Poulan Lawn Mower Accessory 532140602 User Manual

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OWNER’S MANUAL  
Model No. CR38C  
Product No. 954 04 04-01  
38 Inch Mower  
Grass Catcher  
• Assembly  
• Operation  
• Customer Responsibilities  
• Repair Parts  
532140602 Rev. 3 9.08.03 rad  
Printed in U.S.A.  
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SAFETY RULES  
Safe Operation Practices for Ride-On Mowers  
Be sure the area is clear of other people before mowing.  
Stop machine if anyone enters the area.  
Look for this symbol to point out im-  
portant safety precautions. It means  
CAUTION!!! BECOME ALERT!!! YOUR  
SAFETY IS INVOLVED.  
Never carry passengers or children even with the blades  
off.  
Do not mow in reverse unless absolutely necessary.Always  
look down and behind before and while backing.  
Never carry children. They may fall off and be seriously  
injured or interfere with safe machine operation.  
Keepchildrenoutofthemowingareaandunderthewatchful  
care of another responsible adult.  
CAUTION: Do not coast down a hill  
in neutral, you may lose control of  
the tractor.  
Be alert and turn machine off if children enter the area.  
Before and when backing, look behind and down for small  
children.  
Mow up and down slopes (15° Max), not across.  
Remove obstacles such as rocks, tree limbs, etc.  
Watchforholes,ruts,orbumps.Uneventerraincouldoverturn  
the machine. Tall grass can hide obstacles.  
Use slow speed. Choose a low gear so that you will not  
have to stop or shift while on the slope.  
Avoid starting or stopping on a slope. If tires lose traction,  
disengage the blades and proceed slowly straight down the  
slope.  
CAUTION: Tow only the attachments  
that are recommended by and com-  
ply with specifications of the manu-  
facturer of your tractor. Use common  
sense when towing. Operate only at  
the lowest possible speed when on a  
slope. Too heavy of a load, while on  
a slope, is dangerous. Tires can lose  
tractionwiththegroundandcauseyou  
to lose control of your tractor.  
If machine stops while going uphill, disengage blades, shift  
into reverse and back down slowly.  
Do not turn on slopes unless necessary, and then, turn  
slowly and gradually downhill, if possible.  
CAUTION: In order to prevent ac-  
cidental starting when setting up,  
transporting, adjusting or making  
repairs, always disconnect spark  
plug wire and place wire where it  
cannot contact spark plug.  
CONGRATULATIONS on your purchase of a new Grass Catcher. It has been designed, engineered and manufactured to  
give you the best possible dependability and performance.  
Should you experience any problems you cannot easily remedy, please contact your nearest authorized service center/  
department. They have competent, well trained technicians and the proper tools to service or repair this unit.  
Please read and retain this manual.The instructions will enable you to assemble and maintain your Grass Catcher properly.  
Always observe the "SAFETY RULES".  
TABLE OF CONTENTS  
SAFETY RULES .........................................................2-3  
BAG OF PARTS..........................................................4-5  
ASSEMBLY.................................................................... 6  
OPERATION ................................................................ 11  
CUSTOMER RESPONSIBILITIES............................... 12  
STORAGE.................................................................... 12  
REPAIR PARTS...................................Center of Manual  
3
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KNOWYOUR GRASS CATCHER  
READTHISOWNER'SMANUALANDSAFETYRULESBEFOREASSEMBLINGOROPERATINGYOURGRASSCATCHER.  
Compare the illustrations with the carton contents to familiarize yourself with the parts before starting the assembly. Study  
the operating instructions and safety precautions thoroughly to insure proper functioning of your Grass Catcher and to  
prevent injury to yourself and others. Save this manual for future reference.  
The operation of any tractor can result in foreign objects thrown into the eyes, which can result in  
severe eye damage. Always wear safety glasses or eye shields before starting your tractor and  
while mowing. We recommend wide vision safety mask for over the spectacles or standard safety  
glasses.  
00155  
CARTON CONTENTS:  
UNPACKING INSTRUCTIONS  
Remove all parts and packing materials from carton.  
(2) Container Tops  
(1) Mounting Bracket  
Fold flaps to inside of carton and turn carton upside-  
down on floor of work area. To protect grass catcher  
cover during assembly place cover upsidedown on  
overturned carton.  
(2) Container Bottoms (1) Cover Assembly  
(1) Upper Chute  
(1) Lower Chute  
(1) Support Post  
(1) Cover Seal  
(1) Bag of Parts  
(1) Owner's Manual  
(2) Wheel Weights  
Check carton contents against list. Be sure all parts  
are there.  
NOTE: For ease of assembly, aside of your work area, lay out all hardware in the following groups. Each step of the as-  
sembly instructions will identify the group needed for that step.  
BAG OF PARTS CONTENTS  
ASSEMBLY  
LOCATION  
HARDWARE SHOWN ACTUAL SIZE  
GROUP "A"  
MOWER  
DECK  
BAFFLE  
(1) Bolt 3/8-16 x 1-1/4  
(1) Locknut 3/8-16  
GROUP "B"  
GROUP "C"  
REAR  
MOUNTING  
BRACKET  
TO  
DRAW BAR  
(4) Shoulder Bolt Self Tapping  
SUPPORT  
POST  
TO  
CONTAINER  
SUPPORT  
(3) Carriage Bolt 5/16 - 18 x 3/4  
(3) Locknut 5/16-18  
4
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BAG OF PARTS CONTENTS (continued)  
GROUP "D"  
SUPPORT  
POST  
(1) Bracket Support Pin  
TO  
MOUNTING  
BRACKET  
(1) Retainer Spring  
(3) Tubing End Caps  
GROUP "E"  
LOWER  
CHUTE  
ASSEMBLY  
TO  
MOWER  
DECK  
(1) Wing Nut  
(1) Washer 13/32 x 1 x 16 Ga.  
GROUP "F"  
CHUTE  
LATCH  
ASSEMBLY  
to  
(1) Screw #10 x 1-1/8  
(1) Spacer, Split #10  
UPPER  
CHUTE  
(2) Washer 3/16 x 3/4 x 16 Ga.  
(1) Nut, Acorn #10  
(1) Rubber Latch  
GROUP "G"  
CHUTE  
LATCH  
ASSEMBLY  
to  
LOWER  
CHUTE  
(1) Washer, Lock #10  
(1) Washer 3/16 x 3/4 x 16 Ga. (1) Nut, Weld #10  
(1) Screw #10 x 5/8  
GROUP "H"  
**ITEMS NOT SHOWN FULL SIZE**  
WHEEL  
WEIGHTS  
TO  
FRONT  
WHEELS  
(2) "U" Bolt  
(4 ) Locknut  
5
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ASSEMBLY  
PARTS IDENTIFICATION  
COVER  
UPPER CHUTE  
DUMP  
BAGGER  
INDICATOR  
.
.
GRASS  
CATCHER  
CONTAINERS  
CHUTE LATCH  
.
.
.
LOWER CHUTE  
LOWER CHUTE  
ATTACHING  
WING NUT  
WHEEL WEIGHT  
U-BOLT  
NOTE: When right hand (R.H.) and left hand (L.H.) are mentioned in this manual, it means when you are seated on the  
tractor, in the operator's position.  
(1) 3/8" Wrench  
(1) Drive Ratchet  
(1) 1/2" Wrench  
(2) 9/16" Wrenches  
(1) 1/2" Socket  
(1) 3" or longer Extension  
(1) Short Handle  
THESE ARE THE TOOLSYOU WILL NEED TO AS-  
SEMBLEYOUR GRASS CATCHER:  
Phillips Screwdriver  
(1) 9/16" Deep well Socket  
CAUTION: BEFORE ASSEMBLING GRASS CATCHER TO TRACTOR:  
Depress clutch/brake pedal fully and set parking brake.  
Place gearshift/motion control lever in neutral (N) position.  
Place attachment clutch in "DISENGAGED" position.  
Turn ignition key "OFF" and remove key.  
Make sure the blade and all moving parts have completely stopped.  
Disconnect spark plug wire from spark plug and place wire where it cannot come in contact  
with plug.  
6
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MOWER DECK BAFFLE (See Fig. 1)  
Use Hardware - - GROUP "A"  
COVER SEAL (See Fig. 3)  
No hardware required  
1
3
1. Raise your tractor mower deck to its highest position.  
1. Align mark on seal with mark at cover opening.  
2. Install the hex bolt, and locknut through mower deck  
baffle and tighten securely.  
2. Work seal into opening so cover sits between flanges  
of seal.  
HEX BOLT  
ALIGNMENT  
MARKS  
LOCKNUT  
02085  
MOWER DECK BAFFLE  
02342  
FIG. 1  
COVER SEAL  
FIG. 3  
REAR MOUNTING BRACKET  
(See Figs. 2A & 2B)  
NOTE: If your tractor already has four (4) shoulder bolts  
installed on the rear drawbar, simply hang the mounting  
bracket, lanced tabs towards bottom, on the bolts. Discard  
hardware group "B" and disregard the remaining Step 2  
instructions.  
2
SUPPORT POST (See Fig. 4)  
Use Hardware - - GROUP "C"  
4
CAUTION: Container support is spring  
loaded and locked to the cover. Handle  
cover assembly carefully so as not to  
unlatch the cover from the container  
support.  
1. Rotate cover assembly onto its side as shown.  
2. Assemble support post to container support with  
the three (3) carriage bolts and locknuts. Tighten  
securely.  
SHOULDER  
BOLTS  
02  
46  
2
LANCED TABS  
TOWARD BOTTOM  
FIG. 2A  
CARRIAGE  
BOLTS  
If your tractor does not have four (4) shoulder bolts installed  
on the drawbar, follow the instructions below.  
Use Hardware - - GROUP "B"  
1. Using the four formed holes in the drawbar, install the  
four shoulder bolts as shown and tighten securely.  
2. Hangthemountingbracket,lancedtabstowardsbottom,  
on the bolts.  
SUPPORT  
POST  
SELF  
TAPPING  
SHOULDER  
BOLTS  
LOCKNUTS  
FIG. 4  
LANCED TABS  
TOWARD BOTTOM  
FIG. 2B  
7
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MOUNTING TO TRACTOR (See Fig. 5)  
Use Hardware - - GROUP "D"  
CONTAINER ASSEMBLY (See Fig. 6)  
No hardware required  
6
5
NOTE: For ease of assembly, you may wish to obtain the  
assistance of another person for mounting assembly to  
tractor.  
1. Place bottom half inside of top half, as shown.  
2. Place one foot inside bottom half and lift top half to  
meet bottom half.  
3. Press halves tightly together while lifting top to lock  
into place as shown.  
IMPORTANT:BEFORELOCKINGTHETABS,HOOKEDEDGES  
ONBOTHHALVESMUSTOVERLAPTOFORMSEALASSHOWN  
IN INSET.  
1. Raise seat on tractor to allow assembly to be  
mounted.  
2. With cover closed, lift assembly and place support  
post inside mounting bracket. Allow assembly to rest  
on lanced tabs of mounting bracket.  
3. Line up holes in mounting bracket with holes in support  
postandinsertbracketsupportpin.Securewithretainer  
spring.  
4. Repeat for other containers.  
CONTAINER  
BOTTOM HALF  
4. Unlatch and open cover.  
5. Install the three (3) tubing end caps onto container  
support.  
6. Tap each end cap onto container support tubes to seat  
securely.  
2089  
0
BRACKET  
SUPPORT PIN  
COVER ASSEMBLY  
CONTAINER  
TOP HALF  
RETAINER  
SPRING  
PRESS TOGETHER  
TO FORM SEAL  
CONTAINER  
WHILE LIFTING  
TOP HALF  
TOP HALF  
CONTAINER  
BOTTOM  
HALF  
LOCKING  
TAB  
END CAP  
SUPPORT POST  
FIG. 6  
ASSEMBLY CHECK: Squeeze sides of lower half of con-  
tainer and check that there is no gap between upper and  
lower halves. If a gap appears, unlock tabs to separate  
container halves and repeat instructions above.  
LANCED TABS  
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MOUNTING  
BRACKET  
02097  
FIG. 5  
8
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CONTAINER MOUNTING  
(See Fig. 7)  
7
DEFLECTOR SHIELD  
No hardware required  
WASHER  
1. Install one container to left side first with warning to  
outside of unit. Install other container to right side.  
MOWER DECK  
BAFFLE  
NOTE:Rightcontainershouldalwaysoverlapleftcontainer  
at center support.  
2. Close cover and lock latch handle over center support  
tube.  
COVER LATCH  
HANDLE  
HEX BOLT  
WING NUT  
FIG. 8  
CONTAINER  
WARNING  
W
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CHUTE LATCH ASSEMBLY  
(See Fig. 9)  
CONTAINER  
HANDLE  
9
Use Hardware - - GROUPS "F & G"  
CENTER  
SUPPORT  
TUBE  
1. Assemble latch pin to upper chute, as shown.  
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2. Press weld nut into rubber latch and assemble rubber  
latch to lower chute, as shown.  
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3. Tighten all hardware securely.  
CONTAINER  
WARNING  
2082  
0
WASHERS  
3/16 X 3/4 X 16  
FIG. 7  
#10 X 1-1/8" SCREW  
GA.  
SPLIT  
SPACER  
UPPER CHUTE  
ACORN NUT  
LOWER CHUTE (See Fig. 8)  
Use Hardware - - GROUP "E"  
8
1. Raise and hold deflector shield in upright position.  
#10 X 5/8"  
SCREW  
RUBBER  
LATCH  
2. Slide back edge of chute over rear corner of mower  
deck and pivot forward.  
3. Align slot in lower chute with hex bolt in mower deck  
baffle and close chute over deck openning.  
4. Secure with washer and wing nut.  
LOWER CHUTE  
WELD  
NUT  
0
CAUTION: Do not remove discharge  
guard from mower. Raise and hold  
guard when attaching lower chute  
and allow it to rest on chute while in  
operation.  
WASHER  
3/16 X 3/4 X 16 GA.  
2102  
LOCK WASHER  
FIG. 9  
9
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WHEEL WEIGHTS (See Fig. 11)  
Use Hardware - - GROUP "H"  
UPPER CHUTE (See Figs. 10A & 10B)  
10No hardware required  
11  
1. Lower mower deck to its lowest cutting position.  
1. Assemble wheel weights and U-bolts onto the outside  
of front wheels and hold in position.  
2. Fasten locknuts onto U-bolts on the inside of wheel  
and tighten securely.  
2. Assemble upper chute by inserting curved end into  
hole in back of cover.  
NOTE: Handle carefully so as not to damage dump bag  
indicator.  
3. Push in and turn upper chute until it is in line with lower  
chute.  
FRONT WHEEL  
LOCKNUTS  
4. Align the bosses on lower chute with alignment slots  
on upper chute and slide together.  
WHEEL WEIGHT  
5. Secure with rubber latch by hooking hole in latch over  
latch pin.  
U-BOLT  
FIG. 11  
HANDLE  
DUMP BAGGER  
INDICATOR  
UPPER  
CHUTE  
COVER  
LEVEL MOWER DECK  
12No hardware required  
Besuredeckisproperlyleveledforbestmowerperformance.  
See your tractors owner's manual for instructions.  
0
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CHUTE  
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FIG. 10A  
ALIGNMENT  
SLOTS  
LATCH PIN  
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LATCH  
BOSSES  
FIG. 10B  
10  
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OPERATION  
Avoid cutting wet grass or in the morning while the dew  
TIPS FOR IMPROVED BAGGING  
OPERATION:  
is still heavy. Grass clippings collected under these  
conditions tend to be sticky and adhere to the walls of  
the flow path causing clogging.  
Follow the mower operation instructions in your tractor  
owner's manual.  
Your bagger is equipped with a dump bag indicator.As  
the bags become full, the flow indicating ball will drop  
down in its slot, indicating that the bags are full or the  
chutes have become clogged. Care should be taken  
not to damage the parts and that the ball moves freely  
at the beginning of each use.  
When operating your grass catcher on a lawn where grass  
and leaf bagging equipment has not been used, you are  
picking up thatch and debris that has accumulated for long  
periods of time. The amount collected and the total time  
of operation may be greater than you will experience with  
regular use of your grass catcher.  
NOTE: To help prevent clogging of chutes, check/empty  
bags when ball begins to drop down in the slot.Experience  
will teach you the best time to empty the bags.  
Always run throttle at full speed when bagging.  
Select a gear low enough to give good mower cutting  
performance, good quality cut and good bagging  
performance.  
If the grass catcher fails to pick up cut grass or leaves,  
it is an indication that clogging has occurred in the  
system or that the grass catcher containers are full.  
a. Disengage blades, shift into neutral, engage the  
parking brake and stop the engine.  
NOTE: It may be necessary to overlap width of cut to suit  
your conditions.  
- Raise seat. Unlatch and raise cover.  
- Slide out containers and dispose of clippings .  
- Replace containers, close cover, and latch.  
b. Unlatch chutes and check for clogging  
- Remove all debris in chutes.  
If grass is extremely tall, it should be mowed twice.The  
first time relatively high, the second time to desired  
height.  
Use left hand side of mower for trimming.  
Plastic trash bags can be inserted inside grass catcher  
containers for ease of debris disposal. To remove the  
plastic trash bags when full:  
a. Disengage blades, shift into neutral, engage the  
parking brake and stop the engine.  
- Reassemble and latch chutes  
c. Checktoinsuredumpbagindicatorhasnotbecome  
clogged.  
b. Raise seat. Unlatch and raise cover.  
- The air passage hole must be clear of debris.  
Gentlyinsertasmalltwigorwireintopassageway  
to clear.  
c. Remove one container at a time by grasping  
container handles and pulling toward the rear, off  
of the tube rails.  
d. With the container resting on the ground, close  
and secure the top of the plastic lawn bag.  
CAUTION  
e. Tip the container on its side and slide the filled bag  
from the container.  
f. Install a new plastic lawn bag with the edges of the  
bag draped over upper lip of the container.  
g. Repeat for other containers.  
h. Reinstall containers making sure right container  
overlaps left container at center supports.  
• Do not operate mower with grass catcher  
partially installed.  
• Disengage blades and stop engine before  
leaving tractor seat to empty containers,  
unclogging chutes, etc.  
• Close cover before starting.  
j. Closecoverandsecurelatchesovercentersupport  
tubes.  
• Disengage mower when crossing driveways  
or gravel surfaces and other areas where  
thrown objects could be a hazard.  
• Do not attempt to vacuum up cans or other  
potentially hazardous projectiles.  
11  
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CUSTOMER RESPONSIBILITIES  
STORAGE  
GENERAL RECOMMENDATIONS  
When grass catcher is to be stored for a period of time,  
clean it thoroughly, remove all dirt, grass, leaves, etc.Store  
in a clean, dry place.  
Always observe safety rules when performing any main-  
tenance.  
Before each use check for loose fasteners.  
Clean unit thoroughly after each use.  
CAUTION: Donotleavegrassinbagger  
containers. Emptycontainersaftereach  
useandbeforestoring. Failuretodoso  
mayresultinspontaneouscombustion  
which could develop into a fire.  
BLADE CARE  
Forbestresultsmowerbladesmustbekeptsharp. Replace  
bent or damaged blades.  
See BLADE CARE instructions in your tractor owner's  
manual.  
CAUTION:BEFOREPERFORMINGANY  
MAINTENANCE,SERVICEORADJUST-  
MENTS:  
Depress clutch brake pedal fully and  
set parking brake.  
Place gearshift/motion control lever in  
"NEUTRAL" position.  
Placeclutchcontrolin"DISENGAGED"  
position.  
Turn ignition key to "OFF" position.  
Make sure blades and all moving parts  
have completely stopped.  
Disconnect spark plug wire(s) from  
spark plug(s) and place wire where it  
cannot come in contact with plug.  
CAUTION: Grass catcher components  
are subject to wear, damage and  
deterioration, which could expose  
moving parts or allow objects to be  
thrown. Frequentlycheckcomponents  
and replace with manufacturer's  
recommended parts, when necessary.  
12  
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NOTES  
13  
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REPAIR PARTS/PIÈCES DE RECHANGE  
GRASS CATCHER - MODEL NUMBER CR38C / RAMASSE-HERBE - - NUMÉRO DE MODÈLE CR38C  
PRODUCT NUMBER 954 04 04-01 / NUMÉRO DE PRODUIT 954 04 04-01  
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39  
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REPAIR PARTS/PIÈCES DE RECHANGE  
GRASS CATCHER - MODEL NUMBER CR38C / RAMASSE-HERBE - - NUMÉRO DE MODÈLE CR38C  
PRODUCT NUMBER 954 04 04-01 / NUMÉRO DE PRODUIT 954 04 04-01  
DESCRIPTION  
DESCRIPTION  
k #10-24  
KEY PART  
NO. NO.  
DESCRIPTION  
DESCRIPTION  
KEY PART  
NO. NO.  
ercle  
Entretoise de couv  
ercle C.D.  
Ressort de couv  
Poteau de soutien  
Écrou frein 5/16-18  
ue  
Ressort de reten  
r
Spacer, Cove  
Spring, Cove  
Post, Suppor  
22 532133235  
23 532132983  
24 532127720  
25 873800500  
26 532124670  
27 872110506  
28 532170053  
29 532170165  
30 532131137  
31 532174083  
ant #10-24  
ercle  
Écrou auto-serr  
Grillage de couv  
Nut, Crownloc  
2
3
4
532069180  
532127533  
532171061  
r R.H. (gray)  
t
er  
Screen, Cov  
.
Couvercle Ens  
ly  
Cover Assemb  
y No. 3,38,39)  
Locknut 5/16 x 18  
Spring, Retainer  
(Y combris 3,38,39)  
(Includes Ke  
ieure  
Glissière supér  
Vis spéciale  
Chute, Upper  
Screw, Special  
Dump Bag Indicator  
5
6
7
532139569  
818021008  
532140572  
iot 5/16-18 x 3/4  
Boulon de char  
5/16-18 x 3/4  
Carriage Bolt,  
Bracket, Mounting  
Shoulder Bolt  
Support de montage  
Boulon  
Goupille du poteau de soutien  
xtrémité de  
Chapeau de l’e  
au  
tuy  
Cadre de ramasse-herbe  
Goupille de char  
ercle  
Garniture de couv  
Indicateur de sac de  
déchargement  
Vis #10-24 x 1-1/8  
Rondelle 3/16x3/4x16 J  
Entretoise fendue  
Écrou borgne #10-24  
Rondelle frein  
Loquet de glissière  
Axe du loquet  
Boulon H 3/8-16 x 1-1/4  
Rondelle 13/32x1x16 J  
Écrou frein 3/8-16  
Post  
Pin, Support  
Screw, #10-24 x 1-1/8  
Washer 3/16x3/4x16 Ga.  
Spacer, Split  
Nut, Acorn #10-24  
Washer, lock  
Latch, Chute  
Nut, Weld  
Bolt, Hex 3/8-16 x 1-1/4  
Washer 13/32x1x16 Ga.  
Locknut 3/8-16  
8
9
532087175  
819061216  
Plug, Tubing End  
a.  
10 532007206  
11 532060867  
12 810071000  
13 532109808  
14 532125004  
15 874930620  
16 819131616  
17 873930600  
18 532132807  
19 532135651  
20 871081010  
21 532132796  
Bagger, Frame  
Pin, Hinge  
32 532126919  
33 532128600  
34 532127534  
35 532183286  
36 532129586  
38 532130895  
nière  
r
Gasket, Cove  
ieur  
Conteneur supér  
érieur  
p
Container, To  
Conteneur inf  
Poignée de loquet de  
ercle  
Container, Bottom  
, Cover  
Latch Handle  
a.  
couv  
Bande  
Écrou frein 3/8-16  
Étrier  
Strip, Reinforcement  
Locknut 3/8-16  
U-Bolt  
Wheel Weight  
ual  
Owner's Man  
39 532155042  
41 873800600  
42 532137031  
43 532123635  
rieure  
Glissière infé  
r
Chute, Lowe  
Écrou à oreilles 3/8-16  
Vis #10-24 x 5/8  
ercle C.G.  
Ressort de couv  
Wingnut 3/8-16  
Screw #10-24 x 5/8  
Poids de roue  
r L.H. (black)  
Spring, Cove  
iétaire  
Manuel du pror  
532140602  
02480  
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