Exmark ULTRAVAC E Series Manual

ULTRAVAC®E-SERIES
SetupInstructions
ForUltraVacSerialNos.316,000,000&Higher
(TotQuestSPSerialNos.850,000&Higher)
(TotPioneerS-SeriesSerialNos.920,000&Higher)
Important:DuetotheaddedweightoftheUltraVac,itisimportanttoensuretheparkingbrakeonyour
mowerisadjustedproperly.BeforeinstallingtheUltraVac,makesuretore-adjusttheparkingbrakeon
yourmowerasoutlinedinthe“AdjustingtheParkingBrake”procedureintheMaintenancesectionof
thetractorOperator'smanual.
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
LiteraturePack
Manual,Operator's
RequiredCompletingKits
CompletingKits
Note:UsethefollowingchartstoverifythekitsrequiredfortheunityouareinstallingtheUltraVacon.
44InchDeck48InchDeck52InchDeck60InchDeck
QuestSP116-4880116-4882116-4884—
PioneerS-Series116-4885116-4887116-4889116-6498
©2015—ExmarkMfg.Co.,Inc.
P .O.Box808
Beatrice,NE68310
PartNo.4502-776Rev.A
PrintedintheUSA.
AllRightsReserved*4502-776*A

AssemblyDiagram
KeyQtyDescription
11Asm,Hopper
22Pin,Hair
3*1Bolt,Carriage5/16-18x1
42Pin,Retaining
51Tube,Upper
62Asm,Bag&Frame
7*1Bracket,BeltCover(44inchdeck)
81Asm,Blower
91Asm,LowerTube
10*1Bracket,HopperMountLH
11*1Bracket,HopperMountRH
121Frame,Hopper
133Screw ,1/4-20x3/4
141Bracket,WeightMountPlate
153Nut-Nyloc3/8-16Flg
163Screw ,HH3/8-16x1
172Asm,ToeBoardWeight
183Nut-Nyloc1/4-20Flg
19*1
Bracket,BeltCover(48,52,&60inch
deck)
20*1Cover,Belt
21*1Ring,BoltRetaining
22*1Knob,3–Prong
23*▲1Plug,Nylon
24*1Pin,ChutePivot
25*3Pin,Hair
26*1Belt
27*1Sheave,Drive
28*2Bolt,Carriage5/16-18x1
29*2Nut-Nyloc5/16-18Flg
301Vent,Air
311Rod,HoldDown
32*2Nut,Nyloc5/16-18Flg(44inchdeck)
33*2
Bolt,Carriage5/16-18x1(44inch
deck)
34*2
Bolt,Carriage3/8-16x1(48,52,&60
inchdeck)
35*2
Nut-Nyloc3/8-16Flg(48,52,&60
inchdeck)
36*1Bracket–Hydro(60inchdeck)
KeyQtyDescription
37*2Screw-5/16-18x61/2(60inchdeck)
38*2Nut-Nyloc5/16-18(60inchdeck)
39*4Washer-SpringDisc(60inchdeck)
*Includedincompletingkit.
▲NotincludedinkitP/N116-4887
2

Figure1
3

AdjustingtheParkingBrake
Re-adjusttheparkingbrakeonyourmowerasoutlined
inthe“AdjustingtheParkingBrake”procedureinthe
MaintenancesectionofthetractorOperator'smanual.
InstallingtheHopperMount
Brackets
1.Loosenthefront5/16-18x23/4inchboltonthe
LHandRHrearpanels(item7inFigure2).
Figure2
1.5/16inchangednylocnut5.RHhoppermountbracket
2.5/16-18x1inchbolt6.Frontslot
3.5/16-18x23/4inchbolt7.Loosenbolt
4.LHhoppermountbracket
2.Removeandretaintherear5/16-18x23/4inchbolt
and5/16inchangednylocnutonbothbrackets.
3.InstalltheRHhoppermountbracketbyplacingthe
frontslot(item6)ontothebolt(item7)thatwas
loosenedinstep1.
4.Reinstalltherear5/16-18x23/4inchboltand5/16
inchangednylocnut.Installthe5/16-18x1inch
boltand5/16inchangednylocnutintheupper
hole.
5.Tightenthefront5/16-18x23/4inchbolt.
6.Repeatsteps3through5fortheLHhoppermount
bracket.
InstallingtheHydroBracket(60
InchDeck)
1.Removeanddiscardtherearhydromountingbolts
andnuts.
2.Usingtwo5/16–18x61/2inchscrews,four5/16
springdiscwashers,andtwo5/16angednyloc
nuts,mountthehydrobracketunderthehydrosas
showninFigure3.
Figure3
1.5/16–18x61/2inchscrew4.5/16angednylocnut
2.Springdiscwasher5.Hydrogusset
3.LHhydro
InstallingtheHopperFrame
Note:OnQuestSPUnits:Itmaybeeasiertoinstall
thehopperontothehopperframebeforeperforming
thefollowingsteps.
1.Removethehairpinfromthehopperframe.Insert
thehopperframeintotheLHhoppermountbracket
(seeFigure4).Resttheotherendofthehopper
framebetweenthetabsontheRHhoppermount
bracket.Reinstallthehairpintosecurethehopper
frame.
Note:Ifthehopperframedoesnotseatproperlyin
themountbrackets,carefullyusethehopperframe
toslightlyadjustthealignmentofthebrackets.
4

Figure4
1.LHhoppermountbracket
2.Hopperframe
3.Hairpin
4.RHhoppermountbracket
2.Removethehairpinfromtheholddownrod.Insert
theholddownrodintothehopperframeand
reinsertthehairpin(referenceFigure1).
InstallingtheHopper
1.Removeandretainthehairpinsfromtheairvent.
2.Pressthetabsontheairventintothenotchesonthe
insideofthehopperandsecurewithhairpins.
Figure5
1.Hopperframepin3.Hopperhinge
2.Seal(partiallyremovedfor
clarity)
4.Airvent
3.Slidethehopperhingesontothehopperframepins.
4.Makesurethesealispositionedaroundthebrackets
wherethebagsmount.
InstallingtheWeightAssembly
1.Removeandretainthetworetainingpins,three
3/8-16x1inchscrews,andthree3/8-16inchnyloc
nutsthatarefastenedtotheweightmountingplate.
2.Mounttheweightmountingplatetothefrontpanel
ofthetoeboardusingtwo3/8-16x1inchscrews
andtwo3/8-16inchnylocnuts.
Figure6
1.Frontpaneloftoeboard4.Retainingpin
2.Weightmountingplate5.3/8-16x1inchscrew
3.Toeboardweight6.3/8-16inchnylocnut
3.Usingthecenterholeofthebracketasatemplate,
drill.406inchdiameterholethroughthefrontofthe
oorpanasshowninFigure7.
Figure7
44InchUnitShown
1.Drillcenterhole
4.Installone3/8-16x1inchscrewand3/8-16inch
nylocnut.
5.Refertothetablebelowtodeterminethenumber
ofweightsrequired:
44Inch
Deck
48Inch
Deck
52Inch
Deck
60Inch
Deck
Weights
Required
2221*
Note:*For60inchdecks,placetheweightonthe
LHsidetohelpoffsettheblowerweight.
6.Installtheremovableweightsbyhookingthetoe
boardweightassembliesoverthetopoftheweight
5

mountingplate(seeFigure6).Installthetwo
retainingpinsintotheweightmountingplate.
Note:Theremovableweightsareheavy.Usecare
whenliftingthem.Makesurethatyoucanhold
themsecurelybeforeliftingthem.Usecautionwhen
positioningyourhandssothatyouDoNotsetthem
downonyourhandsorngers.
InstallingtheBeltCoverBracket
1.Removehairpin,chutepivotpin,anddischarge
chute.Pivotpinandhairpinmaybestoredinthe
pivotholesofthedischargechuteduringbagging
operation.
2.Removethebeltcover.
•44inchdeck:
Removeandretainthetwoscrewsandthemetal
beltcover(seeFigure8).
Figure8
1.Metalbeltcover3.Dischargebafe
2.Screw4.Mountinghardware
•48,52,and60inchdecks:
A.Removeandretaintheplasticbeltcover.
B.Removeandretainthecoverwireformand
itshardware.
3.Installthebeltcoverbracket.
•44inchdeck:
A.Removeanddiscardthedischargebafe
mountinghardware.
B.Usingtwo5/16-18x1inchcarriagebolts
andtwo5/16-18inchnylocnuts,installthe
dischargebafeandbeltcoverbracketas
showninFigure9.
Figure9
1.Beltcoverbracket
2.5/16-18inchnylocnut
3.Dischargebafe
4.5/16-18x1inchcarriagebolt
•48,52,and60inchdecks:
Installthebeltcoverbracketinthecover
wireformlocationusingtwo3/8-16x1inch
carriageboltsandtwo3/8-16inchnylocnutsas
showninFigure10.
Figure10
1.Beltcoverbracket(60inchdeck)
2.Beltcoverbracket(48and52inchdeck)
3.3/8-16x1inchcarriagebolt
4.3/8-16inchnylocnut
InstallingtheBlowerDriveSheave
1.Removethedeckdrivebeltfromaroundtheright
handspindlesheave.
2.Supporttherightmowerbladeandshaftsothatit
willnotfalloutofthedeckwhentherightsheave
nutisremoved.
3.Removetherightsheavenutandsheavefromthe
spindleshaft.
Blockthebladerotationwithablockofwood
betweenthebladeandbafesasindicatedinthe
bladeservicesectionoftheOperator’smanual.
DoNotusethebladebolttopreventrotation.
6

4.ApplyalightcoatofMobilHTSgrease(orfood
gradeantisieze)tothetopportionofthespindle
shaftwherethesheavemounts.
5.Installthedoublesheaveontotherightspindleshaft
andinstallthenut.Torquethesheavenutto130-160
ft-lb(176–217N-m).
Blockthebladerotationwithablockofwood
betweenthebladeandbafesasindicatedinthe
bladeservicesectionoftheOperator’smanual.
DoNotusethebladebolttopreventrotation.
Figure11
1.Torquesheavenutto130-160ft-lb(176–217N-m).
Checkbladebolttorqueaftercompletingthis
installation.
Torquebladeboltto50-60ft-lb(75-81N-m).
6.Re-installthedeckdrivebeltinthelowergrooveof
thedoublesheave.
On48,52,and60InchDecks:Installthepluginto
theboreofthedoublesheave.
InstallingtheBlowerAssembly
1.Mountthebloweronthedeckbyinsertingthe
mountingpinintothetubeweldedtotherearcorner
ofthedeck.UseFigure12andthetablebelowto
determinethepinlocationintheblowerframe.
Figure12
1.Mountingpin4.Frontlocation
2.Rollpin5.Offsetlocation
3.Backlocation
MountingPinLocationinBlowerFrame
FrontBackOffset
PioneerS-Series–
44inchdeck
Pioneer
S-Series–
48inchdeck
PioneerS-Series–
52inchdeck
PioneerS-Series–
60inchdeck
QuestSP–44
inchdeck
QuestSP–48
inchdeck
QuestSP–52
inchdeck
2.Pivottheblowertowardsthedeckandpulloutward
onthelatchpin.Releasethelatchpinwhenitaligns
withtheholeonthetabofthedecktolockthe
blowerinthisposition.
3.Pullthespringloadedidlerbackandslipthebeltover
thetopdecksheave(seeFigure13andFigure14).
7

G014743
2
1
3
Figure13
1.Impellersheave3.Springloadedidler
2.Decksheave
4.Installthebeltcover(seeFigure14).
Figure14
1.Beltcoverbracket4.Belt
2.Knob5.Decksheave
3.Beltcover
5.Installtheknobanditshardware.
AssemblingtheTubes
1.Removeandretainthehardwareinstalledinthe
uppertube.
2.Theuppertubeneedstobeshortened.Measure5
inches(12.7cm)fromthetopendofthetube,create
marks,andapplymaskingtapearoundthetubeasa
guide.Carefullycutthetubeanddiscardtheend.
Figure15
1.Measure5inches(12.7cm)
2.Cuttube
3.Inserttheuppertubeintothehopperseal–pushin
thenpulloutsothatthesealisextendedoutward.
4.Setthedeckinlowestcuttingposition.
5.Slidethelowertubeontotheblowerandattachthe
latches.
6.Measure3–31/2inches(7.6–8.9cm)fromthetop
endofthelowertubeandcreateguidemarks.
7.Slidethelowertubeinsidetheuppertubeuntilthe
3–31/2inches(7.6–8.9cm)markisreached.Rotate
theuppertubesothattheendinthehopperpoints
towardsthecenterofthehopper.Thepartingline
onthetubewillbeslightlytotherightofthecenter
rivetasshowninFigure16.
Figure16
1.Lowertube
2.Uppertube
3.Hopper
4.Uppertubepointstowardscenterofhopper
5.Centerrivet
6.Partingline
7.Overlap3–31/2inches(7.6–8.9cm)
8

8.Withthedeckinthelowestpositionandthehopper
closed,lookunderneaththehopperandthemeasure
lengthoftheuppertubeprotrudingintothehopper
(seeFigure17).Iftheuppertubeextendsmorethan
3inches(7.6cm)intothehopper,thentheexcess
lengthmustberemoved.Determinetheexcess
lengthandremovetheuppertube.Createmarks,
applymaskingtapearoundthetubeasaguide,and
carefullycutanddiscardthelengththatisover3
inches(7.6cm).Reassemblethetubesasindicated
instep7.
Figure17
1.3inches(7.6cm)2.Removeexcesslength
9.Drillthree7/32inchdiameterholesinthelower
tubeusingtheuppertubeholesasreference.
10.Removethetubesfromunitandassembletheupper
andthelowertubesusingthree1/4-20x3/4inch
screwsandthree1/4inchnylocnuts.Installthe
screwsontheinsideofthetubetoprovideminimum
obstructiontoow.
InstalltheBags
Openthehopperandinstallthebags.Closethehopper
andstretchtherubberlatchovertheholddownrod.
FillOutWarrantyRegistration
Form
Fillouttheonlinewarrantyregistrationform.
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