Z-PLUG ™ For Serial Nos. 404,314,159 and Higher Part No. 4504-453 Rev.
Introduction To the Owner Introduction Read this manual entirely BEFORE operating the Z-Plug. The information presented herein will prepare you to operate the Z-Plug in a safe and knowledgeable manner. Operating the Z-Plug in a proper manner will provide a safer working environment, create more efficient results and promote higher quality. Keep this manual on hand at all times for ready reference.
Contents Introduction ........................................................... 2 To the Owner.................................................. 2 Safety ..................................................................... 4 Safety Alert Symbol ......................................... 4 Safe Operating Practices .................................. 4 Transporting ..................................................10 Safety and Instructional Decals ......................12 Operation .........................
Safety Safety WARNING Chemical substances used in the machine’s chemical system may be hazardous and toxic to you, bystanders, animals, plants, soils or other property. • Carefully read and follow the chemical warning labels and Safety Data Sheets (SDS) for all chemicals used and protect yourself according to the chemical manufacturer's recommendations. Ensure that as little skin as possible is exposed while using chemicals.
Safety • Always wash your hands and other exposed areas as soon as possible after finishing the work. • Keep chemicals in their original packages and in a safe location. • Properly dispose of unused chemicals and chemical containers as instructed by the chemical manufacturer and your local codes. • Chemicals and fumes are dangerous; never enter hopper or place your head over or in the opening. • Follow all local/state/federal requirements for the spreading of chemicals.
Safety Operation DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage. • Always place gasoline containers on the ground away from your vehicle before filling.
Safety • Stop engine, wait for all moving parts to stop, and engage parking brake: • When operating with a heavy load, reduce your speed and allow for sufficient stopping distance. Use extra caution on slopes. – Before refueling. • Reduce speed and load when operating on rough terrain, uneven ground, and near curbs, holes, and other sudden changes in terrain. Loads may shift, causing the machine to become unstable.
Safety Maintenance and Storage • Raise the tines, close the spreader gate, set the parking brake, stop engine and remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing. • Keep engine and engine area free from excessive grease or oil and other debris which can accumulate in these areas. These materials can become combustible and may result in a fire.
Safety DANGER WARNING Charging or jump starting the battery may produce explosive gases. Battery gases can explode causing serious injury. Removal or modification of original equipment, parts and/or accessories may alter the warranty, controllability, and safety of the machine. Unauthorized modifications to the original equipment or failure to use original manufacturer parts could lead to serious injury or death.
Safety Transporting WARNING Loading a machine on a trailer or truck increases the possibility of backward tip-over. Backward tip-over could cause serious injury or death. • Use extreme caution when operating a machine on a ramp. • Use only a single, full width ramp; Do Not use individual ramps for each side of the machine. • If individual ramps must be used, use enough ramps to create an unbroken ramp surface wider than the machine.
Safety 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. Battery Disposal DANGER Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns. Swallowing electrolyte can be fatal or if it touches skin can cause severe burns. • Wear safety glasses to shield eyes, and rubber gloves to protect skin and clothing when handling electrolyte.
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels. • New safety signs may be obtained from your authorized equipment dealer or distributor. • 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. • Replace all worn, damaged, or missing safety signs.
Safety decal135-7771 135-7771 1. Fast 16. Spreader speed—increase 2. Slow 17. Spreader speed—decrease 3. Neutral 18. Spray pump—on; optional sprayer accessory 4. Reverse 19. Spray pump—off; optional sprayer accessory 5. Warning—read the Operator’s Manual; do not operate this 20. Operator presence control machine unless you are trained; wear hearing protection. 6.
Safety decal135-6281c 135-6281 14
Operation Operation and then the brake. Push Joy Sticks forward equally to move unit forward. Should you want the unit to backup in the reverse direction, pull back on the Joy Sticks. If a turn is desired, push opposite Joy Stick of the direction you want the unit to head forward (if wanting to turn left, push the right Joy Stick forward while keeping the left Joy Stick slightly back of the right thus allowing the right tire to turn more than the left.
Operation heavier to the right (placing product to the middle of the impeller). 1. Caster pin locking mechanism Your machine is equipped with a 120 lb. Spyker model spreader. The hydraulic spreader motor with the spreader motor control has the ability to vary spread widths from 3 to 25 feet. This depends on volume/density, particle size and rate of travel, and weather conditions. The pattern can be increased or decreased while spreading depending on needs.
Operation tine head can maneuver around trees and beds while engaged. The 2,000 lb hydraulic cylinder picks up the head in less than 2.5 seconds for turning around or getting headup in the transport position. Forced in the opposite direction, the hydraulic cylinder puts down force on the head adding weight to the tine head for deeper soil penetration. Ball Swivel and pin attach points allow 30 degrees of pivot left to right for better steering in the down position.
Operation g286624 Figure 7 1. Turning right of aerator tine head Note: The removable weights are heavy. Use care when lifting them. Make sure that you can hold them securely before lifting them. Use caution when positioning your hands so that you Do Not set them on your hands, fingers, or feet. It is recommended to use two people when removing weights.
Maintenance Maintenance Periodic Maintenance Always shut off the engine, and remove the key. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning, storing, or repairing it. Engine Maintenance **USE COMPRESSED AIR (NOT WATER) WHEN CLEANING ENGINE** Use only original equipment replacement parts. Other parts may not perform as well, may damage unit, and may result in injury. Oil Recommendations: Exmark Premium 4-Cycle Oil is recommended for best performance.
Maintenance Hydraulic System Maintenance Spreader Maintenance The Z-Plug comes equipped with a 120 lb spreader and requires the same amount of attention and maintenance. **USE COMPRESSED AIR (NOT WATER) WHEN CLEANING HYDRAULIC SYSTEM** **USE COMPRESSED AIR (NOT WATER) WHEN CLEANING HOPPER** Hydro-Gear recommends that the fluid and filter(s) be changed after the first 100 hours and every 500 hours thereafter. Use Exmark Premium Hydro Oil when replacing the oil in your system.
Maintenance Service Actions(s) Daily Weekly Bi-Weekly Monthly X Rear Tire Pressure (18 PSI) Rear Rim Nut Torque (95lbs) X Rear Hub Castle Nut (235 ft-lb) X Idler Pulley Arm (grease) X Belt Tension (1/2 inch deflection at 15lbs) X Belt Wear (cracks, tears or missing material) X Hopper Cables (lubricate w/ Silicone Spray) X Accuway Cable (lubricate w/ Silicone Spray) X Deflector Shield Cable (if applicable) (lubricate w/ Silicone Spray) X X Bottom of Hopper Tub (wire brush cleaning) X
Maintenance Service Actions(s) Daily Weekly Bi-Weekly Monthly Yearly 50 hrs Engine Air Filter Check (change if needed) X Engine Air Pre-Filter Check (change if needed) Replace Engine Fuel Filter Check (change if needed) 25 hrs X Engine Spark Plugs Hydraulic Oil and filter (change) Hydraulic Oil Level (check) X X In-Line Filter (check) X In-Line Filter Gasket (check) X X Pillow Block Bearings X X Aerator Tine Hardware (Nut and Bolt) X Ball Swivel Inspection *Blow off debris daily* Rep
Troubleshooting Troubleshooting Engine: • Not starting. There are a few reasons as to why your engine fails to start. If the engine does not turn over, then the battery could be dead, bad connection to the battery wires, keys which may be bad, 30 AMP fuse on the wiring harness (orange wire) may be blown or the starter solenoid may be bad (you will hear the starter solenoid trying to click on, but nothing is happening). Another common reason for a unit not starting is after unit has been washed.
Troubleshooting through the hopper door area, then Diffuser Guides are loose or worn allowing a gap between the door and the hopper base. Also a potential factor is if the hopper cable is not completely closing the hopper door. • When your hopper door cannot open, there are typically 3 things to look at. One is that your hopper cable may be frozen and locked up, the ball joint end may have broken off or there may be product jammed between the hopper door and the base (due to loose door guides).
Troubleshooting CAUTION Attach meter test leads to the AC output terminals (YELLOW wires) in the connector BEFORE starting the engine. If the stator is grounded (defective) and the meter test leads contact the center DC output pin (RED wire) in the connector, arcing could occur, damaging the wiring. 4. Attach RED (2) and BLACK (1) test lead probes to the YELLOW wire (4) AC output terminals (6), of the connector (3), as shown in Figure 10.
Troubleshooting The DC Shunt MUST be installed on the NEGATIVE (-) terminal of the battery, (Figure 11) to avoid blowing the fuse in the meter when testing the output of the 16 amp system. All connections must be clean and tight for correct readings. 1. Connect stator wire harness to regulator-rectifier. 2. Install DC Shunt (4) on NEGATIVE battery terminal. 3. Insert RED test lead into VΩ receptacle in meter and connect to RED post terminal on shunt (5), Figure 11. g268088 Figure 11 4.
WHITE RED J1616 J1617 SP1603 ORANGE BLACK YELLOW MAIN F26 10A A YELLOW GREEN YELLOW J1612 TERMINAL + J1611 J1610 RED MAIN ORANGE SENSOR + SENSOR - RED BLACK GND P1611 F27 20A SP1609 ORANGE J1603 J1604 SPEEDOMETER BLACK YELLOW YELLOW +12VDC P1609 ORANGE K1601 START SOLENOID ATC-ATO FUSE HOLDER J1609 J1608 J1607 FRAME GROUND SP1602 BLACK RED ORANGE RED J1606 J1605 YELLOW RED SPEED SENSOR & CABLE SP1607 BATTERY BT1601 ORANGE J1601 M 2 S 1 P1601 L 3 FRAME GROUN
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. ©2019 Exmark Mfg. Co., Inc. 2101 Ashland Ave Beatrice, NE 68310 All Rights Reserved Part No. 4504-453 Rev. B (402) 223-6375 Fax (402) 223-5489 Printed in the USA www.exmark.
