Exmark Ultra Vac Laser Z User manual

CV
Page 1of 5
Part # 103-2501
Kit # 103-1313, 103-1314, 103-1315, 103-1317
09/11/01
ULTRA VAC DRIVE KIT
WARNING
POTENTIAL HAZARD
♦An uncovered discharge opening will allow
objects to be thrown in an operator’s or
bystander’s direction. Also, contact with
blade could occur.
WHAT CAN HAPPEN
♦Thrown objects or blade contact can cause
serious injury or death.
HOW TO AVOID THE HAZARD
♦Never operate mower unless discharge chute
or entire grass collection system is in place.
INSTRUCTION SHEET
KEY QTY PART # DESCRIPTION
1 1 1-653363 Pin, Chute Pivot
2 1 1-806003 Pin, Hair
3 1 1-402106 Chute Weldment, 48” SD
(48” decks SN 203376 & below only)
4 1 1-805517 2.25 O.D Washer
(48” decks SN 203376 & below only)
5 2 1-323385 Knob, Belt Shield
6 1 1-653439 Sheave, Blower Drive (52” decks)
11-653362 Sheave, Blower Drive (48” decks)
11-653309 Sheave, Blower Drive (44” decks)
7 1 1-653438 Belt, Blower (52” decks)
11-653333 Belt, Blower (48” decks)
11-653332 Belt, Blower (44” decks)
8 1 103-1316 Cover, Belt (44 and 48” decks)
1103-1318 Cover, Belt (52” decks)
9 1 1-653532-03 Spacer, Counterweight (52” decks)
10 1 322-2 5/16 – 18 X .62 Hex Head Screw
11 1 103-1279 Plug
FIGURE 1

Page 2of 5
Part # 103-2501
Kit # 103-1313, 103-1314, 103-1315, 103-1317
09/11/01
DISCHARGE CHUTE REPLACEMENT INSTRUCTIONS:
1. Remove two (2) capscrews connecting the discharge chute to the deck. Remove the
discharge chute.
For 48” decks, Serial Nos. 203376 and lower, verify that the unit has discharge chute tabs that
measure 4” high from the top of the deck plate before continuing with Step 1. See Fig 3.
For 44” decks, 52” decks, or 48” decks that have deck tabs that measure 2 3/8” high, skip to
Step 15.
2. Position mower on a flat surface.
3. Stop engine, remove key, and wait for all moving parts to stop.
4. Measure the distance between the front and rear swivel blocks on the right side deck lift mechanism.
Dimension A in Figure 2. Write this measurement down for use during re-assembly.
5.
Support the mower deck on blocks so that the chains on the right side are slack when the deck lift handle
is in the 4.5” height position (also transport position).
6.
Set the deck lift handle to the 4.5” height position (also transport position) and remove all force from the
right side deck lift spring by loosening the nuts at the front of the spring. See Fig. 2.
7.
The supplied oversized 2.25” outside diameter (O.D.) flatwasher must replace the existing flatwasher on
the right side deck lift spring at the slotted bracket to the rear of the spring (as shown in Fig. 2). This will
keep the discharge chute from entering the slot at the deck’s lowest positions when chute is in raised
position for transport.
FIGURE 2
SWIVEL ADJUSTMENT
SPRING COMPRESSION ADJUSTMENT
NOTE: Make sure step “4” has been performed to relieve spring tension before proceeding.
8. Remove E-ring and washer holding the front deck mount swivel and pull the swivel out of the
deck lift shaft lever. Remove nuts, swivel block, spring nuts, washer, and spring from
threaded rod. Remove existing flatwasher that is positioned between the spring and frame
bracket and replace with supplied 2.25” O.D. flatwasher. Re-assemble spring, washer, nuts
and swivel to rod. Reinstall the swivel to the deck lift shaft lever. Install washer and E-ring
after reattaching swivel to shaft lever.
9. Verify that the distance between front and rear swivel blocks is the same as dimension A
recorded in step 3. Adjust the position of the front swivel block if dimension A is not met.

Page 3of 5
Part # 103-2501
Kit # 103-1313, 103-1314, 103-1315, 103-1317
09/11/01
10. Remove the blocks from under the deck so that it hangs freely from all four chains
11. Set the deck lift lever to the 4.5” cutting height position (also transport position). Adjust the
spring tension until proper distance is obtained between the two washers (See Fig 2) by
turning the nut at the front of the spring. Lock the nut in position with the jam nut.
12. If the deck is out of adjustment after completing the procedure listed above, refer to your
Lazer HP owners manual for full deck adjustment procedures.
NOTE: When above adjustments have been made, the front of the deck will be slightly
lower than the rear of the deck.
13. Locate and drill a new hole for the chute tabs 2” down from the top and 3/8” from the outside
of the tabs. See Figure 3.
14. Cut off the chute tabs 1 5/8” down from the top. See Figure 3.
15. Install the new discharge chute (Item 3) using the chute pivot pin (Item 1) and hairpin (Item 2) provided
as shown in Figure 4.
FIGURE 3
FIGURE 4

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Part # 103-2501
Kit # 103-1313, 103-1314, 103-1315, 103-1317
09/11/01
BLOWER DRIVE SHEAVE INSTALLATION INSTRUCTIONS:
1. Remove the right side belt shield and the 5/16 x 3 1/4 bolt that secures the shield to the deck.
2. If you are mounting the Ultra Vac on a Lazer HP with serial number 220,000 or higher,
skip to step 3. For Lazer HPs with serial numbers 220,000 and lower, locate and cut off the
corners of the right deck reinforcement plates by measuring 2” down from the top and 2” from
the outside as shown in Figure 5. (This step provides the required belt clearance.)
3. Remove the deck drive belt from around the right sheave.
4. Support the right mower blade so that it will not fall off when the right sheave nut is removed.
5. Remove the right sheave nut, spring disk washer, and drive sheave from the spindle shaft.
NOTE: On units with wrench flats on the spindle just above the blade use a 1-inch
wrench on the flat sides of the spindle shaft to prevent the spindle from turning. On
units that do not have a wrench flat, block the blade rotation with a block of wood
between the blade and baffles as indicated in the blade service section of the Lazer
operator’s manual. Do not use the blade bolt to prevent rotation.
6. Apply a light coat of grease to the top portion of the spindle where the sheave mounts.
7. Install the double sheave (Item 6) onto the right spindle shaft. Install the spring disk washer
and nut removed in Step 5. Torque the sheave nut to 75-80 ft. lbs. Make sure that the spring
disk washer cone is installed towards nut. See Figure 6.
NOTE: On units with wrench flats on the spindle just above the blade use a 1-inch
wrench on the flat sides of the spindle shaft to prevent the spindle from turning. On
units that do not have a wrench flat, block the blade rotation with a block of wood
between the blade and baffles as indicated in the blade service section of the Lazer Z
operator’s manual. Do not use the blade bolt to prevent rotation. Check blade bolt
torque after completing this installation (115 – 120 ft. lbs.).
FIGURE 5

Page 5of 5
Part # 103-2501
Kit # 103-1313, 103-1314, 103-1315, 103-1317
09/11/01
8. Re-install the deck drive belt in the lower groove of the double sheave. Install plug (Item 11)
into bore of double sheave.
9. Install the new belt cover (Item 8) secure with the two (2) belt shield knobs (Item 5) as shown
in Figure 1.
10. Install 5/16-18 x .62 screw (Item 10) into hole that 5/16 – 18 x 3 ¼ bolt was removed from on
deck. Use whizlock nut removed in step 1. Install bolt with head to inside of deck.
NOTE: Do not re-install the 5/16 x 3 1/4 bolt that was removed in step 1.
11. Counterweight Spacer (Item 9) is used only on units with 52 inch decks. Install the spacer at
the rear of the mower between the counterweight and frame using the lower set of screws.
This installation should be done at the same time as installing the Bagger Mount supplied in
the Ultra Vac Accessory. See Ultra Vac Operator’s Manual for detailed instructions.
FIGURE 6