Operator And
Parts Manual
For
38 Inch Consumer Z
Grass Catcher
Model:
110163 / CZ38
MANUAL NO. 539110995 REV. 03 (02/06/06)
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SAFETY RULES
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS
DO NOT:
IV. SERVICE
•
Do not turn on slopes unless necessary,
and then, turn slowly and gradually downhill,
•
`
The operation of any mower can result in
foreign objects thrown into the eyes, which
can result in severe eye damage. Always
wear safety glasses or eye shields while
operating your mower or performing any
adjustments or repairs. We recommend a
wide vision safety mask over spectacles or
standard safety glasses.
if possible.
•
Do not mow near drop-off, ditches, or
embankments. The mower could suddenly
turn over if a wheel is over the edge of a cliff
or ditch, or if an edge caves in.
•
•
•
Do not mow on wet grass. Reduced trac-
tion could cause sliding.
Do not try to stabilize the machine by
putting your foot on the ground.
•
Use extra care in handling gasoline and
other fuels. They are flammable and vapors
are explosive.
Do not use grass catcher on steep slopes.
- Use only an approved container.
- Never remove gas cap or add fuel with the
engine running. Allow engine to cool before
refueling. Do not smoke.
III. CHILDREN
- Never refuel the machine indoors.
- Never store the machine or fuel container
inside where there is an open flame, such
as a water heater.
Never run a machine inside a closed area.
Keep nuts and bolts, especially blade
attachment bolts, tight and keep equipment
in good condition.
Tragic accidents can occur if the operator is not
alert to the presence of children. Children are
often attracted to the machine and the mowing
activity. Never assume that children will remain
where you last saw them.
•
•
•
NEVER allow children to operate the
machine.
•
Keep children out of the mowing area and
under the watchful care of another respon-
sible adult.
•
Never tamper with safety devices. Check
there proper operation regularly.
•
Keep machine free of grass, leaves, or other
debris buildup. Clean oil or fuel spillage.
Allow machine to cool before storing.
Stop and inspect the equipment if you strike
an object. Repair, if necessary, before
restarting.
•
•
•
Be alert and turn off the machine if children
enter the area.
Before and when backing, look behind and
down for small children.
Never carry children. They may fall off and
be seriously injured or interfere with safe
machine operation.
•
•
•
Never make adjustments or repairs with the
engine running.
•
Use extra care when approaching blind
corners, shrubs, trees, or other objects that
may obscure vision.
Grass catcher components are subject to
wear, damage, and deterioration, which
could expose moving parts or allow objects
to be thrown. Frequently check components
and replace with manufacturer’s recom-
mended parts, when necessary.
•
•
Mower blades are sharp and can cut. Wrap
the blade(s) or wear gloves, and use extra
caution when servicing them.
Check brake operation frequently. Adjust and
service as shown in the Operator’s manual.
3
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SAFETY RULES
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS
•
NEVER allow children to operate the
machine.
CAUTION
Look for this symbol to point out impor-
tant safety precautions. It means CAU-
TION!!! BECOME ALERT!!! YOUR SAFETY
IS INVOLVED.
•
Be sure the area is clear of other people
before mowing. Stop machine if anyone
enters the area.
Never carry passengers or children even
with the blades off.
Do not drive 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.
•
•
CAUTION
In order to prevent accidental starting when
setting up, transporting, adjusting or mak-
ing repairs, always disconnect spark plug
wire and place wire where it cannot contact
spark plug.
•
•
Keep children out of the mowing area and
under the watchful care of another respon-
sible adult.
•
•
•
•
•
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 (10° Max), not
across.
Remove obstacles such as rocks, tree
limbs, etc.
WARNING
DO NOT tow any trailers, etc. with this
mower. They may jackknife or over turn
causing damage to the mower and possi-
bly serious injury to the operator.
Watch for holes, ruts, or bumps. Uneven
terrain could overturn the machine. Tall
grass can hide obstacles.
•
•
Use a slow speed while on slope or hill.
Avoid starting or stopping on a slope. If tires
lose traction, disengage the blades and
proceed slowly straight down the slope.
If machine stops while going uphill, disen-
gage blades, shift into reverse and back
down slowly.
Do not turn on slopes unless necessary,
and then, turn slowly and gradually downhill,
if possible.
WARNING
Engine exhaust, some of its constituents,
and certain vehicle components contain or
emit chemicals known to the State of Cali-
fornia to cause cancer and birth defects or
other reproductive harm.
•
•
WARNING
Battery posts, terminals and related acces-
sories contain lead and lead compounds,
chemicals know to the State of California to
cause cancer and birth defects or other re-
productive harm. Wash hands after handling.
4
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CONGRATULATIONS on your purchase of a
new Grass Catcher. It has been designed, engi-
neered and manufactured to give you the best
possible dependability and performance.
KNOW YOUR GRASS CATCHER
READ THIS OPERATION MANUALAND SAFETY
RULES BEFOREASSEMBLING OR OPERATING
YOUR GRASS CATCHER. Compare the illustra-
tions with the carton contents to familiarize your-
self with the parts before starting the assembly.
Study the operating instructions and safety pre-
cautions thoroughly to insure proper functioning of
your Grass Catcher and to prevent injury to your-
self and others. Save this manual for future refer-
ence.
Should you experience any problem you cannot
easily remedy, please contact your nearest au-
thorized service center/ department. They have
competent, well-trained technicians and the
proper tools to service or repair this mower.
Please read and retain this manual. The instruc-
tions will enable you to assemble and maintain
your Grass Catcher properly. Always observe the
"SAFETY RULES”.
WARNING
The operation of any mower 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 mower and while mowing. We
recommend a wide vision safety mask for
over the spectacles or standard safety
glasses.
NOTE: To make debris disposal easier 30 gallon
(3.0 mil) plastic trash bags may be inserted in
plastic grass containers.
TABLE OF CONTENTS
CUSTOMER RESPONSIBILITIES ................. 13
STORAGE ..................................................... 13
PARTS .................................................... 14 - 15
SAFETY RULES ........................................... 2-4
CARTON CONTENTS ..................................... 6
ASSEMBLY .............................................. 7 - 11
OPERATION .................................................. 12
5
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UNPACKING INSTRUCTIONS
CARTON CONTENTS:
2 - Container Tops
2 - Container Bottoms 1 - Inlet
1 - Hose
1 - Lower Chute
2 - High Lift Blades
1 - Cover Assembly
•
Remove all parts and packing materials
from carton.
Check carton contents against list. Be sure
all parts are there.
1 - Bag of Parts
1 - Owner’s Manual
•
TOOLS REQUIRED FOR ASSEMBLY
(2) 9/16" Wrenches
(2) 1/2” Wrenches
(2) 7/16” Wrenches
(1) 9/16” Socket & Ratchet
Standard Screw Driver
Ft/Lbs Torque Wrench
PARTS IDENTIFICATION
COVER
ASSEMBLY
HOSE
GRASS
CATCHER
CONTAINERS
LOWER CHUTE
NOTE: When right hand (R.H.) and left hand (L.H.) are mentioned in this manual, it means when you
are seated on the mower in the operator’s position.
CAUTION
BEFORE ASSEMBLING GRASS CATCHER TO MOWER:
• Set parking brake.
• Place motion control levers in "NEUTRAL " position.
• Turn ignition key "OFF" and remove key.
• Make sure the blades and all moving parts have completely stopped.
• Disconnect spark plug and place wire where it cannot come in contact with plug.
6
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ASSEMBLY
INSTALLATION OF THE REAR GUARD,
PLATE AND HANGER
(See Figure 3A and 3B.)
REMOVAL OF UTILITY BOX, AND
REAR GUARD (See Figure 1.)
3
1
NOTE: Before mounting your new bagger
you will have to remove the mower’s utility
box and rear guard.
1. Using the 6 bolts removed from the rear
bracket, install the new rear bracket (Part No.
110485).
2. Place the hanger over the tab on the plate.
See Figure 3A.
1. Remove the hairpins and clevis pins that
secure the utility box to the unit (all four
corners).
2. Using a 1/2” wrench, remove the six bolts
that secure the rear bracket to the unit.
BOLTS
REAR BRACKET
FIGURE 1
FIGURE 3A
MOWER DECK BAFFLE
(See Figure 2.)
2
3. Using the four bolts (HCS 3/8 x 3/4) and nyloc
nuts (3/8), install the plate to the rear bracket
and front bracket.
4. Secure the hanger to the rear bracket with
two bolts (HCS 5/16 x 3/4) and nyloc nuts
(5/16). See Figure 3B.
1. Raise your mower deck to its highest posi-
tion.
2. Install the hex bolt, and locknut through
mower deck baffle and tighten securely.
HEX BOLT
LOCKNUT
MOWER
DECK
BAFFLE
FIGURE 3B
FIGURE 2
7
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ASSEMBLY
MOUNTING COVER ASSEMBLY TO
SUPPORT ASSEMBLY
(See Figure 5)
INSTALLATION OF THE INLET
(See Figure 4A and 4B)
5
4
1. Place the cover assembly upside down on a
table. Secure the six bolts (HCS 1/4 x 3/4),
nyloc nuts (1/4) and twelve flat washers (1/4).
2. Place one washer on each bolt.
3. Place the inlet in the cover and direct it out of
the large hole on the front side of the cover.
4. Place the bolt and washer thru each of the six
holes. See Figure 4.
NOTE: For ease of assembly, you may wish to
obtain the assistance of another person for
mounting cover assembly to mower.
1. Position cover assembly on ground behind
mower as shown.
2. Lift and rotate cover to align cover brackets
with support assembly.
3. Slide cover assembly down onto the support
assembly.
5. Place the other six washer and nuts on the
bolts and tighten.
COVER
ASSEMBLY
SUPPORT
ASSEMBLY
INSIDE COVER
FIGURE 4A
OUTSIDE COVER
FIGURE 4B
FIGURE 5
8
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ASSEMBLY
CONTAINER MOUNTING
(See Figure 7)
CONTAINER ASSEMBLY
(See Figure 6)
7
6
1. Install one container to left side first with
warning to the outside of unit. Install other
container to the right.
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.
NOTE: Right container should always overlap left
container at center supports.
IMPORTANT: BEFORE LOCKING THE TABS,
HOOKED EDGES ON BOTH HALVES MUST
OVERLAP TO FORM SEAL AS SHOWN IN IN-
SET.
2. Close cover and lock latch handles over
center support tubes.
COVER LATCH
HANDLES
CONTAINER
BOTTOM
HALF
CONTAINER
WARNING
CONTAINER
TOP HALF
CONTAINER
BOTTOM
HALF
CONTAINER
HANDLE
CENTER
SUPPORT
TUBES
PRESS TOGETHER
TO FORM SEAL
WHILE LIFTING
TOP HALF
LOCKING
TAB
CONTAINER
WARNING
ASSEMBLY CHECK: Squeeze sides of lower half
of container and check that there is no gap be-
tween upper and lower halves. If a gap appears,
unlock tabs to separate container halves and re-
peat instructions above.
WARNING
DO NOT operate mower unless container
is properly installed. Container is subject
to wear and deterioration, check contain-
ers frequently, replace when cracked or
damaged. Use only a recommended re-
placement container.
FIGURE 7
FIGURE 6
9
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ASSEMBLY
LOWER CHUTE
(See Figure 8)
HOSE
(See Figures 9A and 9B)
8
9
1. Raise and hold deflector shield in upright
position.
2. Place slot in lower chute over tab on mower
deck and position lower chute over deck
opening as shown.
1. Place both clamps over the hose.
2. Slide the hose over the inlet at the top end.
3. Slide the hose over the lower chute inlet.
4. Remove any twists in the hose by rotating it
at the top or bottom end.
3. Hook rear latch into flange hole on back of
mower deck.
5. Tighten the clamps.
4. Hook front latch into tab hole on front of
mower deck.
COVER
HOSE
CAUTION
Before raising deflector shield, turn mower
engine off. DO NOT remove deflector shield
from mower. Raise and hold shield when at-
taching lower chute and allow it to rest on
chute while in operation.
LOWER
CHUTE
FIGURE 9A
DEFLECTOR
SHIELD
WASHER
MOWER
DECK
BAFFLE
HEX BOLT
WING NUT
FIGURE 9B
FIGURE 8
10
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ASSEMBLY
BLADE REPLACEMENT
LEVEL MOWER DECK
10
11
Tools Needed:
Be sure deck is properly leveled for best mower
performance. See your mower operator’s manual
for instructions.
9/16” Socket and Ratchet
Ft/Lbs Torque Wrench
The mower comes from the factory with a low lift
blade. The blades need to be replaced with the
high lift blades provided in kit. Failure to do this
may result in poor performance of the collection
system.
1. Lift up the front of the mower and secure with
jack stands.
2. Using a 9/16” socket and ratchet, remove the
blade bolts and blades.
3. Reinstall the new high lift blades and bolts.
4. Torque the blade bolts to 35 ft/lbs.
11
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OPERATION
TIPS FOR IMPROVED BAGGING OPERATION:
Follow the mower operation instructions in you
mower operator’s manual.
h. Reinstall containers making sure right con-
tainer overlaps left container at center sup-
ports..
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 regu-
lar use of your grass catcher.
i. Close cover and secure latches over cen-
ter support tubes.
•
•
Avoid cutting wet grass or in the morning while
the dew is still heavy. Grass clippings collected
under these conditions tend to be sticky and
adhere to the walls of the flow path causing
clogging.
•
•
Always run throttle at full speed when bagging.
Select a speed 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 oc-
curred in the system or that the grass catcher
containers are full.
NOTE: It may be necessary to overlap width of
a. Disengage blades, place motion control
levers in neutral position.
cut to suit your conditions.
- Unlatch and raise cover.
•
If grass is extremely tall, it should be mowed
twice. The first time relatively high, the second
time to desired height.
- Slide out containers and dispose of clippings.
- Replace containers, close cover, and latch.
b. Unlatch chutes and check for clogging.
- Remove all debris in chute.
•
•
Use left hand side of mower for trimming.
- Reassemble and latch chutes.
Plastic trash bags (3.0 mil, 30 gallon) can be
inserted inside grass catcher containers for
ease of debris disposal. To remove the plastic
trash bags when full:
CAUTION
a. Disengage blades, shift into neutral, en-
gage the parking brake and stop the en-
gine.
• DO NOT operate mower with grass
catcher partially installed.
• Disengage blades and stop engine be-
fore leaving mower seat to empty con-
tainers, unclogging chutes, etc.
• Close cover before starting.
• Disengage mower blades when crossing
driveways or gravel surfaces and other
areas where thrown objects could be a
hazard.
b. Unlatch and raise cover.
c. Remove one container at a time by grasp-
ing 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.
e. Tip the container on its side and slide the
filled bag from the container.
• DO NOT attempt to vacuum up cans or
other potentially hazardous projectiles.
f. Install a new plastic lawn bag with the
edges of the bag draped over upper lip of
the Container (for replacement bags refer
to REPLACEMENT PARTS).
g. Repeat for other container.
12
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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
maintenance.
•
•
Before each use check for loose fasteners.
Clean unit thoroughly after each use.
BLADE CARE:
CAUTION
For best results mower blades must be kept sharp.
Replace bent or damaged blades.
Do not leave grass in bagger containers.
Empty containers after each use and be-
fore storing. Failure to do so may result in
spontaneous combustion which could de-
velop into a fire.
•
See BLADE CARE instructions in your mow-
er operator’s manual.
CAUTION
BEFORE PERFORMING ANY MAINTE-
NANCE, SERVICE OR ADJUSTMENTS:
• Set parking brake.
• Place motion control levers in "NEU-
TRAL" position.
• Place clutch control in "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. Frequently check compo-
nents and replace with manufacturer’s rec-
ommended parts, when necessary.
13
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PARTS
30
31
24
27
25
34
25
3
2
1
13
2
13
11
13
12
13
14
16
17
13
2
2
15
2
18
2
13
19
4
10
5
6
9
7
8
8
8
37
21
35
20
REF.
29
22
32
36
33
28
35
23
26
14
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PARTS
ITEM PART NO.
QTY.
DESCRIPTION
1 ......... 539111139 ........... 1 ......... COVERASSEMBLY, COMPLETE
..................................................... (INCLUDES ITEM 2 THRU 13)
2 ......... 532063180 .......... 10........ NUT, 3/10-24, CROWNLOCK
3 ......... 532127533 .......... 1 ......... SCREEN, COVER
4 ......... 532132796 .......... 1 ......... SPRING, COVER, L.H.
5 ......... 532133235 .......... 1 ......... SPACER, COVER
6 ......... 532132983 .......... 1 ......... SPRING, COVER R.H.
7 ......... 532124670 .......... 1 ......... SPRING, RETAINER
8 ......... 532174083 .......... 3 ......... PLUG, TUBING END
9 ......... 532179746 .......... 1 ......... BAGGER, FRAME
10 ....... 532128600 .......... 1 ......... PIN, HINGE
11........ 532130895 .......... 1 ......... LATCH HANDLE, COVER
12 ....... 532155042 .......... 1 ......... STRIP, REINFORCEMENT
13 ....... 871161010 ........... 10........ SCREW #10-24 X 5/8
14 ....... 874930620 .......... 1 ......... BOLT, 3/8-16 X 1 1/4
15 ....... 819131616 .......... 1 ......... WASHER, 13/32
16 ....... 873750600 .......... 1 ......... LOCKNUT, 3/8-16
17 ....... 539111005 ........... 1 ......... LOWER CHUTE
18 ....... 532135651 .......... 1 ......... WINGNUT, 3/8-16
19 ....... 532129585 .......... 1 ......... CONTAINER, TOP
20 ....... 532129586 .......... 1 ......... CONTAINER, BOTTOM
21 ....... 539111003 ........... 1 ......... PLATE W/DECAL
22 ....... 539110997 ........... 1 ......... HANGER
23 ....... 539109930 .......... 1 ......... REAR BRACKET W/DECALS
24 ....... 539110992 ........... 1 ......... INLET
25 ....... 539097076 .......... 2 ......... HOSE CLAMP, 6” TO 7”
26 ....... 539976934 .......... 2 ......... HCS, 5/16-18 X 3/4
27 ....... 539976978 .......... 6 ......... NUT, 1/4-20, NYLOC
28 ....... 539976979 .......... 4 ......... NUT, 3/8-16, NYLOC
29 ....... 539990134 .......... 4 ......... HCS, 3/8-16 X 3/4
30 ....... 539990580 .......... 6 ......... HCS, 1/4-20 X 3/4
31 ....... 539990598 .......... 12........ WASHER, 1/4
32 ....... 539990717 .......... 2 ......... NUT, 5/16-18, NYLOC
33 ....... 539109929 .......... 1 ......... DECAL, PAYLOAD/GASOLINE
34 ....... 539110994 ........... 1 ......... HOSE
35 ....... 539109927 .......... 2 ......... DECAL, UTILITY BOX WARNING
36 ....... 539109928 .......... 1 ......... DECAL, UTILITY BOX PAYLOAD
37 ....... 539110052 ........... 1 ......... FRONT BRACKET
........... EHP#138497 ....... 2 ......... HIGH LIFT BLADE (NOT SHOWN)
........... 539976988 .......... 4 ......... HAIRPIN (NOT SHOWN)
........... 539977703 .......... 4 ......... CLEVIS PIN (NOT SHOWN)
15
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HTC
401 N. Commerce St.
Beatrice, NE 68310
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