Exmark COMMERCIAL 21 Operator'S Manual Download | Manualshive

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Troubleshooting

Problem

Possible Cause

Corrective Action

1. The self-propel drive cable is out of

adjustment or is damaged.

1. Adjust the self-propel drive cable. Replace

the cable if necessary.

Lawn mower does not self-propel.
(Self-Propel Units Only)

2. There is debris under the belt cover.

2. Clean the debris from under the belt

cover.

Difficult to pull lawnmower rearward
(Self-Propelled Units Only).

1. Transmission is locked.

1. Push mower forward to disengage the

transmission and then pull rearward.

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Summary of Contents for COMMERCIAL 21

Page 1: ...COMMERCIAL 21 For Serial Nos 316 000 000 Higher Part No 4502 544 Rev A ...

Page 2: ... The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer L...

Page 3: ...com for additional safe operation information such as safety tips training materials and Operator s manuals If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficien...

Page 4: ...it 26 Change Engine Oil 27 Change Oil Filter Kawasaki X Series Units 28 Check Condition Of Belt Self Propelled Units Only 28 Check Spark Plugs 28 Emptying the Fuel Tank and Cleaning the Fuel Filter 29 Adjustments 29 Adjusting the Self Propel Drive Self Propelled Units Only 29 Adjusting the Blade Brake Cable Blade Brake Clutch Units Only 30 Cleaning 31 Clean Grass Build Up Under Deck 31 Cleaning th...

Page 5: ... Manual and other training material If the operator s or mechanic s can not read this manual it is the owner s responsibility to explain this material to them other languages may be available on our website Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never l...

Page 6: ...ot operate without entire exhaust system in place and in proper working condition DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline ...

Page 7: ...ecessary Do Not change the engine governor setting or overspeed the engine Never attempt to make wheel height adjustments while the engine is running Park the machine on level ground Stop engine wait for all moving parts to stop and remove the spark plug wire s Before checking cleaning or working on the mower After striking a foreign object or abnormal vibration occurs inspect the mower for damage...

Page 8: ... change the stability of the machine and cause loss of control Maintenance and Storage Stop the engine and remove the spark plug wire s Wait for all movement to stop before adjusting cleaning or repairing Keep engine and engine area free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may resu...

Page 9: ... be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower ...

Page 10: ...nits 1 Push the primer once 2 Pull the recoil start handle 130 9656 BBC Units 1 Choke 3 Slow 2 Fast 4 Engine stop 130 9670 1 Severing hazard of hand or foot mower blade keep away from moving parts keep all guards and shields in place 10 ...

Page 11: ...p bystanders a safe distance from the machine 5 Warning wear hearing protection 3 Thrown object hazard Do Not operate the mower without the rear discharge plug or bag in place 6 Cutting dismemberment hazard of hand or foot mower blade Do Not operate up and down slopes operate side to side on slopes stop the engine before leaving the operating position pick up objects that could be thrown by the bl...

Page 12: ...ve All other units have a shut off valve Safety Interlock System For units without a Blade Brake Clutch Operator must have the blade control bail depressed to start the engine Releasing the blade control bail will cause the engine to stop Transmission Self Propelled Units Variable Speed Range 0 4 2 mph 6 8 km hr Cutting Deck Cutting Width 21 inches 53 3 cm Blade Brake When the blade engagement con...

Page 13: ... Blade Brake Clutch When the blade control bail is released the system senses that the operator has moved from the normal operating position and will stop the blade For Units without a Blade Brake Clutch When the blade control bail is released the system senses that the operator has moved from the normal operating position and will kill the engine Figure 4 Blade Brake Unit Shown 1 Blade control lo...

Page 14: ...ard Off position will kill the engine Blade Control Lock Lever Blade Brake Clutch Units Only The blade control lock lever is located on the right side of the handle next to the Blade Control Bail as shown in Figure 4 Moving the blade control lock lever into the full forward position releases the blade control bail Squeezing the blade control bail against the handle engages the blade Releasing the ...

Page 15: ...Handle Adjustment The height of the handle can be adjusted for comfortable operation Stand behind the handle to determine the height To adjust the handle height position the hardware into one of the three holes in the handle bracket Open the Fuel Shut Off Valve Rotate the valve 1 4 turn counterclockwise to turn the fuel on if equipped Starting the Engine 1 Connect the wire to the spark plug Figure...

Page 16: ...Propelled Units Only The lawn mower is variable speed the more you squeeze the drive bail against the handle the faster the machine travels 1 Start the engine 2 Squeeze the drive bail against the handle see Figure 4 Note You can vary the ground speed by increasing or decreasing the distance between the ground speed control bail and the handle Lower the control bail to decrease the ground speed whe...

Page 17: ...housing Figure 11 1 Mulch plug 3 Lip 2 Discharge door 4 Mower housing 4 Lower the discharge door Removing the Mulch Plug Note When grass is thick and lush clippings may collect on and around the discharge tunnel plug This may make it difficult to remove the plug Clean the plug thoroughly after each use 1 To remove the mulch plug raise the discharge door and pull the mulch plug out of the discharge...

Page 18: ...rious injury Check the BBC operation before each use Never use the BBC equipped lawn mower with an inoperative safety system Take your lawn mower to an Authorized Service Dealer for repair if the safety system fails to operate properly Test Using the Grass Bag 1 Install the empty grass bag on the discharge tunnel 2 Start the engine 3 For units with a Blade Brake Clutch Push the blade control lock ...

Page 19: ...e indicator to determine the desired setting 3 Release the wheel height adjustment rod to set the pin securely in the desired notch Front Wheel Adjustment 1 Pull up on the height adjuster and pull the front wheel shaft assembly outward as shown in Figure 14 Figure 14 1 Front wheel shaft assembly 4 Front quadrant block cut heights 2 Pull up 5 Pull outward 3 Height adjuster 6 Shaft groove 2 Insert t...

Page 20: ...e grass clippings clog the discharge area stop the engine and gently move the discharge door handle back and forth until you can close the door completely If you still cannot close the door remove the obstruction with a stick not your hand Operating Tips Review the Safety section and read this manual carefully before operating the lawn mower Set the engine speed to the fastest position for the bes...

Page 21: ...hes 64 mm and the rear wheels at 3 inches 76 mm Cutting Leaves After cutting the lawn ensure that half of the lawn shows through the cut leaf cover You may need to make more than one pass over the leaves For light leaf coverage set all the wheels at the same cutting height setting If there are more than 5 inches 12 7 cm of leaves on the lawn set the front cutting height one or two notches higher t...

Page 22: ...intenance Procedure After the first 5 hours Change the engine oil Before each use or daily Check the engine oil level Check the stopping time of the blade brake The blade must stop within 3 seconds of releasing the bail if it does not contact an Authorized Service Dealer for repair Check the mower blade and the engine mounting fasteners Check for loose hardware Check the Blade Brake Clutch Bail op...

Page 23: ...e tube Do Not screw into place Remove the dipstick and read the oil level Figure 16 Honda Engine 1 Lower limit mark 3 Dipstick 2 Upper limit mark Figure 17 Kawasaki Engine 1 Dipstick 3 Add 2 Full 4 If the oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Exmark 4 Cycle Premium Engine Oil is recommended refer to the Engine Owner s manual...

Page 24: ...ting season begins During the year file down any small nicks to maintain the cutting edge DANGER A worn or damaged blade can break A piece of the blade could be thrown into the operator s or bystander s area resulting in serious personal injury or death Inspect the blade periodically for wear or damage Replace a worn or damaged blade If it is necessary to remove the blade for replacement or sharpe...

Page 25: ...rt and blade bolt The sail of the blade must point toward the top of the lawn mower housing for proper installation Torque the blade bolt to 35 45 ft lb 47 61 N m Figure 22 1 Blade Brake Clutch Units front view 4 Blade 2 Blade Brake Clutch Units side view 5 Blade support 3 Blade driver 6 Units without a Blade Brake Clutch 6 Return the lawn mower to its upright position 7 Connect the wire to the sp...

Page 26: ...es Units 1 Cover 3 Paper air filter 2 Foam element 4 Air filter base Figure 24 S Series Units 1 Cover 3 Foam element 2 Paper air filter 4 Remove the paper air filter and discard it as required Note Do Not try to clean a paper air filter 5 Remove the foam element and wash it with a mild detergent and water then blot it dry 6 Saturate the element with clean engine oil then squeeze it Do Not twist to...

Page 27: ...d dry the foam element thoroughly 11 Dip the foam element in clean engine oil then squeeze out the excess oil Note Excess oil in the foam element restricts the air flow through the element and may reach the paper filter and clog it 12 Wipe dirt from the base and the cover with a moist rag Note Be careful to prevent dirt and debris from entering the air duct leading to the carburetor 13 Install the...

Page 28: ... only 9 Fill the crankcase as stated in Check Engine Oil Level section Exmark 4 Cycle Premium Engine oil is recommended Refer to the Engine Owner s Manual for an acceptable alternative 10 Connect the wire to the spark plug 11 Run the engine for about 3 minutes 12 Stop the engine wait for all moving parts to stop and check for oil leakage around the filter 13 Add oil to compensate for the oil in th...

Page 29: ...in the fuel tank move the fuel around in the tank and pour it out into an approved fuel container 10 Install the fuel tank and fuel line Adjustments Note Wait for all moving parts to stop and remove spark plug wire before servicing cleaning or making any adjustments to the unit Adjusting the Self Propel Drive Self Propelled Units Only If the lawn mower does not self propel or has a tendency to cre...

Page 30: ... if the blade control lock lever does not operate properly 1 Stop the engine and wait for all moving parts to stop 2 Disconnect the wire from the spark plug 3 Remove the belt cover by pulling upward on the back of the cover to unsnap the front and back cover tabs see Figure 28 Remove any debris under the cover 4 Loosen the cable clamp screw until the cable conduit slides see Figure 30 Figure 30 1 ...

Page 31: ...ings being washed out from under the housing 5 Disengage the blade stop the engine and wait for all moving parts to stop 6 Turn off the water 7 Start the lawn mower engage the blade and let the lawn mower run for a few minutes to dry out its components Scraping Method If washing does not remove all debris from under the lawn mower scrape it clean 1 Disconnect the wire from the spark plug 2 Drain t...

Page 32: ...abs see Figure 28 4 Lift off the cover and brush out all the debris around the belt area 5 Install the belt cover by pushing down on the rear first and then snapping the front onto the mower housing 6 Connect the wire to the spark plug Cleaning the Blade Brake Clutch Shield Blade Brake Clutch Units Only Service Interval Every 50 hours 1 Stop the engine and wait for all moving parts to stop 2 Disco...

Page 33: ...ade see Figure 33 Figure 33 1 Blade bolt 4 Cover plate 2 Blade support 5 Screw 3 Blade 6 Remove the three screws holding the cover plate onto the unit see Figure 33 7 Remove the cover plate and brush or blow all the debris from under the plate Reinstall the cover plate 8 Install the blade blade support and the blade bolt Torque the blade bolt to 35 45 ft lb 47 61 N m 9 Turn the lawn mower upright ...

Page 34: ...lowly rotate the engine several times using the starter rope to distribute the oil 5 Install the spark plug but Do Not connect the wire to the spark plug General Storage Information 1 Clean the lawn mower housing Refer to Cleaning the Underside of the Lawn Mower Housing section in Cleaning 2 Clean any dirt and chaff from the cylinder cylinder head fins and blower housing 3 Remove grass clippings d...

Page 35: ...awn mower deck 1 The wire is not connected to the spark plug 1 Connect the wire to the spark plug 2 Faulty spark plug 2 Clean adjust or replace spark plug 3 The throttle lever is not in the Fast position 3 Move the throttle lever to the Fast position Engine runs rough 4 The air filter element is dirty and is restricting the air flow 4 Clean the air filter pre cleaner and or replace the paper air f...

Page 36: ... drive cable Replace the cable if necessary Lawn mower does not self propel Self Propel Units Only 2 There is debris under the belt cover 2 Clean the debris from under the belt cover Difficult to pull lawnmower rearward Self Propelled Units Only 1 Transmission is locked 1 Push mower forward to disengage the transmission and then pull rearward 36 ...

Page 37: ...alership To locate a dealer convenient to you access our website at www exmark com U S or Canada customers may also call 402 223 6375 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Re...

Page 38: ...Service Record Date Description of Work Done Service Done By 38 ...

Page 39: ...39 ...

Page 40: ... RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB Some accessories and options not available for some models Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Be...

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