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

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

Figure1

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.

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

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.

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).

G014743

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.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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