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I0403901
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Husqvarna I0403901 Parts Manuals

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Page 1
Operator And Parts Manual
For 38 Inch Consumer Z Grass Catcher
MANUAL NO. 539110995 REV. 01 (05/26/04)
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Model:
110163 / CZ38
Page 2

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.
©2004 HTC. All Rights Reserved.
2
Beatrice, NE. Printed in U.S.A.
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Page 3
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.
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Page 4
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.
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Page 5
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
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CUSTOMER RESPONSIBILITIES ................. 13
STORAGE ..................................................... 13
PARTS .................................................... 14 - 15
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Page 6
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
(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
CARTON CONTENTS:
2 - Container Tops 1 - Cover Assembly 2 - Container Bottoms 1 - Inlet 1 - Hose 1 - Bag of Parts 1 - Lower Chute 1 - Owner’s Manual 2 - High Lift Blades
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.
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Page 7

ASSEMBLY

REMOVAL OF UTILITY BOX, AND REAR GUARD (See Figure 1.)
1
NOTE: Before mounting your new bagger you will have to remove the mower’s utility box and rear guard.
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
INSTALLATION OF THE REAR GUARD, PLATE AND HANGER
3
(See Figure 3A and 3B.)
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.
FIGURE 1
MOWER DECK BAFFLE (See Figure 2.)
2
1. Raise your mower deck to its highest posi­tion.
2. Install the hex bolt, and locknut through mower deck baffle and tighten securely.
HEX BOLT
LOCKNUT
MOWER DECK BAFFLE
FIGURE 3A
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.
FIGURE 2
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FIGURE 3B
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Page 8
ASSEMBLY
INSTALLATION OF THE INLET (See Figure 4A and 4B)
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.
5. Place the other six washer and nuts on the bolts and tighten.
MOUNTING COVER ASSEMBLY TO SUPPORT ASSEMBLY
5
(See Figure 5)
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
INSIDE COVER
FIGURE 4A
SUPPORT ASSEMBLY
OUTSIDE COVER
FIGURE 4B
FIGURE 5
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Page 9
ASSEMBLY
CONTAINER ASSEMBLY (See Figure 6)
6
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: BEFORE LOCKING THE TABS, HOOKED EDGES ON BOTH HALVES MUST OVERLAP TO FORM SEAL AS SHOWN IN IN­SET.
CONTAINER BOTTOM HALF
CONTAINER TOP HALF
CONTAINER MOUNTING (See Figure 7)
7
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 BOTTOM HALF
PRESS TOGETHER 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.
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 6
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FIGURE 7
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Page 10
ASSEMBLY
LOWER CHUTE (See Figure 8)
8
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.
3. Hook rear latch into flange hole on back of mower deck.
4. Hook front latch into tab hole on front of mower deck.
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.
HOSE (See Figures 9A and 9B)
9
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.
5. Tighten the clamps.
COVER
HOSE
LOWER CHUTE
WASHER
WING NUT
HEX BOLT
FIGURE 8
DEFLECTOR SHIELD
MOWER DECK BAFFLE
FIGURE 9A
FIGURE 9B
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Page 11
ASSEMBLY
BLADE REPLACEMENT
10
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
11
Be sure deck is properly leveled for best mower performance. See your mower operator’s manual for instructions.
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Page 12

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.
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• 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.
Page 13
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.
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Page 14
PARTS
30
31
27
24
25
34
25
11
13
19
3
1
13
13
14
16
13
13
10
2
9
8
4
5
6
17
15
18
7
2
13
2
2
2
12
2
20
14
8
8
REF.
29
28
35
36
33
23
26
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35
22
32
Page 15
PARTS
ITEM PART NO. QTY. DESCRIPTION
1 ......... 539111139 ........... 1 ......... COVER ASSEMBLY, 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 ....... 532111005 ........... 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
........... 532138497 ....... 2 ......... HIGH LIFT BLADE (NOT SHOWN)
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Page 16
HTC
700 Park St.
Beatrice, NE 68310
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