Husqvarna Vacuum Cleaner 540200800 User Manual

Z2-7 Collection System  
Models: 540200800  
Operator’s Manual  
Parts Manual  
Please read these instructions carefully and make  
sure you understand them before using the machine.  
MANUAL NO. 540200855 REV 3 (04/14/03)  
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Operators Guide  
Specifications  
Auxiliary Engine (For Gen I and Gen II Units Only)  
Height  
42 in. (107 cm.)  
31 in. (79 cm.)  
39 in. (99 cm.)  
63 in. (160 cm.)  
Length  
Width (without engine mount or vacuum assembly)  
Width (with engine mount and vacuum assembly)  
Engine Options  
5.5 hp Briggs & Stratton Intek  
6 hp Kohler  
Weight (without vacuum assembly)  
107 lb. (49 kg.)  
172 lb. (78 kg.)  
Weight (with 6 hp Kohler vacuum assembly)  
Capacity  
Hose  
8.5 cu ft (7 bu. or 0.24 m3)  
7 in. (18 cm.) upper and lower  
Spindle Drive (For Gen II, iZ and Mini Units Only) (Will Not Fit on 72” Decks)  
Height  
42 in. (107 cm.)  
31 in. (79 cm.)  
39 in. (99 cm.)  
65 in. (165 cm.)  
Length  
Width (without hose or blower)  
Width (with hose and blower)  
Deck Options  
42”  
48”  
52”  
61”  
Weight (without spindle drive/blower assembly)  
95 lb. (43 kg.)  
Weight (with spindle drive/blower assembly)  
155 lb. (70 kg.)  
Capacity  
Hose  
8.5 cu ft (7 bu. or 0.24 m3)  
7 in. (18 cm.) upper and lower  
3
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Operators Guide  
Features and Controls (Auxiliary Engine)  
TopAssembly  
Latch  
Inlet  
Heat  
Shield  
Upper Hose  
Front Weight  
Front Weight  
Bar  
Gas  
Spring  
Boot  
Container  
Lower  
Hose  
Frame  
Vacuum  
Assembly  
Engine  
Mount  
4
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Operators Guide  
Features and Controls (Spindle Drive)  
TopAssembly  
Latch  
Inlet  
Heat  
Shield  
Hose  
Front Weight  
Front Weight  
Bar  
Gas  
Spring  
Container  
Fan  
Assembly  
Frame  
Hitch  
Hose  
Support  
5
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Operators Guide  
General Information  
This manual will assist you in the safe operation and proper maintenance of your Husqvarna  
equipment. Read it thoroughly before attempting to operate the machine. Call your dealer or  
Husqvarna if additional information is required.  
The following safety symbols are used throughout the manual to alert you to information about  
unsafe actions or situations:  
DANGER indicates immediate hazards that may result in severe injury or death  
WARNING indicates unsafe actions or situations that may cause severe injury, death and/or major  
equipment or property damage.  
CAUTION indicates unsafe actions or situations that may cause injury, and/or minor equipment or  
property damage.  
This equipment should not be modified without the manufacturer’s prior written authorization. Doing  
so may not only affect the equipments’ performance and durability, but also create safety hazards for  
the operator and the surroundings. Warranty will be void if changes are made to the equipment  
without the manufacturer’s prior written authorization.  
Safety Procedures  
1 - Training:  
• Read the Operator’s manual. 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’s controls, and safety signs.  
• All operators and mechanics should be trained. The owner is responsible for training the users.  
• Never let children or untrained people operate 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 themselves,  
other people, or property.  
2 - Preparation:  
• Wear appropriate clothing including hard hat, safety glasses and ear protection. Long hair, loose  
clothing or jewelry may get tangled in moving parts.  
• Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and  
wire which can be thrown by the machine.  
• Use extra care when handling gasoline and other fuels. They are flammable and vapors are  
explosive. Use only an approved container. Never remove gas cap or add fuel with engine running.  
Allow engine to cool before refueling. Do not smoke. Never refuel or drain the machine indoors.  
• Check that operator’s controls, safety switches, hoses, and shields are securely attached and  
function properly. Do not operate unless they are functioning properly.  
6
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Operators Guide  
3 - Operation  
Never run an engine in an enclosed area.  
• Only operate in good light, keeping away from holes and hidden hazards.  
• Slow down and use extra care on hillsides. Make turns gradually and at slow speed. Do not  
operate across the sides of slopes. Operate up and down slopes only. Do not operate on steep  
slopes.  
• Turf conditions can affect the machine’s stability. Do not operate on wet grass where traction may  
be reduced.  
• Do not change the engine governor setting or overspeed the engine.  
• Stop equipment and inspect vacuum impellar and hoses after striking objects or if an abnormal  
vibration occurs. Make necessary repairs before resuming operations.  
• Look behind and down before backing up to be sure of a clear path.  
• Slow down and use caution when making turns and crossing roads and sidewalks. Stop vacuum  
and mower blades if not mowing.  
Do not operate machine under the influence of alcohol or drugs.  
Use care when loading or unloading the machine into a trailer or truck.  
Use care when approaching blind corners, shrubs, trees. or other objects that may obscure vision.  
4 - Maintenance and Storage:  
Stop engine and disconnect spark plug wire. Wait for all movement to stop before adjusting,  
cleaning, or repairing.  
Clean grass and debris from muffler and engine to help prevent fires. Clean up oil or fuel spillage.  
Let engine cool before storing and do not store near flame.  
Shut off fuel while storing. Do not store fuel near flames or drain indoors.  
Never allow untrained personnel to service machine.  
Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine  
running.  
Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged  
decals.  
7
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Operators Guide  
Unpacking Instructions  
1. Wear gloves and eye protection.  
2. Cut straps around carton and remove top.  
3. Take hoses out of carton.  
4. Remove wood pieces. NOTE: Watch for nails and wood splinters.  
5. Slide carton sleeve out of bottom tray and lift over Z2-7  
Assembly Instructions  
1. Attach hitch to unit (see hitch instructions).  
2. Mounting the Z2-7  
Hitch  
Tools Required:  
None  
Wire Lock  
Pin  
Frame  
1. Slide the Z2-7 Frame into the Hitch.  
2. Line up through holes in the Hitch and Z2-7 Frame and secure with two (2) 3/8” wire lock pins.  
8
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Operators Guide  
Assembly Instructions (continued)  
3. Attaching the Heat Shield  
Heat  
Shield  
Tools Required:  
1/2” Wrench  
1/2” Socket  
Ratchet  
1. Locate two (2) holes in top corner brace plates of  
Hitch.  
2. Aligning holes in bottom of Heat Shield, place Heat  
Shield onto Hitch.  
3. Secure Heat Shield to Hitch using two (2) 5/16”-18  
x 1” hex bolts, four (4) 5/16” flat washers, and two  
(2) 5/16” nylon lock nuts.  
Hitch  
If installing a spindle drive assembly, skip to step 5.  
9
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Operators Guide  
Assembly Instructions (continued)  
4. Attaching the Engine Mount and Vacuum Assembly  
Vacuum  
Assembly  
Tools Required:  
1. Ratchet  
2. 1/2” Socket  
3. 1/2" Wrench  
4. 9/16” Wrench  
5. 9/16” Socket  
6. 7/16” Socket  
Frame  
Inlet  
Cover  
7. Socket Extension  
Engine Mount  
1. Slide the Engine Mount into the Frame as shown.  
2. Place the Vacuum Assembly on the Engine Mount and secure it tightly with four (4) 5/16” x 1-1/2”  
hex bolts and four (4) 5/16” nylon lock nuts.  
3. Slide the Engine Mount into the Frame so that the Vacuum Assembly is as close to the Frame as  
as possible.  
4. Adjust the Engine Mount to the nearest aligning holes between the Frame and the Engine Mount.  
5. Secure the Engine Mount to the Frame with two (2) 3/8” x 2-1/2” hex bolts, two (2) 3/8” hex nylon  
lock nuts, and four (4) 3/8” flat washers.  
6. Place the Inlet Cover on the VacuumAssembly with the inlet cylinder pointing downward and  
forward toward the mower deck.  
7. Secure the Inlet Cover with six (6) 1/4” flat washers and six (6) 1/4” nylon lock nuts.  
NOTE: Auxiliary Engine kits contain a remote throttle cable that is not used with the Z2-7.  
10  
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Operators Guide  
Assembly Instructions (continued)  
5. Attaching a Spindle Drive Assembly  
1. Remove the discharge chute.  
12. Rest the fan assembly onto the deck end and  
slide the pilot thru the 5/8” hole previously  
mentioned so that fan assembly is supported  
by the pilot and the ¼” stop block welded under  
the clamp at the front of the fan assembly.  
Note: It may be necessary to swing the  
idler pulley away from the assembly  
mounting face to clear the chute mounting  
bar and the discharge chute mounting tab  
on the deck.  
2. Remove the right hand belt shield.  
3. Remove the deck belt from the right spindle  
assembly sheave.  
4. Remove this sheave but keep the ¼” square  
key and the two washers at hand for reinstal-  
lation.  
5. Install the Stepped Sheave and spacer/key  
retainer included in the kit using the original  
key and washers but substituting the original  
7/16” HCS with the longer version provided. 13. Reinstall the clamp at the front of the assembly  
An application of anti-seize is recommended.  
6. Reinstall the deck belt.  
7. The 5/8” hole toward the rear of the ¼” thick  
discharge chute mounting bar at the right end  
so that the tab at the lower end of the clamp  
passes thru the rectangular slot at the right  
front corner of the mower deck, but leave the  
fastener loose to ease belt installation.  
of the deck may be distorted from forming or 14. Rotate the belt idler as far forward as possible  
loaded with paint. Drill out or fill this hole until  
it will accept a 5/8” bolt or piece of bar stock.  
Keep the fit close.  
and install the belt over the top groove of the  
new deck sheave.  
15. Tighten the clamp fastener.  
8. If any weld beads or the edge of the deck top 16. Using a scribe or other small sharp object,  
project past the right end surface of the deck,  
these must be ground back to allow the fan  
assembly to fit up flush to the end of the deck.  
9. Remove the 3/8” fastener, nut, and clamp from  
the inside front corner of the fan assembly.  
10. Remove the sheave floor to expose the fan  
assembly belt sheave from below.  
transfer the mounting hole location at the rear  
edge of the fan assembly onto the mating  
vertical surface at the right rear of the mower  
deck and drill thru with a 25/64” drill.  
17. Install the stops on the deck stop pins located  
at the rear of the deck then install the new belt  
shield.  
11. Loosen the nut retaining the belt guide/retainer, 18. Install the tube support to the main collection  
install the belt from the Drive Kit, retighten the  
nut, verify the belt clears the guide, and  
reinstall the sheave floor.  
assembly using the 3/8” fastener provided, po-  
sitioning so that the tube is 2” to 3” away from  
the tire.  
19. Install the 7” hose to the fan assembly and the  
container input port using the hose clamps  
provided.  
20. Clamp the tube to the tube support.  
11  
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Operators Guide  
Assembly Instructions (continued)  
6. Hose Attachment  
NOTE: Hoses may need to be trimmed to fit. If necessary, see the Hose Trimming section at the end  
of theAssembly Instructions.  
Tools Required: Flat screwdriver  
1. Slide one hose clamp over each end of the 54" Lower Hose. Slide one end of the hose  
over the Vacuum Inlet Cover and the other end over the Boot discharge opening.  
Tighten the hose clamps to secure hose in place.  
2. Slide one hose clamp over each end of the 48" Upper Hose. Slide one end of the hose  
over the Vacuum discharge. Slide the other end over the Container Inlet, ensuring  
that the red decal on the inlet is completely covered by the hose. Tighten the hose clamps  
to secure the hose.  
7. Hose Trimming  
Tools Required: Utility Knife  
1. Carefully measure the length needed. Remember that although the hose is flexible, it will  
not stretch.  
2. Measure the same length on the hose that needs to be trimmed, and with the utility knife,  
cut through the webbing at the proper location.  
3
Continue that cut through the webbing all the way around the hose so that it finishes just  
across the support coil from where the original cut was started.  
4. Use the utility knife to score the support coil between the beginning and end of the web  
cut. Set aside the knife, and finish breaking the coil by hand by working the scored  
portion back and forth until it breaks apart.  
12  
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Operators Guide  
Auxiliary Engine Vacuum Assembly  
Servicing the Engine  
1. Make sure that engine oil is at engine manufacturer’s recommended level (refer to engine  
manual).  
2. Fill the fuel tank. Use fresh, clean, unleaded automotive gasoline.  
Pre-Start Check  
1. Make sure the stop switch is in the OFF position and spark plug wire is disconnected.  
Pull the starter rope slowly to make certain there are no foreign objects in the blower  
housing.  
2. Be sure the spark plug wire and cover are attached to the spark plug.  
Starting the Engine  
1. Turn the stop switch to the ON position.  
2. Move the choke lever to the FULL CHOKE position.  
3. Move the throttle lever to the FULL THROTTLE position.  
4. Grasp the starter handle firmly. Pull the handle with a rapid continuous motion.  
5. When the engine starts, move the choke to 1/2 choke and then to NO CHOKE position  
Operating the Vacuum  
1. NEVER USE THE Z2-7 WITHOUT THE INLET COVER AND ALL HOSES  
SECURELY ATTACHED.  
2. Make sure both hoses are connected at both ends. Inspect hoses prior to each use.  
3. Do not use the Z2-7 on slopes greater than 15 degrees.  
4. The mower must be running in order to vacuum debris through the mower deck.  
5. In heavy grass it may be necessary to mow and vacuum at a slower ground speed.  
6. Never attempt to unclog the Z2-7 until both the mower’s engine and vacuum’s engine  
have been shut off and all moving parts have come to a complete stop.  
7. Do not stand behind the vent at the rear of the Z2-7 due to the potential for small  
pieces of blowing debris to escape through this vent.  
8. Be sure to wear eye and ear protection.  
9. TO STOP THE ENGINE: throttle down to slow for a few seconds, then push switch to  
OFF. Remove any hearing protection and listen for all moving parts to come to a  
complete stop. The flywheel in the power head will coast for a few seconds after the  
engine is shut off before actually stopping.  
13  
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Maintenance and Service Instructions  
Cleaning and Washing  
Regular cleaning, washing, and lubricating will prolong the service of the machine.  
NOTE: Use care with power washers to avoid damage to decals. Limit direct spray on  
these items.  
DO NOT EXCEED 1000 PSI WATER PRESSURE FOR CLEANING.  
For best results, clean exhaust screen inside container regularly. Instructions for  
doing this can be found in the Service section of this manual.  
Storage  
1. Refer to engine manufacturer’s instructions for engine storage information.  
2. Clean machine.  
3. Cover all scratches with touch-up paint.  
4. Covered or indoor storage is recommended.  
Preventative Maintenance Schedule  
Item  
Before  
Each Use  
Every  
5 Hours  
Every  
25 Hours  
Every  
50 Hours  
Check Engine Oil Level  
Change Engine Oil  
X
X
X
X
ChangeAir Cleaner Element  
Replace Spark Plug  
X
Inspect/Clean Exhaust Screen  
Check/Tighten Nuts & Bolts  
Check/Tighten Hoses  
Turn Hose End to End  
Rotate Hose  
X
X
X
X
X
X
X
Clean Machine  
14  
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Maintenance and Service Instructions  
Engine Service and Maintenance  
Follow the engine manufacturer’s maintenance instructions. Should any malfunction occur with the  
engine during the warranty period, take it to an Authorized Service Dealer. DO NOT tear down the  
engine, as this may void the Engine Manufacturer’s Warranty.  
NOTE: Refer to engine manufacturer’s owner’s manual for all engine service information.  
Caring For Vacuum Hoses  
1. Inspect hoses before each use. If hoses have excessive wear, tears, or punctures, replace  
immediately.  
2. To prolong the life of the hose, periodically rotate hose and turn hose end to end. Refer  
to Preventative Maintenance Schedule in this manual.  
3. Avoid twists and sharp turns in the hoses, as they will increase wear on the hoses.  
4. Avoid dragging the lower hose along the sides of buildings or other hard surfaces.  
Cleaning Exhaust Screen  
To assist with “blowout” problems that will develop when air cannot exit the containers, the rubber flap  
bolted to the upper surface of the steel top insert (right rear corner) is designed to open if the top  
assembly is otherwise clogged.  
If the rubber flap opens, it will release debris behind the vacuum system. While the containers will  
typically continue to fill, this is an indication that the top insert needs to be cleaned.  
To clean the top insert:  
1. Shut off all engines.  
2. While wearing gloves, open the top, remove the containers, and reach in and up to wipe debris off  
the expanded metal openings inside the top assembly.  
3. A household water hose can also be used to assist in the cleaning process, but the unit should be  
allowed to dry as the moisture may cause clogging to occur more quickly during operation.  
15  
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Maintenance and Service Instructions  
Trouble Shooting Guide  
! DANGER !  
Before servicing unit wait for all moving parts to come to a complete stop. Turn engine off and remove  
the spark plug wire.  
PROBLEM  
POSSIBLE CAUSE  
CORRECTION  
Engine Does Not Start. 1. Spark plug wire disconnected.  
1. Reconnect wire.  
2. Engine ON/OFF switch in OFF position. 2. Put switch in ON position.  
3. Fuel tank empty.  
4. Stale gasoline.  
3.Add gasoline.  
4. Drain gasoline and add fresh  
gasoline.  
5. Dirty air filter.  
5. Clean or replace.  
Engine Runs Poorly.  
1. Bad spark plug.  
2. Dirty air filter.  
1. Inspect spark plug.  
2. Clean or replace.  
3. Incorrect choke setting.  
4. Stale gasoline.  
3. Put choke in correct setting.  
4. Drain gasoline and add fresh  
gasoline.  
5. Dirt or water in fuel tank.  
5. See engine service dealer.  
Engine Overheats.  
Loss of Vacuum.  
1. Carburetor out of adjustment.  
2. Oil level is low.  
1. See engine service dealer.  
2. Check and add oil.  
1. Vacuum inlet clogged.  
2. Container full.  
3. Engine not reaching full RPM.  
1. Remove hose and clean inlet.  
2. Inspect and empty.  
3. See “Engine Runs Poorly”  
above.  
4. Fan blades bent or broken.  
1. Solid object jammed in unit.  
4. Replace/repair impeller.  
Unusual vibration  
or noise.  
1. Check and remove any  
obstruction.  
2. Engine cylinder shaft or crankshaft  
bent or damaged.  
3. Loose engine mounting bolts/nuts.  
4. Loose or missing bolts on unit.  
5. Engine shaft bearings damaged.  
2. See engine service dealer.  
3. Tighten bolts/nuts.  
4. Tighten or replace bolts.  
5. See engine service dealer.  
16  
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Replacement Parts  
540200800 Assembly  
1
3
2
4
5
ITEM  
PART NO.  
540200853  
540093817  
540092531  
540092767  
540200854  
540200855  
540099693  
540093961  
540099077  
540000413  
540099079  
DESCRIPTION  
QTY.  
1
2
3
4
*
*
5
*
Frame/TopAssembly  
Container, 30 Gal.  
Front Weight  
Heat Shield  
Small Parts Kit, including:  
Manual  
Pin, Wire Lock  
Ear Plugs  
Bolt, Hex, 5/16”-18 x 1”  
Washer, Flat, 5/16”  
Nut, Hex, Nylon Lock, 5/16”-18  
1
2
3
1
1
1
2
1
2
4
2
*
*
*
* Not shown  
17  
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Replacement Parts  
540200853 Top/Frame Assembly  
9
10  
3
7
8
4
1
6
5
2
ITEM  
PART NO.  
DESCRIPTION  
QTY.  
1
2
3
4
5
6
7
8
9
540092704  
540200849  
540001765  
540099065  
540099015  
540099079  
540099082  
540099102  
540104804  
540200027  
Gas Spring  
Frame  
Bolt, Hex, 3/8”-16 x 3”  
Nut, Hex, Nylon Lock, 3/8”-16  
Bolt, Hex, 5/16”-18 x 1-1/2”  
Nut, Hex, Nylon Lock, 5/16”-18  
Pin, Cotter, #13  
Pin, Clevis, 5/16” x 1-1/4” w/ 2 holes  
Decal, Husqvarna  
1
1
1
1
1
1
2
1
1
1
10  
Decal, Caution List  
18  
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Replacement Parts  
540092675 Top Assembly  
1
5
10  
5
10  
6
5
2
4
3
7
11  
9
7
8
ITEM  
1
2
3
4
5
6
7
8
PART NO.  
DESCRIPTION  
Top, Plastic  
Rubber Flap  
Top Insert  
QTY.  
1
1
1
1
22  
3
19  
1
1
16  
2
540092720  
540092761  
540092754  
540092535  
540099074  
540000122  
540099072  
540092702  
540093210  
540000124  
540000134  
540093610  
540093611  
Inlet  
Washer, Flat, 1/4”  
Bolt, Hex, 1/4”-20 x 3/4”, Gd. 5  
Nut, Hex, Nylon Lock, 1/4”-20  
Latch  
9
Spring  
10  
11  
*
Bolt, Hex, 1/4”-20 x 5/8”  
Bolt, Hex, 1/4”-20 x 2”  
Weatherstripping, 1/2” x 1”  
Weatherstripping, 1/2” x 2”  
6 ft  
6 ft  
*
* Not Shown  
19  
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Replacement Parts  
540030166 6 hp Kohler Vacuum Assembly  
540030167 5.5 hp Briggs & Stratton Vacuum Assembly  
1
7
4
5
6
4
5
2
3
8
9
ITEM  
PART NO.  
540094004  
540107832  
540092705  
540099001  
540099012  
540099027  
540099002  
540094082  
540200027  
540097081  
540097055  
540094251  
540099015  
540099079  
540099072  
540099074  
DESCRIPTION  
QTY.  
1
2
3
4
5
6
7
*
*
*
*
*
Blower Housing  
Impeller  
Inlet, Blower Housing  
Washer, Spring, 5/16”  
Bolt, Hex, 5/16”-24 x 3/4”  
Screw, Set, 3/8”-24 x 3/8”  
Key, Square, 3/16” x 3/16” x 1-3/4”1  
Decal, Hot Surfaces  
1
1
1
5
5
2
1
1
2
1
1
4
4
6
6
Decal, Caution List  
Screw, muffler deflector (Kohler only)  
Deflector, exhust (Kohler only)  
Hardware Kit, including:  
Bolt, Hex, 5/16”-18 x 1-1/2”  
Nut, Hex, Nylon Lock, 5/16”-18  
Nut, Hex, Nylon Lock, 1/4”-20  
Washer, Flat, 1/4”  
*
*
8
9
* Not Shown  
20  
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Replacement Parts  
539106782 Spindle Drive Kit, 42”  
539106783 Spindle Drive Kit, 48”  
539106784 Spindle Drive Kit, 52”  
539106785 Spindle Drive Kit, 61”  
3
7
1
2
4
5
8
6
ITEM PART NO. QTY  
DESCRIPTION  
1 ........ 539106778.....1........ 42 SHIELD W/DECALS  
.......... 539106779.....1........ 48 SHIELD W/DECALS  
.......... 539106780.....1........ 52 SHIELD W/DECALS  
.......... 539106781.....1........ 61 SHIELD W/DECALS  
2 ........ 539106739.....1........ SPACER  
3 ........ 539990629.....1........ HCS 3/8 X 2.25 USED ON 48”/52”/61”  
.......... 539976941.....1........ HCS 3/8 X 1.25 (42” ONLY)  
4 ........ 539991120 .....1........ HCS 7/16 X 2.5  
5 ........ 539106723.....1........ BELT-42  
.......... 539106724.....1........ BELT-48  
.......... 539106725.....1........ BELT-52  
.......... 539106726.....1........ BELT-61  
6 ........ 539106744.....1........ STACKED SHEAVE 42-48  
.......... 539106745.....1........ STACKED SHEAVE 52  
.......... 539106746.....1........ STACKED SHEAVE 61  
7 ........ 539976979.....1........ NUT 3/8 NYLOC  
8 ........ 539106787.....2........ STOP - USED ON 42” & 48” ONLY  
21  
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Replacement Parts  
540200817 Accessories, Auxiliary Engine  
PART NO.  
DESCRIPTION  
QTY.  
540062092  
540097154  
540097148  
540092531  
540200717  
540097076  
540099611  
540000415  
540099065  
540002004  
540000403  
540001062  
540061651  
Engine Mount  
Hose, 7” x 54”  
Hose, 7” x 48”  
Front Weight  
Small Parts Kit, including:  
Hose Clamp  
Bolt, Hex, 3/8”-16 x 2-1/2”  
Washer, Flat, 3/8”  
Nut, Hex, Nylon Lock, 3/8”-16  
Nut, Hex, Nylon Lock, #10-24  
Washer, Flat, #10  
Screw, Slotted Rd Hd, #10-24 x 3/4”  
Throttle Cable  
1
1
1
1
1
4
2
4
2
2
2
2
1
22  
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Replacement Parts  
540200671 Boot for Gen II  
540200818 Boot for Gen I  
540200941 Boot for Gen II - 72” Deck  
6
4
7
5
2
1
3
ITEM  
PART NO.  
QTY  
DESCRIPTION  
1 ........ 539200833.....1........ Boot - Gen I  
.......... 539200664.....1........ Boot - Gen II & Gen II - 72” deck  
2 ........ 539080652.....1........ Deck bracket  
3 ........ 539093814.....1........ Boot rod, 14"  
4 ........ 539099046.....4........ Washer, 5/16  
5 ........ 539099077.....2........ Bolt, 5/16-18 x 1  
6 ........ 539099079.....2........ Nut, 51/6-18, nylock  
7 ........ 539099082.....1........ Cotter pin, #13  
23  
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Replacement Parts  
540200798 Custom Kit for Mini  
HITCH  
Parts List  
540200809  
540099020  
540000415  
540099065  
540099031  
540000427  
540093082  
Hitch ................................... 1  
3/8” x 1-1/4” Hex Bolts ........ 2  
3/8” Flat Washers ............... 4  
3/8” Nylon Lock Nuts........... 2  
1/2” x 1-1/4” Hex Bolts ........ 4  
1/2” Flat Washers ............... 8  
1/2” Nylon Lock Nuts........... 4  
Hitch  
Holddown Bar  
FRONT WEIGHT BAR  
Parts List  
540200810  
540092747  
540092731  
540099065  
540001765  
540000415  
540099616  
540099668  
Front Weight Bar............. 1  
Clamp Plates .................. 2  
Holddown Bar.................. 1  
3/8” Nylon Lock Nuts ....... 4  
3/8” x 3” Hex Bolts...........4  
3/8” Flat Washer ............. 8  
#11 Cotter Pin ................. 2  
3/8” x 1” Clevis Pin .......... 2  
Front Weight  
Front Weight Bar  
Clamp Plate  
24  
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Replacement Parts  
540200792 Custom Kit for Gen II  
540200927 Custom Kit for Gen II - 72” Deck  
HITCH  
Parts List  
Hitch Spacer  
Skid Plates  
540200749 Hitch....................................1  
540099020 3/8” x 1-1/4” Hex Bolts ........4  
540000415 3/8” Flat Washers ...............8  
540099065 3/8” Nylon Lock Nuts ...........4  
540099031 1/2” x 1-1/2” Hex Bolts ........4  
540000425 1/2” Flat Washers ...............8  
540093082 1/2” Nylon Lock Nuts ...........4  
540099611 3/8” x 2-1/2” Hex Bolts ........2  
540200788 Hitch Spacer, Blk Fin. ..........2  
Hitch Spacer  
Hitch  
Nuts to Outside  
Holddown Bar  
FRONT WEIGHT BAR  
Parts List  
Front Weight  
540020255 Front Weight Bar .............. 1  
540200921 Front Weight Bar,  
72” deck ............................ 1  
540092519 Clamp Plates .................... 2  
540092731 Holddown Bar ................... 1  
540099065 3/8” Nylon Lock Nuts ......... 4  
540099113 3/8” x 3-1/2” Hex Bolts ...... 4  
540000415 3/8” Flat Washer ............... 8  
540099616 #11 Cotter Pin ................... 2  
540099668 3/8” x 1” Clevis Pin ............ 2  
Front Weight Bar  
Clamp Plate  
25  
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Replacement Parts  
540200799 Custom Kit for Gen I  
HITCH  
Parts List  
540200828 Hitch............................... 1  
540099031 1/2” x 1-1/2” Hex Bolts ... 6  
540000425 1 /2” Flat Washers ......... 12  
540093082 1/2” Nylon Lock Nuts ...... 6  
Hitch  
Locknuts to inside  
Holddown Bar  
FRONT WEIGHT BAR  
Parts List  
540020255 Front Weight Bar .................. 1  
540092519 Clamp Plates........................ 2  
540092731 Holddown Bar ....................... 1  
540099065 3/8” Nylon Lock Nuts ............ 4  
540099697 3/8” x 4-1/2” Hex Bolts .......... 4  
540000415 3/8” Flat Washer................... 8  
540099616 #11 Cotter Pin....................... 2  
540099668 3/8” x 1” Clevis Pin ............... 2  
Front Weight  
Front Weight Bar  
Clamp Plate  
26  
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Replacement Parts  
540200942 Custom Kit for iZ  
HITCH  
Parts List  
540200809  
540099020  
540000415  
540099065  
540099031  
540000427  
540093082  
Hitch .................................... 1  
3/8” x 1-1/4” Hex Bolts ......... 2  
3/8” Flat Washers ................ 4  
3/8” Nylon Lock Nuts............ 2  
1/2” x 1-1/4” Hex Bolts ......... 4  
1/2” Flat Washers ................ 8  
1/2” Nylon Lock Nuts............ 4  
Hitch  
Front Weight  
Holddown Bar  
FRONT WEIGHT BAR  
Parts List  
540200932 Front Weight Bar .................. 1  
540200934 Clamp Plates ........................ 2  
540092731 Holddown Bar ....................... 1  
540099065 3/8” Nylon Lock Nuts............. 4  
540990591 3/8” x 4-1/2” Hex Bolts .......... 4  
540000415 3/8” Flat Washer ................... 8  
540099616 #11 Cotter Pin ....................... 2  
540099668 3/8” x 1” Clevis Pin................ 2  
Front Weight Bar  
Clamp Plate  
27  
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Replacement Parts  
540200803 Spindle Drive Fan Assembly  
19  
22  
28  
21  
23  
4
7
1
20  
6
27  
24  
39  
2
8
23  
21  
14  
27  
38  
11  
10  
42  
36  
40  
9
37  
35  
25  
33  
13  
26  
14  
18  
44  
34  
31  
30  
28  
29  
32  
45  
43  
12  
17  
15  
15  
41  
16  
27  
46  
28  
29  
28  
29  
3
28  
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Replacement Parts  
ITEM  
PART NO.  
QTY  
DESCRIPTION  
1 ........ 539106752.....1........ FAN COVER W/DECALS  
2 ........ 539106693.....1 ........ UPPER HOUSING  
3 ........ 539106706.....1........ LOWER HOUSING  
4 ........ 539106786.....2........ BEARING WITH COLLAR  
6 ........ 539106707.....1 ........ FAN WLDMT.  
7 ........ 539102691.....5........ FLANGETTE  
8 ........ 539990613.....1........ NUT, 3/8-16, FLANGE  
9 ........ 539106711 .....1........ SHEAVE FLOOR  
10 ...... 539106713.....1........ SHEAVE, 4”  
11 ...... 539990563.....1........ BOLT, 3/8-16 X 1  
12 ...... 539106715.....1........ IDLERARM  
13 ...... 539101836.....1........ SLEEVE BUSHING  
14 ...... 539990546.....2........ NUT, 3/8-16, CTR. LOCK  
15 ...... 539990629.....2........ BOLT, 3/8-16 X 2 1/4  
16 ...... 539990655.....1........ BOLT, 3/8-16 X 1 1/2  
17 ...... 539990517.....1........ WASHER, 3/8  
18 ...... 539990122.....1........ WASHER, 3/8, SAE  
19 ...... 539102535.....1........ GREASE CAP  
20 ...... 539100472.....3........ BOLT, 5/16-18 X 1 1/4, CARRIAGE  
21 ...... 539990184.....13 ...... NUT, 5/16-18, CTR. LOCK  
22 ...... 539990717.....3 ........ NUT, 5/16-18, NYLOC  
23 ...... 539990799.....8........ BOLT, 5/16-18 X 5/8, CARRIAGE  
24 ...... 539990208.....1........ BOLT, 5/16-18 X 1  
25 ...... 539990362.....2........ SCREW, 1/4-20 X 5/8, SELF TAP  
26 ...... 539106721.....1........ IDLER  
27 ...... 539990074.....16 ...... BOLT, 1/4-20 X 3/4, CARRIAGE  
28 ...... 539976978.....16 ...... NUT, 1/4-20, NYLOC  
29 ...... 539990598.....14 ...... WASHER, 1/4  
30 ...... 539990188.....1........ WASHER, 5/16  
31 ...... 539106801.....1........ SPRING ROD  
32 ...... 539106720.....1........ SPRING  
33 ...... 539101050.....1........ VINYL GRIP  
34 ...... 539990037.....1........ COTTER PIN 3/32 X 3/4  
35 ...... 539100141.....1........ BOLT, 7/16-20 X 1 1/2  
36 ...... 539106504.....1........ HEAVY WASHER  
37 ...... 539990247.....1........ LOCKWASHER, 7/16  
38 ...... 539106810.....1........ CLAMP  
39 ...... 539106809.....1........ BEARING PLATE  
40 ...... 539106811 .....1........ BELT GUIDE  
41 ...... 539106812.....1........ BACKING  
42 ...... 539102067.....1........ KEY 1/4 X 3/4 SQ.  
43 ...... 539106751.....1........ SUPPORT  
44 ...... 539106748.....1........ HOSE  
45 ...... 539097076.....3........ HOSE CLAMP  
46 ...... 539976979.....1 ........ NUT, 3/8-16, NYLOC  
29  
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