Husqvarna 968999520, Z42E User Manual

Operator And
Parts Manual

For
42 Inch Consumer Z
Grass Catcher

MANUAL NO. 539 110363 REV. IR (01/05/07)

Model:

968999520 / Z42E

SAFETY RULES

SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS

DANGER !

THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING
OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD
RESULT IN SERIOUS INJURY OR DEATH.

I. GENERAL OPERATION

• Read, understand and follow all instruc-

tions in the manual and on the machine
before starting.

• Only allow responsible adults, who are
familiar with the instructions, to operate the
machine.

• Clear the area of objects such as rocks,
stones, toys, wire etc., which could be
picked up and thrown by the blades.

• Be sure the area is clear of all people and
pets before mowing. Stop the machine if
anyone enters the area.

• Never carry passengers or children even with
blades off.

• Do not mow in reverse unless absolutely
necessary. Always look down and behind
before and while backing.

• Be aware of the mower discharge direction
and do not direct it towards anyone. Do not
operate the mower without either the entire
grass catcher or the guard in place.

• Slow down before turning.

• Never leave a running machine unattended.
Always turn off theblades, set the parking
brake, stop the engine and remove the key
before leaving the machine.

• Turn off blades when not mowing.

• Stop engine before removing grass catcher
or unclogging chute.

• Mow only in daylight or good artificial light.

• Do not operate the machine while under the
influence of alcohol or drugs.

• Watch out for traffic when operating near or
crossing roadways.

• Use extra care when loading and unloading
the machine onto a trailer or truck.

• Data indicates that operators, age 60 years
and above, are involved in a large percent­age of riding mower-related injuries. These

operators should evaluate their ability to
operate the riding mower safely enough to
protect themselves and others from serious
injury.

• Keep machine free of grass, leaves or other
debris buildup which can touch hot exhaust/
engine parts and burn. Do not allow the
mower deck to plow leaves or other debris
which can cause buildup to occur. Clean
any oil or fuel spillage before operating or
storing the machine. Allow machine to cool
before storage.

II. SLOPE OPERATION

Slopes are a major factor related to loss-of­control and tip-over accidents, which can result
in severe injury or death. All slopes require extra
caution. If you cannot back up the slope or if you
feel uneasy on it, do not mow it.

DO:

• Mow up and down slopes (10° Max.), not
across.

• Remove obstacles such as rocks, tree
limbs, etc.

• Watch for holes, ruts, or bumps. Uneven
terrain could overturn the machine. Tall

grass can hide obstacles.

• Use slow speed. Choose a low speed so
that you will not have to stop while on the
slope.

• Use extra care with grass catchers or other
attachments. These can change the
stability of the machine.

• Keep all movement on the slopes slow and
gradual. Do not make sudden changes in
speed or direction.

• Avoid starting or stopping on a slope. If tires
lose traction, disengage the blades and
proceed slowly straight down the slope.

©2007 HTC. All Rights Reserved.

2

Beatrice, NE. Printed in U.S.A.

SAFETY RULES

SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS

DO NOT:

• Do not turn on slopes unless necessary,

and then, turn slowly and gradually downhill,
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 trac­tion could cause sliding.

• Do not try to stabilize the machine by
putting your foot on the ground.

• Do not use grass catcher on steep slopes.

III. CHILDREN

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 respon­sible adult.

• 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.

• Use extra care when approaching blind
corners, shrubs, trees, or other objects that
may obscure vision.

IV. SERVICE

• 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.

• Use extra care in 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 the

engine running. Allow engine to cool before
refueling. Do not smoke.

- 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.

• 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.

• Never make adjustments or repairs with the

engine running.

• 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 recom­mended 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

SAFETY RULES

SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS

• NEVER allow children to operate the

machine.

• 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.

• Keep children out of the mowing area and
under the watchful care of another respon­sible 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.

• 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, 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

Look for this symbol to point out impor­tant safety precautions. It means CAU­TION!!! BECOME ALERT!!! YOUR SAFETY
IS INVOLVED.

CAUTION

In order to prevent accidental starting when
setting up, transporting, adjusting or mak­ing repairs, always disconnect spark plug
wire and place wire where it cannot contact
spark plug.

WARNING

DO NOT tow any trailers, etc. with this

mower. They may jackknife or over turn
causing damage to the mower and possi­bly serious injury to the operator.

WARNING

Engine exhaust, some of its constituents,
and certain vehicle components contain or
emit chemicals known to the State of Cali­fornia to cause cancer and birth defects or
other reproductive harm.

WARNING

Battery posts, terminals and related acces­sories contain lead and lead compounds,
chemicals know to the State of California to
cause cancer and birth defects or other re­productive harm. Wash hands after handling.

4

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 problem 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 mower.

Please read and retain this manual. The instruc­tions will enable you to assemble and maintain
your Grass Catcher properly. Always observe the
"SAFETY RULES”.

NOTE: To make debris disposal easier 30 gallon
(3.0 mil) plastic trash bags may be inserted in
plastic grass containers.

KNOW YOUR GRASS CATCHER

READ THIS OPERATION MANUAL AND SAFETY
RULES BEFORE ASSEMBLING OR OPERATING
YOUR GRASS CATCHER. 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.

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.

TABLE OF CONTENTS

SAFETY RULES ........................................... 2-4

CARTON CONTENTS ..................................... 6

ASSEMBLY .............................................. 7 - 11

OPERATION .................................................. 12

CUSTOMER RESPONSIBILITIES ................. 13

STORAGE ..................................................... 13

PARTS .................................................... 14 - 15

5

UNPACKING INSTRUCTIONS

•

Remove all parts and packing materials
from carton.

• Check carton contents against list. Be sure

all parts are there.

TOOLS REQUIRED FOR ASSEMBLY

(1) 1/2” Wrenches
(1) 5/8” Socket
Ft/Lbs Torque Wrench

PARTS IDENTIFICATION

COVER
ASSEMBLY

CARTON CONTENTS:

2 - Container Tops 1 - Cover Assembly
2 - Container Bottoms 1 - Bag of Parts
1 - Upper Chute 1 - Owner’s Manual
1 - Lower Chute
2 - High Lift Blades

UPPER CHUTE

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

ASSEMBLY

COLLECTION MOUNT BRACKETS
(See Figure 2.)

1

1. Remove two lower bolts from rear guard
using a 1/2” wrench.

2. Place receiver bracket against rear guard
and reinstall previously removed bolts.

3. Open hood and place four carriage bolts thru
rear guaard and receiver bracket.

4. Secure with nuts using a 1/2” wrench

5 Place hanger into receiver.

6. Tighten bolts in hanger with 1/2” wrench until
hanger. See Figure 1.

REAR GUARD

HANGER

MOUNTING COVER ASSEMBLY TO
SUPPORT ASSEMBLY

2

(See Figure 2)

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.

COVER
ASSEMBLY

RECEIVER BRACKET

FIGURE 1

SUPPORT
ASSEMBLY

EXISTING BOLT

FIGURE 2

7

ASSEMBLY

CONTAINER ASSEMBLY
(See Figure 3)

3

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.

4. Repeat for other container.

IMPORTANT: BEFORE LOCKING THE TABS,
HOOKED EDGES ON BOTH HALVES MUST
OVERLAP TO FORM SEAL AS SHOWN IN IN­SET.

CONTAINER
BOTTOM
HALF

CONTAINER
TOP HALF

PRESS TOGETHER

CONTAINER
TOP HALF

CONTAINER
BOTTOM
HALF

TO FORM SEAL
WHILE LIFTING
TOP HALF

LOCKING
TAB

ASSEMBLY CHECK: Squeeze sides of lower half

of container 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.

FIGURE 3

8

ASSEMBLY

CONTAINER MOUNTING
(See Figure 4)

4

1. Install one container to left side first with
warning to the outside of unit. Install other
container to the right.

NOTE: Right container should always overlap left
container at center supports.

2. Close cover and lock latch handles over
center support tubes.

COVER LATCH
HANDLES

CONTAINER
WARNING

CONTAINER
HANDLE

CENTER
SUPPORT
TUBES

CONTAINER
WARNING

WARNING

DO NOT operate mower unless container

is properly installed. Container is subject
to wear and deterioration, check contain­ers frequently, replace when cracked or
damaged. Use only a recommended re­placement container.

FIGURE 4

9

ASSEMBLY

LOWER CHUTE
(See Figure 5)

5

1. Raise and hold deflector shield in upright
position.

2. With your left hand, hold lower chute as
shown and hook rear latch to mower deck,
then carefully release deflector shield.

3. Raise deflector shield and align “B” on lower
chute extended edge with “B” on mower
housing.

4. With your right hand, push firmly on the lower
chute until the exteded edge slides under the
deflector shield and along side the hinge
bracket as shown.

5. With chute in proper position, hold the chute
securely, so it does not move, while hooking
the front latch to the mower deck.

NOTE: While hooking the latches, the deflector
shield may try to push the chute away from the
mower deck opening. It is important to hold the
chute in position while hooking the latches to the
mower deck.

ALIGN CHUTE “B”
WITH MOWER “B”

PUSH IN

CAUTION

Before raising deflector shield, turn mower
engine off. DO NOT remove deflector shield
from mower. Raise and hold shield when at­taching lower chute and allow it to rest on
chute while in operation.

EXTENDED EDGE “B”
Must be under deflector
shield and along side
the hinge bracket

DEFLECTOR SHIELD

DEFLECTOR SHIELD
HINGE BRACKET

FRONT
LATCH

10

REAR
LATCH

FIGURE 5

ASSEMBLY

UPPER CHUTE
(See Figures 6A and 6B)

6

1. Lower mower deck to its lowest cutting
position.

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.

4. Align the bosses on lower chute with align­ment slots on upper chute and slide together.

5. Secure with rubber latch by hooking hole in
latch over latch pin.

HANDLE

COVER

UPPER
CHUTE

DUMP BAG
INDICATOR

BLADE REPLACEMENT

7

Tools Needed:

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.

LEVEL MOWER DECK

8

FIGURE 6A

ALIGNMENT
SLOT

Be sure deck is properly leveled for best mower
performance. See your mower operator’s manual
for instructions.

LOWER
CHUTE

LATCH
PIN

RUBBER
LATCH

BOSSES

FIGURE 6B

11

OPERATION

TIPS FOR IMPROVED BAGGING OPERATION:

Follow the mower operation instructions in you
mower operator’s manual.

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.

• 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.

NOTE: It may be necessary to overlap width of
cut to suit your conditions.

• 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 (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:

h. Reinstall containers making sure right con-

tainer overlaps left container at center sup­ports..

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.

• 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, place motion control

levers in neutral position.

- 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 chute.

- Reassemble and latch chutes.

CAUTION

a. Disengage blades, shift into neutral, en-

gage the parking brake and stop the en-

gine.
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.
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

• DO NOT operate mower with grass
catcher partially installed.

• Disengage blades and stop engine be­fore leaving mower seat to empty con­tainers, 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.

• DO NOT attempt to vacuum up cans or
other potentially hazardous projectiles.

CUSTOMER RESPONSIBILITIES

GENERAL RECOMMENDATIONS:

Always observe safety rules when performing any
maintenance.

• Before each use check for loose fasteners.

• Clean unit thoroughly after each use.

BLADE CARE:

For best results mower blades must be kept sharp.
Replace bent or damaged blades.

• See BLADE CARE instructions in your mow­er operator’s manual.

CAUTION

BEFORE PERFORMING ANY MAINTE­NANCE, SERVICE OR ADJUSTMENTS:

• Set parking brake.

• Place motion control levers in "NEU­TRAL" 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.

STORAGE:

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.

CAUTION

Do not leave grass in bagger containers.
Empty containers after each use and be­fore storing. Failure to do so may result in
spontaneous combustion which could de­velop into a fire.

CAUTION

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 rec­ommended parts, when necessary.

13

PARTS

11

2

13

2

2

2

12

3

1

13

22

13

13

13

13

2

19

2

8

13

10

9

4

17

5

6

18

7

14

18

17

15

16

20

36

34

37

35

32

33

29

8

8

31

24

25

27

30

28

14

26

21

23

PARTS

ITEM PART NO. QTY. DESCRIPTION

1 ......... 539 111139 .......... 1 ......... COVER ASSEMBLY, COMPLETE

..................................................... (INCLUDES ITEM 2 THRU 13)

2 ......... 532 063180 ......... 10 ........ NUT, 3/10-24, CROWNLOCK

3 ......... 532 127533 ......... 1 ......... SCREEN, COVER

4 ......... 532 132796 ......... 1 ......... SPRING, COVER, L.H.

5 ......... 532 133235 ......... 1 ......... SPACER, COVER

6 ......... 532 132983 ......... 1 ......... SPRING, COVER, R.H.

7 ......... 532 124670 ......... 1 ......... SPRING, RETAINER

8 ......... 532 174083 ......... 3 ......... PLUG, TUBING END

9 ......... 532 179746 ......... 1 ......... BAGGER, FRAME

10 ....... 532 128600 ......... 1 ......... PIN, HINGE

11 ........ 532 130895 ......... 1 ......... LATCH HANDLE, COVER

12 ....... 532 155042 ......... 1 ......... STRIP, REINFORCEMENT

13 ....... 871 161010 ......... 10 ........ SCREW #10-24 X 5/8

14 ....... 819 061216 ......... 1 ......... WASHER, 3/16 X 3/4, 16GA

15 ....... 810 071000 ......... 1 ......... LOCKWASHER

16 ....... 532 125004 ......... 1 ......... NUT, WELD

17 ....... 532 130760 ......... 1 ......... LATCH, CHUTE

18 ....... 532 130759 ......... 1 ......... RUBBER, LATCH

19 ....... 532 129585 ......... 1 ......... CONTAINER, TOP

20 ....... 532 129586 ......... 1 ......... CONTAINER, BOTTOM

21 ....... 539 990717 ......... 4 ......... NUT, 5/16-18, NYLOC

22 ....... 532 162803 ......... 1 ......... LOWER CHUTE

23 ....... 532 138971 ......... 2 ......... HIGH LIFT BLADE

24 ....... 539 108100 ......... 1 ......... GASKET, COVER

25 ....... 539 113606 .......... 1 ......... BRACKET, HANGER

26 ....... 539 113608 .......... 1 ......... BRACKET, RECEIVER

27 ....... 539 990585 ......... 1 ......... NUT, 5/16-18, WHIZLK

28 ....... 539 990627 ......... 1 ......... HCS, 5/16-18 X 1 1/4, GR5

29 ....... 539 990316 ......... 4 ......... RHSNB, 5/16-18 X 3/4, GR5

30 ....... 539 108447 ......... 1 ......... DECAL, CE

31 ....... 539 113901 .......... 1 ......... UPPER CHUTE

32 ....... 539 108081 ......... 1 ......... SCREW, #10-14 X 1/2, SPECIAL

33 ....... 539 108082 ......... 1 ......... DUMP BAG INDICATOR

34 ....... 539 108083 ......... 1 ......... SCREW, #10-24 X 1 1/8

35 ....... 539 108084 ......... 1 ......... WASHER, 3/16

36 ....... 539 108085 ......... 1 ......... SPACER, SPLIT

37 ....... 539 108086 ......... 1 ......... NUT, #10-24, ACORN

........... 539 976988 ......... 4 ......... HAIRPIN (NOT SHOWN)

........... 539 977703 ......... 4 ......... CLEVIS PIN (NOT SHOWN)

15

HTC

401 N. Commerce St.

Beatrice, NE 68310