Eureka 7700-7900 Vacuum Cleaner User Manual

COMMERCIAL 21
For Serial Nos.
850,000 & Higher
Part No. 4500-674 Rev. A
WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.
Important: The engine in this product is not
equipped with a spark arrester muffler. It is a
violation of California Public Resource Code
(CPRC) Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126.
Other states or federal areas may have similar
laws.
To acquire a spark arrester for your unit, see your
Engine Service Dealer.
This spark ignition system complies with Canadian
ICES-002 Ce système d’allumage par ètincelle de
vèhicule est conforme à la norme NMB-002 du
Canada.
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.
Exmark reserves the right to make changes or
add improvements to its products at any time
without incurring any obligation to make such
changes to products manufactured previously.
Exmark, or its distributors and dealers, accept
no responsibility for variations which may be
evident in the actual specifications of its products
and the statements and descriptions contained
in this publication.
© 2010—Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
2
Contact us at www.Exmark.com.
Printed in the USA
All Rights Reserved
Introduction
CONGRATULATIONS on the purchase of your
Exmark Mower. This product has been carefully
designed and manufactured to give you a maximum
amount of dependability and years of trouble-free
operation.
This manual contains operating, maintenance,
adjustment, and safety instructions for your Exmark
mower.
BEFORE OPERATING YOUR MOWER,
CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
Figure 1
1. Model and serial number location
By following the operating, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
Model No.
Serial No.
If additional information is needed, or should you
require trained mechanic service, contact your
authorized Exmark equipment dealer or distributor.
Exmark parts manuals are available online at
http://www.exmark.com/manuals.htm.
All Exmark equipment dealers and distributors are
kept informed of the latest methods of servicing
and are equipped to provide prompt and efficient
service in the field or at their service stations. They
carry ample stock of service parts or can secure them
promptly for you from the factory.
All Exmark parts are thoroughly tested and inspected
before leaving the factory, however, attention is
required on your part if you are to obtain the fullest
measure of satisfaction and performance.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
Figure 1 identifies the location of the model and serial
numbers on the product. Write the numbers in the
space provided.
3
Contents
Cleaning Under the Belt Cover
(Self-Propelled Units Only)........................ 33
Cleaning the Blade Brake Clutch Shield
(Blade Brake Clutch Units Only) ................ 33
Cleaning Under the Cover Plate
(Non-Blade Brake Clutch Units
Only)......................................................... 33
Waste Disposal .............................................. 34
Storage ................................................................. 35
Preparing the Fuel System.............................. 35
Preparing the Engine ..................................... 35
General Storage Information ......................... 35
Removing the Lawn Mower from
Storage...................................................... 35
Troubleshooting ................................................... 36
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ....................... 9
Specifications ....................................................... 12
Model Numbers ............................................ 12
Systems ......................................................... 12
Dimensions................................................... 12
Product Overview ................................................ 13
Operation ............................................................. 13
Controls ........................................................ 13
Pre-Start........................................................ 15
Operating Instructions .................................. 15
Maintenance ......................................................... 22
Recommended Maintenance Schedule(s) ........... 22
Periodic Maintenance ....................................... 23
Check Engine Oil Level ................................. 23
Checking the Blade Brake Clutch (Blade
Brake Clutch Only).................................... 23
Check the Mower Blade ................................. 24
Check for Loose Hardware ............................ 25
Check the Blade Brake Clutch Bail
Operation (Blade Brake Clutch Units
Only)......................................................... 25
Service Air Filter (Kawasaki Units)................. 26
Service Air Filter (EC21ASHN Units) ............ 26
Service Air Filter (EC21HNBBC and
EC21HNBBCX Units).............................. 27
Change Engine Oil ........................................ 28
Change Oil Filter (EC21KA,
EC21KABBC, EC21KAX,
EC21KAY, EC21KABBCX,
EC21KABBCY, EC21KACA, and
EC21KABBCCA) ..................................... 29
Check Condition Of Belt (Self-Propelled
Units Only) ............................................... 29
Check Spark Plugs ......................................... 29
Emptying the Fuel Tank and Cleaning the
Fuel Filter.................................................. 29
Adjustments ..................................................... 30
Adjusting the Self-Propel Drive
(Self-Propelled Units Only)........................ 30
Adjusting the Blade Brake Cable (Blade
Brake Clutch Units Only)........................... 31
Cleaning ........................................................... 32
Clean Grass Build-Up Under Deck ................ 32
Cleaning the Discharge Tunnel and
Plug........................................................... 32
4
Safety
Safety
Safe Operating Practices
Safety Alert Symbol
Training
• Read the Operator’s Manual and other training
material. If the operator(s) or mechanic(s) can
not read English it is the owner’s responsibility to
explain this material to them.
• 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 let children or untrained people operate
or service the equipment. Local regulations may
restrict the age of the operator.
• Only adults and mature teenagers should operate
a mower, and even mature teenagers should have
adult supervision. Be sure a teenager:
1. has read and understands the Operator’s
Manual and recognizes the risks involved;
2. is sufficiently mature to use caution; and
3. is of sufficient size and weight to operate
the controls comfortably and to manage the
mower without taking risks.
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
This lawn mower meets or exceeds the Consumer
Product Safety Commission blade safety
requirements for walk-behind rotary mowers and
the B71.4 specifications of the American National
Standards Institute in effect at the time of production.
Exmark designed and tested this lawn mower to offer
reasonably safe service; however, failure to comply
with the following instructions may result in personal
injury.
This Safety Alert Symbol (Figure 2) is used both in
this manual and on the machine to identify important
safety messages which must be followed to avoid
accidents.
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
Figure 2
1. Safety alert symbol
The safety alert symbol appears above information
which alerts you to unsafe actions or situations
and will be followed by the word DANGER,
WARNING, or CAUTION.
Preparation
• Evaluate the terrain to determine what accessories
and attachments are needed to properly and
safely perform the job. Only use accessories and
attachments approved by Exmark.
• Wear appropriate clothing including safety glasses,
substantial footwear, long trousers, and hearing
protection. Do Not operate when barefoot or
when wearing open sandals. Long hair, loose
clothing or jewelry may get tangled in moving
parts.
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
WARNING: Black lettering / Orange background.
Indicates a potentially hazardous situation which, if
not avoided, Could result in death or serious injury.
CAUTION: Black lettering / Yellow background.
Indicates a potentially hazardous situation which, if
not avoided, May result in minor or moderate injury.
CAUTION
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
This machine produces sound levels in
excess of 85 dBA at the operator’s ear and
can cause hearing loss through extended
periods of exposure.
Wear hearing protection when operating this
machine.
5
Safety
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects which can be
thrown by the machine and may cause personal
injury to the operator or bystanders.
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.
DANGER
• Always place gasoline containers on the
ground away from your vehicle before
filling.
In certain conditions gasoline is extremely
flammable and vapors are explosive.
A fire or explosion from gasoline can burn
you, others, and cause property damage.
• Do Not fill gasoline containers inside a
vehicle or on a truck or trailer bed because
interior carpets or plastic truck bed liners
may insulate the container and slow the
loss of any static charge.
• Fill the fuel tank outdoors in an open
area, when the engine is cold. Wipe up
any gasoline that spills.
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
• Do Not fill the fuel tank completely
full. Add gasoline to the fuel tank until
the level is 1/4 to 1/2 inch (6–13 mm)
below the bottom of the filler neck. This
empty space in the tank allows gasoline
to expand.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• If a gasoline dispenser nozzle must be
used, keep the nozzle in contact with the
rim of the fuel tank or container opening
at all times until fueling is complete.
• Never smoke when handling gasoline,
and stay away from an open flame or
where gasoline fumes may be ignited by
spark.
• Store gasoline in an approved container
and keep it out of the reach of children.
WARNING
• Add fuel before starting the engine.
Never remove the cap of the fuel tank or
add fuel when engine is running or when
the engine is hot.
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors has caused
cancer in laboratory animals. Failure to use
caution may cause serious injury or illness.
• If fuel is spilled, Do Not attempt to start
the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Keep away from eyes and skin.
• Do Not operate without entire exhaust
system in place and in proper working
condition.
• Never siphon by mouth.
• Check that the operator’s presence controls,
safety switches, and shields are attached and
functioning properly. Do Not operate unless they
are functioning properly.
6
Safety
Operation
• Never attempt to make wheel height adjustments
while the engine is running.
WARNING
• Stop engine, wait for all moving parts to stop,
remove the spark plug wire(s).
Operating engine parts, especially the
muffler, become extremely hot. Severe burns
can occur on contact and debris, such as
leaves, grass, brush, etc. can catch fire.
– Before checking, cleaning or working on the
mower.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
damage and make repairs before restarting
and operating the mower).
• Allow engine parts, especially the muffler,
to cool before touching.
• Remove accumulated debris from muffler
and engine area.
– Before clearing blockages.
– Whenever you leave the mower.
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered, or
brush-covered unimproved land.
• Stop engine, wait for all moving parts to stop:
– Before refueling.
– Before dumping the grass catcher.
– Before making height adjustments.
WARNING
WARNING
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can
kill you.
Hands, feet, hair, clothing, or accessories can
become entangled in rotating parts. Contact
with the rotating parts can cause traumatic
amputation or severe lacerations.
Do Not run engine indoors or in a small
confined area where dangerous carbon
monoxide fumes can collect.
• Do Not operate the machine without
guards, shields, and safety devices in
place and working properly.
• Operate only in daylight or good artificial light,
keeping away from holes and hidden hazards.
• Start the engine carefully according to instructions
with feet well away from the blade.
• Never raise deck with blades running.
• Never operate the mower with damaged guards,
shields, or covers. Always have safety shields,
guards, switches and other devices in place and in
proper working condition.
• Never mow without the discharge door. Do Not
operate unless the discharge door, grass catcher,
mulch plug, or rear discharge chute kit are in place
and working properly.
• Grass catcher components are subject to wear,
damage and deterioration, which could expose
moving parts or allow objects to be thrown.
Frequently check the components and replace
them with the manufacturer’s recommended parts
when necessary.
• Do Not change the engine governor setting or
overspeed the engine.
• Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
• Keep clear of the discharge opening at all times.
• This mower was designed for one operator
only. Keep all others away from mower during
operation.
• DO NOT operate the mower when people,
especially children, or pets are in the area.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
• Stop the blades, slow down, and use caution when
crossing surfaces other than grass and when
transporting the mower to and from the area to
be mowed.
• Be aware of the mower discharge path and direct
discharge away from others.
7
Safety
Maintenance and Storage
• Do Not operate the mower under the influence
of alcohol or drugs.
• Stop the engine and remove the spark plug
wire(s). Wait for all movement to stop before
adjusting, cleaning or repairing.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
• 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 result in a fire.
Slope Operation
Use Extreme caution when mowing and/or turning
on slopes as loss of traction and/or tip-over could
occur. The operator is responsible for safe operation
on slopes.
• Let engine cool before storing and Do Not store
near flame or any enclosed area where open pilot
lights or heat appliances are present.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
DANGER
• Park machine on level ground. Never allow
untrained personnel to service machine.
Operating on wet grass or steep slopes can
cause sliding and loss of control. Loss of
control and/or loss of operator’s footing
could result in a fall with an arm or leg
getting under the mower or engine deck
which may result in serious injury, death or
drowning.
• Remove spark plug wire before making any
repairs.
• Use care when checking blades. Wrap the blade(s)
or wear gloves, and use caution when servicing
them. Only replace damaged blades. Never
straighten or weld them.
• Mow across slopes, never up and down.
• Keep hands and feet away from moving parts.
If possible, Do Not make adjustments with the
engine running.
• Do Not mow slopes when grass is wet.
• Do Not mow near drop-offs or near water.
• Do Not mow excessively steep slopes.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Reduce speed and use extreme caution
on slopes.
• Check all bolts frequently to maintain proper
tightness.
• Avoid sudden turns or rapid speed
changes.
• Frequently check for worn or deteriorating
components that could create a hazard.
• When feasible, avoid operating the equipment in
wet grass.
• All replacement parts must be the same as
or equivalent to the parts supplied as original
equipment.
• Progressively greater care is needed as the slope
increases.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control.
8
Safety
Safety and Instructional Decals
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• Replace all worn, damaged, or missing safety
signs.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• If an attachment or accessory has been installed,
make sure current safety signs are visible.
• New safety signs may 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.
68-7410
103-6328
EC21KABBCX
1. Choke
2. Fast
3. Continuous variable
setting
94-8072
4. Slow
5. Engine—stop
109-8191
EC21KABBC,EC21KAY, EC21KA, EC21KABBCCA,
EC21KACA, EC21KAX, EC21KABBCY
9
Safety
109-8194
EC21KABBCY, EC21KABBCCA
1. Fast
2. Continuous variable
setting
3. Slow
4. Engine—stop
116-1922
109-9317
116-2685
117-2718
116-1900
10
Safety
116-2737
11
Specifications
Specifications
Model Numbers
Serial Nos: 850,000 and Higher
EC21ASHN; EC21ASKA; EC21ASKAP; EC21HNBBC; EC21HNBBCX; EC21KA; EC21KACA; EC21KAX;
EC21KAY; EC21KABBC; EC21KABBCCA; EC21KABBCX; EC21KABBCY
Systems
Cutting Deck
• Cutting Width: 21 inches (53.3 cm)
• Blade Brake: When the blade engagement control
is moved to the disengaged position a friction
brake pad stops the rotation of the blades.
• Blade Size: (1 ea.): 20.88 inches (53.0 cm)
• Deck: 21 inches rigid. Deck design allows for
bagging, mulching or rear discharge.
• Cutting Height Adjustment:
Engine
• Engine Specifications: See your Engine Owner’s
Manual
• RPM: 3000 (No Load): EC21ASHN
• RPM: 3300 (No Load): All units except
EC21ASHN
Fuel System
Adjusts from 1 inch (2.5 cm) to 4 1/2 inches (11.4
cm) in 1/2 inch (1.3 cm) increments.
• Mulching Kit: Standard on EC21KA,
EC21KABBC, EC21HNBBC, EC21KACA,
EC21KABBCCA, EC21KAX, EC21KAY,
EC21KABBCX, and EC21KABBCY Units
• Rear Discharge Kit: Optional
• Capacity:
EC21ASHN, EC21KACA, EC21KABBCCA,
EC21ASKA and EC21ASKAP Units:
2.0 qt (1.9 L)
All other units: 4.0 qt (3.8 L)
• Type of Fuel: Regular unleaded gasoline, 87
octane or higher; containing no more than 10%
methanol or ethanol.
Dimensions
• Fuel Filter: Non-replaceable, in tank
Curb Weight:
• Fuel Shut-Off Valve:
98-122 lb (44-55 kg) Weights may vary slightly
depending on engine option.
EC21KACA, EC21KABBCCA, EC21ASKA and
EC21ASKAP Units Do Not have a shut-off valve.
Overall Width:
All other units have a shut-off valve.
22 inches (55.9 cm)
Safety Interlock System
Overall Length and Height at
2 1/2 inch Cutting Height:
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.
Handle Setting
Length
Height
High
61.00 inches
(154.9 cm)
39.00 inches
(99.1 cm)
Transmission (Self Propelled Units)
Medium
63.00 inches
(160.0 cm)
37.50 inches
(95.3 cm)
Variable
Low
64.50 inches
(163.8 cm)
35.00 inches
(88.9 cm)
Speed Range: 0–4.2 mph (6.8 km/hr)
12
Operation
Product Overview
Operation
Note: Determine the left and right sides of the
machine from the normal operating position.
Controls
Blade Control Bail
Located on the upper handle as shown in Figure 4.
When the blade control bail is depressed, the system
senses that the operator is in the normal operator’s
position.
• For Units with 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 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 3
1. Grass bag
2. Handle
3. Drive Bail
(Self-Propelled Units
Only)
4. Blade Control Bail
5. Discharge door
6. Rear wheel height
adjustment
7. Front wheel height
adjuster
Figure 4
Blade Brake Unit Shown
1.
2.
3.
4.
Blade control lock lever (Blade Brake Units Only)
Blade control bail
Handle
Drive bail (Self-Propelled Units Only)
Self-Propel Drive Bail (Self-Propelled
Units Only)
Located on the upper handle as shown in Figure 4.
When the self-propel drive bail is squeezed, the
unit will move forward based on how far the bail
is depressed toward the handle. When this bail is
released the unit will stop moving.
13
Operation
Throttle-Choke Lever (EC21KABBCX,
EC21KABBCY, EC21KABBCCA)
Located on the left side of the engine as shown in
Figure 11.
The lever is used to control engine speed. Moving
the throttle to the full forward (Choke) position will
place the lever in the choke position. The choke aids
in starting a cold engine. Moving the throttle control
forward will increase engine speed and moving it to
the rear will decrease engine speed.
The throttle-choke control also includes an engine
kill position. Moving the lever into the full rearward
(Stop) position will kill the engine.
Figure 5
Clear plastic cover removed for clarity
1. Engine stop switch
2. Press “STOP” to kill engine
3. Press “I” before starting engine
Note: Some units will not have the choke position.
Choke Control (EC21HNBBC,
EC21HNBBCX)
Fuel Shut-Off Valve
Located on the front left side of the engine as shown
in Figure 10.
The fuel shut off valve is located between the
carburetor and the fuel tank. The fuel shut off valve
shuts off the flow of fuel when the machine will
not be used for a few days, when parking inside a
building, and during transport to and from the job.
The choke aids in starting a cold engine. Pulling
outward will place the control in the choke position.
Pushing the control inward shuts off the choke.
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 blade control bail
automatically disengages the blade. The blade control
lock lever will reset to lock the blade control bail.
Figure 6
Kawasaki Unit
1. Fuel valve
Engine Stop Switch
Located on the left side of the engine in front of
the fuel tank as shown in Figure 5. The engine stop
switch is used on EC21HNBBC, EC21HNBBCX,
and EC21KABBC (see Figure 10 and Figure 11 ).
Press the switch to “STOP” to kill the engine. Press
“|” before starting the engine.
14
Operation
Pre-Start
Fill fuel tank. For best results use only clean, fresh
regular grade unleaded gasoline with an octane rating
of 87 or higher. To ensure freshness, purchase only
the quantity of gasoline that you expect to use in
30 days. Using unleaded gasoline results in fewer
combustion deposits and longer engine life. See
Engine Owner’s Manual.
Important: Never use methanol, gasoline
containing methanol, gasohol containing more
than 10% ethanol, premium gasoline, or white
gas because the fuel system could be damaged.
Figure 7
Honda Unit
1. Air cleaner
2. Fuel valve
3. Fuel cap
Do Not add oil to gasoline.
On EC21KA, EC21KABBC, EC21KAX, EC21KAY,
EC21KABBCX, EC21KABBCY, and EC21ASHN
units, rotate the valve 1/4 turn clockwise to shut off
fuel. Rotate the valve 1/4 turn counterclockwise to
turn on fuel.
Do Not use gasoline that has been stored since the
last mowing season or longer.
Do Not overfill fuel tank. Never fill the fuel tank so
that the fuel level rises above a level that is 1/2 inch
below the bottom of the filler neck to allow for fuel
expansion and prevent fuel spillage.
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
Figure 8
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
1. Rotate clockwise to close
2. Rotate counterclockwise to open
Operating Instructions
On EC21HNBBC and EC21HNBBCX units, the
fuel shut off valve is located on the engine as shown
in Figure 9. Rotate 1/4 turn clockwise to shut off
fuel. Rotate the valve 1/4 turn counterclockwise to
turn on fuel.
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
Figure 9
1. Fuel valve
1. Connect the wire to the spark plug.
15
Operation
3. For EC21KABBCX Unit: Move the choke
control to the Choke position
For EC21KABBC Unit: Turn the engine stop
switch to “|” (see Figure 5).
For EC21KABBC, EC21KABBCCA,
EC21KABBCY, EC21KAX, EC21KACA, and
EC21KAY Units: Press the primer bulb two
times (see Figure 12).
Figure 10
Honda unit
1.
2.
3.
4.
5.
6.
7.
8.
Muffler
Oil fill/dipstick
Fuel tank cap (fuel tank varies)
Recoil starter handle (located on handle bar for zone
start units)
Engine stop switch (if equipped)
Air filter
Choke
Spark plug
Figure 12
For EC21HNBBC and EC21HNBBCX Units:
Turn the engine stop switch to “|” and pull
outward on the choke control.
Note: Do Not use the choke when the engine
is warmed up.
4. For units without a Blade Brake Clutch: Hold
the blade control bail to the handle.
5. Pull the starter handle lightly until you feel
resistance, then pull it sharply. Allow the rope to
return slowly.
6. For EC21KABBCCA, EC21KABBCX and
EC21KABBCY Units: When the engine starts,
move the throttle control to the Fast position.
7. For EC21HNBBC and EC21HNBBCX Units:
Gradually push in the choke control as the engine
warms up.
Figure 11
Kawasaki units with large fuel tank shown
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Muffler
Oil fill/dipstick
Recoil starter handle
Fuel tank cap (fuel tank varies)
Engine stop switch (if equipped)
Throttle-Choke (if equipped)
Throttle Only (if equipped)
Oil filter
Air cleaner
Primer bulb (if equipped)
Spark plug
Stopping the Engine
1. Bring the unit to a full stop.
• For units without a Blade Brake Clutch:
Release the blade control bail. Both the
engine and the blade should stop within three
seconds.
• For units with a Blade Brake Clutch:
Release the blade control bail and the blade
control lock lever resets. The blade should
stop within three seconds; the engine will
continue to run.
2. Open the fuel valve.
16
Operation
Operating the Blade Control Bail
(Units Without Blade Brake Clutch)
EC21KABBCCA, EC21KABBCX, and
EC21KABBCY: Move the throttle to the
(Stop) position to kill the engine.
1. Squeeze the blade control bail against the handle.
EC21KABBC, EC21HNBBCX, and
EC21HNBBC: Press the switch to “STOP”
to kill the engine (see Figure 5).
2. Start the engine.
3. When the blade control bail is squeezed against
the handle, the blade should engage.
Note: If the blade does not stop within 3
seconds after releasing the blade control bail,
contact an Authorized Service Dealer.
4. Release the blade control bail. Both the engine
and the blade should stop.
2. Close the fuel shut-off valve, if equipped, when
the machine will not be in use for a few days,
when transporting, or when the unit is parked
inside a building.
Operating the Blade Control Lever
(Blade Brake Clutch Units Only)
Operating the Self-Propel Drive
(Self-Propelled Units Only)
2. Push and hold the blade control lock lever forward
to release the blade control bail (Figure 13).
1. Start the engine.
The lawn mower is variable speed, the more you
squeeze the drive bail the faster the machine travels.
1. Start the engine.
2. Squeeze the drive bail against the handle (see
Figure 4).
Figure 13
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 when you are making a turn or if the lawn
mower is moving too fast for you. If you lower
the control bail too far the lawn mower stops
self-propelling. Squeeze the ground speed control
bail closer to the handle to increase the ground
speed. When you hold the ground speed control
bail tight against the handle, the lawn mower
self-propels at the maximum ground speed.
Release the drive bail to stop moving when you
use the lawn mower for trimming or whenever
you leave the lawn mower.
1. Blade control lock lever
2. Locked position
3. Blade control bail
4. Push forward
5. Unlocked position
6. Squeeze against handle
3. Squeeze the blade control bail against the handle
and release the blade control lock lever; the blade
should engage.
4. Release the blade control bail to disengage the
blade. The blade control lock lever will reset to
lock the blade control bail.
Using the Mulch Plug
Occasionally you may wish to use the mulch plug to
mulch the grass and leaf clippings back into the lawn.
3. To disengage the self-propel drive, release the
drive bail.
• Installing the Mulch Plug:
Note: The mower comes with freewheeling
clutches which make it easier to pull the mower
rearward. To disengage the clutches, you may
need to push the mower forward one inch (2.5
cm) or more after you release the self-propel
drive bail.
1. Stop the engine and wait for all moving parts
to stop.
2. Remove the grass bag if it is on the mower.
3. Raise the discharge door and insert the mulch
plug into the discharge opening. The lip on
the plug will snap into the mower housing.
17
Operation
Figure 15
1. Crumpled newspaper
2. 5 inches (12.7 cm)
Figure 14
1. Mulch plug
2. Discharge door
3. Lip
4. Mower housing
5. Place the ball of newspaper 5 inches (12.7 cm) in
front of the lawn mower.
6. Start the engine.
4. Lower the discharge door.
7. Push the blade control lock lever forward to
release the blade control bail (Figure 4).
• 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.
8. Squeeze the blade control bail against the handle.
blade should engage.
9. Release the blade control bail. You should hear a
“bang.” The blade should stop in three seconds.
The blade control lock lever should reset to lock
the blade control bail.
1. To remove the mulch plug, raise the discharge
door and pull the mulch plug out of the
discharge tunnel.
10. Immediately push the lawn mower over the
newspaper ball.
2. Lower the discharge door.
11. Stop the engine and wait for all moving parts to
stop.
Checking the Blade Brake Clutch
(Blade Brake Clutch Units Only)
12. Walk around the lawn mower to check for the
newspaper ball. If the ball did not go under the
deck, repeat steps 6 through 11.
Check the Blade Brake Clutch (BBC) system before
each use to ensure that it is operating properly.
13. Pull the lawn mower away from the newspaper.
If the newspaper ball unravels or is shredded,
the blade has not properly stopped, resulting
in an unsafe operating condition. Contact an
Authorized Service Dealer.
Normal Test:
1. Stop the engine and wait for all moving parts to
stop.
2. Move the lawn mower onto a paved surface in
a non-windy area.
3. Set all four wheels to the 2 1/2 inches (6.4 cm)
cutting height (see Figure 16 and Figure 17)
4. Take a half sheet of newspaper and crumple
it into ball small enough to go under the deck
(about 3 inches or 7.6 cm in diameter) as shown
in Figure 15.
18
Operation
DANGER
WARNING
If the blade brake clutch system is
inoperative, the blade will continue to rotate
when you release the blade control bail.
Contact with the blade could occur, causing
serious injury.
Adjusting the cutting height levers could
bring your hands into contact with a moving
blade. A moving blade can cause serious
injury.
• Stop the engine and wait for all movement
to stop before adjusting the cutting
height.
• Check the BBC operation before each
use.
• Never use the BBC-equipped lawn mower
with an inoperative safety system.
• Do Not put your fingers under the
housing when adjusting the cutting
height.
• Take your lawn mower to an Authorized
Service Dealer for repair if the safety
system fails to operate properly.
• Rear Wheel Adjustment:
1. Pull the wheel height adjustment rod upward
to release the pin from the notch in the
adjustment bracket (Figure 16).
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 lever forward to release the
blade control bail (Figure 4).
4. Squeeze the blade control bail against the handle.
5. The bag should begin to inflate, indicating that
the blade is engaged and rotating.
6. Release the blade control bail. If the bag does not
immediately deflate, it indicates that the blade is
still rotating. The blade brake clutch mechanism
may be deteriorating, and, if ignored could result
in an unsafe operating condition. Have the lawn
mower inspected and serviced by an Authorized
Service Dealer.
Figure 16
1. Pull upward
4. Pin
2. Wheel height adjustment 5. Rotate to desired setting
rod
3. Adjustment bracket
6. Indicator
Adjusting the Cutting Height
The rear wheels are adjusted together with a height
adjustment rod located on the mower housing by
the left rear wheel. The front wheels are adjusted
separately by removing the front wheel shaft
assemblies, adjusting the height, and then replacing
the shaft assemblies. The cutting height can be
adjusted from 1 inch (25 mm) to 4 1/2 inches (114
mm) in 1/2 inch (12.7 mm) increments.
2. Apply downward pressure or lift the housing
to rotate the height adjustment bracket. Use
the 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 17.
19
Operation
• Mowing with the Grass Bag
WARNING
A worn grass bag could allow small stones
and other similar debris to be thrown in the
operator’s or bystander’s direction. Thrown
objects can result in serious personal injury
or death to the operator or bystanders.
Figure 17
1. Front wheel shaft
assembly
2. Pull up
3. Height adjuster
Check the grass bag frequently. If it is
damaged, install a new Exmark replacement
bag.
4. Front quadrant block cut
heights
5. Pull outward
6. Shaft groove
Cut the grass until the bag is full.
2. Insert the front wheel shaft assembly into the
desired cut height setting in the front quadrant
block. Lower the height adjuster into the
groove on the front wheel shaft. Pull and
push the wheel shaft assembly to make sure it
has locked into place.
Note: Do Not overfill the bag.
• Removing the Grass Bag
1. Stop the engine and wait for all moving parts
to stop.
2. Raise the rear discharge door and grasp the
handle on the bag.
Using the Grass Bag
• Installing the Grass Bag
1. Stop the engine and wait for all moving parts
to stop.
2. Open the rear door.
3. Grasp the handle on the bag and set the rear
of the bag frame onto the handle bracket
notch (Figure 18).
3. Lift the bag off of the lawn mower and lower
the rear discharge door.
4. Gradually tip the bag forward to empty the
clippings.
5. To install the bag, refer to the section on
Installing the Grass Bag.
DANGER
If the discharge door does not close
completely, the lawn mower could throw
objects. Thrown objects can result in serious
personal injury or death to the operator or
bystanders.
• Never open the door to the discharge
opening when the engine is running.
• If you cannot close the door because the
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.
Figure 18
1. Bag
2. Handle
3. Bag frame
4. Handle bracket notch
5. Rear door
6. Lower
4. Once the bag is seated, lower the rear door
onto the bag.
20
Operation
Operating Tips
• For light leaf coverage, set all the wheels at the
same cutting height setting.
• Review the Safety section and read this manual
carefully before operating the lawn mower.
• Set the engine speed to the fastest position for
the best cutting results.
• Maintain a sharp blade throughout the cutting
season. Periodically file down nicks on the blade.
Replace the blade when necessary with an original
Exmark replacement blade.
• Clean the air filter frequently. Mulching stirs up
more clippings and dust which clogs the air filter
and reduces engine performance.
• If there are more than 5 inches (12.7 cm) of leaves
on the lawn, set the front cutting height 1 or 2
notches higher than the rear cutting height. This
makes it easier to feed the leaves under the lawn
mower deck.
• Slow down your mowing speed if the lawn mower
does not cut the leaves finely enough.
• If you mow over oak leaves, you can add lime to
the grass in the spring to reduce the acidity of the
oak leaves.
Cutting Grass
• Grass grows at different rates at different times
of the year. In the summer heat, it is best to cut
grass at the 2 1/2 inch (64 mm), 3 inch (76 mm),
or 3 1/2 inch (89 mm) cutting height settings.
Cut only about a third of the grass blade at a time.
Do Not cut below the 2 1/2 inch (64 mm) setting
unless the grass is sparse or it is late fall when
grass growth begins to slow down.
• When cutting grass over 6 inches (15 cm) tall,
first mow at the highest cutting height setting and
walk slower; then mow again at a lower setting for
the best lawn appearance. If the grass is too long
and the leaves clump on top of the lawn, the lawn
mower may plug and cause the engine to stall.
• Alternate the mowing direction. This helps
disperse the clippings over the lawn for even
fertilization.
If the finished lawn appearance is unsatisfactory,
try one or more of the following:
– Sharpen the blade.
– Walk at a slower pace while mowing.
– Cut the grass more frequently.
– Overlap cutting swaths instead of cutting a
full swath with each pass.
– Set the cutting height on the front wheels
one notch lower than the rear wheels. For
example, set the front wheels at 2 1/2 inches
(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.
21
Maintenance
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
WARNING
WARNING
If you leave the wire on the spark plug,
someone could accidentally start the engine.
Accidental starting of the engine could
seriously injure you or other bystanders.
Tipping the lawn mower may cause the fuel
to leak from the carburetor or the fuel tank.
Gasoline is extremely flammable, highly
explosive, and under certain conditions, can
cause personal injury or property damage.
Disconnect the wire from the spark plug
before you do any maintenance. Set the wire
aside so that it does not accidentally contact
the spark plug.
Avoid fuel spills by running the engine dry or
by removing the gasoline with a hand pump;
never siphon.
WARNING
The engine can become very hot. Touching
a hot engine can cause severe burns.
Allow the engine to cool completely before
service or making repairs around the engine
area.
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance 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 operation (Blade Brake Clutch Units Only)
• Clean the grass build-up from under the deck.
• Clean the discharge tunnel and plug.
Every 25 hours
• Clean the foam pre-cleaner (Kawasaki Units).
• Clean the cover, base, foam and paper elements (EC21ASHN Units).
• Clean the cover, base, foam and paper elements (EC21HNBBC and EC21HNBBCX Units).
Every 40 hours
• Check the condition of the belt(s).
Every 50 hours
•
•
•
•
•
Change the engine oil. (May need more often under severe conditions.)
Check for leaks in the fuel systems and /or deteriorating fuel hose.
Clean under the belt cover (self-propelled units only).
Clean the blade brake clutch shield.
Clean under the cover plate (Non-BBC Units).
22
Maintenance
Maintenance Service
Interval
Maintenance Procedure
Every 100 hours
• Change the oil filter (EC21KA, EC21KABBC, EC21KAX, EC21KAY, EC21KABBCX,
EC21KABBCY, EC21KACA, and EC21KABBCCA Units).
• Check the spark plugs.
• Clean the fuel filter element.
Every 250 hours
• Replace the air filter elements (EC21ASHN Units). (May need more often if they are
damaged or excessively dirty.)
• Replace the air filter elements (EC21HNBBC and EC21HNBBCX Units). (May need more
often if they are damaged or excessively dirty.)
Every 300 hours
• Replace the paper air filter (Kawasaki Units). (May need more often in dusty conditions.
See the Engine manual for additional information.)
Yearly or before storage
• Empty the fuel tank before repairs as directed or before storage.
Periodic Maintenance
Check Engine Oil Level
Service Interval: Before each use or daily
1. Stop engine and wait for all moving parts to stop.
Make sure unit is on a level surface.
2. Check with engine cold.
3. Clean area around dipstick. Remove dipstick and
wipe oil off. Reinsert the dipstick and push it all
the way down into the tube. Do Not screw into
place. Remove the dipstick and read the oil level.
Figure 20
Kawasaki Engine
1. Dipstick
2. Full
3. Add
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. Use oil as specified in
Engine Owner’s Manual. Do Not overfill.
Figure 19
Honda Engine
1. Lower limit mark
2. Upper limit mark
Important: Do Not operate the engine with the
oil level below the “LOW” (or “ADD”) mark on
the dipstick, or over the “FULL” mark.
3. Dipstick
Checking the Blade Brake
Clutch (Blade Brake Clutch
Only)
Service Interval: Before each use or daily
23
Maintenance
Refer to Checking the Blade Brake Clutch in the
Operating Instructions section.
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.
Check the Mower Blade
Service Interval: Before each use or daily
Always mow with a sharp blade. A sharp blade cuts
cleanly and without tearing or shredding the grass
blade.
1. Stop the engine and wait for all moving parts to
stop.
2. Disconnect the wire from the spark plug
(Figure 10 and Figure 11).
3. Drain the gasoline from the fuel tank. Refer to
Emptying the Fuel Tank and Cleaning the
Fuel Filter section.
4. Tip the lawn mower onto its right side.
5. Inspect the blade for sharpness and wear,
especially where the flat and the curved parts
meet (see Figure 21). Because sand and abrasive
material can wear away the metal that connects
the flat and curved parts of the blade, check
the blade before using the lawn mower. If you
notice a slot or wear (Figure 21B and Figure 21C),
replace the blade.
• 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 sharpening, complete the
following steps:
A. To remove the blade, use a block of wood to
hold the blade steady (see Figure 22). Make
sure to grasp the end of the blade using a rag
or a thickly padded glove.
• For Blade Brake Clutch Units: Remove
the blade nuts, blade support, and blade.
• For Units without a Blade Brake
Clutch: Remove the blade bolt, blade
support, and blade.
Figure 22
B. For Sharpening: File the top side of the
blade to maintain its original cutting angle
(Figure 23A and B) and inner cutting edge
radius (Figure 23A). The blade will remain
balanced if you remove the same amount of
material from both cutting edges.
Figure 21
1. Sail
2. Flat
3. Wear
4. Slot
Note: For the best performance, install a new
blade before the cutting season begins. During
the year, file down any small nicks to maintain the
cutting edge.
24
Maintenance
Figure 23
1. Inner cutting edge radius 2. Cutting angle
C. Check the balance of the blade by placing
the center hole of the blade over a nail or
screwdriver shank clamped horizontally in a
vise (Figure 24). If either end of the blade
rotates downward, file that end (not the
cutting edge). The blade is properly balanced
when neither end drops.
Figure 25
1. Blade Brake Clutch Units
2. Units without a Blade Brake Clutch
6. Return the lawn mower to its upright position.
7. Connect the wire to the spark plug.
Figure 24
1. Blade
2. Vise
Check for Loose Hardware
3. Screwdriver
Service Interval: Before each use or daily
D. For Installation: Make sure to grasp the end of
the blade using a rag or a thickly padded glove.
1. Stop engine, wait for all moving parts to stop.
2. Visually inspect machine for any loose hardware
or any other possible problem. Tighten hardware
or correct the problem before operating.
For Blade Brake Clutch Units: Install a sharp,
balanced Exmark blade, blade support, and
the blade nuts. The sail of the blade must
point toward the top of the lawn mower
housing for proper installation. Torque the
blade nuts to 23-27 ft-lb (31-37 N m).
Check the Blade Brake
Clutch Bail Operation (Blade
Brake Clutch Units Only)
For Units without a Blade Brake Clutch:
Install a sharp, balanced Exmark blade, blade
support, 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).
Service Interval: Before each use or daily
Check the Blade Brake Clutch (BBC) bail operation
for any operation problems or deteriorating
components, such as the spring. Replace components
or correct any problems before operating. Refer to
Operating the Blade Control Lever in Operation.
25
Maintenance
Service Air Filter
(Kawasaki Units)
Service Interval: Every 25 hours—Clean
the foam pre-cleaner
(Kawasaki Units).
Every 300 hours—
Replace the paper air
filter (Kawasaki Units).
(May need more often in
dusty conditions. See
the Engine manual for
additional information.)
Note: Do Not operate the engine without the air
filter assembly; extreme engine damage will occur.
1. Stop engine, wait for all moving parts to stop.
2. Disconnect the wire from the spark plug
(Figure 11).
Figure 27
EC21ASKA and EC21ASKAP Units
3. Remove the cover and clean it thoroughly.
1. Cover
2. Paper air filter
3. Foam element
4. Remove the paper air filter and discard it as
required.
5.
6.
7.
8.
9.
Figure 26
EC21KA, EC21KACA, EC21KAX, EC21KAY,
EC21KABBC, EC21KABBCCA, EC21KABBCX,
EC21KABBCY Units
1. Cover
2. Foam element
Note: Do Not try to clean a paper air filter.
Remove the foam element and wash it with a mild
detergent and water, then blot it dry.
Saturate the element with clean engine oil, then
squeeze it (Do Not twist) to remove the excess oil.
Install the foam element.
Install the new paper air filter.
Install the cover.
Service Air Filter
(EC21ASHN Units)
3. Paper air filter
4. Air filter base
Service Interval: Every 25 hours—Clean
the cover, base, foam
and paper elements
(EC21ASHN Units).
Every 250 hours— Replace
the air filter elements
(EC21ASHN Units). (May
need more often if they are
26
Maintenance
damaged or excessively
dirty.)
10. Install the foam element.
11. Remove dirt from the air cleaner housing and
cover using a moist rag. Do Not wipe dirt into
the air duct.
Note: Do Not operate the engine without the air
cleaner assembly; extreme engine damage will occur.
12. Install the filter.
1. Stop the engine and wait for all moving parts to
stop.
13. Close the cover.
2. Disconnect the wire from the spark plug
(Figure 10).
Service Air Filter
(EC21HNBBC and
EC21HNBBCX Units)
3. Press down on the latch tabs on top of the air
cleaner cover.
Service Interval: Every 25 hours—Clean
the cover, base, foam
and paper elements
(EC21HNBBC and
EC21HNBBCX Units).
Every 250 hours—
Replace the air filter
elements (EC21HNBBC
and EC21HNBBCX Units).
(May need more often
if they are damaged or
excessively dirty.)
Note: Do Not operate the engine without the air
cleaner assembly; extreme engine damage will occur.
Figure 28
1. Cover
2. Foam element
3. Screen grid
1. Stop the engine and wait for all moving parts to
stop.
4. Paper filter
5. Air cleaner housing
2. Disconnect the wire from the spark plug
(Figure 10).
4. Open the cover
3. Remove the two wing nuts that secure the cover
(Figure 29).
5. Remove screen grid and paper filter assembly.
6. If the air filter is damaged or is wet with oil or
fuel, replace it.
7. If the air filter is dirty, tap it on a hard surface
several times or blow compressed air less than
30 psi (207 kPa) through the side of the filter
that faces the engine. If the paper element is
excessively dirty, replace it.
Note: Do Not brush the dirt off the filter;
brushing forces dirt into the fibers.
8. Remove the foam element and wash it with a mild
detergent and water, then blot it dry.
9. Saturate the element with clean engine oil, then
squeeze it (Do Not twist) to remove the excess oil.
27
Maintenance
Note: Be careful to prevent dirt and debris from
entering the air duct leading to the carburetor.
13. Install the air cleaner elements and ensure that
they are properly positioned.
14. Securely install the cover with the two wing nuts.
Change Engine Oil
Service Interval: After the first 5 hours
Every 50 hours (May need
more often under severe
conditions.)
1. Run the engine to warm the engine oil.
Note: Warm oil flows better and carries more
contaminates.
Figure 29
1. Wing nuts
2. Cover
3. Paper element
4. Foam element
5. Base
WARNING
Oil may be hot after engine has been
run. Contact with hot oil can cause severe
personal injury.
4. Remove the cover.
5.
6.
7.
8.
Note: Be careful to prevent dirt and debris from
falling into the base.
Remove the foam and paper elements from the
base.
Remove the foam element from the paper
element.
Inspect the foam and paper elements, and replace
them if they are damaged or excessively dirty.
Tap the paper element on a hard surface several
times or use compressed air not exceeding 30
psi (207 kPa) through the filter from the wire
screen side to remove any excess dirt. If the paper
element is excessively dirty, replace it.
Avoid contacting the hot engine oil when you
drain it.
2. Stop engine, wait for all moving parts to stop.
3. Disconnect the wire from the spark plug.
4. Drain the gasoline from the fuel tank. Refer to
Emptying the Fuel Tank and Cleaning the
Fuel Filter section.
5. Place a suitable drain pan under the dipstick/oil
drain.
6. Clean around the dipstick.
7. Remove the dipstick by rotating the cap
counterclockwise and pulling it out.
8. Raise the left side of the lawn mower to drain the
oil from the dipstick fill tube into the drain pan.
9. After draining the oil, return the lawn mower to
the operating position.
10. Fill the crankcase with fresh oil to the upper limit
mark on the dipstick.
11. Insert the dipstick into the filler neck and rotate
the cap clockwise until it is tight.
12. Wipe up any spilled oil.
13. Connect the wire to the spark plug.
14. Recycle the used oil according to local codes.
Note: Never try to brush dirt off the paper
element; brushing forces the dirt into the fibers.
9. Clean the foam element in warm, soapy water or
in a nonflammable solvent.
10. Rinse and 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.
28
Maintenance
Change Oil Filter
(EC21KA, EC21KABBC,
EC21KAX, EC21KAY,
EC21KABBCX,
EC21KABBCY, EC21KACA,
and EC21KABBCCA)
Check Condition Of Belt
(Self-Propelled Units Only)
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop.
2. Remove the belt cover to the lawn mower housing.
3. Check the belt for cracks, frayed edges, burn
marks or any other damage.
4. Replace the damaged belt.
Service Interval: Every 100 hours
1. Run the engine to warm the oil.
Check Spark Plugs
2. Stop the engine and wait for all moving parts to
stop.
Service Interval: Every 100 hours
1. Stop the engine and wait for all moving parts to
stop.
2. Disconnect the wire from the spark plug
(Figure 10 and Figure 11).
3. Clean around the spark plug.
4. Remove the spark plug from the cylinder head.
3. Disconnect the wire from the spark plug.
4. Drain the engine oil.
5. Place a rag under the oil filter to catch any oil that
may leak out as you remove the filter.
6. Remove the oil filter.
7. Use your finger to coat the gasket on the new
filter with clean engine oil (see Figure 30).
Note: Replace a cracked, fouled, or dirty spark
plug. Do Not clean the electrodes because grit
entering the cylinder can damage the engine.
5. Set the gap on the plug to 0.030 inch (0.76 mm)
(Figure 31).
Figure 30
1. Gasket
Figure 31
1. Side electrode
8. Install the new filter and hand tighten it 2/3 turn
only.
3. Air gap—0.030 inch
(0.76 mm)
2. Center electrode
insulator
9. Fill the crankcase to the Full line on the dipstick
with fresh oil.
6. Install the spark plug and the gasket seal.
7. Torque the plug to 17 ft-lb (23 N-m).
8. Connect the wire to the spark plug.
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.
Emptying the Fuel Tank and
Cleaning the Fuel Filter
13. Add oil to compensate for the oil in the oil filter.
14. Recycle the used oil filter according to local codes.
Service Interval: Every 100 hours
29
Maintenance
The fuel filter (screen) element is located inside the
fuel tank (if applicable).
Adjustments
Note: The EC21ASHN does not have a removable
fuel tank.
Note: Wait for all moving parts to stop and remove
spark plug wire before servicing, cleaning, or making
any adjustments to the unit.
1. Stop the engine and wait for it to cool down.
Adjusting the Self-Propel
Drive
(Self-Propelled Units Only)
Note: Drain gasoline for a cold engine only.
2. Disconnect the wire from the spark plug
(Figure 11).
3. Close the fuel valve.
If the lawn mower does not self-propel or has a
tendency to creep forward when the control bail
is released, adjust the drive cable nuts as shown in
Figure 33.
4. Disconnect the fuel line by loosening the tube
clamp at the carburetor.
5. Open the fuel valve by turning the lever to the
open position.
DANGER
6. Drain the gasoline completely from the tank and
fuel line into an approved fuel container.
Checking the operation of the mower with
the belt cover removed will allow debris to
be thrown in the operator’s or bystander’s
direction and can result in serious personal
injury or death.
7. Remove the fuel tank from the mower.
8. Close the fuel valve.
9. Pour a small amount of fuel in the fuel tank, move
the fuel around in the tank, and pour it out into
an approved fuel container.
Do Not operate the unit when cover is not
in place.
10. Install the fuel tank and fuel line.
1. Stop the engine and wait for all moving parts to
stop.
2. Remove the belt cover by pulling upward on the
back of the cover to unsnap the front and back
cover tabs. Remove any debris under the cover.
Figure 32
1. Belt cover tabs
3. If the lawn mower does not self propel with bail
engaged, tighten the belt by turning the drive
30
Maintenance
cable nuts clockwise. To maximize belt life, Do
Not overtighten the belt.
If the lawn mower creeps forward without the
bail engaged, loosen the belt by turning the drive
cable nuts counterclockwise.
Figure 33
Figure 34
1. Adjustment of drive cable nuts
1. Spring
2. Cable conduit
4. Reinstall the belt cover by pushing down on the
rear first and then snapping the front onto the
mower housing.
5. Check the operation for desired drive control.
6. Repeat steps 2 through 5 as necessary for further
adjustment.
3. Cable clamp screw
5. Pull the cable until there is approximately 1/8
inch in slack. Do Not put tension on the spring.
6. Tighten the screw to lock the adjustment in place.
7. Reinstall the belt cover by pushing down on the
rear first and then snapping the front onto the
mower housing.
Note: Adjustment to obtain desired ground
speed at full bail travel may be made in order to
accommodate slower speeds.
8. Connect the wire to the spark plug.
9. Check the operation of the blade control lock
lever (see Figure 13). The lever must reset itself
to lock out the blade control bail. If it does not,
repeat steps 4 through 8.
Adjusting the Blade
Brake Cable
(Blade Brake Clutch Units
Only)
10. Perform the “Checking the Blade Brake Clutch
(Blade Brake Clutch Units Only)” procedure in
Operation.
Adjust whenever a new blade brake cable assembly
is installed or 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 32). Remove any debris
under the cover.
4. Loosen the cable clamp screw until the cable
conduit slides (see Figure 34).
31
Maintenance
Cleaning
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.
Clean Grass Build-Up Under
Deck
Scraping Method
Service Interval: Before each use or daily
If washing does not remove all debris from under the
lawn mower, scrape it clean.
1. Stop engine, wait for all moving parts to stop, and
remove spark plug wire.
1. Disconnect the wire from the spark plug.
2. To ensure the best performance, keep the
underside of the lawn mower housing clean.
2. Drain the fuel from the fuel tank. Refer to
Emptying the Fuel Tank and Cleaning the
Fuel Filter section.
CAUTION
3. Tip the lawn mower onto its right side.
The mower may dislodge material from
under the mower housing.
4. Remove the dirt and grass clippings with a
hardwood scraper. Avoid burrs and sharp edges.
• Wear eye protection.
5. Turn the lawn mower upright.
• Stay in the operating position (behind the
handle).
6. Fill the fuel tank.
7. Connect the wire to the spark plug.
• Do Not allow bystanders in the area.
Cleaning the Discharge
Tunnel and Plug
Washing Method
1. Position the lawn mower on a flat concrete or
asphalt surface near a garden hose.
Service Interval: Before each use or daily
2. Start the engine.
Always be sure that the discharge tunnel door closes
securely when you release the handle. If the debris
prevents the discharge door from closing securely,
clean the inside of the discharge tunnel and the door
thoroughly.
3. Hold the running garden hose at handle level and
direct the water to flow on the ground just in
front of the right rear tire (Figure 35).
WARNING
Grass clippings and other objects can be
thrown from an open discharge tunnel.
Thrown objects can cause serious injury or
kill the operator or bystanders.
Figure 35
Never start or operate the lawn mower unless
one of the following is true:
4. Engage the blade.
• The discharge tunnel plug is locked
securely in the discharge tunnel.
Note: The blade will draw in water and wash out
clippings. Let the water run until you no longer
see clippings being washed out from under the
housing.
• The grass bag is locked in place.
• The optional rear discharge chute is
locked in place.
5. Disengage the blade, stop the engine and wait for
all moving parts to stop.
• The discharge tunnel door is closed.
32
Maintenance
Cleaning Under the Belt
Cover (Self-Propelled Units
Only)
Service Interval: Every 50 hours
1. Stop the engine and wait for all moving parts to
stop.
2. Disconnect the wire from the spark plug (see
Figure 10 and Figure 11).
3. Pull upward on the back of the cover to unsnap
the front and back cover tabs (see Figure 32).
Figure 36
4. Lift off the cover and brush out all the debris
around the belt area.
1. Screws
2. BBC Shield
5. Install the belt cover by pushing down on the rear
first and then snapping the front onto the mower
housing.
6. Remove the three screws holding the BBC shield
onto the unit (see Figure 36).
6. Connect the wire to the spark plug.
7. Remove the BBC shield and brush or blow all
the debris from under the shield and around the
BBC system.
Cleaning the Blade
Brake Clutch Shield
(Blade Brake Clutch Units
Only)
8. Install the BBC shield. Tighten the screws to
secure the BBC shield to the deck.
9. Install the blade and the two blade nuts.
10. Turn the lawn mower upright.
11. Connect the wire to the spark plug.
Service Interval: Every 50 hours
1. Stop the engine and wait for all moving parts to
stop.
Cleaning Under the Cover
Plate (Non-Blade Brake
Clutch Units Only)
2. Disconnect the wire from the spark plug (see
Figure 10 and Figure 11).
3. Drain the gasoline from the fuel tank. Refer to
Emptying the Fuel Tank and Cleaning the
Fuel Filter section.
Service Interval: Every 50 hours
1. Stop the engine and wait for all moving parts to
stop.
4. Tip the lawn mower onto its right side (air filter
up).
2. Disconnect the wire from the spark plug (see
Figure 10 and Figure 11).
5. Remove the blade nuts and the blade (see
Figure 25).
3. Drain the gasoline from the fuel tank. Refer to
Emptying the Fuel Tank and Cleaning the
Fuel Filter section.
4. Tip the lawn mower onto its right side (air filter
up).
5. Remove the blade bolt, blade support, and the
blade (see Figure 25).
33
Maintenance
Figure 37
1. Blade bolt
2. Blade support
3. Blade
4. Cover plate
5. Screw
6. Remove the three screws holding the cover plate
onto the unit (see Figure 37).
7. Remove the cover plate and brush or blow all the
debris from under the plate.
8. Reinstall the cover plate and torque the screws to
35-45 ft-lb (47-61 N-m).
9. Install the blade, blade support, and the blade
bolt.
10. Turn the lawn mower upright.
11. Connect the wire to the spark plug.
Waste Disposal
Motor Oil Disposal
Engine oil and hydraulic oil are both pollutants to
the environment. Dispose of used oil at a certified
recycling center or according to your state and local
regulations.
34
Storage
Storage
General Storage Information
Preparing the Fuel System
1. Clean the lawn mower housing. Refer to
Cleaning the Underside of the Lawn Mower
Housing section in Cleaning.
To prepare the lawn mower for off season storage,
perform the recommended maintenance procedures.
2. Clean any dirt and chaff from the cylinder,
cylinder head fins, and blower housing.
Store the lawn mower in a cool, clean, dry place.
Cover the lawn mower to keep it clean and protected.
3. Remove grass clippings, dirt, and grime from the
external parts of the engine, the shrouding, and
the top of the lawn mower housing.
WARNING
4. Clean the BBC shield. Refer to Cleaning the
Blade Brake Clutch Shield section in Cleaning.
Gasoline can vaporize if you store it over long
periods of time. Gasoline vapors can explode
if they come into contact with an open flame.
5. Check the condition of the blade. Refer
to Maintaining the Blade section in the
Maintenance.
• Do Not store gasoline over long periods
of time.
6. Service the air filter. Refer to Servicing the Air
Filter in Maintenance.
• Do Not store the lawn mower with
gasoline in the fuel tank or the carburetor
in an enclosure with an open flame. (For
example, a furnace or a water heater pilot
light.)
7. Tighten all nuts, bolts, and screws.
8. Touch up all rusted or chipped paint surfaces with
paint available from an Authorized Service Dealer.
• Allow the engine to cool before storing
it in any enclosure.
Removing the Lawn Mower
from Storage
Empty the fuel tank when mowing the last time
before storing the lawn mower.
1. Check and tighten all fasteners.
2. Remove the spark plug and spin the engine rapidly
by pulling the starter rope to blow excess oil from
the cylinder.
1. Run the lawn mower until the engine stops from
running out of fuel.
2. Prime the engine and start it again.
3. Clean the spark plug or replace it if it is cracked,
broken, or if the electrodes are worn.
3. Allow the engine to run until it stops. When you
can no longer start the engine it is sufficiently dry.
4. Install the spark plug and torque it to 17 ft-lb (23
N-m).
Preparing the Engine
5. Perform any needed maintenance procedures.
1. While the engine is still warm, change the oil from
the crankcase. Refer to Changing the Engine
Oil section in Maintenance.
6. Fill the fuel in the fuel tank with fresh gasoline.
2. Remove the spark plug.
8. Connect the wire to the spark plug.
7. Check the engine oil level.
3. Using an oil can, add about one tablespoon of oil
to the crankcase through the spark plug hole.
4. Slowly 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.
35
Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, Do Not overlook the simple causes. For example: starting problems could be
caused by an empty fuel tank.
The following table lists some of the common causes of trouble. If a problem continues, contact an Authorized
Service Dealer.
Problem
Engine will not start, starts hard, or fails to
keep running.
Engine loses power.
Engine runs rough.
Lawn mower or engine vibrates excessively.
Uneven cutting pattern.
Discharge chute plugs
Possible Cause
Corrective Action
1. Fuel tank is empty.
1. Fill the fuel tank.
2. Fuel shut-off valve is closed.
3. The throttle lever is not in the correct
position.
4. Dirt, water, or stale fuel is in the fuel
system.
5. Faulty spark plug.
6. Spark plug wire is not connected.
2. Open the fuel shut-off valve.
3. Move the throttle lever to the Choke
position.
4. Contact an Authorized Service Dealer.
1. Air cleaner is dirty.
1. Clean or replace the air cleaner element.
2.
3.
4.
5.
Oil level in the crankcase is low.
Vent hole in the fuel cap is plugged.
Dirt in fuel filter.
Dirt, water, or stale fuel is in the fuel
system.
6. The underside of the lawn mower deck
contains clippings and debris
2.
3.
4.
5.
1. The wire is not connected to the spark
plug.
1. Connect the wire to the spark plug.
2. Faulty spark plug.
3. The throttle lever is not in the Fast
position.
4. The air filter element is dirty and is
restricting the air flow.
2. Clean, adjust or replace spark plug.
3. Move the throttle lever to the Fast
position.
4. Clean the air filter pre-cleaner and/or
replace the paper air filter.
1. The blade is bent or is out of balance.
1. Balance the blade. If the blade is bent,
replace it.
2. The blade mounting bolt is loose.
3. The underside of the lawn mower deck
contains clippings and debris.
4. The engine mounting bolts are loose.
2. Tighten the blade mounting bolt.
3. Clean the underside of the lawn mower
deck.
4. Tighten the engine mounting bolts.
5. Clean, adjust or replace spark plug.
6. Check the spark plug wire connection.
Add oil to the crankcase.
Clean or replace the fuel cap.
Replace the fuel filter.
Contact an Authorized Service Dealer.
6. Clean the underside of the lawn mower
deck.
1. All four wheels are not at the same height.
1. Place all four wheels at the same height.
2. The blade is dull.
3. Mowing in the same pattern repeatedly.
4. The underside of the lawn mower deck
contains clippings and debris.
2. Sharpen and balance the blade.
3. Change the mowing pattern.
4. Clean the underside of the lawn mower
deck.
1. The throttle lever is not in the Fast
position.
1. Move the throttle lever to the Fast
position.
2. Cutting too much grass in one pass
2. Raise the cutting height. If necessary, cut
second time at lower cutting height.
3. Slow down.
4. Allow the grass to dry before mowing.
5. Clean the underside of the lawn mower
deck.
3. Mowing too fast.
4. The grass is wet.
5. The underside of the lawn mower deck
contains clippings and debris.
36
Troubleshooting
Problem
Lawn mower does not self-propel
(Self-Propelled Units Only)
Difficult to pull lawnmower rearward
(Self-Propelled Units Only).
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.
2. There is debris under the belt cover.
2. Clean the debris from under the belt
cover.
1. Transmission is locked.
1. Push mower forward to disengage the
transmission and then pull rearward.
37
Exmark Commercial Turf Equipment
1 Year Limited Warranty
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
Conditions and Products Covered
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty
Company, pursuant to an agreement between them, jointly
warrant on the terms and conditions herein, that we will repair,
replace or adjust any part on these products and found by us
(in the exercise of our reasonable discretion) to be defective in
factory materials or workmanship for a period of one year.
This warranty applies to Exmark commercial turf equipment
sold in the U.S. or Canada. This warranty may only be
assigned or transferred to a second (or third) owner by an
authorized Exmark dealer. The warranty period commences
upon the date of the original retail purchase.
Warranty Exceptions
• Bags, Belts and Tires
• Engine
Owner’s Responsibilities
If your product requires warranty service it must be returned
to an authorized Exmark service dealer within the warranty
period. This warranty extends only to turf equipment operated
under normal conditions. You must read the operator’s
manual. You must also properly service and maintain your
Exmark product as described in the operator’s manual. Such
routine maintenance, whether performed by a dealer or by
you, is at your expense.
Warranty Period
90 days
2 years*
* The Engine warranty is covered by the engine manufacturer.
Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet.
This warranty only includes the cost of parts and labor.
General Conditions
The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair or replacement of
defective components as set forth herein. Neither Exmark
nor Exmark Warranty Company shall be liable for any
incidental or consequential loss or damage.
Items and Conditions Not Covered
This warranty does not cover the following:
• Pickup and delivery charges to and from any authorized
Exmark Service Dealer.
• Any damage or deterioration due to normal use, wear and
tear, or exposure.
• Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune-up parts, and adjustments.
• Any product or part which has been altered or misused or
required replacement or repair due to normal wear,
accidents, or lack of proper maintenance.
• Any repairs necessary due to use of parts, accessories or
supplies, including gasoline, oil or lubricants, incompatible
with the turf equipment or other than as recommended in
the operator's manual or other operational instructions
provided by Exmark.
Such damages include but are not limited to:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other
extraordinary repair charges or charges relating to repairs or
replacements outside of normal business hours at the place
of business of the authorized Exmark Service Dealer.
• Rental of like or similar replacement equipment during the
period of any warranty, repair or replacement work.
• Any telephone or telegram charges or travel charges.
• Loss or damage to person or property other than that
covered by the terms of this warranty.
• Any claims for lost revenue, lost profit or additional cost as
a result of a claim of breach of warranty.
• Attorney's fees.
There are no other express warranties except for engine and
special emission system coverage.
No Claim of breach of warranty shall be cause for cancellation
or rescission of the contract of sale of any Exmark mower.
All implied warranties of merchantability (that the
product is fit for ordinary use) and fitness for use (that the
product is fit for a particular purpose) are limited to the
duration of the express warranty.
Some states do not allow exclusions of incidental or
consequential damages, or limitations on how long an
implied warranty lasts, so the above exclusions and
limitations may not apply to you.
All warranty work must be performed by an authorized
Exmark Service Dealer using Exmark approved replacement
parts.
Instructions for Obtaining Warranty Service
The product must be registered with original proof of purchase
by an Exmark Service Dealer before obtaining any warranty
service.
Contact any Exmark Service Dealer to arrange service at their
dealership. 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.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
G4500-426_B
38
Service Record
Date:
Description of Work Done:
39
Service Done By:
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS
MID-MOUNT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
OPERATOR CONTROLLED DISCHARGE
FULL SUSPENSION SEAT
ROLL OVER PROTECTION SYSTEM (ROPS)
DECK LIFT ASSIST KIT
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
TURF STRIPER
12V POWER PORT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
OUT-FRONT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
SNOW BLADE
DUAL-TAIL WHEEL
SNOWBLOWER
FLOOR PAN EXTENDER
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
ROLL OVER PROTECTION SYSTEM (ROPS)
WEATHER CAB
WALK-BEHIND ACCESSORIES AND OPTIONS
GRASS CATCHER
TURF STRIPER
MICRO-MULCH SYSTEM
STANDON
Place Model No. and Serial No.
Label Here (Included in the Literature
Pack) or Fill in Below
Model No.
Date Purchased
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
Serial No.
© 2010 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
All Rights Reserved
Part No. 4500-674 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
www.exmark.com