Exmark Z-Plug User manual

Brand: Exmark

Model: Z-Plug

Category: Spreader

Type: User manual

Z-PLUG™

ForSerialNos.

404,314,159andHigher

PartNo.4504-453Rev.B

Introduction

TotheOwner

Introduction

ReadthismanualentirelyBEFOREoperatingthe

Z-Plug.

Theinformationpresentedhereinwillprepareyou

tooperatetheZ-Pluginasafeandknowledgeable

manner.OperatingtheZ-Pluginapropermanner

willprovideasaferworkingenvironment,create

moreefcientresultsandpromotehigherquality.

Keepthismanualonhandatalltimesforready

reference.Thetestedsafetyanddesign(s)ofthe

Z-Plugisdependentuponitsoperationwithinthe

guidelinesandlimitationsoutlinedinthismanual.

OperatingtheZ-Plugoutsideofthestatedsafety

guidelinespresentedinthismanualruntheriskof

injuryandavoidinthewarranty.

ProductRegistration

Immediatelyrecordthemodelandserialnumberof

yourZ-Pluginthespacesbelow.Thesenumbers

canbefoundontheleftsideoftheengineplate.

Providingthisinformationwillhelpassurethatyou

getthecorrectparts,informedaboutanyupdatesor

productreviews.

ModelNumber:

____________________________________

SerialNumber:

____________________________________

2101AshlandAve

Beatrice,NE68310

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Contents

Introduction...........................................................2

TotheOwner..................................................2

Safety.....................................................................4

SafetyAlertSymbol.........................................4

SafeOperatingPractices..................................4

Transporting..................................................10

SafetyandInstructionalDecals......................12

Operation..............................................................15

SpreaderOperations.......................................15

SpreaderSystem.............................................16

AeratorOperations........................................16

Maintenance..........................................................19

PeriodicMaintenance........................................19

EngineMaintenance.......................................19

HydraulicSystemMaintenance.......................20

TractionUnitMaintenance.............................20

SpreaderMaintenance....................................20

AeratorHead/TineMaintenance....................20

Troubleshooting....................................................23

Engine:...........................................................23

Hydraulics:.....................................................23

Tracking:........................................................23

Granular:........................................................23

ChargingIssues:.............................................24

Schematics............................................................27

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure1)isusedbothin

thismanualandonthemachinetoidentifyimportant

safetymessageswhichmustbefollowedtoavoid

accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

g000502

Figure1

SafetyAlertSymbol

Thesafetyalertsymbolappearsaboveinformation

whichalertsyoutounsafeactionsorsituations

andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Indicatesanimminentlyhazardous

situationwhich,ifnotavoided,Willresultindeathor

seriousinjury.

WARNING:Indicatesapotentiallyhazardous

situationwhich,ifnotavoided,Couldresultindeath

orseriousinjury.

CAUTION:Indicatesapotentiallyhazardous

situationwhich,ifnotavoided,Mayresultinminor

ormoderateinjury.

Thismanualusestwootherwordstohighlight

information.Importantcallsattentiontospecial

mechanicalinformationandNoteemphasizes

generalinformationworthyofspecialattention.

SafeOperatingPractices

Alwaysshutofftheengine,andremovethekey.Wait

forallmovementtostopandallowthemachineto

coolbeforeadjusting,cleaning,storing,orrepairingit.

ChemicalSafety

TheintendeduseoftheZ-Plugmachineisforlawn

care.

WARNING

Chemicalsubstancesusedinthemachine’s

chemicalsystemmaybehazardousandtoxicto

you,bystanders,animals,plants,soilsorother

property.

•Carefullyreadandfollowthechemical

warninglabelsandSafetyDataSheets(SDS)

forallchemicalsusedandprotectyourself

accordingtothechemicalmanufacturer's

recommendations.Ensurethataslittle

skinaspossibleisexposedwhileusing

chemicals.UseappropriatePersonal

ProtectiveEquipment(PPE)toguardagainst

personalcontactwithchemicals,suchas:

–safetyglasses,goggles,and/orfaceshield

–chemicalresistantgloves

–rubberbootsorothersubstantialfootwear

–hearingprotection

–respiratororltermask

–cleanchangeofclothes,soap,and

disposabletowels,tobekepton-hand,inthe

eventofachemicalspill.

•Keepinmindthattheremaybemorethan

onechemicalused,andinformationoneach

chemicalshouldbeassessed.

•Refusetooperateorworkonthemachineif

thisinformationisnotavailable!

•Beforeworkingonthemachine’schemical

system,makesurethatthesystemhas

beentriplerinsedandneutralizedaccording

totherecommendationsofthechemical

manufacturer(s).

•Verifythereisanadequatesupplyofclean

waterandsoapnearby,andimmediatelywash

offanychemicalsthatcontactyou.

•Obtainpropertrainingbeforeusingorhandling

chemicals.

•Usethecorrectchemicalforthejob.

•Followthechemicalmanufacturer'sinstructions

forthesafeapplicationofthechemical.

•Handlechemicalsinawellventilatedarea.

•Havecleanwateravailable.

•DoNoteat,drink,orsmokewhileworkingwith

chemicals.

Safety

•Alwayswashyourhandsandotherexposedareas

assoonaspossibleafternishingthework.

•Keepchemicalsintheiroriginalpackagesandina

safelocation.

•Properlydisposeofunusedchemicalsand

chemicalcontainersasinstructedbythechemical

manufacturerandyourlocalcodes.

•Chemicalsandfumesaredangerous;neverenter

hopperorplaceyourheadoverorintheopening.

•Followalllocal/state/federalrequirementsforthe

spreadingofchemicals.

Training

•ReadtheOperator’sManualandothertraining

material.Iftheoperator(s)ormechanic(s)cannot

readthismanual,itistheowner’sresponsibilityto

explainthismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.

Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate

orservicetheequipment.Localregulationsmay

restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate

themachine,andevenmatureteenagersshould

haveadultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator's

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe

machinewithouttakingrisks.

•Theowner/usercanpreventandisresponsible

foraccidentsorinjuriesoccurringtohimselfor

herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories

andattachmentsareneededtoproperlyandsafely

performthejob.Onlyuseapprovedaccessories

andattachments.

•Wearappropriateclothingincludingsafetyglasses,

substantialslip-resistantfootwear,andhearing

protection.Tiebacklonghairandavoidloose

clothingorloosejewelrywhichmaygettangledin

movingparts.

CAUTION

Thismachineproducessoundlevelsinexcess

of85dBAattheoperator’searandcancause

hearinglossthroughextendedperiodsof

exposure.

Wearhearingprotectionwhenoperatingthis

machine.

•Inspecttheareawheretheequipmentistobe

usedandremoveallrocks,toys,sticks,wires,

bones,andotherforeignobjectswhichmaybe

contaminatedbychemicalsand/oraffectthe

stabilityofthemachine.

DANGER

Incertainconditionsgasolineisextremely

ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn

you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground,

inanopenarea,whentheengineiscold.

Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe

machineindoorsorinsideanenclosed

trailer.

•DoNotllthefueltankcompletelyfull.

Fillthefueltanktothebottomoftheller

neck.Theemptyspaceinthetankallows

gasolinetoexpand.Overllingmayresult

infuelleakageordamagetotheengine

oremissionsystem.

•Neversmokewhenhandlinggasoline,and

stayawayfromanopenameorwhere

gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer

andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never

removethecapofthefueltankoradd

fuelwhenengineisrunningorwhenthe

engineishot.

•Iffuelisspilled,DoNotattempttostart

theengine.Moveawayfromtheareaof

thespillandavoidcreatinganysourceof

ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust

systeminplaceandinproperworking

condition.

Safety

DANGER

Incertainconditionsduringfueling,static

electricitycanbereleasedcausingaspark

whichcanignitegasolinevapors.Areor

explosionfromgasolinecanburnyouand

othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe

groundawayfromyourvehiclebefore

lling.

•DoNotllgasolinecontainersinsidea

vehicleoronatruckortrailerbedbecause

interiorcarpetsorplastictruckbedliners

mayinsulatethecontainerandslowthe

lossofanystaticcharge.

•Whenpractical,removegas-powered

equipmentfromthetruckortrailerand

refueltheequipmentwithitswheelson

theground.

•Ifthisisnotpossible,thenrefuelsuch

equipmentonatruckortrailerfroma

portablecontainer,ratherthanfroma

gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe

used,keepthenozzleincontactwiththe

rimofthefueltankorcontaineropening

atalltimesuntilfuelingiscomplete.Do

Notuseanozzlelockopendevice.

WARNING

Gasolineisharmfulorfatalifswallowed.

Long-termexposuretovaporshascaused

cancerinlaboratoryanimals.Failuretouse

cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas

tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperatorpresencecontrols,

safetyswitches,andshieldsareattachedand

functioningproperly.DoNotoperateunlessthey

arefunctioningproperly.

•DoNotll,calibrate,orcleanthemachinewhen

people,especiallychildren,orpetsareinthearea.

•Makesuretheoperatorplatformiscleanandfree

fromchemicalresidueanddebrisbuildup.

Operation

WARNING

Operatingengineparts,especiallythemufer,

becomeextremelyhot.Severeburnscanoccur

oncontactanddebris,suchasleaves,grass,

brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to

coolbeforetouching.

•Removeaccumulateddebrisfrommuferand

enginearea.

WARNING

Engineexhaustcontainscarbonmonoxide,

whichisanodorlessdeadlypoisonthatcankill

you.

DoNotrunengineindoorsorinasmallconned

areawheredangerouscarbonmonoxidefumes

cancollect.

•Operateonlyindaylightorgoodarticiallight,

keepingawayfromholesandhiddenhazards.

•Lightningcancausesevereinjuryordeath.If

lightningisseenorthunderisheardinthearea,

DoNotoperatethemachine;seekshelter.

•Beawareofweatherconditionsandcheckthat

spreaderpatternsandvolumearesuitable.

•Besurealldrivesareinneutralandparkingbrake

isengagedbeforestartingengine.

•Neveroperatethemachinewithdamagedguards,

shields,orcovers.Alwayshavesafetyshields,

guards,switchesandotherdevicesinplaceandin

properworkingcondition.

•DoNotchangetheenginegovernorsettingor

overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait

forallmovingpartstostop,removekeyand

engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

machine.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemachinefor

damageandmakerepairsbeforerestarting

andoperatingthemachine).

–Beforeclearingblockages.

–Wheneveryouleavethemachine.

Safety

•Stopengine,waitforallmovingpartstostop,and

engageparkingbrake:

–Beforerefueling.

WARNING

Hands,feet,hair,clothing,oraccessoriescan

becomeentangledinrotatingparts.Contact

withtherotatingpartscancausetraumatic

amputationorseverelacerations.

•DoNotoperatethemachinewithout

guards,shields,andsafetydevicesinplace

andworkingproperly.

•Keephands,feet,hair,loosejewelry,or

clothingawayfromrotatingparts.

•NEVERcarrypassengers.DONOToperate

themachinewhenpeople,especiallychildren,or

petsareinthearea.

•Bealert,slowdownandusecautionwhen

makingturns.Lookbehindandtothesidebefore

changingdirections.

•Stopspreadingwhenmakingtightturnsto

minimizeunevendistributionpattern,application

rate,andchemicaldrift.

•Raisethetines,slowdownandusecautionwhen

crossingsurfacesotherthangrassandwhen

transportingthemachinetoandfromthework

area.DoNotmakeazeroturnwhenthetinesare

downasturftearingwillresult.

•Chemicalsmaydriftandcauseinjurytopeople

andanimals;itmayalsodamageplants,soil,or

otherproperty.

•DoNotoperatethemachineundertheinuence

ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe

machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscurevision.

•Reducetheweightoftheloadwhenoperating

onhillsandroughterraintoavoidtippingor

overturningofthemachine.

•Granularmaterialscanshift.Thisshifting

happensmostoftenwhileturning,goingupor

downhills,suddenlychangingspeeds,orwhile

drivingoverroughsurfaces.Shiftingloadscan

causetheunittotipover.

•Whenoperatingwithaheavyload,reduceyour

speedandallowforsufcientstoppingdistance.

Useextracautiononslopes.

•Reducespeedandloadwhenoperatingonrough

terrain,unevenground,andnearcurbs,holes,and

othersuddenchangesinterrain.Loadsmayshift,

causingthemachinetobecomeunstable.

WARNING

Suddenchangesinterrainmaycauseabrupt

steeringcontrolmovement,possiblyresulting

inhandandarminjuries.

Reducespeedwhenoperatingonrough

terrainornearcurbs.

SlopeOperation

•Slopesareamajorfactorrelatedtolossofcontrol

androlloveraccidents,whichcanresultinsevere

injuryordeath.Theoperatorisresponsiblefor

safeslopeoperation.Operatingthemachineon

anysloperequiresextracaution.Beforeusingthe

machineonaslope,theoperatormust:

–Reviewandunderstandtheslopeinstructions

inthemanualandonthemachine.

–Evaluatethesiteconditionsofthedayto

determineiftheslopeissafeformachine

operation.Usecommonsenseandgood

judgmentwhenperformingthisevaluation.

Changesintheterrain,suchasmoisture,can

quicklyaffecttheoperationofthemachine

onaslope.

•Operateacrossslopes,neverupanddown.Avoid

operationonexcessivelysteeporwetslopes.

•Identifyhazardsatthebaseoftheslope.Do

notoperatethemachineneardropoffs,ditches,

embankments,waterorotherhazards.The

machinecouldsuddenlyrolloverifawheelgoes

overtheedgeortheedgecollapses.Keepasafe

distance(twicethewidthofthemachine)between

themachineandanyhazard.Useawalkbehind

machineorahandheldtooltooperateinthese

areas.

Safety

g222400

Figure2

1.SafeZone—Usethe

machinehere

4.W=widthofthemachine

2.DangerZone-Usea

walkbehindmachine

orahandheldtool

neardropoffs,ditches,

embankments,wateror

otherhazards.

5.Keepasafedistance

(twicethewidthofthe

machine)betweenthe

machineandanyhazard.

3.Water

•Avoidstarting,stoppingorturningthemachine

onslopes.Avoidmakingsuddenchangesinspeed

ordirection;turnslowlyandgradually.

•Donotoperateamachineunderanyconditions

wheretraction,steeringorstabilityisinquestion.

Beawarethatoperatingthemachineonwetgrass,

acrossslopesordownhillmaycausethemachine

tolosetraction.Lossoftractiontothedrive

wheelsmayresultinslidingandalossofbraking

andsteering.Themachinecanslideevenifthe

drivewheelsarestopped.

•Removeormarkobstaclessuchasditches,holes,

ruts,bumps,rocksorotherhiddenhazards.Tall

grasscanhideobstacles.Uneventerraincould

overturnthemachine.

•Useextracarewhileoperatingwithaccessories

orattachments.Thesecanchangethestabilityof

themachineandcausealossofcontrol.Follow

directionsforcounterweights.

•Ifyoulosecontrolofthemachine,stepoffand

awayfromthedirectionoftravelofthemachine.

MaintenanceandStorage

•Raisethetines,closethespreadergate,setthe

parkingbrake,stopengineandremovekeyor

disconnectsparkplugwire.Waitforallmovement

tostopbeforeadjusting,cleaningorrepairing.

•Keepengineandengineareafreefromexcessive

greaseoroilandotherdebriswhichcan

accumulateintheseareas.Thesematerialscan

becomecombustibleandmayresultinare.

•Letenginecoolbeforestoringanddonotstore

nearameoranyenclosedareawhereopenpilot

lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do

Notstorefuelnearamesordrainindoors.

•Parkmachineonlevel,hardground.Neverallow

untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen

required.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Emptythehopperbeforetiltingthemachinefor

maintenanceandbeforestoring.

•Usecarewhencheckingandservicingtines.Wrap

thetine(s)orweargloves,andusecautionwhen

servicingthem.Onlyreplacedamagedtines.

Neverstraightenorweldthem.

•Disconnectbatteryorremovesparkplugwire

beforemakinganyrepairs.Disconnectthe

negativeterminalrstandthepositivelast.

Reconnectpositiverstandnegativelast.

•Keephandsandfeetawayfrommovingparts.

Ifpossible,donotmakeadjustmentswiththe

enginerunning.

•Chargebatteriesinanopenwellventilatedarea,

awayfromsparkandames.Unplugcharger

beforeconnectingordisconnectingfrombattery.

Wearprotectiveclothinganduseinsulatedtools.

Safety

DANGER

Chargingorjumpstartingthebatterymay

produceexplosivegases.Batterygasescan

explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway

frombattery.

•Ventilatewhenchargingorusingbattery

inanenclosedspace.

•Makesureventingpathofbatteryis

alwaysopenoncebatteryislledwith

acid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid,

whichispoisonousandcancausesevere

burns.Swallowingelectrolytecanbefatalor

ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and

rubberglovestoprotectskinandclothing

whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith

waterandcalladoctorimmediately.

CAUTION

Iftheignitionisinthe“ON”positionthere

ispotentialforsparksandengagementof

components.Sparkscouldcauseanexplosion

ormovingpartscouldaccidentallyengage

causingpersonalinjury.

Besureignitionswitchisinthe“OFF”

positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin

placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper

tightness.

•Frequentlycheckforwornordeteriorating

componentsthatcouldcreateahazard.

WARNING

Removalormodicationoforiginal

equipment,partsand/oraccessoriesmay

alterthewarranty,controllability,andsafety

ofthemachine.Unauthorizedmodications

totheoriginalequipmentorfailuretouse

originalmanufacturerpartscouldlead

toseriousinjuryordeath.Unauthorized

changestothemachine,engine,fuelor

ventingsystem,mayviolateapplicablesafety

standardssuchas:ANSI,OSHAandNFPA

and/orgovernmentregulationssuchasEPA

andCARB.

WARNING

Hydraulicuidescapingunderpressure

canpenetrateskinandcauseinjury.Fluid

accidentallyinjectedintotheskinmustbe

surgicallyremovedwithinafewhoursbya

doctorfamiliarwiththisformofinjuryor

gangrenemayresult.

•Ifequipped,makesureallhydraulicuid

hosesandlinesareingoodconditionand

allhydraulicconnectionsandttingsare

tightbeforeapplyingpressuretohydraulic

system.

•Keepbodyandhandsawayfrompinhole

leaksornozzlesthatejecthighpressure

hydraulicuid.

•Usecardboardorpaper,notyourhands,

tondhydraulicleaks.

•Beforeperforminganyworkonthe

hydraulicsystem:

–Safelyrelieveallpressureintheground

drivehydraulicsystembyplacingthe

motioncontrolleversinneutraland

shuttingofftheengine.

–Safelyrelieveallpressureintheauxiliary

hydraulicsystembyshuttingoffthe

engine,turningtheignitionswitchto

the“ON”position,andpressingthetine

groundengagementswitch.Oncethe

tineshaveloweredtotheground,release

thetinegroundengagementswitchand

turntheignitionswitchtothe“OFF”

position.

Safety

Transporting

Note:Refertothechemicalwarningproduct

label(s)beforetransportingtheunitandfollowall

local/state/federalrequirementsfortransporting

chemicals.

Note:Makesurethespreaderhoppercoverissecure

beforetransporting.

TransportingaUnit

Useaheavy-dutytrailerortrucktotransportthe

machine.Lockbrakeandblockwheels.Besurethe

fuelshut-offvalveisclosedduringtransport.Securely

fastenthemachinetothetrailerortruckwithstraps,

chains,cable,orropes.Whensecuringthefrontof

theunit,onlyusethetiedownlocations.Ifpossible,

bothfrontandrearstrapsshouldbedirecteddown

andoutwardfromthemachine.Besurethatthe

trailerortruckhasallnecessarylightingandmarking

asrequiredbylaw.Secureatrailerwithasafetychain.

WARNING

Securingthemachineonanyupperframe

locationwillcausetheparkingbraketonot

functionproperly,whichcouldcauseserious

injuryordeath.

Onlyusethefronttiedownlocationsonthe

lowerframetosecurethemachine.

CAUTION

Thismachinedoesnothaveproperturnsignals,

lights,reectivemarkings,oraslowmoving

vehicleemblem.Drivingonastreetorroadway

withoutsuchequipmentisdangerousand

canleadtoaccidentscausingpersonalinjury.

Drivingonastreetorroadwaywithoutsuch

equipmentmayalsobeaviolationofStatelaws

andtheoperatormaybesubjecttotrafctickets

and/ornes.

DoNotdriveamachineonapublicstreetor

roadway.

WARNING

Loadingamachineonatrailerortruckincreases

thepossibilityofbackwardtip-over.Backward

tip-overcouldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatinga

machineonaramp.

•Useonlyasingle,fullwidthramp;DoNotuse

individualrampsforeachsideofthemachine.

•Ifindividualrampsmustbeused,useenough

rampstocreateanunbrokenrampsurface

widerthanthemachine.

•Avoidsuddenaccelerationwhiledriving

machineuparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking

machinedownaramptoavoidtipping

backward.

LoadingaMachine

Useextremecautionwhenloadingmachineson

trailersortrucks.Onefullwidthrampthatis

wideenoughtoextendbeyondthereartiresis

recommendedinsteadofindividualrampsforeach

sideofthemachine.Ifitisnotpossibletouseone

fullwidthramp,useenoughindividualrampsto

simulateafullwidthcontinuousramp.

Asteeprampanglemaycausecomponentstoget

caughtasthemachinemovesfromramptotraileror

truck.Steeperanglesmayalsocausethemachineto

tipbackward.Ifloadingonornearaslope,position

thetrailerortrucksoitisonthedownsideofthe

slopeandtherampsextendsuptheslope.Thiswill

minimizetherampangle.Thetrailerortruckshould

beaslevelaspossible.

Important:DoNotattempttoturnthemachine

whileontheramp,youmaylosecontroland

driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp

andsuddendecelerationwhenbackingdowna

ramp.Bothmaneuverscancausethemachinetotip

backward.

WasteDisposal

ChemicalDisposal:Improperchemicaldisposal

canpollutetheenvironmentandcausehealthissues.

Followthedisposaldirectionsonthechemical

manufacturer’slabel.Disposeofchemicalsand

containersinaccordancetolocal/state/federallaws.

Safety

MotorOilDisposal:Engineoilandhydraulicoilare

bothpollutantstotheenvironment.Disposeofused

oilatacertiedrecyclingcenteroraccordingtoyour

stateandlocalregulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,which

ispoisonousandcancausesevereburns.

Swallowingelectrolytecanbefatalorifittouches

skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber

glovestoprotectskinandclothingwhen

handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater

andcalladoctorimmediately.

Federallawstatesthatbatteriesshouldnotbeplaced

inthegarbage.Managementanddisposalpractices

mustbewithinrelevantfederal,state,orlocallaws.

Ifabatteryisbeingreplacedoriftheunitcontaining

thebatteryisnolongeroperatingandisbeing

scrapped,takethebatterytoalocalcertiedrecycling

center.Ifnolocalrecyclingisavailablereturnthe

batterytoanycertiedbatteryreseller.

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,

dirtanddebrisfromsafetysignsandinstructional

labels.

•Replaceallworn,damaged,ormissingsafety

signs.

•Whenreplacementcomponentsareinstalled,be

surethatcurrentsafetysignsareafxedtothe

replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,

makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfromyour

authorizedequipmentdealerordistributor.

•Safetysignsmaybeafxedbypeelingoffthe

backingtoexposetheadhesivesurface.Apply

onlytoaclean,drysurface.Smoothtoremove

anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns

andinstructionlabels.Theyarecriticaltothesafe

operationofyourmachine.

decal126-2055

126-2055

1.Wheellugnut—torqueto129N∙m(95ft-lb).

2.Wheelhubnut—torqueto319N∙m(235ft-lb).

3.ReadtheOperator’sManualbeforeperforming

maintenance;checkthetorqueaftertherst100hours

andevery500hoursafter.

decal135-6430

135-6430

1.Pressandholdthefoot

pedaltolockthecaster

wheelsinthestraight

position.

2.Releasethefootpedalto

unlockthecasterwheels

toallowturning.

decal135-6725

135-6725

1.Cutting/dismembermenthazardofhand,spinner—stay

awayfrommovingparts.

Safety

decal135-7771

135-7771

1.Fast

16.Spreaderspeed—increase

2.Slow17.Spreaderspeed—decrease

3.Neutral

18.Spraypump—on;optionalsprayeraccessory

4.Reverse

19.Spraypump—off;optionalsprayeraccessory

5.Warning—readtheOperator’sManual;donotoperatethis

machineunlessyouaretrained;wearhearingprotection.

20.Operatorpresencecontrol

6.Warning—stayawayfrommovingparts;keepallguards

andshieldsinplace;shutofftheengineandremovethe

keybeforeperformingmaintenance.

21.Throttle—fast

7.Warning—disengagethesprayercontrols,movethedrive

levertotheneutralposition,engagetheparkingbrake,

andshutofftheenginebeforeleavingthemachine.

22.Continuousvariablesetting

8.Crushing/dismembermenthazardofbystanders,forward

andreverse—donotcarrypassengers;lookbehindand

downwhenreversing.

23.Throttle—slow

9.Thrownobjecthazard—keepbystandersaway.24.Hourmeter

10.Warning—onlyoperateacrossslopes;donotoperateup

anddownslopes.

25.Engine—off

11.Causticliquid/chemicalburnhazard;asphyxiationhazard,

poisonousfumesortoxicgases—wearhandandskin

protection;weareyeandrespiratoryprotection.

26.Engine—on

12.Warning—usefresh,cleanwaterforrst-aidwashingand

rinsingthetank.

27.Engine—start

13.Parkbrake—engaged28.PressLHmotioncontrolbuttontolowertines.

14.Parkbrake—disengaged29.PressRHmotioncontrolbuttontoraisetines.

15.Spreaderspeed

Safety

decal135-6281c

135-6281

Operation

SpreaderOperations

Overview

TheSpreaderMotorControldeterminesthespeedof

theimpellerinthefrontonthemachine.Themachine

iscapableofvaryingitsspreadpatternfrom3–25

feetwiththiscontrol.Beinghydraulicallydriven,the

spreadpatternisindependentofthegroundspeed.

Thehoppercontrolcableopensandclosesthedoor

insidethebaseofthehopper.Themaximumsizeof

theopeningwillbedeterminedbytherateadjustment

ontheknobdial.Thiswillsetyourrategatelinkage

bartolimitandstoptheratethedoorcanopen.

TheDiffuseradjustmentallowstheusertoadjustthe

intensityofthespreadpattern.Asmallturnshifts

theproductplacementontheimpeller.Thisinturn

balancesthespreadpatternheaviertotheleft(back

sideramp)orheaviertotheright(frontsideramp).

Adjustmentisverysensitive,somultipleadjustments

mayberequired.

Themachineisequippedwiththe120lbmodel

spreader.Thehydraulicspreadermotorwiththe

spreadermotorcontrolhastheabilitytovary

spreadwidthsfrom3to25feet.Thisdependson

volume/density,particlesizeandrateoftravel,and

weatherconditions.Thepatterncanbeincreasedor

decreasedwhilespreadingdependingonneeds.A

typicalpatternistooverlapfertilizerpatternbackto

thetiretracks.

Thespreadthinsandfeathersattheouteredges,

eliminatingsharp“edgetoedge”lineswhichcause

stripesandstreaks.

Determineadialsettingonthelowside.Ifsetting

istoolow,covertheareamorethanonetime.A

highersettingcanbeusedwhenaprovendialsetting

isestablished.Travelataconstantspeed.

Remember-Publisheddialsettingsareapproximate

only.Openthehopperdoorafterthespreaderis

turnedonatoperatingspeed.

Operations

Uponturningthekeyontostarttheunit,applyfull

choke.Onceunithasstarted,releaserstthechoke

andthenthebrake.PushJoySticksforwardequally

tomoveunitforward.Shouldyouwanttheunitto

backupinthereversedirection,pullbackontheJoy

Sticks.Ifaturnisdesired,pushoppositeJoyStickof

thedirectionyouwanttheunittoheadforward(if

wantingtoturnleft,pushtherightJoyStickforward

whilekeepingtheleftJoyStickslightlybackofthe

rightthusallowingtherighttiretoturnmorethanthe

left.PushmoreontheleftJoyStickifyoudesireto

turntheunittotheright).Becautiousasturnradius

changeswiththespeedyouaregoingandtheamount

eachJoyStickispositionedforwardorbackward.

Usingthespreadersystem,therearetwocablesto

operatethehopperdoor(topcable),thediffuser

(rightcable).Bypullingonthetophopperdoor

cable,thiswillopenthedoorandallowproductto

fallonthespinner.Adjustmentsastohowwidethe

dooropensaremadeonthefrontonthehopper

withtheHopperRateDial.Thislimitshowwide

thedoorwillopenandhowmuchgranularproduct

willbecomingout.Thediffusercable(rightcable)

controlsthespreadpattern.Turningthecableknob

counter-clockwisewillloosenthecablelockandallow

youtoadjust(pullfurtheroutorpushfurtherin)this

cable.Doingthiswillallowyoutospreadgranular

productheaviertotheleft,consistentinthemiddle

orheaviertotheright.Onceyouhaveadjustedto

yourdesiredpattern,turntheknobclockwisetolock

inposition.

Duringnormalspreadingapplications,thedeector

shieldwouldstayintheupposition.Whenwanting

tocloseofftheleftsideandusethedeectorshield,

engagetheparkingbrakeandshutoffthemachine.

Waitforallmovingpartstostopbeforeleavingthe

operator’sposition.Gotothefrontofthemachine

andpushthedeectortothedownposition.

TheLockingCasterSystem(Figure3)allowsthe

operatortolockthefrontcasterwheelsinthe

forwardpositiontocreatemoresidehillstability.The

LockingCasterSystemisappliedwhentheoperator

compressestheLockingCasterSystemfootpedal

locatedontherightsideofthefootplate.When

compressingthefootpedal,lockingmechanism

slidesoverthecasterpinlockingthewheelinthe

forward/straightposition.Thissystemisspring

loaded,sobyreleasingthispedalitwillreleasethe

lockonthefrontcasterwheels.

Operation

g271157

Figure3

1.Casterpinlockingmechanism

SpreaderSystem

SpreaderCalibration/Layout

TheSpreaderMotorControldeterminesthespeed

oftheimpellerinthefrontonthemachine.Your

machineiscapableofvaryingitsspreadpatternfrom

3–25feetwiththiscontrol.Beinghydraulically

driven,thespreadpatternisindependentofthe

groundspeed.

Thehoppercontrolcableopensandclosesthedoor

insidethebaseofthehopper.Themaximumsizeof

theopeningwillbedeterminedbytherateadjustment

ontheHopperRateDial.Thiswillsetyourrategate

linkagebartolimitandstoptheratethedoorcan

open.

g286783

Figure4

1.Hopper

2.Diffuser

TheDiffuseradjustmentallowstheusertoadjustthe

intensityofthespreadpattern.Asmallpullshifts

theproductplacementontheimpellereithertothe

edgeoftheimpellerorthemiddleoftheimpeller.

Thisinturnshiftsthespreadpatternheaviertothe

left(placingproducttotheedgeoftheimpeller)or

heaviertotheright(placingproducttothemiddle

oftheimpeller).

Yourmachineisequippedwitha120lb.Spyker

modelspreader.Thehydraulicspreadermotorwith

thespreadermotorcontrolhastheabilitytovary

spreadwidthsfrom3to25feet.Thisdependson

volume/density,particlesizeandrateoftravel,and

weatherconditions.Thepatterncanbeincreasedor

decreasedwhilespreadingdependingonneeds.A

typicalpatternistooverlapfertilizerpatternbackto

thetiretracksandthespraypatternboomtoboom.

Thisfeathersmaterialattheouteredges,eliminating

sharp“edgetospread”lineswhichcausestripesand

streaks.

Determineadialsettingonthelowside.Ifsetting

istoolow,covertheareamorethanonetime.A

highersettingcanbeusedwhenaprovendialsetting

isestablished.Travelataconstantspeed.

g271240

Figure5

1.Dial

2.Diffuser

Remember-Publisheddialsettingsareapproximate

only.Openthehopperdoorafterthespreaderis

turnedonatoperatingspeed.

*Spray/SpreadCalibrationDecalChartsareavailable

fromthepartsdepartment.

AeratorOperations

Overview

TheZ-Plugcancover100,000squarefeetperhour

andproduceupto31/2inchcores.Thefulloating

Operation

tineheadcanmaneuveraroundtreesandbedswhile

engaged.The2,000lbhydrauliccylinderpicksup

theheadinlessthan2.5secondsforturningaround

orgettingheadupinthetransportposition.Forced

intheoppositedirection,thehydrauliccylinderputs

downforceontheheadaddingweighttothetine

headfordeepersoilpenetration.BallSwivelandpin

attachpointsallow30degreesofpivotlefttoright

forbettersteeringinthedownposition.TheBall

Swivelandpinattachpointsalsoallowforeasyattach

anddisassembleoftheAeratorhead(oranyother

attachmentdesignedfortheZ-Plug).

Operations

Uponturningthekeyontostarttheunit,applyfull

choke.Onceunithasstarted,release(pushdownor

pulldown)rstthechokeandthenthebrakelever.

BringunituptoacomfortablespeedwiththeControl

Lever.Whenyouarrivetodesiredaeratingarea,use

theThumbSwitchtoloweraeratortinesintotheturf

(aeratorheadcanoatupto30degreesandmake

gradualturnsaroundbedsandtrees).

Onceyouhavecometoadesignatedturnaround

location,usethehydraulicThumbSwitchtolifttine

headtotransportposition.Makedesignatedturnand

repeatprocessofloweringtineheadintoturfand

resumeaeration.

g286617

Figure6

1.RHmotioncontrolthumb

switchraisestines

2.LHmotioncontrolthumb

switchlowerstines

Ifaeratingonhillsides,theLockingCasterSystem

allowstheoperatortolockthefrontcasterwheels

intheforwardpositiontocreatemoresidehill

stability.TheLockingCasterSystemisappliedwhen

theoperatorcompressestheLockingCasterSystem

footpedallocatedontherightsideofthefoot

plate.Whencompressingthefootpedal,locking

mechanismslidesoverthecasterpinlockingthe

wheelintheforward/straightposition.Thissystemis

springloaded,sobyreleasingthispedalitwillrelease

thelockonthefrontcasterwheels..

AeratorTineHeadRemoval

Theaeratortineheadisremovableforservice,

cleaningandremovingfromtractionunittoinstall

otherattachments.Toremovethetineheadfromthe

tractionunit,rstadjustthehydrauliccylindersothat

thetineheadstartstomakecontactwiththeground

(takingweightoffofthehead).Pullpindisconnecting

theballswivellinkagetotheaeratorhead.Lower

cylinderreleasingtensiononthechainsandremove

the2ballswivelchainsconnectedtotheouterframe

section(weldedtochainandspringsupports).

Pullthepinfromtheaeratorfrontframeneck(itwill

beattachedtothefrontframeofthetractionunit)

anddismounttheballswivelfromthepin(pullneck

downward).Lowerfrontneckoftheaeratorhead

andpositionyourselfbackonthetractionunit.Drive

awayfromtheaeratorheadbyturningeitherleftor

right(turningtotherightofthehead—reference

Figure7)byturningthefrontofthetractionunitin

eitherdirection.Toinstallheadbackontheunit,

reversetheunitalongthebackofthetines.Oncethe

rearinsidetirelinesuptothecenteroftheaerator

head,slowlystartturningunitovertheaeratorhead

(makesurethatyoulineuptheballswivelintheneck

oftheaeratorandthepullpinbeneaththenoseof

thetractionunittomakeiteasyformounting).

Operation

g286624

Figure7

1.Turningrightofaeratortinehead

Note:Theremovableweightsareheavy.Usecare

whenliftingthem.Makesurethatyoucanhold

themsecurelybeforeliftingthem.Usecautionwhen

positioningyourhandssothatyouDoNotsetthem

onyourhands,ngers,orfeet.Itisrecommendedto

usetwopeoplewhenremovingweights.

Maintenance

PeriodicMaintenance

Alwaysshutofftheengine,andremovethekey.Wait

forallmovementtostopandallowthemachineto

coolbeforeadjusting,cleaning,storing,orrepairingit.

EngineMaintenance

**USECOMPRESSEDAIR(NOTWATER)

WHENCLEANINGENGINE**

Useonlyoriginalequipmentreplacementparts.

Otherpartsmaynotperformaswell,maydamage

unit,andmayresultininjury.

OilRecommendations:ExmarkPremium4-Cycle

Oilisrecommendedforbestperformance.Other

high-qualitydetergentoilareacceptableifclassied

forserviceSF,SG,SH,SJorhigher.Donotuse

specialadditives.Changeengineoilafterrst5hours

andthenevery50hoursthereafter.

IftheoillevelisbelowtheADDmark,addoiluntil

itreachestheFULLmark.Starttheengineandrun

forafewseconds.Turnengineoffandcheckdipstick

forproperlllevel.

g286804

Figure8

1.Engineoildrainhosebehindengine

FuelRecommendations:Fuelmustmeetthese

requirements

•Clean,fresh,unleadedgasoline.

•Aminimumof87octane/87AKI(91RON).

•Gasolinewithupto10%ethanol(gasohol)or

upto15%MTBE(methyltertiarybutylether)

isacceptable.

Fullmaintenanceinformationcanbelocatedinthe

enginemanualprovided.

Maintenance

HydraulicSystem

Maintenance

**USECOMPRESSEDAIR(NOTWATER)

WHENCLEANINGHYDRAULICSYSTEM**

Hydro-Gearrecommendsthattheuidandlter(s)

bechangedaftertherst100hoursandevery500

hoursthereafter.UseExmarkPremiumHydroOil

whenreplacingtheoilinyoursystem.Thehydraulic

reservoirshouldbelledsotheoillevelishalfway

upthesightwindow.

Hydraulicsystemrequires25micronoilltersor

equivalenttobeused.

Checkforhydraulicleaksdailytoensureproperuid

levels.

TractionUnitMaintenance

Themachinehas11greasettingsthatrequire

periodicgreasing.Theselocationscanbefound

onthewheelassembly(1oneachfrontwheel

assembly),onthecasterassembly(1oneachfront

casterassembly),andthedrivebeltidler(1onidler

arm),PillowBlockBearings(4each)and2onthe

LiftCylinder..

Inspectwheelandcasterassemblyevery25hoursfor

bearingwear,damage,debris,andproperinstallation.

Inspectidlerarmbushingevery50hoursforwear.

Thesebushingsareawearitemandwillhavetobe

replacedperiodically.

Inspectallbolts,washers,nuts,pinsandother

mountinghardwareofZ-Plugonceaweektoensure

thathardwarepiecesareproperlytightened.

SpreaderMaintenance

TheZ-Plugcomesequippedwitha120lbspreader

andrequiresthesameamountofattentionand

maintenance.

**USECOMPRESSEDAIR(NOTWATER)

WHENCLEANINGHOPPER**

Lubricate(SiliconeSpray)Hopper,Deectorand

Diffusercablesweekly.

CleandebrisandproductfromHopperdailyto

eliminatebuildup.

Keephydraulichosettingstightandfreeofleaks.

BesurethattheRateGate&DiffuserGuidesarenot

damagedtoallowthehopperdoortoslidefreely.

Checkagitatorwireonadailybasis.Ifwireisnot

present,productwillruntheriskofbuildingupprior

toreachinghopperdoorandnotspreadingevenly.

AeratorHead/Tine

Maintenance

Checkalltinestoensurethatthereisnobends,

cracksand/ordamagestothetines(replaceanybent,

crackedand/ordamagedtines).

Checktomakesurethatallnutsontinehead

assemblyaretightandsecure.

Checktoensurethatpillowblockbearingassemblyis

securedandbearingsaremovingfreely.

MaintenanceChart

ServiceInterval:Asrequired

Service

Actions(s)

DailyWeeklyBi-WeeklyMonthlyYearly

Hours

FrontCaster

Wheels

(grease)

FrontCaster

Yokes(grease)

FrontTire

Pressure(22

PSI)

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Exmark Z-Plug User manual

Brand: Exmark

Model: Z-Plug

Category: Spreader

Type: User manual

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Exmark Z-Plug User manual

Exmark Z-Plug User manual

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