HTC Lawn Mower Accessory 110163 CZ38 User Manual

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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