Slider Upgrade

Download PDF

Belt Tensioner System from
Air Tensioner to
Slider Tensioner Upgrade

1. Place the rear generator cart on a hard surface and
   support it on all 4 corners. Use a jackstand on the front
   right corner and the axle flip downs and jack that were
   supplied with your Zapper.
2. Remove the large 1000 rpm PTO shaft.
3. Place a floor jack under the 21″ PTO pulley.
4. Remove the 4 vertical 3/4″ bolts that hold the
   bearing plates to the front and rear box iron tube.
5. Raise the 21″ pulley with the floor jack.
6. Remove the aluminum pulley, mounting arm and
   mounting base from the machine.
7. Cut out the front and rear 2.5″ square tubes that the
   bearing plates were mounted to.
8. Lower the floor jack with the entire 21” PTO pulley
   assembly and 2” shaft and slide it out.
9. Remove bearings and plates from 2″ PTO shaft.
10. Remove 3 x 1/2″ bolts(13/16″ socket) that secure
    and hold the split pulley bushing to the pulley.
11. Install the bolts in the threaded empty holes in the
    bushing. These are used to push bushing from
    the shaft. Tighten evenly.
12. Clean any excess weld from the 3″ x 3″ lower square
    tubes.
13. Install the 1/2″ thick angle bracket onto the 3″ x 3″
    right and left square tubes. The U-notch should face
    downward. They should be slid all the way to the rear of
    the 3″ x 3″ square tubes on either side. They will
    contact the rear main 3″ x 3″ tube.

14. The bent return will be on the bottom of the 3″ x 3″
    right and left tubes.
15. Assemble slider unit by installing the black plastic
    split socket blocks (4) to the slider with the long
    1/2″ carriage bolts. KEEP the blocks paired and
    clocked!!!
16. Slide the chrome shafts through holes in blocks.
17. Tighten 1/2″ carriage bolts with a ratchet, not an
    impact. Make sure that chrome shafts move freely
    after tightening the bolts. Adjust bolt tightness
    accordingly.
18. Slide the 3/16″ flat plates onto the ends of the
    chrome shafts outside of plastic blocks.
19. The slider plate has an upward protruding mount
    with a single hole in it. This points up and goes to
    the right-hand (transformer) side of the cart.
20. Install slider assembly into cart by lifting it up with
    floor jack while aligning chrome shafts with the
    U-sockets on either side. They will engage the parts that
    were welded into place.
21. Slide the 3/16″ plates out to contact the welded-inplace 1/2″ plates.
22. Install 2 bolts on either side.
23. Reinstall pulley, shaft and bearings in reverse order
    of the way they were removed (steps 9-11).
24. Put Loctite on bolts that hold bushing to pulley.
    Then torque to 65′ lbs with torque wrench and 13/16″
    socket.
25. Using a 48″ straight edge, align the pulleys making
    sure all 4 points of pulley are within 1/16″ of the
    straight edge. Snug the 3/4″ vertical bolts.
26. Put Loctite on the small Allen set screws that lock
    bearings to the 2″ shaft. Tighten them.
27. Recheck alignment.
28. Tighten 3/4″ bolts.
29. Install the 1000 rpm PTO shaft. Put Loctite on the
    Allen set screws (We recommend you remove the
    Allen-head set screw that comes in contact with the 2”
    shaft and replace it with a short ½” bolt).
30. Using the U-bolts that were provided, bolt the
    hinged part to the outer 3″ x 3″ frame on the
    passenger side. Make sure it aligns with the upward
    protruding eye on the slider.
31. Install the springs onto the hinged part and bottom
    out the nuts on the bolt threads completely.
32. Install turnbuckle.
    33.Tighten it until the springs compress to
    approximately 1 1/8” between the flat fender washers
    on either side of the springs. If you have the multi-tool,
    the washers should touch the side of the tab.

Use the following link to see a video for the slider
installation. It varies a little from model to model but
still very much applies to all units
https://youtu.be/OsQ5apZc0UI