Exmark ULTRA VAC 103-5629 Manual

ULTRAVAC®
LazerZ®HP
SetupInstructions
ForSerialNos.790,000&Higher
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer
extranet.
DealerPack
Part#DescriptionQty.Use
—Assemblingthetubes.
—WarrantyRegistrationReminderFillouttheonlinewarrantyregistration
form.
LiteraturePack
Part#DescriptionQty.Use
—Manual,Operator’s1
—Manual,Parts1Readbeforeoperatingthemachine.
ModelsandRequiredCompletingKits
Note:UsethefollowingchartstoverifythekitsrequiredfortheunityouareinstallingtheUltraVacon.
LHPUV4448
44inchDeckDriveKitFrontWeightKit*
AllSerialNumbers103-1315103-5629
48inchDeckDriveKitFrontWeightKit*
SerialNumbers203376&Higher103-1314103-5629
LHPUV4650
46inchDeckDriveKitFrontWeightKit
AllSerialNumbers109-1013103-5629
50inchDeckDriveKitFrontWeightKit
AllSerialNumbers109-1014103-5629
LHPUV5256
52inchDeckDriveKitFrontWeightKit*
AllSerialNumbers109-1185103-5629
56inchDeckDriveKitFrontWeightKit
AllSerialNumbers109-1015103-5629
*Requiredonunitswitha2postROPSinstalled.
©2008—ExmarkMfg.Co.,Inc.
P .O.Box808
Beatrice,NE68310
PartNo.4500-419Rev.A
PrintedintheUSA
AllRightsReserved

AssemblyDiagrams
KeyQtyDescription
1Ref
EngineGuard44,
46,48,50units
21
BaggerMount
Weldment
38
5/16-18X1inch
HexHeadScrew
41HoodAssembly
52BagAssembly
61UpperTube
71
LowerTube
Assembly
83
#10-24X3/4
inchHexHead
Screw
KeyQtyDescription
93#10FlatWasher
103#10-24NylocNut
111BlowerAssembly
12Ref
RearWeight52
inchand56inch
units
13Ref
Spacer52inch
unitonly
148
5/16-18X1-3/4
inchHexHead
Screw
154
5/16-18inch
WhizlockNut
162ClevisPin
172HairPin
Figure1
2

UltraVacDriveKit
KeyQtyDescription
131Spacer,
Counterweight
(52inchand56
inchdecks)(See
Figure1)
181Pin,ChutePivot
191Pin,Hair
201ChuteWeldment
(48inchdecks
SerialNumbers
203376&lower)
2112.25ODWasher
(48inchdecks
SerialNumbers
203376&lower)
222Knob,BeltShield
231Sheave,Blower
Drive
241Belt,Blower
251Cover,Belt
2615/16-18X5/8
inchHexHead
Screw
271Plug
UltraVacWeightKit–Unitswitha2postROPSonly
KeyQtyDescription
281Asm,Weight
292Plate,Weight
Mounting
3045/16-18x1inch
HexHeadScrew
*3045/16-18x11/2
inchHexHead
Screw
~311FlatWasher,5/8
inch
~3225/16-18x1inch
CarriageBolt
~331Strap
*342Pin,Hair
*3545/16inchWasher
*3645/16-18inch
Whizlock
*46inch,50inch,and56inchTritonunits.Also52
inchunitswithstandardweightplateboltedtothefront
oftheoorpan.
~LHPUnitswithserialnumbers>600,000.
Figure2
3

Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure3)isusedbothin
thissetupinstructionsandonthemachinetoidentify
importantsafetymessageswhichmustbefollowedto
avoidaccidents
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure3
1.Safetyalertsymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituationsandwill
befollowedbythewordDANGER,WARNING,or
CAUTION.
DANGER:Whitelettering/Redbackground.Indicates
animminentlyhazardoussituationwhich,ifnotavoided,
Willresultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,ifnot
avoided,Couldresultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,ifnot
avoided,Mayresultinminorormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizesgeneral
informationworthyofspecialattention.
InstallingtheDriveKit
1.Identifythepartnumberofthedrivekittobe
installedontheunit.
2.Forweightkit103-5629followtheinstructionsheet
providedinthekit.
3.Fordrivekits,103-1314,103-1315,109-1013,
109-1014,109-1015,109-1185followthe
instructionsbelow:
ReplacingtheDischargeChute
1.Removethetwocapscrewsconnectingthedischarge
chutetothedeck.Removethedischargechute.
2.Reinstallthedischargechute(item20)usingthe
chutepivotpin(item18)andhairpin(item19)
providedasshowninFigure4.
Figure4
Installthechutewiththetabstothe
rearofthedecktabsasshown.
1.Hairpin(item19)
2.ChutePivotPin(item2)
3.DischargeChute(item3)
InstallingtheBlowerDriveSheave
44,48,and52inchLHPUnitsWithout
SplinedBladeDriver
1.Stoptheengine,removethekey,andwaitforall
movingpartstostop.
2.Removetherightsidebeltshieldandthe5/16x3
1/4inchboltthatsecurestheshieldtothedeck.
3.Removethedeckdrivebeltfromaroundtheright
sheave.
4.Supporttherightmowerbladesothatitwillnotfall
offwhentherightsheavenutisremoved.
5.Removetherightsheavenut,thespringdiscwasher,
andthedrivesheavefromthespindleshaft.
Note:Blockthebladerotationwithablockof
woodbetweenthebladeandthebafesasindicated
inthebladeservicesectionoftheLazerZHP
operator’smanual.DoNotusethebladeboltto
preventrotation.
6.ApplyalightcoatofMobilHTSgrease(orafood
gradeantisieze)tothetopportionofthespindle
wherethesheavemounts.
7.Installthedoublesheave(item23)ontotheright
spindleshaft.Installthespringdiscwasherand
thenutremovedinStep5).Makesurethatthe
springdiscwasherconeisinstalledtowardsnut(See
Figure5).Torquethesheavenutto:3/4-16inchnut
(11/4Hex)to140-145ft-lb(190-197N-m).
Note:Blockthebladerotationwithablockof
woodbetweenthebladeandbafesasindicated
inthebladeservicesectionoftheLazerZHP
4

operator’smanual.DoNotusethebladeboltto
preventrotation.
Figure5
1.3/4-16inchnut-torqueto140-145ft-lb(190-197N-m)
2.Springdiscwasher(conetowardsnut)
Checkbladebolttorqueaftercompletingthis
installation
Forunitswitha5/8-18x23/4inchbladebolt,
torqueto115-120ft-lb(156-163N-m)
8.Reinstallthedeckdrivebeltinthelowergrooveof
thedoublesheave.Installtheplug(item27)intothe
boreofthedoublesheave.
9.Install5/16-18x5/8inchscrew(item26)intohole
that5/16-18x31/4inchboltwasremovedfromon
thedeck.Usethewhizlocknutremovedinstep2).
Installboltwithheadtoinsideofdeck.
10.Installthenewbeltcover(item25)securewithtwo
beltshieldknobs(item22)asshowninFigure2.
Note:DoNotre-installthe5/16x31/4inchbolt
thatwasremovedinstep2.
44,48,and52inchLHPUnitsWith
SplinedBladeDriver
1.Stoptheengine,removethekey,andwaitforall
movingpartstostop.
2.Removetherightsidebeltshieldandthe5/16x3
1/4inchboltthatsecurestheshieldtothedeck.
3.Removethebladefromtherightspindle.
4.Insertthespecialtool109-2979intothesplinedend
ofthespindleshaft.
5.Removetherightsheavenut,thespringdiscwasher,
andthedrivesheavefromthespindleshaft.
6.Usethespecialtool109-2979toholdspindlefrom
rotating–keepthehardwareforre-use.DoNotuse
thebladebolttopreventrotation.
7.ApplyalightcoatofMobilHTSgrease(orfood
gradeantiseize)tothetopportionofthespindle
shaftwherethesheavemounts.
8.Installthedoublesheave(item23)ontotheright
spindleshaft.Installthespringdiscwasherand
nut.Makesurethatthespringdiscwasherconeis
installedtowardsnut(SeeFigure6).Torquethe
sheavenutto140-145ft-lb(190-197N-m).Use
specialtool109-2979toholdspindlefromrotating.
DoNotusethebladebolttopreventrotation.
Figure6
1.Sheavenut-torqueto140-145ft-lb(190-197N-m)
2.Springdiscwasher(conetowardsnut)
3.Doublesheave(item23)
4.Specialtool109-2979
9.Reinstallthebladeonrightspindle.Forunitswith
a1/2-20x2inchbladebolt,torqueto50-60ft-lb
(75-81N-m).
10.Reinstallthedeckdrivebeltinthelowergrooveof
thedoublesheave.Installtheplug(item27)into
boreofdoublesheave.
11.Installthe5/16-18x5/8inchscrew(item26)into
theholethat5/16-18x31/4inchboltwasremoved
fromonthedeck.Usethewhizlocknutremoved
instep2.Installtheboltwiththeheadtoinsideof
deck.
12.Installthenewbeltcover(item25)securewiththe
twobeltshieldknobs(item22)asshowninFigure2.
Note:DoNotreinstallthe5/16x31/4boltthat
wasremovedinstep2.
5

46,50,and56inchLHPUnits
1.Stoptheengine,removethekey,andwaitforall
movingpartstostop.
2.Removetherightsidebeltshieldandthebeltshield
studthatsecurestheshieldtothedeckandsavethe
three-prongedknobforlateruse.
3.Removethebladefromtherightspindle.
4.Insertthespecialtool109-2979intosplinedendof
thespindleshaft.
5.Removetherightsheavenylocknut,washer,and
thesplinedwasherfromthespindleshaft.DoNot
removethebladedrivesheave.Retainthenutfor
lateruse.
6.Usethespecialtool109-2979toholdthespindle
fromrotatingandkeepthehardwareforre-use.Do
Notusethebladebolttopreventrotation.
7.InstalltheUltraVacdrivesheaveontotheright
spindleshaft.Installthewasherthatissuppliedwith
theUltraVacdrivekit(item31)andthenutremoved
instep1.Torquethesheavenutto:5/8-18inchNut
(15/16Hex)to90-110ft-lb(122-149N-m).Usethe
specialtool109-2979toholdspindlefromrotating.
DoNotusethebladebolttopreventrotation.
Figure7
1.5/8-18inchSheavenut-torqueto90-110ft-lb(122-149N-m)
2.Washer(item3)
3.UltraVacdrivesheave
4.Specialtool109–2979
8.Reinstallthebladeontherightspindle.
Note:Forunitswitha1/2-20x21/4inchblade
bolt,torqueto50-60ft-lb(75-81N-m)
9.Installtheplug(item27)intotheboreofthedouble
sheave.
10.Install5/16-18x5/8inchscrew(item26)intothe
holethatbeltshieldstudwasremovedfromon
thedeck.Usethewhizlocknutremovedinstep2.
Installtheboltwiththeheadtoinsideofthedeck.
11.Placethecarriagebolts(item32)intothesquare
holesonthedeckstiffeners.Securelooselywiththe
beltshieldknobs(item22)Installthebeltcoverand
tighten.
Note:DoNotreinstallthebeltshieldstudthatwas
removedinstep2.
InstallingtheWeightAssembly
For44,48,and52inchLHPunits
(alsorequiredonLHPunitswithSerial
Numbers439,999andbelowwitha2
postROPSinstalled):
1.Removethehardwarefromthefrontoftheoor
pan.Discardthescrewsandretainthewashersand
whizlocknuts.
2.Assembletheweightmountingplate(item29)to
theoorpanusingfour5/16-18x1inchhexhead
screws(item30)andthefourwashersandfour
whizlocknutsremovedinstep1.
Note:Some52inchunitshaveastandardweight
plateboltedtothefrontoftheoorpan.Usefour
ofthe5/16-18x11/2inchhexheadscrews(item
30)forthisapplicationandthefourwashersandthe
fourwhizlocknutsremovedinstep1.
3.Hooktheweightplateassembly(item28)overthe
topoftheweightmountingplatesandsecurewith
twohairpins(item34).
Figure8
For46,50,and56inchLHPunits:
1.Slidethemountingstrap(item33)behindthefront
panelofoorpan,abovethereinforcingbarsthat
areweldedtothefrontframe.Attachtheweight
mountingplateusingtwoofthe5/16-18x1.50hex
headscrews(item30)twowashersandtwowhizlock
nuts(items35and36)(SeeFigure9).
6

2.Usetheuppermountingholesoftheweight
mountingplatetomarkthelocationtodrillthe
mountingholesinthefrontpaneloftheoorpan.
Removetheweightmountingplateanddrillthe3/8
inchuppermountingholesinthefrontpanelofthe
oorpan.
3.Permanentlymounttheweightmountingplateto
thefrontpaneloftheoorpanusingfour5/16-18
x11/2inchhexheadscrews,fourwashers,four
whizlocknutsandthemountingstrap(items30,
33,35,36).
4.Hooktheweightplateassembly(item28)overthe
topoftheweightmountingplatesandsecurewith
twohairpins(item34).
Figure9
1.Drill
InstallingtheHoodAssemblyand
Bags
44,46,48and50inchLHPUnits
1.Removethetwelveboltsthatretainthe“HOT”
engineguardshield(item1).Discardeightofthe
boltsandretainfour.Keepalltwelvenutsforreuse
inStep3.
2.Workingfromthefrontsideofthebaggermount,
slidethetopendoftheengineguardupandinto
themount.Pivotthelowerendthroughthebagger
mountandslideitdownintoplaceuntiltheholes
alignwiththeholesinthebaggermount(See
Figure10).
Figure10
1.Slideupandintothe
baggermount
3.Slidetheshielddown&
aligntheholes
2.Pivottheshieldintoplace
3.Installthebaggermountweldment(item2)and
engineguardshieldusingtheeight5/16-18x1
inchesscrewsprovided(item3)andeightwhizlock
nutsremovedinstep1.
4.Alignthesideholesintheengineguardshieldto
holesintheframeoneachsideoftheunit.Reattach
thesidesoftheengineguardshieldusingthefour
boltsandremainingfourwhizlocknutsretainedin
step1.Continueatstep1oftheAllUnitssection.
52and56inchLHPUnits
1.Removeanddiscardtheeightboltsthatretainthe
rearweight(item12).Keepthewhizlocknutsfor
useinsteps2and3.
2.Installthebaggermountweldment(item2)tothe
rearoftheframeusingfourofthe5/16-18x1
screws(item3)andfourofthe5/16-18whizlock
nuts(item15).Useonlythebottomfourholeson
thebaggermountweldment.
3.Installtherearweight(item12)andspacer(item13)
fromthedrivekitusingtheeightofthe5/16-18
x13/4inchscrews(item14)andwhizlocknuts
removedinstep1.Thecounterweightspacer(item
13)shouldbeplacedbetweenrearweight(item12)
andbaggermountweldment(item2).
AllLHPunits
1.Slidethetubeendsofhoodassembly(item4)into
thetubesofthemountweldment(item2).Install
twoclevispins(item16)throughholesinthetubes.
Retainwithfourofthehairpins(item17).
2.Hangthetwobagassemblies(item5)fromtheslots
inthebaggerupright(item4).Closeandlatchthe
hood.
AssemblingtheTubes
1.Sliptheupperandthelowertubestogether(items
6and7).
7

2.Inserttheuppertube(item6)intothehopperseal
(item4)–pushinthenpulloutsothatthesealis
extendedoutward.
3.Alignthedimpleontheuppertube(item6)with
theendofhoppersealandcenterbetweenthetwo
screws(item4)asshowninFigure11.
Figure11
1.Dimple
4.Setthedeckinlowestcuttingposition.
5.Slidethelowertube(item7)ontotheblower(item
11)andattachthelatches.(Makesurethattheupper
tubedoesnotmoveoutofalignment).
6.Drillthe7/32inchholesinthelowertube(item
7)usingtheuppertube(item6)holesasreference.
SeeFigure12.
7.Removethetubesfromunitandassembletheupper
(item6)andthelowertubes(item7)usingthree
#10-24x3/4inchhexwasherheadscrews(item8),
three#10washers(item9),andthree#10-24nyloc
nuts(item10).Thescrewheadshouldbeinstalled
totheinsideofthetubetoprovideminimum
obstructiontoow.Makesurethattheupperand
thelowerendsareorientedproperlyasthetubesare
assembled.(Partinglinesshouldroughlybelinedup.)
Figure12
1.Drilltheholeshere
InstallingtheBlowerAssembly
1.Removethebeltguideontheblower(item11).(See
Figure13)
2.Installthebelt(fromtheDriveKit–item24)onto
theblowerassembly(item11)asshown.
Figure13
ViewfromT opofBlower
1.Springloadedidler4.Beltguide
2.Impellersheave5.Decksheave
3.Fixedidler
3.Reinstallthebeltguideremovedinstep1.
4.Removethedischargechute(item20)bypulling
thehairpin(item19)andchutepivotpin(item18)
(fromthedrivekitinstalledinthesectionDischarge
ChuteReplacement).
5.Removethebeltcoverontherightsideofthedeck.
Installtheblowerbyinsertingthemountingpin
intothetubeweldedtotherearcornerofthedeck.
Pivotthebloweruntilthefrontpinengagestheslot
inthedeck.Adjustthepositionofthefrontpinif
necessarytoengagetheslot.Usethelatchtolock
theblowerinthisposition(seeFigure14).Adjust
8

thetensiononthelatchtodrawthebloweruptothe
deck,yetallowthereleasebyhand.
Figure14
Installtheblowerlatchintothecorrectposition.
1.InstalllatchinthislocationonallLHPunitswithserial
numberbelow600,000
2.InstalllatchinthislocationonallLHPunitswithserial
number600,000andhigher
6.Pulltheidlerreleasehandleandinstallthebeltinthe
uppergrooveofthedecksheave.
7.Installthebeltcover(item25)usingthetwoknobs.
Installthedischargetubeassemblybyslippingthe
upperendintothehood,thenslidingthelowerend
overtheblowerdischargeopening.Usethelatches
toretainthelowerendtotheblower.
8.ForLHPunitswithSerialNumberabove
600,000(Tritondeck):
AdjustthedoglegbafetomatchUltraVacblower
intakeopening.Adjustingtoowidemayallow
objectstobethrownfromunderthemowerdeck
athighspeed.Adjustingtoonarrowmaycause
pluggingissues.
WARNING
Iftheblowerintakeopeningisnotcorrectit
willallowobjectstobethrowninoperator’s
orbystander’sdirection.Also,contactwith
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryorkillyouor
bystanders.
Adjustthedoglegbafetomatchtheintake
opening.
AdjustingtheBlowerDriveBelt
Position
1.Readtheoperator’smanualfortheUltraVacand
mowerbeforeperformingthisadjustment.Make
surethatyouunderstandthecontrols,theirlocations
theirfunctionsandsafetyrequirements.
2.Ensuretheblower,beltcover,bags,tubeandhood
areingoodcondition,properlyattachedandlatched.
3.RuntheunitwiththePTOandtheblowerengaged
fortwominutes.
4.DisengagethePTO,stoptheengineandremove
thekey.
5.Removethebeltcoverandchecktomakesurethat
thebeltisridingnearthecenteroftheatidleron
theidlerarm.Ifthebeltisnotridingnearthecenter
oftheidler,removetheblower,andbendtheidler
armslightly.
6.Reinstalltheblowerandbeltcoverandperform
steps3-5againtoverifybeltposition.
FillOutWarrantyRegistration
Form
Fillouttheonlinewarrantyregistrationform.
9