Exmark Z-Plug Operator's Manual
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Exmark Z-Plug Operator's Manual

Exmark Z-Plug Operator's Manual

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Z-PLUG
™
For Serial Nos.
404,314,159 and Higher
Part No. 4504-453 Rev. B

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Summary of Contents for Exmark Z-Plug

  • Page 1 Z-PLUG ™ For Serial Nos. 404,314,159 and Higher Part No. 4504-453 Rev. B...

  • Page 2: 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.

  • Page 3: Table Of Contents

    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 ..............15 Spreader Operations........15 Spreader System ..........16 Aerator Operations ........16 Maintenance ............19 Periodic Maintenance ........19 Engine Maintenance........19 Hydraulic System Maintenance .......20...

  • Page 4: Safety

    Chemical Safety • Handle chemicals in a well ventilated area. The intended use of the Z-Plug machine is for lawn • Have clean water available. care. • Do Not eat, drink, or smoke while working with...
  • Page 5 Safety • Always wash your hands and other exposed areas CAUTION as soon as possible after finishing the work. This machine produces sound levels in excess • Keep chemicals in their original packages and in a of 85 dBA at the operator’s ear and can cause safe location.
  • Page 6 Safety Operation DANGER In certain conditions during fueling, static WARNING electricity can be released causing a spark Operating engine parts, especially the muffler, which can ignite gasoline vapors. A fire or become extremely hot. Severe burns can occur explosion from gasoline can burn you and on contact and debris, such as leaves, grass, others and cause property damage.

  • Page 7: Slope Operation

    Safety • Stop engine, wait for all moving parts to stop, and • When operating with a heavy load, reduce your engage parking brake: speed and allow for sufficient stopping distance. Use extra caution on slopes. – Before refueling. • Reduce speed and load when operating on rough WARNING terrain, uneven ground, and near curbs, holes, and other sudden changes in terrain.

  • Page 8: Maintenance And Storage

    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.
  • Page 9 Safety DANGER WARNING Charging or jump starting the battery may Removal or modification of original produce explosive gases. Battery gases can equipment, parts and/or accessories may explode causing serious injury. alter the warranty, controllability, and safety of the machine. Unauthorized modifications •...

  • Page 10: Transporting

    Safety Transporting WARNING Loading a machine on a trailer or truck increases Note: Refer to the chemical warning product the possibility of backward tip-over. Backward label(s) before transporting the unit and follow all tip-over could cause serious injury or death. local/state/federal requirements for transporting chemicals.

  • Page 11: Battery Disposal

    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.

  • Page 12: Safety And Instructional Decals

    Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease, • New safety signs may be obtained from your dirt and debris from safety signs and instructional authorized equipment dealer or distributor. labels. • Safety signs may be affixed by peeling off the •...
  • Page 13 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;...
  • Page 14 Safety decal135-6281c 135-6281...

  • Page 15: Operation

    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 Spreader Operations 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 Overview...

  • Page 16: Spreader System

    This in turn shifts the spread pattern heavier to the The Z-Plug can cover 100,000 square feet per hour left (placing product to the edge of the impeller) or and produce up to 3 1/2 inch cores. The full floating...
  • Page 17 Aerator head (or any other the tine head starts to make contact with the ground attachment designed for the Z-Plug). (taking weight off of the head). Pull pin disconnecting the ball swivel linkage to the aerator head. Lower...
  • Page 18 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.

  • Page 19: Maintenance

    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. Other high-quality detergent oil are acceptable if classified for service SF, SG, SH, SJ or higher.

  • Page 20: Hydraulic System Maintenance

    Maintenance Hydraulic System Spreader Maintenance Maintenance The Z-Plug comes equipped with a 120 lb spreader and requires the same amount of attention and **USE COMPRESSED AIR (NOT WATER) maintenance. WHEN CLEANING HYDRAULIC SYSTEM** **USE COMPRESSED AIR (NOT WATER) Hydro-Gear recommends that the fluid and filter(s)
  • Page 21 Maintenance Service Daily Weekly Bi-Weekly Monthly Yearly Hours Actions(s) Rear Tire Pressure (18 PSI) Rear Rim Nut Torque (95lbs) Rear Hub Castle Nut (235 ft-lb) Idler Pulley Arm (grease) Belt Tension (1/2 inch deflection at 15lbs) Belt Wear (cracks, tears or missing material) Hopper...
  • Page 22 Maintenance Service Daily Weekly Bi-Weekly Monthly Yearly Hours Actions(s) Engine Air 50 hrs Filter Check (change if needed) Engine Air Replace Pre-Filter Check (change if needed) Engine Fuel 25 hrs Filter Check (change if needed) Engine Spark Replace Plugs Hydraulic After first Oil and filter 100 hrs and...

  • Page 23: Troubleshooting

    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).

  • Page 24: Charging Issues

    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).
  • Page 25 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. 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.
  • Page 26 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. Connect stator wire harness to regulator-rectifier.

  • Page 27: Schematics

    Schematics Schematics Electrical Schematic g287990...
  • Page 28 Pack) or Fill in Below Engine Model No. and Spec. No. Model No. Engine Serial No. (E/No) Serial No. ©2019 Exmark Mfg. Co., Inc. Part No. 4504-453 Rev. B 2101 Ashland Ave (402) 223-6375 Beatrice, NE 68310 Fax (402) 223-5489...

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