Exmark Z-Plug Operator's 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:
____________________________________

©2019ExmarkMfg.Co.,Inc.
2101AshlandAve
Beatrice,NE68310

Contactusatwww.Exmark.com.

2

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!

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.

WARNING

Chemicalsubstancesusedinthemachine’s
chemicalsystemmaybehazardousandtoxicto
you,bystanders,animals,plants,soilsorother
property.

•Carefullyreadandfollowthechemical
warninglabelsandSafetyDataSheets(SDS)
forallchemicalsusedandprotectyourself
accordingtothechemicalmanufacturer's
recommendations.Ensurethataslittle
skinaspossibleisexposedwhileusing
chemicals.UseappropriatePersonal
ProtectiveEquipment(PPE)toguardagainst

g000502

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.

SafeOperatingPractices

Alwaysshutofftheengine,andremovethekey.Wait
forallmovementtostopandallowthemachineto
coolbeforeadjusting,cleaning,storing,orrepairingit.

ChemicalSafety

TheintendeduseoftheZ-Plugmachineisforlawn
care.

•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.

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.

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.

•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.

•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.

•Granularmaterialscanshift.Thisshifting
happensmostoftenwhileturning,goingupor
downhills,suddenlychangingspeeds,orwhile
drivingoverroughsurfaces.Shiftingloadscan
causetheunittotipover.

7

Safety

1.SafeZone—Usethe
machinehere

2.DangerZone-Usea
walkbehindmachine
orahandheldtool
neardropoffs,ditches,
embankments,wateror
otherhazards.

3.Water

Figure2

4.W=widthofthemachine

5.Keepasafedistance
(twicethewidthofthe
machine)betweenthe
machineandanyhazard.

MaintenanceandStorage

•Raisethetines,closethespreadergate,setthe
parkingbrake,stopengineandremovekeyor
disconnectsparkplugwire.Waitforallmovement
tostopbeforeadjusting,cleaningorrepairing.

•Keepengineandengineareafreefromexcessive
greaseoroilandotherdebriswhichcan
accumulateintheseareas.Thesematerialscan
becomecombustibleandmayresultinare.

•Letenginecoolbeforestoringanddonotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do

g222400

Notstorefuelnearamesordrainindoors.

•Parkmachineonlevel,hardground.Neverallow
untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Emptythehopperbeforetiltingthemachinefor
maintenanceandbeforestoring.

•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.

•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

MotorOilDisposal:Engineoilandhydraulicoilare
bothpollutantstotheenvironment.Disposeofused
oilatacertiedrecyclingcenteroraccordingtoyour
stateandlocalregulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,which
ispoisonousandcancausesevereburns.
Swallowingelectrolytecanbefatalorifittouches
skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber
glovestoprotectskinandclothingwhen
handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater
andcalladoctorimmediately.

Safety

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.

decal126-2055

126-2055

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

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

3.ReadtheOperator’sManualbeforeperforming
maintenance;checkthetorqueaftertherst100hours
andevery500hoursafter.

•Newsafetysignsmaybeobtainedfromyour
authorizedequipmentdealerordistributor.

•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourmachine.

decal135-6725

135-6725

1.Cutting/dismembermenthazardofhand,spinner—stay
awayfrommovingparts.

1.Pressandholdthefoot
pedaltolockthecaster
wheelsinthestraight
position.

decal135-6430

135-6430

2.Releasethefootpedalto
unlockthecasterwheels
toallowturning.

12

Safety

decal135-7771

135-7771

1.Fast

2.Slow17.Spreaderspeed—decrease

3.Neutral

4.Reverse

5.Warning—readtheOperator’sManual;donotoperatethis
machineunlessyouaretrained;wearhearingprotection.

6.Warning—stayawayfrommovingparts;keepallguards
andshieldsinplace;shutofftheengineandremovethe
keybeforeperformingmaintenance.

7.Warning—disengagethesprayercontrols,movethedrive
levertotheneutralposition,engagetheparkingbrake,
andshutofftheenginebeforeleavingthemachine.

8.Crushing/dismembermenthazardofbystanders,forward
andreverse—donotcarrypassengers;lookbehindand
downwhenreversing.

9.Thrownobjecthazard—keepbystandersaway .24.Hourmeter

10.Warning—onlyoperateacrossslopes;donotoperateup
anddownslopes.

11.Causticliquid/chemicalburnhazard;asphyxiationhazard,
poisonousfumesortoxicgases—wearhandandskin
protection;weareyeandrespiratoryprotection.

12.Warning—usefresh,cleanwaterforrst-aidwashingand
rinsingthetank.

13.Parkbrake—engaged28.PressLHmotioncontrolbuttontolowertines.

14.Parkbrake—disengaged29.PressRHmotioncontrolbuttontoraisetines.

15.Spreaderspeed

16.Spreaderspeed—increase

18.Spraypump—on;optionalsprayeraccessory

19.Spraypump—off;optionalsprayeraccessory

20.Operatorpresencecontrol

21.Throttle—fast

22.Continuousvariablesetting

23.Throttle—slow

25.Engine—off

26.Engine—on

27.Engine—start

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

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.

Uponturningthekeyontostarttheunit,applyfull
choke.Onceunithasstarted,releaserstthechoke

15

Operation

Figure3

1.Casterpinlockingmechanism

SpreaderSystem

SpreaderCalibration/Layout

TheSpreaderMotorControldeterminesthespeed
oftheimpellerinthefrontonthemachine.Your
machineiscapableofvaryingitsspreadpatternfrom
3–25feetwiththiscontrol.Beinghydraulically
driven,thespreadpatternisindependentofthe
groundspeed.

heaviertotheright(placingproducttothemiddle
oftheimpeller).

Yourmachineisequippedwitha120lb.Spyker
modelspreader.Thehydraulicspreadermotorwith
thespreadermotorcontrolhastheabilitytovary
spreadwidthsfrom3to25feet.Thisdependson
volume/density,particlesizeandrateoftravel,and

g271157

weatherconditions.Thepatterncanbeincreasedor
decreasedwhilespreadingdependingonneeds.A
typicalpatternistooverlapfertilizerpatternbackto
thetiretracksandthespraypatternboomtoboom.

Thisfeathersmaterialattheouteredges,eliminating
sharp“edgetospread”lineswhichcausestripesand
streaks.

Determineadialsettingonthelowside.Ifsetting
istoolow,covertheareamorethanonetime.A
highersettingcanbeusedwhenaprovendialsetting
isestablished.Travelataconstantspeed.

Thehoppercontrolcableopensandclosesthedoor
insidethebaseofthehopper.Themaximumsizeof
theopeningwillbedeterminedbytherateadjustment
ontheHopperRateDial.Thiswillsetyourrategate
linkagebartolimitandstoptheratethedoorcan
open.

Figure4

1.Hopper

2.Diffuser

TheDiffuseradjustmentallowstheusertoadjustthe
intensityofthespreadpattern.Asmallpullshifts
theproductplacementontheimpellereithertothe
edgeoftheimpellerorthemiddleoftheimpeller.
Thisinturnshiftsthespreadpatternheaviertothe
left(placingproducttotheedgeoftheimpeller)or

g271240

Figure5

1.Dial

2.Diffuser

Remember-Publisheddialsettingsareapproximate
only.Openthehopperdoorafterthespreaderis

g286783

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.

wheelintheforward/straightposition.Thissystemis
springloaded,sobyreleasingthispedalitwillrelease
thelockonthefrontcasterwheels..

AeratorTineHeadRemoval

Theaeratortineheadisremovableforservice,
cleaningandremovingfromtractionunittoinstall
otherattachments.T oremovethetineheadfromthe
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).

Figure6

1.RHmotioncontrolthumb
switchraisestines

2.LHmotioncontrolthumb
switchlowerstines

Ifaeratingonhillsides,theLockingCasterSystem
allowstheoperatortolockthefrontcasterwheels
intheforwardpositiontocreatemoresidehill
stability.TheLockingCasterSystemisappliedwhen
theoperatorcompressestheLockingCasterSystem
footpedallocatedontherightsideofthefoot
plate.Whencompressingthefootpedal,locking
mechanismslidesoverthecasterpinlockingthe

g286617

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.

Figure8

1.Engineoildrainhosebehindengine

FuelRecommendations:Fuelmustmeetthese
requirements

•Clean,fresh,unleadedgasoline.

•Aminimumof87octane/87AKI(91RON).

•Gasolinewithupto10%ethanol(gasohol)or
upto15%MTBE(methyltertiarybutylether)
isacceptable.

Fullmaintenanceinformationcanbelocatedinthe
enginemanualprovided.

19

g286804

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)

FrontCaster
Wheels
(grease)

FrontCaster
Yokes(grease)

FrontTire
Pressure(22
PSI)

DailyWeeklyBi-WeeklyMonthlyYearly

X

X

X

20

Hours

Maintenance

Service
Actions(s)

RearTire
Pressure(18
PSI)

RearRimNut
Torque(95lbs)

RearHub
CastleNut
(235ft-lb)

IdlerPulley
Arm(grease)

BeltTension
(1/2inch
deectionat
15lbs)

BeltWear
(cracks,tears
ormissing
material)

Hopper
Cables
(lubricatew/
SiliconeSpray)

Accuway
Cable
(lubricatew/
SiliconeSpray)

Deector
ShieldCable
(ifapplicable)
(lubricatew/
SiliconeSpray)

Bottomof
HopperTub
(wirebrush
cleaning)

Hopper
Bottom
Bushing
(changeif
needed)

Impeller
(changeif
needed)

EngineOil
(check)

DailyWeeklyBi-WeeklyMonthlyYearly

X

X

X

X

X

X

X

X

X

X

X

X

X

Replace

Hours

21

Maintenance

Service
Actions(s)

EngineAir
FilterCheck
(changeif
needed)

EngineAir
Pre-Filter
Check(change
ifneeded)

EngineFuel
FilterCheck
(changeif
needed)

EngineSpark
Plugs

Hydraulic
Oilandlter
(change)

HydraulicOil
Level(check)

HydroSystem
Fittings(check
forleaks)

In-LineFilter
(check)

In-LineFilter
Gasket(check)

PillowBlock
Bearings

AeratorTine
Inspection

AeratorTine
Hardware
(NutandBolt)

BallSwivel
Inspection

*Blowoff
debrisdaily*

DailyWeeklyBi-WeeklyMonthlyYearly

X

X

X

X

X

X

X

X

X

X

X

Replace

Replace

Hours

50hrs

25hrs

Afterrst
100hrsand
every500hrs
thereafter

22

Troubleshooting

Troubleshooting

Engine:

•Notstarting.Thereareafewreasonsastowhyyourenginefailstostart.Iftheenginedoesnotturnover,
thenthebatterycouldbedead,badconnectiontothebatterywires,keyswhichmaybebad,30AMPfuse
onthewiringharness(orangewire)maybeblownorthestartersolenoidmaybebad(youwillhearthe
startersolenoidtryingtoclickon,butnothingishappening).Anothercommonreasonforaunitnot
startingisafterunithasbeenwashed.W atergetsintothesparkplugbootandgetsthesparkplugwet.Pull
sparkplugbootanddry(sprayWD-40).

•Engineturnsoverbutdoesn’tstart.Thereareafewreasonsastowhyyourenginewillturnoverbutnot
start:looseorbadsparkplug,waterinfuel,chokepartiallyclosedorwetand/orfoulplugs.Checkforfuel..

•Enginewon’tstayrunning.Fewthingstolookforifyourenginedoesnotstayrunningarecloggedfuel
lter,cloggedand/ordirtyairlter,waterinfuelorlowfuel.

Hydraulics:

•Hydraulicsystemmakingloudnoisewhenrunning.Thiscouldbecausedbyacoupleofthings.Themost
commonisifthereisairinthesystem.Thiscanbecausedwhenchangingoutahydropump,replacinga
hydraulichoseorhavingaloosettingontheintakelines.Ifairisnotpresent,checkforlowlevelsinthe
system.Thishappenswhenthereisaleakinthehydraulicsystemsomewhereorhydraulicuidswerejust
changedanddidnotgetbacktotheproperlllevel.

•Needtotowmyunit;whatdoIneedtodoinordertonotruinmyhydropumps?ThereareTowValves
oneachofthehydropumps(hexheadwithholerunningthroughitontheleftsiderearofthehydraulic
pump)thatneedstobeturnatleast1½revolutionscounterclockwisetoopenthehydraulicsystem
(butNEVERremove).Oncetheunitisbroughttoadesiredlocation,remembertotightenthetow
valvesbacktight(clockwise).

Tracking:

Unitnottrackingstraightwhenpushingbothcontrolarmstothespeedbar.Thisiscausedwhenthelinkage
tothehydraulicpumpisnotevenorahydraulicpumpisgoingbad.Traditionallythelinkageneedstobe
adjustedsothattheybothhavethesameamountofpull.Ifitispullingtotheleft,thelefthydraulicpump
linkageislongerthantheright;youcaneitheradjusttherighttoalongerlength,oradjustthelefttoashorter
lengthtomatchtheright.

Granular:

•Therearenumerouspotentialchallengesthatcanoccuronthegranularsideduetotheamountofusethis
portionoftheunitsees.Ifproductisnotspreadingevenlyorconsistently,thenlookforafewthingswith
yourhopperimpellerorhopperdiffuser.IfthereisbuildupattheendoftheImpellertipsorthetipsare
worn,thiswillcauseanunevenand/orinconsistentspreadpattern.Anotherpotentialchallengeisifthe
patternisnotevenwhentheAccuwayisnotpartofthepicture.Thisissometimescausedwhengranular
productismoistandholdingonlongerthannormal.

•Ifgranularproductisleakingoutfromthehopper,determinewhereitiscomingfromandlookattherepair
options.Ifthegranularproductisleakingthroughthehoppershaftarea,thenyourhopperbushingisworn.
Thiswillallowproducttogetinbetweentheshaftandthehopperbushing.Ifgranularproductisleaking

23

Troubleshooting

throughthehopperdoorarea,thenDiffuserGuidesarelooseorwornallowingagapbetweenthedoorand
thehopperbase.Alsoapotentialfactorisifthehoppercableisnotcompletelyclosingthehopperdoor.

•Whenyourhopperdoorcannotopen,therearetypically3thingstolookat.Oneisthatyourhoppercable
maybefrozenandlockedup,theballjointendmayhavebrokenoffortheremaybeproductjammed
betweenthehopperdoorandthebase(duetoloosedoorguides).

ChargingIssues:

16AmpRegulatedAlternator

The16ampregulatedalternatorsystemprovidesACcurrentthroughtwooutputleadstotheregulator-rectier.
Theregulator-rectierconvertstheACcurrenttoDC,andregulatescurrenttothebattery.Thecharging
ratewillvarywithengineRPMandtemperature.

1.BLACKtestleadfrommeter(1)(Figure9)

2.REDtestleadfrommeter(2)

3.Connector(3)

4.TwoYELLOWACinputleads(4)

5.REDDCOUTPUTWIRE(5)

6.ACOutputterminals(6)

7.REDDCoutputlead(7)toconnector

Note:Stator,regulator-rectierandy-wheelareNOTINTERCHANGEABLEwithanyothercharging
system.

Figure9

OutputTest

g268055

WHENCHECKINGTHEALTERNATORCOMPONENTS,PERFORMTHETESTINTHE
FOLLOWINGSEQUENCE:

Temporarilydisconnectstatorwireharnessfromregulator-rectier.

1.InsertREDtestleadintoVΩreceptacleinmeter.

2.InsertBLACKtestleadintoCOMreceptacle.

3.RotateselectortoV~(ACVOLTS)position.

24

Troubleshooting

CAUTION

AttachmetertestleadstotheACoutputterminals(YELLOWwires)intheconnectorBEFORE
startingtheengine.Ifthestatorisgrounded(defective)andthemetertestleadscontactthecenter
DCoutputpin(REDwire)intheconnector,arcingcouldoccur,damagingthewiring.

4.AttachRED(2)andBLACK(1)testleadprobestotheYELLOWwire(4)ACoutputterminals(6),ofthe
connector(3),asshowninFigure10.(MetertestclipleadsmaybeattachedtoeitherACoutputterminal).

Figure10

5.IfNOorLOWoutputisfoundcheckforbarewiresorotherdefects.Ifshortedleadsarenotvisible,
replacethestator.

6.Withtheenginerunningat3600RPMoutputshouldbenolessthan26Volts.

DCOutputChargingWireTest

AsimpletestcanbeusedtotesttheDCoutputchargingwirecircuit.Ifawiringproblemexistsitcanbe
correctedbeforetestingregulator-rectier.

Leavestatorwireharnessdisconnectedfromregulator-rectier.EquipmentkeyswitchmustbeinOFF
position.

1.1.InsertREDtestleadintoVΩreceptacleinmeter.

2.InsertBLACKtestleadintoCOMreceptacle.

3.RotateselectortoV==(DCvolts)position.

4.AttachREDtestleadprobe(2)totheREDwire(5)DCoutputterminal(7),oftheconnector(Figure10).

5.AttachBLACKtestleadprobe(1)tonegativebatteryterminal.

6.TurnequipmentkeyswitchtoONposition.MetershoulddisplayBATTERYVOLTAGE.

g268086

7.Ifmeterdoesnotdisplayvoltage,checkforblownfuseorbrokenorshortedwire.

Regulator-RectierT est

25

Troubleshooting

TheDCShuntMUSTbeinstalledontheNEGATIVE(-)terminalofthebattery,(Figure11)toavoid
blowingthefuseinthemeterwhentestingtheoutputofthe16ampsystem.Allconnectionsmustbeclean
andtightforcorrectreadings.

1.Connectstatorwireharnesstoregulator-rectier.

2.InstallDCShunt(4)onNEGATIVEbatteryterminal.

3.InsertREDtestleadintoVΩreceptacleinmeterandconnecttoREDpostterminalonshunt(5),Figure11.

g268088

Figure11

4.InsertBLACKtestleadinCOMreceptacleinmeter.ConnecttoBLACKpostterminalonshunt(3).

5.Rotateselectorto300mVposition.

6.Withtheenginerunningat3600RPM,theoutputshouldbe3-20Amps.

Note:Dependingonbatteryvoltageand/orcurrentdrawonsystem

IfNOorLOWoutputisfound,besurethatregulator-rectierisgroundedproperlyandallequipment
connectionsarecleanandsecure.IfthereisstillNOorLOWoutput,replacetheregulator-rectier.

26

Schematics

GREEN

YELLOW

IGNITION SWITCH

P1601

P1601

BLACK

4

G

B

5

START

RUN

L

3

SW1601

OFF

S

A

1

2

J1601

M

YELLOW

YELLOW

YELLOW

SP1602

J1603 J1604

BLACK

BLACK

RED

RED

OPC SWITCH

SW1604

FRAME GROUND

FRAME GROUND

J1605

START

FRAME GROUND

J1619

J1623

YELLOW

P1606

ENGINE

ENG13

IGNITION

MODULES

FLYWHEEL

ALT

GND-S/D

REG

RED

RED

BLACK

BLACK

BLACK

BLACK

SOLENOIDS &

CYLINDER

RAISE

LOWER

J1626

J1628

RIGHT

THUMB SWITCH

LEFT

THUMB SWITCH

BLACK

BLACK

ORANGEORANGEORANGE

BLACK

J1627

RED

SP1608

SP1609

ATC-ATO FUSE HOLDER

MAIN

F27 20A

SPEEDOMETER

+12VDC

GND

SENSOR +

SENSOR -

P1609

SP1607

P1611

RED

BLACK

RED

BLACK

YELLOWYELLOW

SPEED SENSOR

& CABLE

FRAME GROUND

FRAME GROUND

FRAME GROUND

J1622

ATC-ATO FUSE HOLDER

SPEEDOMETER

WHITE

J1616 J1617

J1613

J1614

K1601

START SOLENOID

RED

RED

RED

ORANGE

ORANGEORANGERED

BLACK

SP1603

MAIN

ATC-ATO FUSE HOLDER

J1605

J1606

J1607

J1611

BT1601

J1612

J1608

J1609

J1610

BATTERY

TERMINAL -

TERMINAL +

F26 10A

HR

HOUR METER

DIS 1601

1

1

J1602

DC

REG

Schematics

ElectricalSchematic

g287990

27

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

©2019ExmarkMfg.Co.,Inc.
2101AshlandAve
Beatrice,NE68310
AllRightsReserved

PartNo.4504-453Rev.B
[phone]
Fax[phone]
PrintedintheUSA

*4504-453*B

www.exmark.com