Exmark Lawn Mower 4500 420 User Manual

ULTRA VAC® QDS  
LAZER Z® HP MODELS  
For Ultra Vac Serial Nos.  
790,000 & Higher  
Part No. 4500-420 Rev. A  
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Ultra Vac QDS. This product has been  
carefully designed and manufactured to give you  
a maximum amount of dependability and years of  
trouble-free operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
Ultra Vac QDS.  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
Figure 1  
1. Model and serial number location  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your Ultra  
Vac QDS, maintain its maximum efficiency, and  
promote safe operation.  
Model No.  
Serial No.  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
All Exmark equipment dealers and distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Contents  
Introduction ........................................................... 3  
Torque Requirements .................................... 10  
Periodic Maintenance ....................................... 16  
Check Blower Housing/Impeller................... 16  
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Safety  
• Never let children or untrained people operate  
Safety  
Safety Alert Symbol  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
Preparation  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and safely  
perform the job. Only use on machines approved  
by Exmark.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals.  
Figure 2  
1. Safety alert symbol  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
CAUTION  
This machine produces sound levels in  
excess of 85 dBA at the operator’s ear and  
can cause hearing loss through extended  
periods of exposure.  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
Wear hearing protection when operating this  
machine.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
Operation  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
Safe Operating Practices  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
Training  
• Read the tractor and Ultra Vac QDS Operator’s  
Manuals and other training material. If the  
operator(s) or mechanic(s) can not read English  
it is the owner’s responsibility to explain this  
material to them.  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
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Safety  
Slope Operation  
DANGER  
Use Extreme caution when mowing and/or turning  
on slopes as loss of traction and/or tip-over could  
occur. The operator is responsible for safe operation  
on slopes.  
There are rotating blades in the blower and  
under the mower deck. Blade contact can  
cause serious operator or bystander injury  
or even death.  
• Do Not reach into blower unless rotation  
indicator has stopped. Disengage PTO,  
stop engine, remove key, wait for all  
moving parts to stop. Engage parking  
brake.  
DANGER  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. Wheels  
dropping over edges, ditches, steep banks, or  
water can cause rollovers, which may result  
in serious injury, death or drowning.  
• Never operate mower unless discharge  
deflector, entire grass collection system,  
or mulch kit is installed.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Stop engine, wait for all moving parts to stop,  
remove key and engage parking brake:  
• Do Not mow slopes greater than 15  
degrees.  
– Before checking, cleaning or working on the  
mower.  
• Reduce speed and use extreme caution  
on slopes.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating the mower).  
• Avoid sudden turns or rapid speed  
changes.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
– Before clearing blockages.  
– Whenever you leave the mower.  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
WARNING  
• Use a walk behind mower and/or a hand trimmer  
near drop-offs, ditches, steep banks or water.  
(Figure 3).  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
6
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Safety  
Use progressively greater care on slopes as the  
hopper fills.  
Maintenance and Storage  
• Disengage drives, set parking brake, stop engine  
and remove key or disconnect spark plug wire.  
Wait for all movement to stop before adjusting,  
cleaning or repairing.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
Figure 3  
1. Safe Zone-Use the mower here on slopes less than 15  
degrees  
2. Danger Zone-Use a walk behind mower and/or hand  
trimmer on slopes greater than 15 degrees, near  
drop-offs and water.  
• Check all bolts frequently to maintain proper  
tightness.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
3. Water  
• All replacement parts must be the same as  
or equivalent to the parts supplied as original  
equipment.  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
• Avoid sudden starts when mowing uphill because  
the mower may tip backwards.  
• Be aware that operating on wet grass, across steep  
slopes or downhill may cause the mower to lose  
traction. Loss of traction to the drive wheels may  
result in sliding and a loss of braking and steering.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
• Follow the manufacturer’s recommendations for  
counter weights to improve stability. Always  
install and remove the Ultra Vac QDS, including  
counter weights, as instructed. Failure to do so  
will cause a reduction in stability or traction. Do  
Not operate the mower with only a portion of the  
Ultra Vac QDS installed.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control. The stability  
and traction of the machine will change as the  
Ultra Vac QDS hopper fills with grass clippings.  
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• Safety signs may be affixed by peeling off the  
backing to expose the adhesive surface. Apply  
only to a clean, dry surface. Smooth to remove  
any air bubbles.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
103-6605  
For Units with a Two-Post ROPS Only  
1-653554  
1-653558  
98-5954  
103-6604  
For Units with a Two-Post ROPS Only  
8
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Safety  
103-3508  
9
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 790,000 and Higher  
LHPUVD4448; LHPUVD4650; LHPUVD5256  
w/Ultra Vac QDS  
Systems  
52 inch Deck  
56 inch Deck  
95.00 inches (241.3 cm)  
99.86 inches (253.6 cm)  
Bagging System  
• Collection Hopper:  
Curb Weight:  
– Commercial grade, steel and polyethylene  
hopper with rear discharge door, commercial  
grade cloth mesh door panel.  
Lazer Z HP -220 lb (100 kg), including the front  
weight.  
– Capacity: 6.7 bushels  
• Dump Mechanism: Single motion actuation from  
operator’s seat.  
Torque Requirements  
Bolt Location  
Torque  
• Blower Tube: Fixed, abrasion resistant molded  
polyethylene.  
Impeller Spindle Bottom 55-60 ft-lb (75-81 N-m)  
Nut  
• Impeller: 5–bladed, 1/4 inch (6.4 mm) thick  
abrasion resistant steel, with vertical axis.  
Impeller Spindle Top Nut 75-80 ft-lb (102-108 N-m)  
• Impeller bearings: 1 inch (2.5 cm) sealed  
non-greaseable bearings.  
Dimensions  
Overall Width:  
w/Ultra Vac QDS  
44 inch Deck  
46 inch Deck  
48 inch Deck  
50 inch Deck  
52 inch Deck  
56 inch Deck  
58.47 inches (148.5 cm)  
60.67 inches (154.1 cm)  
61.73 inches (159.8 cm)  
64.66 inches (164.2 cm)  
66.47 inches (168.8 cm)  
70.85 inches (180.0 cm)  
Overall Length:  
w/Ultra Vac QDS  
44 inch Deck  
46 inch Deck  
48 inch Deck  
50 inch Deck  
93.76 inches (283.2 cm)  
96.69 inches (245.6 cm)  
93.76 inches (283.2 cm)  
97.12 inches (246.7 cm)  
10  
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Operation  
Product Overview  
Operation  
Note: Determine the left and right sides of the  
machine from the normal operating position.  
Pre-Start  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Ensure the blower, door mesh, tube and hopper are  
in good condition, properly attached, and latched.  
For units above Serial Number 600,000 with Triton  
decks: Make sure that the adjustable dog leg baffle is  
closed to match the intake into the Ultra Vac Blower.  
Figure 4  
1. Hood  
2. Weight  
4. Tube  
5. Door  
3. Blower  
WARNING  
If the deck discharge opening and the blower  
intake opening do not match correctly, it  
will allow objects to be thrown in operator’s  
or bystander’s direction. Also, contact with  
blade could occur. Thrown objects or blade  
contact can cause serious injury or kill you  
or bystanders.  
Adjust dog leg baffle to match intake  
opening.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Operating Instructions  
Mowing  
1. The Ultra Vac QDS blower operates when deck  
drive is engaged. Be sure that all persons are clear  
of the mower deck before engaging the cutting  
blades. Set the throttle to “midway” position. Pull  
outward on the PTO switch to the “ROTATE”  
position. Accelerate to full throttle to begin  
mowing.  
2. To disengage the PTO and blower, set the  
throttle to “midway” position. Push in on the  
PTO switch to the “STOP” position to stop the  
cutting blades and blower. The cutting blades will  
require a slightly longer amount of time to come  
to a complete stop when the blower is installed  
on the deck. Verify that all rotation indicators  
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Operation  
have stopped before clearing blower assembly or  
mower deck  
3. To empty the hopper, first shut off deck drive.  
Lift up on the handle to open the door and  
empty the hopper. If the unit is to be driven  
onto a truck or trailer with the hopper full,  
always back the unit up the ramp. This will  
reduce the chance of rearward tip up. See the  
Transporting section for additional information  
regarding loading a unit on a truck or trailer.  
4. Close and latch the door before continuing  
mowing. Do Not engage the cutting blades while  
the door is in the open position.  
Figure 5  
4. Hairpin  
5. Clevis Pin  
Tips for mowing conditions:  
1. Hopper Assembly  
2. Tube  
3. Blower  
• When mowing in areas with sandy soil, use  
low lift blades on the cutting deck and higher  
cutting heights to minimize wear on the blower  
components.  
3. Remove the belt cover by loosening the knobs.  
• When mowing in wet conditions, such as just after  
a rain or in heavy dew, use low lift blades on the  
cutting deck to minimize plugging of the blower.  
CAUTION  
• Maintaining a ground speed that does not pull  
down the engine RPM will allow for the highest  
productivity and best quality of cut. Bogging the  
engine RPM down by going too fast will cause  
plugging and quality of cut issues.  
The deck sheave will become very hot.  
Touching a hot deck sheave can cause severe  
burns.  
Allow the deck sheave to cool completely  
before removing the belt.  
• When the hopper gets full, the sound of the  
blower will change and there will be slight  
blowout from the front right corner of the deck.  
Emptying the hopper at this point will minimize  
the potential for the tube to plug.  
For units below Serial Number 600,000:  
Anti-blowout kits are available for leaf collection.  
They help to prevent “chasing” the leaves. To  
reduce “plowing” leaves, raise the deck slightly.  
On Triton: Raise front adjustable baffle to  
reduce plowing. Lowering front adjustable baffle  
may prevent “chasing”. Match discharge opening  
to Ultra Vac intake for best performance.  
Figure 6  
1. Hairpin  
2. Chute pivot pin  
3. Discharge chute  
4. Belt shield  
5. Weight  
6. Knob  
Bagger Removal for Side Discharge  
1. Shut off the deck drive, stop engine and wait for  
all moving parts to stop. Remove key.  
4. Pull the idler release handle and remove the belt  
from the upper groove of the deck sheave.  
2. Remove the discharge tube by releasing the latch  
at the blower. Slide the tube off the blower outlet  
and remove the upper end from the hopper.  
5. Unlatch the front end of the blower. Pivot the  
blower back and lift it off the deck.  
12  
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Operation  
6. Install the discharge chute using the chute pivot  
pin and hairpin (see Figure 7).  
operate the mower with only a portion of the  
Ultra Vac installed.  
WARNING  
Caster or front floor pan weights installed  
without bagger may cause loss of traction  
and steering control. Loss of control can  
result in an accident, which may cause death,  
injury, or property damage.  
Install caster or front floor pan weights  
ONLY when bagger is installed.  
Figure 7  
11. The machine can now be used for side discharge  
mowing.  
Viewed from the right side  
1. Hairpin  
3. Discharge chute  
2. Chute pivot pin  
Bagger Installation for Bagging  
1. Stop engine, remove key, and wait for all moving  
parts to stop.  
Note: Install chute with the tabs to the rear of  
the deck tabs as shown.  
2. Remove hairpin and chute pivot pin. Remove  
discharge chute. Pivot pin and hair pin may be  
stored in the pivot holes of the discharge chute  
during bagging operation.  
WARNING  
An uncovered discharge opening will  
allow objects to be thrown in operator’s or  
bystander’s direction. Also, contact with  
blade could occur. Thrown objects or blade  
contact can cause serious injury or kill you  
or bystanders.  
3. Slide tube ends of hopper assembly into the tubes  
of the mount weldment (see Figure 5). Install two  
clevis pins through holes in tubes. Retain with  
two hair pins.  
4. Remove the belt cover on the right side of the  
deck (see Figure 6). Install the blower by inserting  
the mounting pin into the tube welded to the rear  
corner of the deck. Pivot the blower until the  
front pin engages the slot in the deck. Adjust the  
position of the front pin if necessary to engage  
the slot. Use the latch to lock the blower in this  
position.  
Never operate mower unless discharge  
deflector, or entire grass collection system, or  
mulch kit is installed.  
7. Re-install the plastic belt cover and tighten the  
knobs.  
8. Remove the hair pins and clevis pins holding the  
hopper assembly to the mount weldment.  
5. Pull the idler release handle and install the belt in  
the upper groove of the deck sheave.  
9. Lift the hopper assembly off the mount.  
6. Install the belt cover using the two knobs.  
10. Remove the hairpins and lift the front weights off  
of the mount plate.  
7. Install the discharge tube assembly by slipping the  
upper end into the hood, then sliding the lower  
end over the blower discharge opening. Use the  
latches to retain the lower end to the blower.  
Note: The removable weights are heavy. Use  
care when lifting them. Make sure that you can  
hold them securely before lifting them. Use  
caution when positioning your hands so that you  
Do Not set them down on your hands or fingers.  
8. For Units Serial Number 600,000 and Higher  
with Triton Decks: Adjust position of dog leg  
baffle to match the intake of the Ultra Vac blower  
baffle adjusted too wide may allow objects to be  
thrown from under deck. Baffle adjusted too  
narrow may cause plugging issues.  
Note: The portions of the Ultra Vac bagger that  
are not bolted to the mower are designed to be  
installed or removed in their entirety. Do Not  
13  
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Operation  
Transporting  
WARNING  
Loading a unit on a trailer or truck increases  
the possibility of backward tip-over.  
Backward tip-over could cause serious injury  
or death.  
Transporting a Unit  
Use a heavy-duty trailer or truck to transport the  
machine. Lock brake and block wheels. Securely  
fasten the machine to the trailer or truck with straps,  
chains, cable, or ropes. Be sure that the trailer or truck  
has all necessary lighting and marking as required by  
law. Secure a trailer with a safety chain.  
• Use extreme caution when operating a  
unit on a ramp.  
• Use only a single, full width ramp; Do  
Not use individual ramps for each side  
of the unit.  
CAUTION  
This unit does not have proper turn  
• If individual ramps must be used, use  
enough ramps to create an unbroken  
ramp surface wider than the unit.  
signals, lights, reflective markings, or a  
slow moving vehicle emblem. Driving on a  
street or roadway without such equipment  
is dangerous and can lead to accidents  
causing personal injury. Driving on a street  
or roadway without such equipment may also  
be a violation of State laws and the operator  
may be subject to traffic tickets and/or fines.  
• Do Not exceed a 15° angle between ramp  
and ground or between ramp and trailer  
or truck.  
• Avoid sudden acceleration while driving  
unit up a ramp to avoid tipping backward.  
• Avoid sudden deceleration while backing  
unit down a ramp to avoid tipping  
backward.  
Do Not drive a unit on a public street or  
roadway.  
Loading a Unit  
If the unit is to be driven onto a truck or trailer  
with the hopper full, always back the unit up the  
ramp. This will reduce the chance of rearward  
tip up.  
Dump contents of hopper before transport Do Not  
transport the unit with the hopper full.  
Use extreme caution when loading units on trailers or  
trucks. One full width ramp that is wide enough to  
extend beyond the rear tires is recommended instead  
of individual ramps for each side of the unit. The  
lower rear section of the tractor frame extends back  
between the rear wheels and serves as a stop for  
tipping backward. Having a full width ramp provides  
a surface for the frame members to contact if the  
unit starts to tip backward. If it is not possible to use  
one full width ramp, use enough individual ramps to  
simulate a full width continuous ramp.  
Ramp should be long enough so that the angles  
between the ramp and the ground and the ramp and  
the trailer or truck Do Not exceed 15°. A steeper  
angle may cause mower deck components to get  
14  
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Operation  
caught as the unit moves from ramp to trailer or  
truck. Steeper angles may also cause the unit to tip  
backward. If loading on or near a slope, position  
the trailer or truck so it is on the down side of the  
slope and the ramp extends up the slope. This will  
minimize the ramp angle. The trailer or truck should  
be as level as possible.  
Important: Do Not attempt to turn the unit  
while on the ramp, you may lose control and  
drive off the side.  
Avoid sudden acceleration when driving up a ramp  
and sudden deceleration when backing down a ramp.  
Both maneuvers can cause the unit to tip backward.  
15  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could  
seriously injure you or other bystanders.  
The engine can become very hot. Touching  
a hot engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine  
area.  
Remove the key from the ignition switch,  
engage parking brake, and pull the wire(s)  
off the spark plug(s) before you do any  
maintenance. Also push the wire(s) aside  
so it does not accidentally contact the spark  
plug(s).  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Check the blower housing/impeller.  
• Check door cloth mesh.  
• Clean muffler and rear frame area.  
Before each use or daily  
• Clean rear screen in the hood.  
• Lubricate grease fittings.  
• Check condition of belt.  
• Clean blower.  
Every 25 hours  
Every 50 hours  
Yearly or before storage  
Periodic Maintenance  
Check Door Cloth Mesh  
Service Interval: Before each use or daily  
Check Blower  
Housing/Impeller  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Inspect the bags for wear, tears, or damage.  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
WARNING  
Under normal use the cloth mesh will  
deteriorate and wear. Objects could exit  
through worn cloth mesh at high speeds.  
Thrown objects can cause serious injury or  
kill you or bystanders.  
2. Inspect for wear or damage daily. Replace or  
repair worn parts as needed  
Note: When mowing in areas with sandy soil,  
use low lift blades on the cutting deck and higher  
cutting heights to minimize wear on the blower  
components.  
Check cloth mesh frequently for tears and  
holes. Replace worn cloth mesh.  
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Maintenance  
3. Inspect the belt for damage or wear. Replace belt  
with one of the following:  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
Part No.  
1-653332  
1-653438  
1-653333  
103-0866  
1-653438  
109-9249  
Deck  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
44 inch Deck  
46 inch Deck  
48 inch Deck  
50 inch Deck  
52 inch Deck  
56 inch Deck  
2. Lubricate fittings with NGLI grade #2  
multi-purpose gun grease.  
Refer to the following chart for fitting locations  
and lubrication schedule.  
Lubrication Chart  
A. To replace belt, remove the belt guide on the  
blower (Figure 8)  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
1–2  
1
25 Hours  
1. Idler  
Bushings  
Check Condition of Belt  
Service Interval: Every 50 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Figure 8  
2. Inspect the belt position on the idler arm.  
1. Spring loaded idler  
2. Impeller sheave  
3. Fixed idler  
4. Belt guide  
5. Deck sheave  
The idler arm may become bent during use or  
transport. A bent idler arm could cause the belt  
to jump off of the idler and be damaged.  
A. Make sure the belt cover is installed and run  
the blower for one to two minutes.  
B. Install the belt onto the blower assembly as  
shown.  
B. Shut off the deck drive, stop engine and wait  
for all moving parts to stop. Remove key.  
Remove the belt cover and check to make sure  
that the belt is riding near the center of the  
flat idler on the idler arm.  
C. Reinstall the belt guide removed previously.  
C. If the belt is not riding near the center of the  
idler, remove the blower, and bend the idler  
arm slightly.  
D. Reinstall the blower and belt cover and repeat  
steps A through C until the belt is positioned  
near the center of the idler.  
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Maintenance  
Adjustments  
Note: The Ultra Vac QDS was adjusted at the  
factory to operate properly. However, there are three  
basic adjustments that can be made, should your unit  
require them:  
3. Door opening: After adjusting the hinge links  
for door closing, the hinge stops (Figure 10B) can  
be adjusted to obtain maximum door opening.  
The stop plates should be adjusted so that the  
door link contacts them when the upper tube of  
the door frame is within 1/4 inch (6.4 mm) ± 1/8  
inch (3.2 mm) from the lower lip of the molded  
hood. Both left and right stops must make  
contact when the door link arm is at this position.  
Figure 9  
Figure 10  
1. Bellcrank arm  
2. Upper frame tube  
1. 1/4 inch (6.4 mm) ± 1/8 inch (3.2 mm)  
3. Maintain same distance on both sides  
1. Arm Position: The left and right bellcrank arms  
control the timing of the left and right door  
opening mechanisms. The ends of these arms  
must be positioned equally from the upper frame  
tube for proper actuation. Check this distance  
with the door closed. If adjustment is necessary,  
loosen the allen head clamping screw on the hub  
of the right hand arm. Position the arms so that  
their ends are the same distance from the upper  
frame tube. Tighten the clamping bolt to hold  
them in this position (see Figure 9).  
2. Door closing: The closing of the door is  
controlled by the two hinge links (Figure 10A).  
The length of the hinge links can be changed  
to provide complete closing of the door and  
reasonable force on the handle to latch or unlatch  
the door. Lengthen the links to reduce the force.  
Shorten the links to increase the force. The left  
and right sides must be approximately equal. With  
the door closed, both links should be slightly tight  
to minimize rattling.  
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Maintenance  
Cleaning  
Clean Muffler and Rear  
Frame Area  
Service Interval: Before each use or daily  
Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
WARNING  
Operating engine parts, especially the  
muffler, become extremely hot. Severe burns  
can occur on contact and debris, such as  
leaves, grass, brush, etc. can catch fire.  
• Allow engine parts, especially the muffler,  
to cool before touching.  
• Remove accumulated debris from muffler  
and engine area.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered,  
brush-covered unimproved land.  
Clean Rear Screen In Hood  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Open door and remove clippings that are stuck  
to the screen.  
Clean Blower  
Service Interval: Yearly or before storage  
Grass build up may cause problems with the impeller  
when the unit is put back into operation.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove grass buildup from around the impeller  
before placing it in storage.  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, Do Not overlook the simple causes. For example: starting problems could be  
caused by an empty fuel tank.  
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major  
items or any items that call for special timing or adjustment procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.  
Problem  
Abnormal vibration.  
Possible Cause  
Corrective Action  
1. Install new cutting blade(s).  
1. Cutting blade(s) is/are bent or unbalanced.  
2. Blade mounting bolt is loose.  
3. Loose blower pulley or pulley assembly.  
4. Blower impeller blades are bent.  
2. Tighten the blade mounting bolt.  
3. Tighten the appropriate pulley.  
4. Contact an Authorized Service Dealer.  
Blower drive belt snaps or breaks frequently.  
Excessive grass blowout from the deck.  
1. Idler arm is out of alignment.  
1. Correct the alignment of the idler arm.  
1. Dump more frequently.  
1. Hopper is full.  
2. Plugged screen in bagger hood.  
2. Remove debris, leaves or grass clippings  
from the screen.  
3. Ground speed is too fast.  
4. Blower belt is worn, loose, or broken.  
5. Plugged tube or blower.  
6. Conditions are dry.  
3. Drive slower at full throttle.  
4. Install new blower belt.  
5. Locate and remove plugged debris.  
6. Use lower lift blade.  
Blower and tubes plug too frequently.  
1. Hopper is too full.  
1. Dump more frequently  
2. Ground speed is too fast.  
3. Grass is too wet.  
2. Drive slower at full throttle.  
3. Cut grass when it is dry.  
4. Grass is too long.  
4. Cut grass more frequently or at higher cut  
height.  
5. Plugged screen in bagger hood.  
5. Remove debris, leaves, or grass clippings  
from the screen.  
6. Blower drive belt is worn, loose, or  
broken.  
6. Install new belt.  
7. Blower is plugged.  
7. Use low lift blades in wet conditions.  
Blower impeller does not spin freely.  
1. Plugged blower.  
1. Remove debris, leaves, or grass clippings  
from the blower impeller.  
2. Impeller not aligned.  
1. Deck is too low.  
2. Contact an Authorized Service Dealer.  
Plowing leaves.  
Chasing leaves.  
1. Units below Serial Number  
600,000: Raise the deck slightly.  
Triton: Raise the front adjustable baffle.  
1. Units below Serial Number 600,000:  
Install an anti-blowout kit–contact  
an Authorized Service Dealer.  
Triton: Lower the front adjustable  
baffle. Match discharge opening to Ultra  
Vac intake.  
1. Blowout from deck.  
Blower components show signs of wear  
and/or air cleaners and cooling fins are dirty.  
1. Sand or dry conditions.  
1. Use low lift blades on the cutting  
deck and higher cutting heights.  
Clean air cleaners and cooling fins  
frequently.  
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Exmark Commercial Attachments and Accessories  
1Year Limited Warranty  
Conditions and Products Covered  
Owner’s Responsibilities  
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty  
Company, pursuant to an agreement between them, jointly  
warrant on the terms and conditions herein, that we will repair,  
replace or adjust any part on these products and found by us  
(in the exercise of our reasonable discretion) to be defective in  
factory materials or workmanship for a period of one year.  
The Exmark attachment or accessory, including any defective  
part, must be returned to an authorized Exmark service dealer  
within the warranty period. This warranty extends only to  
commercial attachments and accessories operated under  
normal conditions. You must read the operator’s manual. You  
must also properly service and maintain your Exmark product  
as described in the operator’s manual or other operational  
instructions provided by Exmark. Such routine maintenance,  
whether performed by a dealer or by you, is at your expense.  
This warranty applies to Exmark commercial attachments and  
accessories sold in the U.S. or Canada. This warranty may  
only be assigned or transferred to a second (or third) owner by  
an authorized Exmark dealer. The warranty period commences  
upon the date of the original retail purchase.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company  
with respect to this warranty shall be repair or replacement of  
defective components as set forth herein. Neither Exmark  
nor Exmark Warranty Company shall be liable for any  
incidental or consequential loss or damage.  
Warranty Exceptions  
Warranty Period  
• Bags, Belts and Tires  
90 days  
This warranty only includes the cost of parts and labor.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Pickup and delivery charges to and from any authorized  
Exmark Service Dealer.  
• Any damage or deterioration due to normal use, wear and  
tear, or exposure.  
• Cost of regular maintenance service or parts, such as filters,  
fuel, lubricants, tune-up parts, and adjustments.  
• Any product or part which has been altered or misused or  
required replacement or repair due to normal wear,  
accidents, or lack of proper maintenance.  
Such damages include but are not limited to:  
• Expenses related to gasoline, oil or lubricants.  
• Travel time, overtime, after hours time or other  
extraordinary repair charges or charges relating to repairs or  
replacements outside of normal business hours at the place  
of business of the authorized Exmark Service Dealer.  
• Rental of like or similar replacement equipment during the  
period of any warranty, repair or replacement work.  
• Any telephone or telegram charges or travel charges.  
• Loss or damage to person or property other than that  
covered by the terms of this warranty.  
• Any repairs necessary due to use of parts, accessories or  
supplies, including gasoline, oil or lubricants, incompatible  
with the attachment or accessory or other than as  
recommended in the operator's manual or other operational  
instructions provided by Exmark.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark attachment  
or accessory.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
All implied warranties of merchantability (that the  
product is fit for ordinary use) and fitness for use (that the  
product is fit for a particular purpose) are limited to the  
duration of the express warranty.  
Instructions for Obtaining Warranty Service  
The product must be registered with original proof of purchase  
by an Exmark Service Dealer before obtaining any warranty  
service.  
Some states do not allow exclusions of incidental or  
consequential damages, or limitations on how long an  
implied warranty lasts, so the above exclusions and  
limitations may not apply to you.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
G4500-433  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Model No.  
Serial No.  
© 2008 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-420 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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