Exmark ULTRAVAC BAGGER Setup Instructions

Brand
Exmark
Model
ULTRAVAC BAGGER
Category
Lawnmowers
Type
Setup Instructions

This manual is also suitable for

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
3296-2
Nut,Nyloc#10-24inch
3
3256-61Washer3
32105-13
Screw,HWH#10-24x3/4inch
3
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)
510,000to789,999
109-1179DriveKitand
103-5633FrontWeightKit
LazerZ604(IncludesAS)352,000to509,999109-1189DriveKit*
LazerZXS604
440,000to599,999
109-1193DriveKitand
103-5633FrontWeightKit
LazerZXP604352,000to599,999109-1193DriveKit*
LazerZ724(IncludesAS)
510,000to789,999
109-1194DriveKitand
103-5633FrontWeightKit
LazerZ724352,000to509,999109-1191DriveKit*
LazerZXS724
440,000to599,999
109-1194DriveKitand
103-5633FrontWeightKit
LazerZXP724352,000to599,999109-1194DriveKit*
LazerZ605Triton600,000to789,999109-1167DriveKit
LazerZXSAir-Cooled605Triton600,000&Higher109-1167DriveKit
LazerZXSLiquid-Cooled
605Triton
600,000&Higher
109-1167DriveKitand
109-2203FloorPanWeight
LazerZDS605
312,000,000&Higher
109-1167DriveKitand
109-2203FloorPanWeight
LazerZ665Triton600,000to789,999109-1168DriveKit
LazerZXSAir-Cooled665Triton600,000&Higher109-1168DriveKit
LazerZXSLiquid-Cooled665Triton
600,000&Higher
109-1168DriveKitand
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
Item
DescriptionQuantity
1
BagAssembly
33333
2
UpperTube
11111
3
LowerTube
11111
4
#10-24CRPHScrew
33333
5
#10-24NylocNut
33333
6
#10FlatWasher
33333
7
HoodAssembly
11111
8
BlowerAssembly
11111
9
BaggerMount
Weldment
11111
10
BeltCover
11111
11
CasterWeight
22222
12
Jackshaft
11111
13
BlowerDriveBelt
11111
14
FrameBracketRH
1
15
FrameBracketLH
1
16
FrameBracket
2222
17
MountSpacer
22
44
18
MountPinWeldment
11111
19
ClevisPin
44444
20
HairPin(large)
44444
21
ChutePivotPin
11111
22
HairPin(small)
11111
23
3/8-16x11/4Hex
Screw
8
14141414
24
3/8WhizlockNut
11
13131313
25
3/8SpringDisc
Washer
12
14141414
27
BeltShieldStud
11111
28
3/8-16x.75Hex
Screw
33333
29
BeltCoverSpacer1-60only1-60only1-60only1-60only1-60only
30
7/16SpringDisc
Washer
2-60only2-60only2-60only2-60only2-60only
31
WeightBracket
22222
32
3/8-16SquareHead
Bolt
44444
33
WeightPlate
445
34
5/16-18x1.75Hex
Screw
444
5/16-18x1.5Hex
Screw
444
35
5/16FlatWasher
444
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
Item
DescriptionQuantity
36
5/16-18Whizlock
nut
444
40
Plug
11111
41
WeightPlate
Weldment
11
42
WeightMounting
Plate
22
43Hairpin
22
44
DrillTemplate
111
45Spacer6
46
Nut,NylocThin
2
47
Washer
111
48
DeectorPlate
111
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.Lowerrollbartubes
5.3/8-16inchthinnylocnut
(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.Latchpinassembly
4.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
removethebladedrivesheave.Retainthenutfor
lateruse.
Usespecialtool109-2979toholdspindlefrom
rotating.DoNotusethebladebolttoprevent
rotation.
6.InstalltheUltraVacdrivesheaveontotheright
spindleshaft.Installthewasherthatissuppliedwith
theUltraVacdrivekit(item47)andthenutremoved
instep5.Torquethesheavenutto:5/8-18inchnut
(15/16Hex)to90-110ft-lb(122-149N-m).
Usespecialtool109-2979toholdspindlefrom
rotating(seeFigure11).DoNotusetheblade
bolttopreventrotation.
Figure11
1.5/8-18inchSheave
nut-torqueto90-110ft-lb
(122-149N-m)
3.UltraVacdrivesheave
(item12)
2.Washer(item38)4.Specialtool109-2979
7.Reinstallbladeandtorqueboltto:
Forunitswitha1/2-20x2inchbladebolt,
torqueto50-60ft-lb(75-81N-m).
8.Reinstallthedeckdrivebeltinthelowergroveof
thedoublesheave.Installplug(item40)intobore
oftopsheave.
9.Removethedischargechutefromthedeck.Discard
themountinghardware,butsavethedischargechute
foruseduringsidedischargeoperation.Thechute
pivotpin(item21)andhairpin(item22)maybe
storedinthepivotholesonthedischargechute
duringbaggingoperation.
10.Installdeector(item48)atthefrontrightcorner
ofdeckasshowninFigure12.Usecarriagebolt,
nutandwasherthatretainsrightcornerofadjustable
frontbafe.
Figure12
11.Installthebeltcovermountingstud(item27).
For60inchunitsonly,installthespacer(item29),
two7/16springdiscwashers(item30)andthe
plasticknob(seeFigure13).Theknobdoesnot
needtobetightenedagainstthewashersatthistime.
Figure13
1.Knob
3.Mountingstud(item27)
2.Springdiscwashers(item
30)
4.Spacer(item29)
12.Installthemountingpinweldment(item18)tothe
blowerassemblyusingthe3/8-16x3/4inchbolts
(item28)andwhizlocknuts(item24).Maximum
deckclearancewillbeprovidediftheboltsare
installedfrombelowthemountingpin.Themount
pincanbeinstalledintwopositions.For60inch
decks,SerialNumber599,999andLower,thepin
shouldbeinstalledasfarawayfromthebumperend
aspossible.Forall72inchdecksand60inchand66
inchdecksSerialNumber600,000andHigher,the
11
pinshouldbeinstalledclosetothebumperend(see
Figure14).
Figure14
1.Positionfor60inchUnitsSerialNumber599,999andLower
2.Positionforall72inchUnitsand60inchand66inchUnits
SerialNumber600,000andHigher
13.Installthebelt(item13)ontotheblowerbyworking
itaroundtheimpellersheave.
Figure15
BlowerLatchPosition
1.AllUnitsSerialNumber600,000andHigherwithTritonand
Series5decks.
2.LazerZ,LazerZXP ,andLazerZXSUnitsSerialNumber
599,999andLowerandallLazerASUnits.
14.Mountthebloweronthedeckbyslidingthe
mountingpinintothetubeattherearrightcorner
ofthedeck.Swingtheblowerclosed.Adjustthe
positionofthefrontpintoengagetheslotinthe
frontofthedeck.Usethelatchtolocktheblower
inthisposition.Adjustthetensiononthelatchto
holdthebloweruptothedeck,yetallowforrelease
byhand.
15.Pullthespringloadedidlerbackandslipthebelt
overthetopdeckspindlesheave.
16.Installtheplasticbeltcover(item10).On60and
66inchunitstheoutsideendofthecoverisslotted
andcanslipbetweenthetwowashersassembled
instep11intheUnitsSerialNumber600,000and
Highersection.Theplasticknobdoesnotneedto
beremoved.On72inchunitsthecoverhasahole,
andtheplasticknobmustbeinstalledafterthecover
hasbeenpositioned.
OnUnitsSerialNumber600,000and
HigherwithTritonandSeries5Decks:
AdjustdoglegbafetomatchUltraVacblowerintake
opening.Adjustingtoowidemayallowobjectstobe
thrownfromunderthemowerdeckathighspeed.
Adjustingtoonarrowmaycausepluggingissues.
WARNING
Ifthedeckdischargeopeningandtheblowerintake
openingdonotmatchcorrectly,itwillallowobjects
tobethrowninoperator’sorbystander’sdirection.
Also,contactwithbladecouldoccur.Thrown
objectsorbladecontactcancauseseriousinjury
orkillyouorbystanders.
Adjustdoglegbafetomatchintakeopening.
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.Makesurethatthespringdiscwasherconeis
12
installedtowardsnut(seeFigure16).Torquethe
sheavenutto140-145ft-lb(190–197N-m).
Blockthebladerotationwithablockofwood
betweenthebladeandbafesasindicatedinthe
bladeservicesectionoftheLazerZOperator’s
manual.DoNotusethebladebolttoprevent
rotation.
Figure16
1.Torquesheavenutto
140-145ft-lb(190–197
N-m).
2.Installwithconetowards
nut.
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(seeFigure17).Torquethe
sheavenutto140-145ft-lb(190-197N-m).
Usespecialtool109-2979toholdspindlefrom
rotating.DoNotusethebladebolttoprevent
rotation.
Figure17
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
13
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
removethebladedrivesheave.Retainthenutfor
lateruse.
Usespecialtool109-2979toholdspindlefrom
rotating.DoNotusethebladebolttoprevent
rotation.
6.InstalltheUltraVacdrivesheaveontotheright
spindleshaft.Installthewasherthatissuppliedwith
theUltraVacdrivekit(item47)andthenutremoved
instep5.Torquethesheavenutto:5/8-18inchnut
(15/16Hex)to90-110ft-lb(122-149N-m).
Usespecialtool109-2979toholdspindlefrom
rotating(seeFigure18).DoNotusetheblade
bolttopreventrotation.
Figure18
1.5/8-18inchSheave
nut-torqueto90-110ft-lb
(122-149N-m)
3.UltraVacdrivesheave
(item12)
2.Washer(item38)4.Specialtool109-2979
7.Reinstallbladeandtorqueboltto:
Forunitswitha1/2-20x2inchbladebolt,
torqueto50-60ft-lb(75-81N-m).
8.Reinstallthedeckdrivebeltinthelowergroveof
thedoublesheave.Installplug(item40)intobore
oftopsheave.
9.Removethedischargechutefromthedeck.Discard
themountinghardware,butsavethedischargechute
foruseduringsidedischargeoperation.Thechute
pivotpin(item21)andhairpin(item22)maybe
storedinthepivotholesonthedischargechute
duringbaggingoperation.
10.Installdeector(item48)atthefrontrightcorner
ofdeckasshowninFigure19.Usecarriagebolt,
nutandwasherthatretainsrightcornerofadjustable
frontbafe.
Figure19
11.Installthebeltcovermountingstud(item27).
For60inchunitsonly,installthespacer(item29),
two7/16springdiscwashers(item30)andthe
plasticknob(seeFigure20).Theknobdoesnot
needtobetightenedagainstthewashersatthistime.
14
Figure20
1.Knob
3.Mountingstud(item27)
2.Springdiscwashers(item
30)
4.Spacer(item29)
12.Installthemountingpinweldment(item18)tothe
blowerassemblyusingthe3/8-16x3/4inchbolts
(item28)andwhizlocknuts(item24).Maximum
deckclearancewillbeprovidediftheboltsare
installedfrombelowthemountingpin.Themount
pincanbeinstalledintwopositions.For60inch
decks,SerialNumber599,999andLower,thepin
shouldbeinstalledasfarawayfromthebumperend
aspossible.Forall72inchdecksand60inchand66
inchdecksSerialNumber600,000andHigher,the
pinshouldbeinstalledclosetothebumperend(see
Figure21).
Figure21
1.Positionfor60inchUnitsSerialNumber599,999andLower
2.Positionforall72inchUnitsand60inchand66inchUnits
SerialNumber600,000andHigher
13.Installthebelt(item13)ontotheblowerbyworking
itaroundtheimpellersheave.
Figure22
BlowerLatchPosition
1.AllUnitsSerialNumber600,000andHigherwithTritonand
Series5decks.
2.LazerZ,LazerZXP ,andLazerZXSUnitsSerialNumber
599,999andLowerandallLazerASUnits.
14.Mountthebloweronthedeckbyslidingthe
mountingpinintothetubeattherearrightcorner
ofthedeck.Swingtheblowerclosed.Adjustthe
positionofthefrontpintoengagetheslotinthe
frontofthedeck.Usethelatchtolocktheblower
inthisposition.Adjustthetensiononthelatchto
holdthebloweruptothedeck,yetallowforrelease
byhand.
15.Pullthespringloadedidlerbackandslipthebelt
overthetopdeckspindlesheave.
16.Installtheplasticbeltcover(item10).On60and
66inchunitstheoutsideendofthecoverisslotted
andcanslipbetweenthetwowashersassembled
instep11intheUnitsSerialNumber600,000and
Highersection.Theplasticknobdoesnotneedto
beremoved.On72inchunitsthecoverhasahole,
andtheplasticknobmustbeinstalledafterthecover
hasbeenpositioned.
OnUnitsSerialNumber600,000and
HigherwithTritonandSeries5Decks:
AdjustdoglegbafetomatchUltraVacblowerintake
opening.Adjustingtoowidemayallowobjectstobe
thrownfromunderthemowerdeckathighspeed.
Adjustingtoonarrowmaycausepluggingissues.
15
WARNING
Ifthedeckdischargeopeningandtheblowerintake
openingdonotmatchcorrectly,itwillallowobjects
tobethrowninoperator’sorbystander’sdirection.
Also,contactwithbladecouldoccur.Thrown
objectsorbladecontactcancauseseriousinjury
orkillyouorbystanders.
Adjustdoglegbafetomatchintakeopening.
InstallingtheWeightAssembly
AllUnitsSerialNumber599,999and
LowerandLiquidCooledXSUnits
SerialNumber600,000andHigher
andLazerZDSUnitsSerialNumber
312,000,000andHigherOnly:
Note:WeightplatesarenotrequiredonAir-Cooled
TritonUnitsSerialNumber600,000andHigher.
Thefourweightplates(item33)mustbeinstalledunder
thefrontpaneloftheoorpan.Theseweightsgive
properbalancetothemachinewhentheremovable
portionsofthebaggerareremoved.
UnitsbelowSerialNumber600,000withthe2post
foldableROPSinstalledrequireadditionalmounting
plates(item42)andafrontweight(item41)tobe
installed.Thefrontweightisremovableandretained
byusinghairpins(item43).
UnitsSerialNumber439,999and
Lower:
1.Locatethepositionofthemountingholes.Clamp
aweightplatetothefrontoftheoorpan(see
Figure23).Theearsontheweightplateshouldbe
towardsthebottom(upsidedownfromtheactual
mountedposition).Alignthebottomedgeofthe
weightplatewiththebottomedgeoftheoorpan
frontpanel.Centertheweightplatesidetoside.
Markthepositionofallfourholesusingacenter
punch.
2.Drill3/8inchholesatthepointsmarked.
Figure23
1.Positionearsonweightas
shown.
2.Alignplatestothisedge
tolocateanddrillholes
(Notethepositionofears).
3.Installfourweightplatesbehindthefrontpanel
andtwoweightmountingplates(items33and39)
asshowninFigure24usingfour5/16-18x2inch
screws,four5/16inchatwashers,andfour5/16-18
inchwhizlocknuts(items34,35,and36).
Figure24
4.Hookweightplateassembly(item40)overthetop
oftheweightmountingplatesandsecurewithtwo
hairpins(item42)asshowninFigure24.
Note:Theremovableweightisheavy.Usecare
whenlifting.Makesurethatyoucanholdthe
weightsecurelybeforelifting.Usecautionwhen
positioningyourhandssothatyouDoNotset
theweightdownonyourhandsorngers.
ForUnitsSerialNumber
440,000–599,999:
1.Locatethepositionofthemountingholesbyaligning
thetemplate(P/N103-5865)onthefrontfaceofthe
oorpanasshowninFigure25.Clampthetemplate
inplace.Usingacenterpunch,markthepositions
oftheholesontheoorpan.Flipthetemplateover
andrepeatontheotherendoftheoorpanface.
16
Figure25
1.Aligntemplatealongthesethreeedges.
2.Drill3/8inchholesatthepointsmarked.
3.Installfourweightplatesbehindthefrontpanel
andtwoweightmountingplates(items33and39)
asshowninFigure26usingfour5/16-18x2inch
screws,four5/16inchatwashers,andfour5/16-18
inchwhizlocknuts(items34,35,and36).
Figure26
4.Hookweightplateassembly(item40)overthetop
oftheweightmountingplatesandsecurewithtwo
hairpins(item42)asshowninFigure26.
Note:Theremovableweightisheavy.Usecare
whenlifting.Makesurethatyoucanholdthe
weightsecurelybeforelifting.Usecautionwhen
positioningyourhandssothatyouDoNotset
theweightdownonyourhandsorngers.
ForLazerZXSLiquid-CooledUnits
SerialNumber600,000andHigher
andLazerZDSUnitsSerialNumber
312,000,000andHigher:
1.Locatethepositionofthemountingholesbyaligning
thetemplate(P/N103-5865)onthefrontfaceofthe
oorpanasshowninFigure25.Clampthetemplate
inplace.Usingacenterpunch,markthepositions
oftheholesontheoorpan.Flipthetemplateover
andrepeatontheotherendoftheoorpanface.
2.Drill3/8inchholesatthepointsmarked.
3.Installthefourweightplatesbehindthefrontpanel
andoneweightplateonthefrontusingthe5/16-18
x13/4inchscrews,5/16inchwashers,and5/16-18
inchwhizlocknuts(items34,35,and36).The
weightplateswillonlytwiththeearslocatednear
thebendintheoorpan(see).Thedecalonthe
outsideoftheoorpanwillstillbevisiblewiththe
weightplatesmounted.
InstallingtheRemovableWeights:
Note:Theremovableweightsareheavy.Usecare
whenliftingthem.Makesurethatyoucanhold
themsecurelybeforeliftingthem.Usecaution
whenpositioningyourhandssothatyouDoNotset
themdownonyourhandsorngers.
1.Assembletheweightbrackets(item31)tothe
removableweights(item11)usingthe3/8-16inch
squareheadbolts(item32)and3/8inchwhizlock
nuts(item24).
Unit
11/2inch
Bracket
2inchBracket
LazerZAS60
inchUnits,All
1
*
1
LazerZ60inch
Units-NonTriton1
*
1
LazerZ60inch
Units-Triton2
LazerZ66inch
Units2
LazerZAS72
inchUnits
2
LazerZ72inch
Units
2
LazerZXP60
inchUnits
2
LazerZXP72
inchUnits
2
LazerZXS60
inchUnits
2
LazerZXS66
inchUnits
2
LazerZXS72
inchUnits
2
LazerZDS60
inchUnits
2
LazerZDS72
inchUnits
2
*11/2inchbracketisincludedinUltraVac
completionkit109-1179or109-1189.
2.Installtheremovableweightassembliesoverthe
casterarms.Onsome60inchunitsoneweighthasa
widemountingbracketandonehasanarrowbracket.
17
Theywillonlytthemachineoneway.Weightsfor
allotherunitsareinterchangeableleftandright.
3.Installaclevispin(item19)andhairpin(item20)on
eachcasterweighttoretainthem.
4.Tightenknobonweightassemblyuntiltheweightis
clampedsecurelytothecasterarm.
Figure27
AssemblingtheTubes
1.Sliptheupperandthelowertubestogether.
2.Inserttheuppertubeintothehopperseal–pushin
thenpulloutsothatthesealisextendedoutward.
3.Aligndimpleonuppertubewithendofhopperseal
andpositionverticallybetweenthetwoscrewsas
showninFigure28.
Figure28
1.Dimple
4.Setthedeckinlowestcuttingposition.
5.Slidelowertubeontoblowerandlatch(makesure
thatuppertubedoesnotmoveoutofalignment).
6.Drill7/32inchholesinlowertubeusinguppertube
holesasreference(seeFigure29).
7.Removethetubesfromunitandassembletheupper
(item2)andthelowertubes(item3)usingthree
#10-24x3/4inchhexwasherheadscrews(item4),
three#10washers(item6),andthree#10-24nyloc
nuts(item5).Thescrewheadshouldbeinstalled
totheinsideofthetubetoprovideminimum
obstructiontoow.Makesurethattheupperand
thelowerendsareorientedproperlyasthetubesare
assembled.(Partinglinesshouldroughlybelinedup.)
Figure29
1.Drilltheholeshere
8.Sliptheupperendofthetubeassemblyintothe
hoodopening.Slidethelowerendofthetube
assemblyoverthebloweroutletandalignthenotch
withthetubelatch.Latchthetubetotheblower.
Operation
Pre-Start:
1.ReadtheOperator’smanualforthemowerand
UltraVactofamiliarizeyourselfwithallcontrols
beforeoperatingthemachine.Makesurethat
youunderstandthecontrols,theirlocations,their
functions,andtheirsafetyrequirements.
2.Ensuretheblower,beltcover,bags,tubeandhood
areingoodcondition,properlyattached,andlatched.
RunIn
1.Verifythattheblowerdriveoperatescorrectlyprior
todeliverytocustomer.
2.TheUltraVacbloweroperateswhendeckdriveis
engaged.Besurethatallpersonsareclearofthe
18
mowerdeckandblowerbeforeengagingthecutting
blades.Setthethrottleto“midway”position.Pull
outwardonthePTOswitchtothe“ROTATE”
position.
3.Todisengagethedeckdriveandblower,setthe
throttleto“midway”position.PushinonthePTO
switchtothe“STOP”positiontostopthecutting
bladesandblower.Thecuttingbladeswillrequirea
slightlylongeramountoftimetocometoacomplete
stopwhentheblowerisinstalledonthedeck.
FillOutWarrantyRegistration
Form
Fillouttheonlinewarrantyregistrationform.
19
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Exmark ULTRAVAC BAGGER Setup Instructions

Brand
Exmark
Model
ULTRAVAC BAGGER
Category
Lawnmowers
Type
Setup Instructions
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