Exmark ULTRAVAC E Series Manual

ULTRAVAC®BAGGER

126-6122

SetupInstructions

ForUltraVacSerialNos.402,082,300&Higher

(TotRadiusModelsSerialNos.400,000,000&Higher)

WARNING

CALIFORNIA

Proposition65Warning

ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato

causecancer,birthdefects,orreproductiveharm.

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer

extranet.

DealerPack

PartNo.DescriptionQty.Use

—Fillouttheonlinewarrantyregistration

form.

LiteraturePack

Manual-Operator's

P .O.Box808

Beatrice,NE68310

PartNo.4503-657Rev.A

PrintedintheUSA.

AllRightsReserved*4503-657*A

ModelsandRequiredCompletingKits

CompletingKits

Note:UsethefollowingchartstoverifythekitsrequiredfortheunityouareinstallingtheUltraVacon.

E-andS-Series

DeckCompletingKit

48inch126-6196

52inch126-6197

60inch126-6198

X-Series

DeckCompletingKit

48inch126-6209

52inch126-6210

60inch126-6211

InstallingtheHopperMount

Brackets

1.Raisethedecktothetransportposition.Raisethe

backofthemachineupandsupportthemachine

withjackstands.

CAUTION

Raisingthemowerdeckforserviceor

maintenancerelyingsolelyonmechanical

orhydraulicjackscouldbedangerous.The

mechanicalorhydraulicjacksmaynotbe

enoughsupportormaymalfunctionallowing

theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic

jacksforsupport.Useadequatejackstandsor

equivalentsupport.

2.Removethereartiresfromthemachine.

3.Removeandretaintherearweightanditsmounting

hardware(ifapplicable).

4.Removeandretainthenutsfromtheboltsonthe

bottomofeachhydroasshowninFigure1.Install

thetransmissionsupportbracketandsecurewith

nuts.

g189992

Figure1

1.Retainnuts3.Rearweight

2.Transmissionsupport

bracket

4.Torxbolts

5.Removeanddiscardthetorxboltsandnutsonthe

leftandrightsidesoftherearguardthatattaches

ittotheframe.

6.InstallthelegsoftheLHandRHbaggersupport

bracketontothetransmissionstudsandsecurewith

thenutsretainedinstep4(seeFigure2).

g037961

Figure2

1.LHsupportbracket4.5/16atwasher

2.RHsupportbracket5.5/16inchangednylocnut

3.5/16-18x31/4inchhex

screw

7.Securethesidesofthebaggersupportbracketsto

therearframeusing5/16-18x31/4inchhexscrews

and5/16inchangednylocnuts(seeFigure2).

8.Ifequipped,removeanddiscardthescrewsandnuts

thatsecuretheleftandrightuppersupportbracket

totherearguard.Installtheupperrearmount

brackettotheLHandRHbaggersupportbrackets.

g189991

Figure3

1.Upperrearmountbracket4.Hitchcover

2.5/16-18x31/4inch

carriagescrew

5.Uppersupportbracket(if

equipped)

3.5/16inchangednylocnut

9.Placethehitchcoverontotherearguard(see

Figure3).

Note:Itmaybenecessarytotapitintoplacewith

amallet.

InstallingtheWeightAssembly

WARNING

Casterortoeboardweightsinstalledwithoutthe

collectionsystemmaycauselossoftractionand

steeringcontrol.Lossofcontrolcanresultinan

accidentwhichmaycausedeath,injury,orproperty

damage.

InstallcasterortoeboardweightsONLYwhenthe

collectionsystemisinstalled.

Note:Theremovableweightsareheavy.Usecarewhen

liftingthem.Makesurethatyoucanholdthemsecurely

beforeliftingthem.Usecautionwhenpositioningyour

handssothatyouDoNotsetthemdownonyourhands

orngers.

1.Assembletheweightsbyplacingtheweightbracket

plateinsidethemountchannel.Installthetabbed

weightbracketplateinsidethemountchanneland

againsttheweightbracketplateasshowninFigure4.

Securethemountchannelassemblytotheweight

usingtwo3/8-16x21/2inchboltsandtwo3/8

inchwhizlocknuts.

g185955

Figure4

1.Weight4.Tabbedweightbracket

plate

2.Mountchannel5.3/8-16x21/2inchsquare

headbolt

3.Weightbracketplate6.3/8inchwhizlocknut

For48InchDeckOnly:

Removeandretainthetwomountingnutsonthe

topsideofthecasterweight.Installtheextraat

weightontopofthecasterweightandsecurewith

thetwonuts(seeFigure5).

g037628

Figure5

1.Nut3.Casterweight

2.Flatweight

2.Installoneremovablecasterweightoneachcaster

armasshowninFigure6.

g037183

Figure6

1.Bolt3.Washer

2.Knob4.Casterweight

3.Inserttheboltthroughthebracketholeandinstall

thewasherandknob.

4.Tightentheknobonweightassemblyuntilthe

weightisclampedsecurelytothecasterarm.

Note:TheportionsoftheUltraVaccollection

systemthatarenotboltedtothemoweraredesigned

tobeinstalledorremovedintheirentirety.Do

Notoperatethemowerwithonlyaportionofthe

UltraVacinstalled.

InstallingtheBeltCoverBracket

1.Removeandretainthedischargedeectorandits

mountinghardware.

2.Lowerthedeckfully.Removeandretainthe

standardrightsidebeltcover,wireformbracketand

itshardware.

3.Installthebeltcoverbracket.

•48and52InchDecks:Usetwo3/8-16x1

1/4inchcarriageboltsandtwo3/8inchanged

nylocnutsasshowninFigure7.

g037341

Figure7

48and52InchDecks

1.3/8-16x11/4inchcarriagebolt

2.Beltcoverbracket

3.3/8inchangednylocnut

•60InchDeck:Usetwo3/8-16x11/4inch

carriageboltsandtwo3/8inchangednyloc

nutstoinstallcoverbracketasshowninFigure8.

Installtheblockerplatetotheoutsideofthedeck

using3/8-16x11/4inchcarriageboltand3/8

inchangednylocnut.

g037349

Figure8

60InchDecks

1.3/8-16x11/4inchcarriage

bolt

4.Blockerplate

2.Beltcoverbracket5.3/8-16x11/4carriagebolt

3.3/8inchnylocnut

InstallingtheBlowerDriveSheave

1.Removethedeckdrivebeltfromaroundtheright

handspindlesheave.

2.Supporttherightmowerbladeandshaftsothatit

willnotfalloutofthedeckwhentherightsheave

nutisremoved.

3.Removetherightsheavenutandsheavefromthe

spindleshaft.

4.Installthedoublesheaveontotherightspindleshaft

andinstallthenut.Torquethesheavenutto130-160

ft-lb(176–217N-m).

Blockthebladerotationwithablockofwood

betweenthebladeandbafesasindicatedinthe

bladeservicesectionoftheOperator’smanual.

DoNotusethebladebolttopreventrotation.

g007021

Figure9

1.Torquesheavenutto130-160ft-lb(176–217N-m).

2.Installwithconetowardsnut.

Checkbladebolttorqueaftercompletingthis

installation.

Torquebladeboltto50-60ft-lb(75-81N-m).

5.Re-installthedeckdrivebeltinthelowergrooveof

thedoublesheave.Installtheplugintotheboreof

thedoublesheave.

g190023

Figure10

1.Beltcoverbracket4.Belt

2.Beltcover5.Decksheaveandnyloc

plug

3.Knob

InstallingtheBlowerAssembly

1.Mountthebloweronthedeckbyinsertingthe

mountingpinintothetubeweldedtotherearcorner

ofthedeck.UseFigure11todeterminethepin

locationintheblowerframe.

g037990

Figure11

1.Mountingpin4.48inchdecklocation

2.Rollpin5.60inchdecklocation

3.52inchdecklocation

2.Pivottheblowertowardsthedeckandpulloutward

onthelatchpin.Releasethelatchpinwhenitaligns

withtheholeonthetabofthedecktolockthe

blowerinthisposition.

3.Pullthespringloadedidlerbackandslipthebelt

overthetopdecksheave.Thebeltshouldberouted

asshowninFigure12.

g190065

Figure12

ViewfromT opofBlower

4.Positionthebeltcoveratanangleandslideitunder

themowerframe(seeFigure13).

g038057

Figure13

1.Blower3.Mowerframe

2.Beltcover

5.Pushdownonthebackofthecoverandslideit

backwardsundertheblower.

6.Withthebeltcoverrestingonthedeck,slideit

forwarduntilitisseatedunderbothlipsonthedeck.

g038066

Figure14

1.Blower3.Decklip

2.Beltcover

7.Installtheknobanditshardware.

InstallingtheHopperFrame

1.Removethehairpinfromthehopperframe.Insert

thehopperframeintotheLHhoppermountbracket

(seeFigure15).Resttheotherendofthehopper

framebetweenthetabsontheRHhoppermount

bracket.Reinstallthehairpintosecurethehopper

frame.

Note:Ifthehopperframedoesnotseatproperlyin

themountbrackets,carefullyusethehopperframe

toslightlyadjustthealignmentofthebrackets.The

frameisdesignedtoinitiallyttightinthemounting

brackets.Itmaybenecessarytouseamalletto

install.

g190024

Figure15

1.LHhoppermountbracket

2.Hopperframe

3.Hairpin

4.RHhoppermountbracket

5.Holddownrod

2.Removethehairpinfromtheholddownrod.Insert

theholddownrodintothehopperframeand

reinsertthehairpin(reference).

InstallingtheHopper

1.Removeandretainthehairpinsfromtheairvent.

2.Pressthetabsontheairventintothenotchesonthe

insideofthehopperandsecurewithhairpins.

g037999

Figure16

1.Hopperframepin3.Hopperhinge

2.Seal(partiallyremovedfor

clarity)

4.Airvent

3.Slidethehopperhingesontothehopperframepins.

4.Makesurethesealispositionedaroundthebrackets

wherethebagsmount.

AssemblingtheTubes

1.Sliptheupperandthelowertubestogether.

2.Inserttheuppertubeintothehopperseal–pushin

thenpulloutsothatthesealisextendedoutward.

3.Alignthedimpleontheuppertubewiththeendof

hoppersealandcenterbetweenthetwoscrewsas

showninFigure17.

g007027

Figure17

1.Dimple

4.Setthedeckinthelowestcuttingposition.

5.Slidethelowertubeontotheblowerandattachthe

latches.(Makesurethattheuppertubedoesnot

moveoutofalignment).

For60InchDeckOnly:Ifthereistoomuch

overlapbetweentheupperandlowertubes,itmay

benecessarytoshortentheuppertube.

Toshorten:

A.Determinehowmuchneedstobecutofffrom

theendofthetube.Locatethethreeholes

intheuppertube.Measurefromtheendof

thetubetwicethedistancethatneedstobe

removed.Markthelocationofallthreeholes

(seeFigure18).

g204645

Figure18

1.Newholelocation

2.Measurefornewholelocation

3.Measureforcutline

4.Cuttube

B.Drillthree3/8inchholes.

C.Measurefromtheendofthetubetheamountto

remove,createmarks,andapplymaskingtape

aroundthetubeasaguide.

D.Carefullycutthetubeanddiscardtheend.

6.Drillthe7/32inchholesinthelowertubeusingthe

uppertubeholesasreference.SeeFigure19.

7.Removetubesfromtheunitandassembletheupper

andthelowertubesusingthree#10-24x3/4inch

hexwasherheadscrews,three#10washers,and

three#10-24nylocnuts.Thescrewheadshould

beinstalledtotheinsideofthetubetoprovide

minimumobstructiontoow.Makesurethatthe

upperandthelowerendsareorientedproperlyasthe

tubesareassembled.(Partinglinesshouldroughly

belinedup.)

g007028

Figure19

1.Drilltheholeshere

InstallingtheROPSPin

TopreventtheROPSbarfromdamagingthehopper,

installtheROPSpinassembly.

1.Using11/64or#19drillbit,drilltheinnerRHROPS

hole3/4inch(19mm)deepasshowninFigure20.

g038069

Figure20

1.Drill3.#10-24x3/4inchhex

screw

2.#10washer4.ROPSpinwithlanyard

2.Placethe#10washerandlanyardcableendonto

the#10-24x3/4inchhexscrewandinstallintothe

RHROPShole.

3.InstalltheROPSpin.

4.Repeatsteps1through3fortheLHROPS.

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