Operator And
Parts Manual
Grass Catcher
For
48 Inch and 54 Inch
Model:
968999515 - 48”/54”
MANUAL NO. (539) 113943 REV. 01 (02/15/07)
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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
CAUTION
WARNING
Look for this symbol to point out impor-
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.
tant safety precautions. It means CAU-
TION!!! BECOME ALERT!!! YOUR SAFETY
IS INVOLVED.
CAUTION
WARNING
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.
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
SAFETY RULES ........................................... 2-4
CARTON CONTENTS ..................................... 6
ASSEMBLY .............................................. 7 - 10
OPERATION .................................................. 11
CUSTOMER RESPONSIBILITIES ................. 12
STORAGE ..................................................... 12
PARTS .................................................... 14 - 17
TORQUE SPECIFICATIONS ......................... 18
5
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UNPACKING INSTRUCTIONS
CARTON CONTENTS:
3 - Container Tops
3 - Container Bottoms 2 - Weight Brackets
2 - Weight Plates
•
Remove all parts and packing materials
from carton.
Check carton contents against list. Be sure
all parts are there.
1 - Upper Chute
1 - Lower Chute
1 - Catcher Mount
1 - Cover Assembly
1 - Cast Weight
4 - Bolts 3/8-16 x 3 3/4"
8 - Nuts 3/8-16, nyloc
8 - Bolts 5/16-18 x 1", GR5
4 - Bolts 3/8-16 x 3 1/2”, GR5
•
TOOLS REQUIRED FOR ASSEMBLY
(2) 1/2" Wrenches
(1) 9/16" Wrench
(1) 9/16" Socket wrench
PARTS IDENTIFICATION
COVER
ASSEMBLY
DUMP BAG
INDICATOR
CHUTE LATCH
UPPER CHUTE
GRASS
CATCHER
CONTAINERS
LOWER CHUTE
ATTACHING
STRAPS
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
MOUNTING COVER ASSEMBLY TO
SUPPORT ASSEMBLY
(See Figure 2)
BAGGER SUPPORT ASSEMBLY
(See Figures 1A and 1B)
2
1
1. Remove rear engine guard (if installed) by
removing the six bolts that attach the guard to
the frame.
2. Place hitch Part No. 539113090 on the rear of
the mower.
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 tubes.
3. Slide cover assembly down onto the support
tubes.
ENGINE
GUARD
BOLTS
REAR ENGINE GUARD
COVER
ASSEMBLY
ENGINE
GUARD
BOLTS
ENGINE
GUARD
BOLTS
SUPPORT
ASSEMBLY
FIGURE 1A
3. Install two (2) previously removed bolts
(539107475) thru rear of the hitch weldment.
4. Secure the sides of the hitch to the frame
with four (4) bolts (539107899) and four (4)
washers (539990598) two per each side.
BOLT, 5/16-18 X 3/4, GR8
WASHER, 1/4
FIGURE 2
HITCH
PREVIOULY REMOVED
HARDWARE
FIGURE 1B
7
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ASSEMBLY
CONTAINER MOUNTING
(See Figure 4)
CONTAINER ASSEMBLY
(See Figure 3)
4
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.
1. Install one container to left side first with
warning to the outside of unit. Install another
container to center position and one in right
position.
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.
4. Repeat for other containers.
CONTAINER
BOTTOM
HALF
COVER LATCH
HANDLES
CONTAINER
WARNING
CENTER
SUPPORT
TUBES
CONTAINER
TOP HALF
PRESS TOGETHER
TO FORM SEAL
WHILE LIFTING
TOP HALF
CONTAINER
BOTTOM
HALF
CONTAINER
WARNING
CONTAINER
HANDLE
WARNING
LOCKING
TAB
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.
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.
FIGURE 4
FIGURE 3
8
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ASSEMBLY
UPPER CHUTE
(See Figures 6A & 6B)
LOWER CHUTE
(See Figure 5)
5
6
1. Turn mower engine off.
2. Raise and hold deflector shield in upright
position.
3. Place slot in lower chute over tab on mower
deck and position lower chute over deck
opening as shown.
4. Hook rear latch into flange hole on back of
mower deck.
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.
5. Hook front latch into tab hole on front of
mower deck.
4. Align the bosses on lower chute with align-
ment slots on upper chute with alignment
slots on upper chute and slide together.
5. Secure with rubber latch by hooking hole in
latch over latch pin.
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.
DUMP BAG
UPPER
CHUTE
HANDLE
INDICATOR
COVER
DEFLECTOR
SHIELD
LOWER
CHUTE
FIGURE 6A
ALIGNMENT
SLOT
LATCH PIN
RUBBER
LATCH
BOSSES
T
H
FIGURE 6B
LEVEL MOWER DECK
7
Be sure deck is properly leveled for best mower
performance. See your mower operator’s manual
REAR LATCH
FIGURE 5
for instructions.
9
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ASSEMBLY
FRONT WEIGHTS
8 (See Figure 8)
CAUTION
DO NOT operate mower with grass catcher,
unless the front weights are installed.
5. Secure the weight bracket to the frame with
the four (4) previously removed bolts.
6. Install weight to the weight bracket with two
(2) bolts (539990588) and two (2) nuts
(539976979).
7. Install foot rest on the weight bracket with six
(6) (539113183 and two (2) (539113182)
screws.
1. Remove foot rest from the front of the mower.
2. Remove the two (2) front bolts that secure
the caster casting to the sides of the frame.
3. Remove the two (2) bolts that secure the
caster castin to the bottom of the frame.
4. Place weight bracket on the front of the
frame.
NOTE: the shorter screws go in the center.
FOOT REST
PREVIOULY REMOVED
HARDWARE
539113183
(SCREW #10-12 X 1 1/4)
539113182
(SCREW #10-12 X 1)
539976979
(NUT, 3/8-16, NYLOC)
539113225
(WEIGHT BRACKET)
539113177 (CAST WEIGHT)
539990588
(BOLT, 3/8-16 X 2, GR5)
FIGURE 8
10
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OPERATION
TIPS FOR IMPROVED BAGGING OPERATION:
Follow the mower operation instructions in your
mower operator’s manual.
•
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.
Your bagger is equipped with a dump bag indi-
cator. As the bags become full, the flow indi-
cating ball will drop down in its slot, indicating
that the bags are full or the chutes have be-
come clogged. Care should be taken not to dam-
age the parts and that the ball moves freely at
the beginning of each use.
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.
•
•
•
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
cut to suit your conditions.
a. Disengage blades, place motion control
levers in neutral position, engage parking
brake and stop engine.
•
If grass is extremely tall, it should be mowed
twice. The first time relatively high, the second
time to desired height.
- Unlatch and raise cover.
•
•
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:
- 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.
a. Disengage blades, shift into neutral, en-
gage the parkingbrake and stop the engine.
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.
c. Check to insure dump bag indicator has
not become clogged.
- The air passage hole must be clear of
debris.
Gently insert a small twig or wire into
passageway to clear.
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).
CAUTION
• 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.
g. Repeat for other containers.
• 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.
h. Reinstall containers making sure right con-
tainer overlaps left container at center sup-
ports.
i. Close cover and secure latches over cen-
ter support tubes.
11
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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.
12
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PARTS ILLUSTRATION
13
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PARTS
2
3
4
5
6
25
7
7
10
11
12
25
9
15
24
15
24
1
8
20
23
13
14
15
15
7
13
10
19
16
12
17
18
19
17
21
22
14
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PARTS
28
29
27
26
ITEM PART NO.
QTY.
DESCRIPTION
1 ......... 532 192709 ......... 1 ......... Screen, cover
2 ......... 532 195373 ......... 1 ......... Cover
3 ......... 539 108141 ......... 1 ......... Chute, upper,
4 ......... 539 108081 ......... 1 ......... Screw, #10-14 x 1/2, special
5 ......... 539 108082 ......... 1 ......... Dump bag indicator
6 ......... 539 108083 ......... 1 ......... Screw, #10-24 x 1 1/8
7 ......... 539 108084 ......... 4 ......... Washer, 3/16 x 3/4 x 16 Ga.
8 ......... 539 108085 ......... 1 ......... Spacer, split
9 ......... 539 108086 ......... 1 ......... Nut, #10-24, acorn
10 ....... 539 109552 ......... 3 ......... Lockwasher, 3/16
11........ 539 108088 ......... 2 ......... Latch, chute
12 ....... 539 108089 ......... 6 ......... Nut, weld
13 ....... 539 108194 ......... 4 ......... Latch, assembly
14 ....... 539 113204.......... 1 ......... Chute, lower, 54” deck
........... 539 108092 ......... 1 ......... Chute, lower, 48” deck
15 ....... 539 976952 ......... 6 ......... Screw, #10-24 x 5/8
16 ....... 539 108096 ......... 2 ......... Spring, retainer
17 ....... 539 108097 ......... 4 ......... Plug, tubing end
18 ....... 539 108098 ......... 1 ......... Bagger, frame
19 ....... 532 192786 ......... 2 ......... Pin, hinge
20 ....... 532 192550 ......... 1 ......... Gasket, cover
21 ....... 539 108101 ......... 3 ......... Container, top
22 ....... 539 108102 ......... 3 ......... Container, bottom
23 ....... 532 192603 ......... 1 ......... Seal, cover
24 ....... 532 130895 ......... 2 ......... Handle, bagger cover
25 ....... 539 976977 ......... 14........ Nut, #10-24, crownlock
26 ....... 539 990627 ......... 2 ......... HCS, 5/16-18 x 1 1/4, Gr5
27 ....... 539 990188 ......... 4 ......... Washer, 5/16, SAE
28 ....... 539 990717 ......... 2 ......... Nut, 5/16-18, nyloc
29 ....... 539 110234.......... 1 ......... Support, chute
........... 539 108447 ......... 1 ......... Decal, CE, (Not shown)
........... 539 108163 ......... 1 ......... Decal, Catcher, (Not shown)
15
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PARTS
1
2
3
9
8
7
4
6
5
16
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PARTS
ITEM PART NO.
QTY.
DESCRIPTION
1 ......... 539 990598 ......... 4 ......... Washer, 1/4
2 ......... 539 107899 ......... 4 ......... HCS, 5/16-18 x 3/4, Gr8
3 ......... 539 113090.......... 1 ......... Rear Collection Hitch
4 ......... 539 113177.......... 1 ......... Weight, Cast
5 ......... 539 990588 ......... 2 ......... HCS, 3/8-16 x 2, Gr5
6 ......... 539 976979 ......... 2 ......... Nut, 3/8-16, nyloc
7 ......... 539 113225.......... 2 ......... Weight bracket
8 ......... 539 113182.......... 2 ......... Screw, #10-12 x 1, wash hd
9 ......... 539 113183.......... 6 ......... Screw, #10-12 x 1 1/4, wash hd
17
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