver should move back with a slight amount of re sistance (friction). If the FSC lever movement is “stiff”, the friction needs to be decreased.

3. The FSC friction is increased or decreased by tightening or loosening the friction adjustment nut. Loosen or tighten the nut and check the control function until the conditions of both steps 1 and 2 (above) are met.

FSC Friction

Adjustment Nut

FSC Friction Adjustment Nut

58

R21 Service

Neutral Function Adjustment

1. Securely block up tractor so the drive tires are a couple inches off the ground. The deck should remain attached.

2. Adjust the tracking adjustment nuts at the front of both control rods so that 2 or 3 threads are visible, then loosen the jam nuts on the ball joints at the back of the control rods.

Control Rods Control Arms

Tracking Adjustment Nuts

Transmission Control Rod and Arm Location

(Shown with Parts Removed for Clarity)

WARNING

The following adjustments are made with the engine running. Keep all body parts and tools away from rotating and hot components, and secure all loose clothing.

3. With the seat panel lowered and the FSC in

NEUTRAL-PARK, start the engine. With the engine at normal operating speed, check for movement of the drive wheels.

4. Using a wrench on one tracking adjustment nut, rotate the control rod counterclockwise just until the wheel on that side begins to move forward.

Then, counting the turns required, rotate the control rod clockwise just until the wheel stops and then begins to move in reverse.

Rotate the control rod back coun terclockwise half the number of turns required to make the wheel go from moving forward to reverse. The transmission is now centered in the neutral window. Tighten the jam nut on the ball joint and repeat the same procedure on the other transmission.

5. Turn off the engine, and then lower the drive tires onto the ground.

Tracking Adjust ment Nut

(Adjusts Length of

Control Rod)

Control Rod

REV

FWD

Jam Nut

Ball Joint

Transmission

Control Arm

Tracking Adjustment Components

59

Service R21

Straight Tracking Adjustment

1. Sit in the seat, start the engine, and set the throttle at full speed. With the FSC in the

NEUTRAL-PARK po sition, check for move ment of either drive wheel. If either wheel moves backward or forward, perform the

“Neutral Function Adjustment” on page 59.

2. Check for straight ground tracking on a level surface (with hands off the steering levers).

Set the FSC at several different speeds and ob serve if the machine moves in a straight line using a cement joint or other line on ground for refer ence.

3. If tracking is not straight, shorten the control rod on the faster side by turning the tracking adjustment nut of that side clockwise using 1/2 in. (13 mm) wrench.

Tracking Adjust ment Nuts tracking adjustment nut counterclockwise until straight tracking and neutral are both achieved.

IMPORTANT: After tracking adjustments are complete, confirm that there is at least one (1) thread visible on both control rods past the tracking adjustment nuts.

If the machine is tracking straight throughout the speed range except at maximum speed, use the following adjustment procedure:

1. Raise the seat panel to access the maximum speed adjustment set screw.

Loosen the jam nut and turn the adjust ment screw counterclockwise to allow the

FSC lever to move (over-travel) to the full forward position.

2. Lower the seat to the normal operating position and observe if one steering lever is ahead of the other. Raise the seat and turn the adjustment screw clockwise until the steering levers are aligned with each other with the FSC lever full forward (this may take several trials to bring the levers to alignment). Tighten the jam nut.

3. Test drive the machine to confirm that straight tracking is being achieved at maximum forward speed (FSC lever in full forward position).

Tracking Adjustment Nuts

NOTE: If tracking issues only occur at maximum speed, proceed to the next step.

□ If straight tracking and neutral are both achieved, the adjustment is complete.

□ If straight tracking and neutral cannot both be achieved, turn the tracking adjustment nut on the faster side counterclockwise until neutral is restored. Lengthen the con trol rod on the slower side by turning the

T-Handle

Hex Wrench

Maximum

Speed Adjust ment Screw

Maximum Speed Tracking Adjustment

60

Appendix: Assembly Instructions

In This Section...

Assembling the Tractor .....................................................................

61

Assembling the Deck ........................................................................

62

Installing the Deck ............................................................................

63

WARNING

It is critical to follow the steps provided for setup and assembly of the tractor and deck to ensure the safety of the operator and performance of the equipment.

Walker Mowers are shipped partially assembled to our distribution network. These steps should be completed before the customer takes possession of their new mower.

Assembling the Tractor

The following steps need to be performed to pre pare the R21 for initial use after shipment from the factory.

1. Install the seat.

A. Remove the protective sheet from the seat panel.

B. Install the seat using the four (4) 1-1/4 x

3/4 Shock Mounts and 5/16-18 Whiz Lock nuts supplied on the bottom of the seat.

C. Connect the safety switch wire harness to the receptacle on the bottom of the seat.

2. Install the steering lever handles. The steer ing lever handles and necessary hardware are included in the hardware bag. Attach each handle using two (2) 1/4-20 x .770 Knurled bolts and 1/4-20 self-locking nuts and one (1)

.625 x .040 washer on the adjustment slot.

Steering Lever Handles Installed

3. The tires ship installed. Check and adjust the inflation of the tires. The tire inflation recom mendations are:

Drive =

Tailwheel =

15 PSI (103 kPa)

20 PSI (137 kPa)

For tractors shipping outside the US the following additional steps will need to be performed.

4. Add fuel to the gas tank. Use only clean, fresh automotive grade unleaded gasoline (87 oc tane minimum, 10% ethanol maximum).

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 storage container and funnel.

IMPORTANT: DO NOT mix oil with gasoline.

Always use fresh, automotive grade unleaded gasoline. DO NOT use gasoline containing greater than 10% ethanol. DO NOT use ad ditives, such as carburetor cleaners, deicers, or moisture removing agents. DO NOT use gasoline blended with methyl alcohol.

61

Assembly Instructions for the R21

DANGER

Handle gasoline with care. Gasoline is highly flammable and its vapors are explo sive. Use safe refueling procedures:

● DO NOT smoke while refueling.

● Avoid spilling fuel; use a funnel or spout.

5. Connect the battery cable to the negative bat tery terminal using the hardware provided in the hardware bag. You will need a 1/4-20 x

5/8 hex bolt, a 1/4 SAE washer, and a 1/4-20

Keps nut to make the cable connection. Slide the rubber boot up and over the battery post completely to prevent an electrical short.

Assembling the Deck

CAUTION

The engine must be off during the tractor assembly and deck installation.

The following steps prepare the deck for the R21 for initial use after shipment from the factory.

Deck Caster Wheel Installation

1. Remove the bolt and nut from each deck caster wheel fork.

2. Fit a bearing cup on the outside of each wheel bearing and slide the wheel assembly into the wheel fork.

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

4. Tighten the bolt and nut until the axle spacer tube and inner bearing race bottom against the inside of the wheel fork (will not turn) while the wheel spins freely without binding.

Axle Spacer

Tube

Bearing

Cup

Axle Bolt

Deck Caster Wheel Installation

5. Grease the caster wheel bearings and caster pivot bearings—two (2) grease fittings for each wheel.

Tilt-Up Roller Wheel Installation

Mount the two (2) tilt-up roller wheels on the brackets on the rear skirt of the deck housing us ing the axle bolt (Walker P/N 8490), 3/8 in. plain washer, 3/8 in. wave spring washer (between bracket and wheel) and 3/8-16 Whiz locknut.

Tighten the axle bolt until the wheel rolls freely but is not loose.

Roller

Wheels

Roller Wheel Installation

62

Installing the Deck

CAUTION

The engine must be off during the tractor assembly and deck installation.

WARNING

Part of this procedure can be more easily ac complished with two (2) people.

1. Remove and discard the shipping link from the

RH deck support arm by clipping the cable tie.

Assembly Instructions for the R21

3. Lift the deck belt access panel to verify the belt placement. The belts should run flat be tween the pulleys.

Lift panel to verify belt placement

Belt Access Panel

4. Roll the deck to the tractor with the excess belt sliding under the tractor and align the car rier frame with the deck arms.

Deck

Arms

Remove and

Discard

Shipping Link

Shipping Link on RH Deck Support Arm

2. Install the two (2) deck counterweight springs on the tractor posts. Make sure the spring hooks are positioned to the outside between the rubber spacer tube and the washer. Do not place the spring on the spacer tube.

Not on the spacer or directly beside the chassis

Spring positioned between the spacer and the washer

Deck Arms Aligned with Carrier Frame

5. Lift the carrier frame and install the 7/16-14 x 2 carriage bolt on each side. Position the bolts so the nuts will face out.

Counterweight Spring Installed on Tractor Post

63

Assembly Instructions for the R21

64

Install Carriage Bolt

6. Push down the deck lock lever, lift up the car rier frame, and release the deck lock lever to lock the deck pivot hinge on each side.

Install Counterweight Spring on Carrier Frame

IMPORTANT: Make sure the counterweight spring hook is connected to the post on the carrier frame and not on the carriage bolt.

Counterweight spring on the carrier frame post

Deck Lock

Levers

Deck Pivot Hinges Locked

7. Install the deck tilt bar and with the aid of a second person, lift the front of the deck. Slide the deck counterweight spring over the end of each carriage bolt onto the carrier frame.

NOTE: If a second person is not available, lift the front of the deck and place blocks under the front wheels to secure the deck before installing the counterweight springs.

Counterweight Spring on Carrier Frame

8. Lower the deck and install the nut onto each carriage bolt. Using a 11/16 in. wrench, tighten the nuts and then loosen them 1/2 turn until the pivot joint moves freely to allow for the deck to pivot and tilt up.

Install Nut on Carriage Bolt

9. Raise the footrest.

10. Remove the four (4) wing nuts on the deck belt cover and slide the cover out.

11. For a 42", 48" deck: Remove the belt from the LH spindle pulley.

LH

Spindle

Pulley

42", 48" Deck: Remove Belt from

LH Spindle Pulley

For a 54" deck: Remove the extension spring, and remove the belt from the RH spindle pulley.

Assembly Instructions for the R21

1/4 Twist

Quarter Twist on Each Side

NOTE: The Belt Routing decal located under the seat panel shows correct belt placement.

RH Spindle

Pulley

Extension

Spring

54" Deck: Remove Belt from

RH Spindle Pulley

12. Lift the seat panel. Unlock and lift the belt tensioner lever to disengage.

13. On the engine side, position the belt between the rear idler pulleys and around the clutch pulley. Be sure to add the 1/4 twist on each side forward of the rear idler pulleys. See the

Belt Routing Decal for details.

Belt Routing Decal

14. Re-tension the blade drive belt in the deck.

For a 42", 48" deck: Push back on the ten sioned idler, and reinstall the belt around the

LH spindle.

For a 54" deck: Pull back on the RH Vgroove idler to rotate the deck idler arm and reinstall the extension spring.

15. Re-engage the belt tensioner lever in the tractor by pushing down on it. The lock will automatically engage. Lower the seat panel.

NOTE: The pulley beside the tensioner ex tension spring may need to be pushed down to increase clearance for the tensioner arm before the lever can be engaged.

65

Assembly Instructions for the R21

16. Check and adjust the effective belt length.

With the drive belt in place, check the position of the front idler on the tensioning arm. The top of the idler should be even with to 1/2" below the edge of the chassis. If the idler is too high, adjust the positions of the deck idlers to effectively lengthen the belt. If the idler is too low, adjust the positions of the deck idlers to effectively shorten the belt.

Idler even with to 1/2" below chassis edge

Idler

Pulley

For a 54" deck: The RH and LH fixed idlers can be moved forward (one or both) to effec tively shorten the belt. They come mounted in the rear holes from the factory.

RH Fixed

Idler

LH Fixed

Idler

66

Belt Tensioner

Lever (Ref)

Check Position of Front Idler o n Tensioning Arm

For a 42", 48" deck: To adjust for varia tions in belt length, the idler stop has two (2) mounting positions; it can be mounted forward to effectively shorten the drive belt or back to lengthen the belt. It comes from the factory mounted in the back position. The LH fixed idler has three (3) mount holes to effectively shorten or lengthen the belt and it comes from the factory mounted in the middle hole. Use any combination of mounting the idler stop and LH idler pulley to adjust for the correct

Position of Front Idler on Tensioning Arm

(as shown in illustration).

RH Tensioning Idler

RH Idler Stop

LH Fixed

Idler

Shortens

Belt Shortens

Belt

Adjust Effective Belt Length (54")

Tension Idler LH Fixed Idler

Idler Pulleys (42" Shown)

17. Reinstall the belt cover on the deck.

18. Lower the footrest.

Lengthens

Belt

Shortens

Belt

Adjust Effective Belt Length (42", 48")

LIMITED WARRANTY

FOR

WALKER MODEL R21

RIDER MOWERS

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 three (3) years or 300 hours whichever comes first after date of sale to the original retail purchaser. At Walker’s request, customer will make the defective part available for inspection by

Walker and/or return the defective part to Walker, transportation charges prepaid. All parts and components of the Walker

Mower are covered by this warranty except the following components which are warranted separately by their respective manufacturers:

Kohler Engine

Battery

The available warranties covering these items are furnished with each mower. Walker does not assume any warranty obligation, liability or modification for these items, which are covered exclusively by the stated warranty of the respective manufacturers noted above.

2. WHAT THIS WARRANTY DOES NOT COVER:

A. This warranty does not cover defects caused by depreciation or damage caused by normal wear, accidents, improper maintenance, improper use or abuse of the product, alterations, or failure to follow the instructions contained in the

Operator’s Manual for operation and maintenance.

B. The customer shall pay any charges for making service calls and/or for transporting the mower to and from the place where the inspection and/or warranty work is performed.

3. HOW TO OBTAIN SERVICE UNDER THIS WARRANTY:

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

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

4. WARRANTY LIMITATION:

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

CHASE INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY LIM-

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

IMPLIED WARRANTIES ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

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

OR EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply to you.

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

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

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

FORM NO. 112923 PRINTED IN USA www.walker.com ©2023 WALKER MFG. CO

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