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Exmark Z-Plug User manual

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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:
____________________________________
©2019ExmarkMfg.Co.,Inc.
2101AshlandAve
Beatrice,NE68310
2
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
3
Safety
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.
4
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.
5
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.
6
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.
7
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.
8
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.
9
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.
10
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.
11
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.
12
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
13
Safety
decal135-6281c
135-6281
14
Operation
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.
15
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
16
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).
17
Operation
g286624
Figure7
1.Turningrightofaeratortinehead
Note:Theremovableweightsareheavy.Usecare
whenliftingthem.Makesurethatyoucanhold
themsecurelybeforeliftingthem.Usecautionwhen
positioningyourhandssothatyouDoNotsetthem
onyourhands,ngers,orfeet.Itisrecommendedto
usetwopeoplewhenremovingweights.
18
Maintenance
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.
19
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)
X
FrontCaster
Yokes(grease)
X
FrontTire
Pressure(22
PSI)
X
20
/