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