Exmark COMMERCIAL 21 Operator's Manual

COMMERCIAL21

ForSerialNos.
316,000,000&Higher

PartNo.4502-544Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemical

orchemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Theengineinthisproductisnot
equippedwithasparkarrestermufer.Itisa
violationofCaliforniaPublicResourceCode
(CPRC)Section4442touseoroperatethis
engineonanyforest-covered,brush-covered,
orgrass-coveredlandasdenedinCPRC4126.
Otherstatesorfederalareasmayhavesimilar
laws.

noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.

Toacquireasparkarresterforyourunit,seeyour
EngineServiceDealer.

Thissparkignitionsystemcomplieswiththe
CanadianstandardICES-002.Cesystèmed’allumage
parètincelledevèhiculeestconformeàlanorme
NMB-002duCanada.

TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.

Labeledpowerratingsaresuppliedbytheengine
manufacturerinaccordancewithSAEtesting
andgross/netpowerratingstandards(J1940,
J1995,J1349).

Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept

©2015ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310

Contactusatwww.Exmark.com.

2

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

Figure1

Important:Tomaximizesafety,performance,

andproperoperationofthismachine,itis
essentialthatalloperatorscarefullyreadand
fullyunderstandthecontentsoftheOperator’s
manualprovidedwiththeproduct.Safe
operationofExmarkequipmentisessential.
Failuretocomplywiththeoperatinginstructions
orreceivepropertrainingmayresultininjury.

Gotohttp://www.Exmark.comforadditional
safeoperationinformation,suchassafetytips,
trainingmaterials,andOperator’smanuals.

Ifadditionalinformationisneeded,orshould
yourequiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.

AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.

3

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.......................9

Specications........................................................12

Systems..........................................................12

Dimensions....................................................12

ProductOverview.................................................13

Operation..............................................................13

Controls.........................................................13

Pre-Start.........................................................15

OperatingInstructions...................................15

Maintenance..........................................................22

RecommendedMaintenanceSchedule(s)............22

PeriodicMaintenance........................................23

CheckEngineOilLevel..................................23

CheckingtheBladeBrakeClutch(Blade

BrakeClutchOnly).....................................23

CheckingtheMowerBlade.............................23

CheckforLooseHardware.............................25

ChecktheBladeBrakeClutchBail

Operation(BladeBrakeClutchUnits

Only)..........................................................25

ServiceAirFilter(KawasakiUnits)..................26

ServiceAirFilter(HondaUnit).......................26

ChangeEngineOil.........................................27

ChangeOilFilter(KawasakiX-Series

Units).........................................................28

CheckConditionOfBelt(Self-Propelled

UnitsOnly)................................................28

CheckSparkPlugs..........................................28

EmptyingtheFuelTankandCleaningthe

FuelFilter...................................................29

Adjustments......................................................29

AdjustingtheSelf-PropelDrive

(Self-PropelledUnitsOnly).........................29

AdjustingtheBladeBrakeCable(Blade

BrakeClutchUnitsOnly)............................30

Cleaning............................................................31

CleanGrassBuild-UpUnderDeck.................31

CleaningtheDischargeTunneland

Plug............................................................31

CleaningUndertheBeltCover

(Self-PropelledUnitsOnly).........................32

CleaningtheBladeBrakeClutchShield

(BladeBrakeClutchUnitsOnly).................32

CleaningUndertheCoverPlate(Non-Blade

BrakeClutchUnitsOnly)............................33

WasteDisposal...............................................33

Storage..................................................................34

PreparingtheFuelSystem...............................34

PreparingtheEngine......................................34

GeneralStorageInformation..........................34

RemovingtheLawnMowerfrom

Storage.......................................................34

Troubleshooting....................................................35

4

Safety

Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheConsumer
ProductSafetyCommission(CPSC)bladesafety
requirementsforwalk-behindrotarymowersand
theB71.4specicationsoftheAmericanNational
StandardsInstituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer
reasonablysafeservice;however,failuretocomply
withthefollowinginstructionsmayresultinpersonal
injury.

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readthismanual,itistheowner’sresponsibilityto
explainthismaterialtothem;otherlanguagesmay
beavailableonourwebsite.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate
amower,andevenmatureteenagersshouldhave
adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator's

Manualandrecognizestherisksinvolved;

Figure2

SafetyAlertSymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Indicatesanimminentlyhazardous

situationwhich,ifnotavoided,Willresultindeathor
seriousinjury.

WARNING:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Couldresultindeath
orseriousinjury.

CAUTION:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Mayresultinminor
ormoderateinjury.

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe
mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,andhearingprotection.Do
Notoperatewhenbarefootorwhenwearingopen
sandals.Longhair,looseclothingorjewelrymay
gettangledinmovingparts.

CAUTION

Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.

Wearhearingprotectionwhenoperatingthis
machine.

5

Safety

•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.

DANGER

Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground,
inanopenarea,whentheengineiscold.
Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.

•DoNotllthefueltankcompletelyfull.
Fillthefueltanktothebottomoftheller
neck.Theemptyspaceinthetankallows
gasolinetoexpand.Overllingmayresult
infuelleakageordamagetotheengine
oremissionsystem.

•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.

DANGER

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.

•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.Do
Notuseanozzlelockopendevice.

•Addfuelbeforestartingtheengine.Never
removethecapofthefueltankoradd
fuelwhenengineisrunningorwhenthe
engineishot.

•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

WARNING

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas
tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperatorpresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.

6

Safety

Operation

WARNING

Operatingengineparts,especiallythemufer,
becomeextremelyhot.Severeburnscanoccur
oncontactanddebris,suchasleaves,grass,
brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to
coolbeforetouching.

•Removeaccumulateddebrisfrommuferand
enginearea.

WARNING

Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcankill
you.

DoNotrunengineindoorsorinasmallconned
areawheredangerouscarbonmonoxidefumes
cancollect.

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,
DoNotoperatethemachine;seekshelter.

•Starttheenginecarefullyaccordingtoinstructions
withfeetwellawayfromtheblade.

•Neverraisedeckwithbladerunning.

•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.

•Nevermowwiththedischargedoorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly .

•Grasscatchercomponentsaresubjecttowear,
damageanddeterioration,whichcouldexpose
movingpartsorallowobjectstobethrown.
Frequentlycheckthecomponentsandreplace
themwiththemanufacturer’srecommendedparts
whennecessary.

•DoNotchangetheenginegovernorsettingor
overspeedtheengine.

•Parkthemachineonlevelground.Stopengine,
waitforallmovingpartstostop,andremovethe
sparkplugwire(s).

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

–Beforemakingheightadjustments.

WARNING

Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesinplace
andworkingproperly.

•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.

•Keepclearofthedischargeopeningatalltimes.

•Thismowerwasdesignedforoneoperator
only.Keepallothersawayfrommowerduring
operation.

•DONOToperatethemowerwhenpeople,
especiallychildren,orpetsareinthearea.

•Bealert,slowdownandusecautionwhen
makingturns.Lookbehindandtothesidebefore
changingdirections.

•Stoptheblades,slowdown,andusecaution
whencrossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.

•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.

•Neverattempttomakewheelheightadjustments
whiletheengineisrunning.

•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.

7

Safety

•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.

•Usefullwidthrampsforloadingmachineinto
trailerortruck.

•Tiethemachinedownsecurelyusingstraps,
chains,cable,orropes.Ifpossible,bothfrontand
rearstrapsshouldbedirecteddownandoutward
fromthemachine.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.

DANGER

Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Lossofcontrol
and/orlossofoperator'sfootingcouldresultina
fallwithanarmorleggettingunderthemower
orenginedeckwhichmayresultinseriousinjury,
deathordrowning.

•Mowacrossslopes,neverupanddown.

•DoNotmowslopeswhengrassiswet.

•Useextremecautionwhenmowingnear
drop-offsornearwater.

MaintenanceandStorage

•Stoptheengineandremovethesparkplug
wire(s).Waitforallmovementtostopbefore
adjusting,cleaningorrepairing.

•Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.

•LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.

•Removesparkplugwirebeforemakingany
repairs.

•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.

•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•DoNotmowexcessivelysteepslopes.

•Reducespeedanduseextremecautionon
slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Whenfeasible,avoidoperatingtheequipmentin
wetgrass.

•Progressivelygreatercareisneededastheslope
increases.

•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.

•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

WARNING

Removalormodicationoforiginalequipment,
partsand/oraccessoriesmayalterthewarranty,
controllability,andsafetyofthemachine.
Unauthorizedmodicationstotheoriginal
equipmentorfailuretouseoriginalExmark
partscouldleadtoseriousinjuryordeath.
Unauthorizedchangestothemachine,engine,
fuelorventingsystem,mayviolateapplicable
safetystandardssuchas:ANSI,OSHAand
NFPAand/orgovernmentregulationssuchas
EPAandCARB.

8

SafetyandInstructionalDecals

Safety

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

1.Choke–on

2.Throttle–fast

3.Continuousvariablesetting

4.Throttle–slow

94-8072

116-1922

117–2718

103-6327

ECX160CHN21000

119-0217

1.Warning—stoptheengine;stayawayfrommoving
parts;keepallguardsandshieldsinplace.

9

Safety

130-9670

1.Severinghazardofhandorfoot;mowerblade—keep
awayfrommovingparts;keepallguardsandshields
inplace.

125-8403

KawasakiNon-BBCUnits

1.Pushtheprimeronce.2.Pulltherecoil-start

130-9656

BBCUnits

handle.

1.Choke3.Slow

2.Fast4.Engine—stop

10

Safety

116-7583

1.Warning–ReadtheOperator’sManual.DoNotoperate
thismachineunlessyouaretrained.

2.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.

3.Thrownobjecthazard—DoNotoperatethemowerwithout
thereardischargeplugorbaginplace.

4.Cutting/dismembermenthazardofhandorfoot,mower
blade—stayawayfrommovingparts;keepallguardsin
place.

5.Warning—wearhearingprotection.

6.Cutting/dismembermenthazardofhandorfoot,mower
blade—DoNotoperateupanddownslopes;operate
sidetosideonslopes;stoptheenginebeforeleavingthe
operatingposition—pickupobjectsthatcouldbethrown
bytheblades;andlookbehindyouwhenbackingup.

11

Specications

Specications

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s
Manual

•EngineOilType:Exmark4–CyclePremium
EngineOil

•RPM:3300RPM(NoLoad)

FuelSystem

•Capacity:

S-SeriesUnit:2.0qt(1.9L)

X-SeriesUnits:4.0qt(3.8L)

•FuelRecommendations:

–Forbestresults,useonlyclean,fresh,unleaded

gasolinewithanoctaneratingof87orhigher
((R+M)/2ratingmethod).

Transmission(SelfPropelledUnits)

Variable

SpeedRange:0–4.2mph(6.8km/hr)

CuttingDeck

•CuttingWidth:21inches(53.3cm)

•BladeBrake:Whenthebladeengagementcontrol
ismovedtothedisengagedpositionafriction
brakepadstopstherotationoftheblades.

•BladeSize:(1ea.):20.88inches(53.0cm)

•Deck:21inchesrigid.Deckdesignallowsfor
bagging,mulchingorreardischarge.

•CuttingHeightAdjustment:

Adjustsfrom1inch(2.5cm)to41/2inches(11.4
cm)in1/2inch(1.3cm)increments.

•MulchingKit:StandardonX-SeriesUnits

Dimensions

–Oxygenatedfuelwithupto10%ethanolor

15%MTBEbyvolumeisacceptable.

–DoNotuseethanolblendsofgasoline(such

asE15orE85)withmorethan10%ethanol
byvolume.Performanceproblemsand/or
enginedamagemayresultwhichmaynotbe
coveredunderwarranty.

–DoNotusegasolinecontainingmethanol.

–DoNotstorefueleitherinthefueltankor

fuelcontainersoverthewinterunlessafuel
stabilizerisused.

–DoNotaddoiltogasoline.

•FuelFilter:Non-replaceable,intank

•FuelShut-OffValve:

S-SeriesUnit:DoesNothaveashut-offvalve.

Allotherunitshaveashut-offvalve.

SafetyInterlockSystem

CurbWeight:

98-122lb(44-55kg)Weightsmayvaryslightly
dependingonengineoption.

OverallWidth:

22inches(55.9cm)

OverallLengthandHeightat
21/2inchCuttingHeight:

HandleSettingLengthHeight

High61.00inches

(154.9cm)

Medium

Low

63.00inches
(160.0cm)

64.50inches
(163.8cm)

39.00inches
(99.1cm)

37.50inches
(95.3cm)

35.00inches
(88.9cm)

ForunitswithoutaBladeBrakeClutch:Operator
musthavethebladecontrolbaildepressedtostart
theengine.Releasingthebladecontrolbailwillcause
theenginetostop.

12