Exmark ULTRAVAC BAGGER Manual

ULTRAVAC®BAGGER
LazerZ®Models
SetupInstructions
ForUltraVacSerialNos.316,000,000&Higher
(totLazerZ(LZ),LazerZAS(LAS),andLazerZXPUnits352,000–789,999)
(totLazerZXSUnits352,000&Higher)
(totLazerZDS(LZDS)312,000,000andHigher)
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer
extranet.
DealerPack
Part#DescriptionQty.Use
3296-2Nut,Nyloc#10-24inch3
3256-61Washer3
32105-13Screw,HWH#10-24x3/4inch3
Assemblingthetubes.
LiteraturePack
Manual,Operator's
©2015—ExmarkMfg.Co.,Inc.
P .O.Box808
Beatrice,NE68310
PartNo.4502-765Rev.A
PrintedintheUSA.
AllRightsReserved*4502-765*A

ModelsandRequiredCompletingKits
Note:UsethefollowingchartstoverifythekitsrequiredfortheunityouareinstallingtheUltraVacon.
UNITSERIALNUMBERREQ'DTOMOUNTULTRAVAC
LazerZ604(IncludesAS)510,000to789,999109-1179DriveKitand
103-5633FrontWeightKit
LazerZ604(IncludesAS)352,000to509,999109-1189DriveKit*
LazerZXS604440,000to599,999109-1193DriveKitand
103-5633FrontWeightKit
LazerZXP604352,000to599,999109-1193DriveKit*
LazerZ724(IncludesAS)510,000to789,999109-1194DriveKitand
103-5633FrontWeightKit
LazerZ724352,000to509,999109-1191DriveKit*
LazerZXS724440,000to599,999109-1194DriveKitand
103-5633FrontWeightKit
LazerZXP724352,000to599,999109-1194DriveKit*
LazerZ605Triton600,000to789,999109-1167DriveKit
LazerZXSAir-Cooled605Triton600,000&Higher109-1167DriveKit
LazerZXSLiquid-Cooled
605Triton600,000&Higher109-1167DriveKitand 109-2203FloorPanWeight
LazerZDS605312,000,000&Higher109-1167DriveKitand
109-2203FloorPanWeight
LazerZ665Triton600,000to789,999109-1168DriveKit
LazerZXSAir-Cooled665Triton600,000&Higher109-1168DriveKit
LazerZXSLiquid-Cooled665Triton600,000&Higher109-1168DriveKitand
109-2203FloorPanWeight
LazerZ725Triton600,000to789,999109-1169DriveKit
LazerZXSAir-Cooled725Triton600,000&Higher109-1169DriveKit
LazerZXSLiquid-Cooled725Triton600,000&Higher
109-1169DriveKitand
109-2203FloorPanWeight
LazerZDS725312,000,000&Higher
109-1169DriveKitand
109-2203FloorPanWeight
*Unitswitha2-postfoldableROPSinstalledwillalsorequiretheuseof103-5633FrontWeightKit.
2

AssemblyDiagrams
60&72LZandAS
352,000-509,999
AllXS,XPBelow
600,000&60AS
510,000-789,999
60&72LZ
510,000-599,999
AllLZ
600,000-789,999
withTritondeck
AllXSAirCooled
600,000&Higher
AllXSLiq.Cooled
600,000&Higher
AllLazerZDS
312,000,000&
Higher
ItemDescriptionQuantity
1BagAssembly33333
2UpperTube11111
3LowerTube11111
4#10-24CRPHScrew33333
5#10-24NylocNut33333
6#10FlatWasher33333
7HoodAssembly11111
8BlowerAssembly11111
9BaggerMount
Weldment
11111
10BeltCover11111
11CasterWeight22222
12Jackshaft11111
13BlowerDriveBelt11111
14FrameBracketRH1
15FrameBracketLH1
16FrameBracket2222
17MountSpacer2244
18MountPinWeldment11111
19ClevisPin44444
20HairPin(large)44444
21ChutePivotPin11111
22HairPin(small)11111
233/8-16x11/4Hex
Screw
814141414
243/8WhizlockNut1113131313
253/8SpringDisc
Washer
1214141414
27BeltShieldStud11111
283/8-16x.75Hex
Screw
33333
29BeltCoverSpacer1-60only1-60only1-60only1-60only1-60only
307/16SpringDisc
Washer
2-60only2-60only2-60only2-60only2-60only
31WeightBracket22222
323/8-16SquareHead
Bolt
44444
33WeightPlate445
345/16-18x1.75Hex
Screw
444
5/16-18x1.5Hex
Screw
444
355/16FlatWasher444
3

60&72LZandAS
352,000-509,999
AllXS,XPBelow
600,000&60AS
510,000-789,999
60&72LZ
510,000-599,999
AllLZ
600,000-789,999
withTritondeck
AllXSAirCooled
600,000&Higher
AllXSLiq.Cooled
600,000&Higher
AllLazerZDS
312,000,000&
Higher
ItemDescriptionQuantity
365/16-18Whizlock
nut
444
40Plug11111
41WeightPlate
Weldment
11
42WeightMounting
Plate
22
43Hairpin22
44DrillTemplate111
45Spacer6
46Nut,NylocThin2
47Washer111
48DeectorPlate111
Items21,22,29,30,44,46,&48notshown.
SeeFigure13forinstallationofitems29&30.
SeeFigure12forinstallationofitem48.
SeeFigure6foritem46.
4

Figure1
AllLazerZXP&LazerZXSandLazerZSerialNumber510,000&Higher
(ShownwithoutROPSforclarity)
*LazerZXSLiquid-CooledUnitsSerialNumber600,000andHigher
andLazerZDS312,000,000andHigher
requireanadditionalweight(item33)onthefrontpanel.
Figure2
LazerZSerialNumber352,000–509,000AssemblyDiagram
(ShownwithoutROPSforclarity)
5

InstallingtheHoodAssemblyand
theBags
ForLazerZUnitsSerialNumber
510,000–789,999:
Note:ReferenceFigure1andFigure2fortheitem
numberscalledoutintheinstallationinstructions.
1.TemporarilyremovetheROPStoallowfor
installationoftheUltraVac.Retainthehardwarefor
reuse.
2.WheninstallingtheUltraVacontoaliquid-cooled
LazerZ,therearbumperplatemustberemoved.
Removerearbumperplate.Reattachthelowerside
bumperbarstothevertical“HOT”engineguard
shieldusingtwooftheoriginalscrews,washersand
whizlocknutsremovedfromthebumperplate.
3.Removethelowertwoscrewsholdingtheclutch
guardplate(“HOT”engineguardonliquid-cooled
units)totherearframeoftheLazerZunit.
4.Installthemountweldment(item9)looselytothe
rearofthemachineusingthetwoboltsandnuts
removedinstep2.
5.Installtheframebrackets(item16)andspacers
(item17)looselytothemountweldment(item9)
asshown.Secureusingfour3/8-16x11/4inch
screws(item23),four3/8springdiscwashers(item
25)andfour3/8-16inchwhizlocknuts(item24).
Makesurethattheraisedportionofthespringdisc
washerfacestheheadofthescrew(seeFigure3).
Figure3
6.Installtheframebrackets(item16),andROPSlower
rollbartubeslooselytothemountingpadsonboth
sidesoftheLazerframe.Usethehardwaresupplied
inthepartsbag:eight3/8-16x11/4inchscrews,
eight3/8springdiscwashersandeight3/8-16inch
whizlocknuts.Makesurethattheraisedportionof
thespringdiscwasherfacestheheadofthescrew
(seeFigure4).
Figure4
1.3/8-16x11/4inch
capscrews
3.3/8-16inchwhizlocknuts
2.Springdiscwashers
LazerZUnitswithSerialNumber
352,000–509,999:
Note:ForunitswithROPSinstalled,temporarily
removetheROPStoallowforinstallationofthe
UltraVac.Retainthehardwareforre-use.
Important:ForUnitswithoutaROPS,afree
retrotkitisavailableandshouldbeinstalledbefore
usingtheUltraVac;contactyourAuthorizedService
Dealerfordetails.
1.WheninstallingtheUltraVacontoaliquid-cooled
LazerZ,therearbumperplatemustberemoved.
Removerearbumperplate.Reattachthelowerside
bumperbarstothevertical“HOT”engineguard
shieldusingtwooftheoriginalscrews,washersand
whizlocknutsremovedfromthebumperplate.
2.Removethelowertwoscrewsholdingtheclutch
guardplate(“HOT”engineguardonliquid–cooled
units)totherearframeoftheLazerZunit.
3.Installthemountweldment(item9)looselytothe
rearofthemachineusingthetwoboltsandnuts
removedinstep2.
4.Jacktherearoftheunitupandsafelysupportiton
jackstands.Removetherearwheels.
6

CAUTION
Raisingthemowerdeckforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
theunittofall,whichcouldcauseinjury.
DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstandsor
equivalentsupport.
5.Installtherightandlefthandframebrackets(items
14and15)looselytothemountweldmentandwheel
channelsonbothsidesoftheLazerZframe.The
angesonthesideplatesshouldfaceintowardsthe
unittoprovidethemaximumtireclearance.
6.Secureusingeight3/8-16x11/4inchbolts(item
23),eight3/8springdiscwashers(item25)andeight
3/8-16inchwhizlocknuts(item24).Makesurethat
theraisedportionofthespringdiscwasherfaces
theheadofthebolt.
G007237
1
Figure5
ForUnitswithaROPS
1.DoNotinstallthisscrewatthistime.
Note:OnunitswithaROPSinstalled,thelower
frontscrewthatattachestothewheelmotorchannel
mustbeleftuninstalled.UnitswithSerialNumber
440,000through509,999willhaveacapturedboltin
thisposition(seeFigure5).
Note:On60inchunits,thelowerboltonthe
wheelchannelisbestinstalledbypositioningthenut
behindtheholeusingadeepsocketandturningthe
boltthroughtheholeintothenut.
7.InstalltheROPSbyaligningthethreespacers(item
45)oneachsideandtapingwithmaskingtapetothe
rearframeasshowninFigure6.
Figure6
1.Lowerrollbartubes5.3/8-16inchthinnylocnut
(item46)
2.Alignspacersandtapeto
frame.
6.3/8-16x41/2inch
capscrew
3.Raiserearofunithereand
supportwithjackstands.
7.3/8-16x11/2inch
capscrew
4.Wheelnuts
8.Alignlowerrollbartubesalongwheelmotor
channelsasshowninFigure6.
9.Looselyinstallthelowerrollbarhardwaretothe
tubesinthefollowingorder(referenceFigure6for
alignmentandinstallationinstructionsbelow).
10.Discardthe3/8-16inchregularnylocnutprovided
withtheLazerZunitorROPSkitandreplacewith
the3/8-16inchthinnylocnut(item46)provided
withthisUltraVac.
11.Installthe3/8-16inchthinnylocnut(item46)anda
springdiscwashertotheboltprotrudingfromthe
wheelmotorchannelasshown.
Note:Besurethespringdiscwasherconeis
installedtowardsthenylocnut.
UnitswithSerialNumber399,999andlowerrequire
useofa3/8-16x11/2inchscrew ,springdisc
washerandwhizlocknut.Theseitemsareincluded
withROPSkitnumberFRPSLZ.
Note:On60inchunits,thelowerboltonthe
wheelchannelisbestinstalledbypositioningthenut
behindtheholeusingadeepsocketandturningthe
boltthroughtheholeintothenut.
12.Installone3/8-16x11/2inchhexcapscrew,spring
discwasherand3/8-16inchwhizlocknuttothetop
frontholeasshown(itwillbenecessarytopushthe
capscrewthroughthemaskingtapeappliedinstep7).
13.Installone3/8-16x11/2hexcapscrew,springdisc
washerand3/8-16inchwhizlocknuttothetop
rearholeasshown(itwillbenecessarytopushthe
capscrewthroughthemaskingtapeappliedinstep7).
7

Installone3/8-16x41/2hexcapscrew,springdisc
washerand3/8-16inchwhizlocknutthroughthe
toptubeasshown(itwillbenecessarytopushthe
capscrewthroughthemaskingtapeappliedinstep7).
Note:Besurethespringdiscwasherconeis
installedtowardstheheadofallcapscrews.
AllLazerZXP ,LazerZXS,andLazer
ZDSUnits:
1.TemporarilyremovetheROPStoallowfor
installationoftheUltraVac.Retainthehardwarefor
reuse.
2.Installmountweldment(item9)looselytotherear
bumperusingthetwoholesprovided.Secureusing
four3/8-16x11/4inchscrews(item23),four3/8
springdiscwashers(item25)andfour3/8-16inch
whizlocknuts(item24).
3.Installtheframebrackets(item16)andspacers
(item17)looselytothemountweldment(item9)
asshown.Secureusingtwo3/8-16x11/4inch
screws(item23),two3/8springdiscwashers(item
25)andtwo3/8-16inchwhizlocknuts(item24).
Makesurethattheraisedportionofthespringdisc
washerfacestheheadofthescrew.
•ForLazerZXPUnitsseeFigure3.
•ForLazerZXSandLazerZDSUnitssee
Figure7.
Figure7
4.Installtheframebrackets(item16),andROPSlower
rollbartubeslooselytothemountingpadsonboth
sidesoftheLazerframe.UsetheROPSmounting
hardware,eight3/8-16x11/2inchscrews,eight3/8
springdiscwashersandeight3/8-16inchwhizlock
nuts.Makesurethattheraisedportionofthespring
discwasherfacestheheadofthescrew(seeFigure4).
AllUnits–InstalltheUpperROPSRoll
Bar:
1.Installtheupperu-shapedsectionoftherollbar.
(ReferenceFigure8foralignmentandinstallation
instructionsbelow):
2.Locatethelatchpinassemblies(pinandhairpin
connectedwithalanyard).
3.Installa1/2-13x31/4inchcapscrewinthewasher
onthelanyardofeachpinassembly.
Note:Makesurethebenttabinthewasherpoints
towardtheheadofthecapscrew.
4.Lightlyoiltheinsidesurfacesoftheear-shapedplates
attheupperendofthelowerrollbartubes.
5.Locatetheupperu-shapedsectionoftherollbar.
Installtheupperrollbarsectionusingone1/2-13x
31/4inchcapscrew(fromstep3)andone1/2-13
inchhexangelocknutoneachside.DoNotover
tighten.Makesureupperrollbarcanpivotfreely.
Note:Makesurethecapscrewandnutsareinstalled
withthenuttotheinsideoftherollbar.
Note:Makesurethetabonthelanyardwasheris
installedasshownandpointstowardthefrontof
theunit.
6.Raisetherollbarintotheuprightpositionandsecure
withthelatchpinassembliesoneachside.Install
latchpinfromoutersurfaceofrollbarassemblyand
securewiththehairpintotheinside.
7.Tightenthefrontknobsagainsttheupperrollbar
ends.
8

Figure8
1.Latchpinassembly4.Applyoiltoinsidesurface
ofearshapedplates.
2.1/2-13x31/4inch
capscrew
5.Upperrollbartube
3.1/2-13inchhexangelock
nuts
AllUnits:
TightenallhardwarethatattachestheUltraVacmount
tothemachineframe.Startwiththescrewsthathold
themountweldmenttotherearoftheunitandwork
forward.
AllUnits–TorqueLowerRollBar
Hardware:
Torquealllowerrollbarhardwareattachedtothe
machineframeto30-35ft-lb(41-47N-m).
LazerZUnitswithSerialNumber
352,000–509,999:
Reinstalltherearwheelsandlowertheunitfromthe
jackstands.
AllUnits:
Applyalightcoatofgreasetothefrontandrearof
theuppertubeofthemountweldment.Installthe
hoodassembly(item7)ontothemountbyslippingthe
hookportionoverthetopmountingtubeofthemount
weldment.Securetheassemblytothemountusingthe
clevispins(item19)andhairpins(item20).
Installthebagassemblies(item1)byinsertingthehook
portionintotheslotsinthecrossbarofthehood
assembly.
InstallingtheBlowerAssembly
UnitsSerialNumber352,000–509,999
withoutSplinedBladeDriver:
1.Stoptheengine,removethekey,andwaitforall
movingpartstostop.
2.Lowerthedeckfully.Removetherighthandbelt
cover.Removethebeltcovermountingstudthat
protrudesfromthedeck.
3.Removethedeckdrivebeltfromaroundtheright
handspindlesheave.
4.Supporttherightmowerbladeandshaftsothatit
willnotfalloutofthedeckwhentherightsheave
nutisremoved.
5.Removetherightsheavenut,springdiscwasher,and
sheavefromthespindleshaft.
Blockthebladerotationwithablockofwood
betweenthebladeandbafesasindicatedin
thebladeservicesectionoftheunitsOperator’s
manual.DoNotusethebladebolttoprevent
rotation.
6.ApplyalightcoatofMobilHTSgrease(orfood
gradeantisieze)tothetopportionofthespindle
shaftwherethesheavemounts.
7.Installthedoublesheave(item12)ontotheright
spindleshaft.Installthespringdiscwasherand
nut.Makesurethatthespringdiscwashercone
isinstalledtowardsnut(seeFigure9).Torquethe
sheavenutto140-145ft-lb(190–197N-m).
Blockthebladerotationwithablockofwood
betweenthebladeandbafesasindicatedinthe
bladeservicesectionoftheLazerZOperator’s
manual.DoNotusethebladebolttoprevent
rotation.
Figure9
1.Torquesheavenutto
140-145ft-lb(190–197
N-m).
2.Installwithconetowards
nut.
9

Checkbladebolttorqueaftercompletingthis
installation.
Forunitswitha5/8-18x23/4inchbladebolt,
torqueto115-120ft-lb(156-163N-m).
8.Re-installthedeckdrivebeltinthelowergrooveof
thedoublesheave.Installtheplug(item40)intothe
boreofthedoublesheave.
9.Removethedischargechutefromthedeck.Discard
themountinghardware,butsavethedischargechute
foruseduringsidedischargeoperation.Thechute
pivotpin(item21)andhairpin(item22)maybe
storedinthepivotholesonthedischargechute
duringbaggingoperation.
UnitsSerialNumber599,999andLower
WithSplinedBladeDriver:
1.Stoptheengine,removethekey,andwaitforall
movingpartstostop.
2.Lowerthedeckfully.Removetherighthandbelt
cover.Removethebeltcovermountingstudthat
protrudesfromthedeck.
3.Removetherightsidebeltshieldandthe5/16x3
1/4inchboltthatsecurestheshieldtothedeck.
4.Removethebladefromtherightspindle.
5.Insertspecialtool109-2979intosplinedendof
spindleshaft.
6.Removetherightsheavenut,springdiscwasher,and
drivesheavefromthespindleshaft–keephardware
forre-use.
Usespecialtool109-2979toholdspindlefrom
rotating.DoNotusethebladebolttoprevent
rotation.
7.ApplyalightcoatofMobilHTSgrease(orfood
gradeantiseize)tothetopportionofthespindle
shaftwherethesheavemounts.
8.Installthedoublesheave(item12)ontotheright
spindleshaft.Installthespringdiscwasherand
nut.Makesurethatthespringdiscwasherconeis
installedtowardsnut(seeFigure10).Torquethe
sheavenutto140-145ft-lb(190-197N-m).
Usespecialtool109-2979toholdspindlefrom
rotating.DoNotusethebladebolttoprevent
rotation.
Figure10
1.Sheavenut-torqueto140-145ft-lb(190-197N-m)
2.Springdiscwasher(conetowardsnut)
3.Doublesheave(item12)
4.Specialtool109-2979
9.Reinstallthebladeandtorqueboltto:
Forunitswitha1/2-20x2inchbladebolt,
torqueto50-60ft-lb(75-81N-m).
10.Reinstallthedeckdrivebeltinthelowergrooveof
thedoublesheave.Installplug(item40)intoboreof
doublesheave.
11.Removethedischargechutefromthedeck.Discard
themountinghardware,butsavethedischargechute
foruseduringsidedischargeoperation.Thechute
pivotpin(item21)andhairpin(item22)maybe
storedinthepivotholesonthedischargechute
duringbaggingoperation.
UnitsSerialNumber600,000and
Higher:
1.Stoptheengine,removethekey,andwaitforall
movingpartstostop.
2.Lowerthedeckfully.Removetherighthandbelt
cover.Removethebeltcovermountingstudthat
protrudesfromthedeck.Savetheknobforlateruse.
3.Removethebladefromtherightspindle.
4.Insertthespecialtool109-2979intosplinedendof
thespindleshaft.
5.Removetherightsheavenylocnut,washer,and
splinedwasherfromthespindleshaft.DoNot
10