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Serial Numbers
8084019
and Higher
Model #
____________________
Engine Model # ____________________
Serial #
____________________
Engine Serial #
____________________
Date Purchased ____________________
Engine Spec. #
____________________
Iron Eagle Owner’s Manual
700127
March, 2008
www.mymowerparts.com
For Dixie Chopper Discount Parts Call 606-678-9623 or 606-561-4983
About This Manual
AUTHORIZED DEALER
This owner’s manual is considered a permanent part of the mower. It must be available to all of the
operators and/or person(s) servicing the mower. Should the mower be resold, this manual must remain
with the mower.
All information, illustrations, and specifications contained in this manual were in effect at the time of
publication. Dixie Chopper reserves the right to change, modify, and/or discontinue specifications and/
or design without notice. If there is a change that has been made to your mower which is not shown
or reflected in this manual, please see your authorized Dixie Chopper Mower dealer before operating
and/or servicing the equipment.
Congratulations on the purchase of your new Dixie Chopper commercial mower. We at Dixie Chopper are confident that this mower will provide you with years of excellent performance, durability, and
trouble free service when operated and maintained as directed in this manual.
Should you ever have any questions regarding the operation, maintenance, or safety of your mower,
please contact your authorized Dixie Chopper Mower dealer who has been specially trained on operation and service of Dixie Chopper Mowers.
A space has been provided on the cover and below to record information about your new Dixie Chopper
Mower. Please take time to record such information for future reference, especially when you contact
an authorized Dixie Chopper Mower dealer with questions.
Date Purchased:
___________________________________________
Model Number:
___________________________________________
Serial Number:
___________________________________________
Purchased From:
___________________________________________
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TABLE OF CONTENTS
Introduction
Warranty
General Safety Precautions
Special Features, Capabilities, and Specifications
Using This Manual
Controls and Indicators
Start-Up and Operation of Mower
Basic Mower Adjustments, Maintenance, and Repairs
Mower Cleaning and Off-Season Storage
Routine Maintenance
Lubrication Points
Notes
Dixie Chopper • 6302 E. County Road 100 N. • Coatesville, IN • 46121 • www.dixiechopper.com
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3
4
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9
10
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18
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Introduction
Prior to operating the Dixie Chopper lawn mower, you
should be trained in its proper use and warned of its
dangers before operating, adjusting, or servicing it. Read
and understand this entire manual.
This symbol, if used, warns of
immediate hazards which will
result in severe personal injury or death.
DANGER
This symbol refers to a hazard
or unsafe practice which can
result in severe personal injury or death.
WARNING
This symbol refers to a hazard
or unsafe practice which can
result in severe personal injury or product or property damage.
WARNING
Familiarize yourself with the controls and
know how to stop the mower quickly.
Inspect your work area carefully. Remove
debris from the turf area to be cut.
Avoid contact with moving parts. Keep
away from whirling blades. Keep feet
and hands away from underneath mower
deck.
Never direct discharge of material toward
bystanders nor allow anyone near the machine while in operation.
This machine is not meant for highway or
street use. It is not a recreational vehicle
and you should never carry passengers.
Never tamper with safety devices or guards.
If a guard or safety device is damaged or
removed, replace before operating mower.
Handle gasoline carefully. Never add fuel to
tank while the engine is running or hot.
Warranty
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIE EXPRESSED OR IMPLIED (INCLUDING BUT NOT LIMITED TO ANY REGARDING
THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), NOT SPECIFIED
HEREIN, REGARDING THE EQUIPMENT WHICH IS THE SUBJECT OF THIS WARRANTY.
Owner/Operator Knowledge Responsibility
As a condition of the Dixie Chopper warranty, the owner and operator(s) are fully responsible for having read, and
reasonably understanding the proper operation and care of the Dixie Chopper unit Before Attempting to Operate the
Machine. Through the terms and conditions contained herein, Magic Circle Corporation (Dixie Chopper) warrants
that it will adjust, repair, or replace, any factory original part used in the manufacturing of a Dixie Chopper complete
unit, found to be defective in material or workmanship.
Complete Unit (Residential Units ONLY)
The warranty period is limited to two years from the date of retail purchase on behalf of the original owner of a Dixie
Chopper complete unit. This warranty will provide the cost of repair or replacement (at the discretion of Dixie Chopper) of the defective part, including labor. This warranty applies only to original retail purchaser of a Dixie Chopper
complete unit for personal use, and not used for income producing purposes.
Transaxle Drive Train
The transaxle drive components of the Dixie Chopper complete unit will be warranted for two years from the retail
purchase date on behalf of the original owner against defects in materials or workmanship. Labor required to repair
or replace components of the transaxle drive system will be covered by Dixie Chopper during this period.
Deck Spindle Assembly
Parts and labor for the replacement of the complete deck spindle assembly (deck hub, deck spindle bearings, deck
hub spacer, and blade spindle shaft), of the Dixie Chopper complete unit will be warranted for three years from the
retail purchase date on behalf of the original owner against defects in materials or workmanship.
Battery
Dixie Chopper original equipment batteries are warranted against OEM factory defects in materials or workmanship
(“discharged only” and “abuse” are not covered). If battery failure occurs within 6 months of unit purchase date, battery will be replaced at no charge. Battery failures occurring beyond 6 months but less than 1 year from date of unit
purchase will be replaced at 50% of the cost of the standard replacement battery.
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Warranty
(Continued)
Front Forks
Dixie Chopper will provide to the original purchaser beyond the initial two years warranty, any front fork due to
breakage.
Engine
The engine warranty is provided by the engine manufacturer. Please refer to the engine manufacturer warranty
statement included with the ownership materials provided with the unit. Dixie Chopper is not authorized to handle
warranty adjustments on engines. Engine warranty claims must be filed with the appropriate engine manufacturer
for necessary warranty repairs. In general, engines used on Dixie Chopper units are warranted by the respective
engine manufacturer for a period of two years from the retail purchase date on behalf of the original owner.
Tires and Belts
Tires and belts are considered to be consumable-wear items, and are therefore, warranted for a period of 90 days
against materials or workmanship defects, not for wear or abuse.
Transportation for Warranty Repairs
A Dixie Chopper complete unit (including any defective parts) requiring warranty repair, must be returned to an
authorized Dixie Chopper Service Dealer within the warranty period. The expense of transporting the unit to and
from the dealer for warranty work will be the responsibility of the unit owner.
Limitation of Warranty
The product registration card must be submitted to Dixie Chopper within 3 days of the original retail purchase
date to enable validation of the warranty period provided. Proof of purchase may be required of the unit owner to
substantiate any warranty claim.
All warranty work must be performed by an authorized Dixie Chopper Servicing Dealer ONLY.
This warranty covers only Dixie Chopper complete units, which are properly serviced, maintained, and operated
under conditions considered normal for turf equipment.
Expressly Not Covered
a)
b)
c)
d)
e)
f)
g)
h)
i)
Replacement of service items such as oil, lubricants, spark plugs, belts, rubber hoses, or other items subject
to normal service replacement.
Maintenance services such as cleaning, lubrication, oil change, blade sharpening, etc.
Damage, defects or deterioration due to normal use, wear, or exposure to elements.
Damage or defects resulting from misuse, neglect, alteration, accident or negligence.
Use of fuels, oils, or lubricants other than as specified.
Damage or defects resulting from repairs by person(s) other than an authorized Dixie Chopper service
dealer or installation of
parts other than genuine Dixie Chopper parts or parts recommended by Dixie Chopper.
Repairs, alterations or installations of accessories, which have an adverse affect on the operation, perfor
mance, or durability of the
Dixie Chopper complete unit.
Repair or replacements resulting from operations of Dixie Chopper equipment that has been modified,
altered, or affected with
respect to the intended use of the product.
Repair or replacement as a result of Dixie Chopper equipment operated in a manner which is not in accord
with the instructions as
specified in the operator’s manual or other instructions provided by Dixie Chopper.
Dixie Chopper Is Not Responsible For…(nor limited to the following)
j)
k)
Travel time, overtime, after-hours time or other extraordinary repair charges or charges relating to repairs
or replacements outside
of normal business hours at the place of business of the authorized Dixie Chopper service dealer.
Loss, cost or expense relating to transportation of Dixie Chopper equipment from the location of owner
or location where used by owner to or from any authorized Dixie Chopper service dealer.
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Warranty
l)
m)
n)
o)
p)
(Continued)
Expenses relating to gasoline, oil, or lubricants.
Rental of like or similar equipment during the time of any warranty, or replacement work.
Any claims for lost revenue, lost profit or additional cost or expense incurred as a result of a claim of
breach of warranty.
Loss or damage to person or property other than that covered by the terms of this warranty.
Any telephone, telegram, travel charges, or attorney’s fees.
Disclaimer
Any and all statements or representations made by seller of this equipment, including those set forth in any sales
literature or made orally by any sales representative, are superceded by the terms of this warranty. There are no
representations or warranties, which have been authorized and provided to the buyer of Dixie Chopper equipment,
other than as set forth in this warranty. Any affirmation of fact or promise made by Dixie Chopper or any of its representatives to the buyer which relates to the goods that are the subject of this warranty shall not be regarded as part
of the basis of the bargain and shall not be deemed to create any express warranty that such goods shall conform to
the affirmation or promise.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
General Safety Precautions
Know the location and function of the controls and how to operate them. Know how to stop quickly.
READ AND UNDERSTAND THIS OPERATION MANUAL AND THE INSTRUCTIONS FURNISHED
WITH ATTACHMENTS BEFORE ATTEMPTING TO OPERATE THIS MOWER.
Do not allow children to operate machine. Do not allow adults to operate machine without proper
instruction.
Do not carry passengers. Do not mow when children, pets, or others are present. The operator
is responsible for the safety of others within the vicinity of the operation of this mower.
Keep hands, feet, and clothing away from rotating blades or other rotating parts while engine is running.
Clear the work area of objects (wire, rocks, and debris of any kind) that can be picked up and
thrown by the mower, and possibly damage the equipment or cause personal injury to the operator
or bystanders.
Disengage all attachment clutches, set parking brake, and place steering speed control levers into neutral
lock (open) position before attempting to start engine.
Disengage power to attachments, stop engine, and remove ignition key before leaving the operator
position or leaving machine unattended.
Do not attempt to adjust or repair the mower deck, the drive system, the mower blades, or any moving
parts of the vehicle while the engine is running. You must disengage power to attachments, disengage
PTO, set parking brake, set steering control levers to neutral
lock, shut off the engine, and remove key before making any repairs or adjustments or attempting
any of the following tasks:
a. Deck pitch adjustment
b. Unclogging the chute
c. Checking blade mounting bolts for proper
tightness at frequent intervals
d. Refueling
Failure to comply can result in personal injury or death.
Disengage power to attachments when transporting or not in use.
Attempting to use this mower on slopes exceeding 15 degrees is not recommended. Reduce
speed and exercise extreme caution on slopes to prevent tipping or loss of control. Be especially cautious
ands slow down when changing directions on slopes. DO NOT mow slopes when grass is wet.
Stay alert for holes, rocks, and roots in the terrain which can cause the vehicle to upset. Keep away
from dropoffs.
When mowing uphill, avoid sudden stops to prevent tipping over. When mowing downhill, loss of traction
and/or braking ability can occur. To compensate, slightly increase ground speed and make
shallow turns gradually, until tighter control is regained.
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General Safety Precautions
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
(Continued)
Use care when pulling loads or using heavy equipment.
a. Use only approved drawbar hitch points.
b. Limit loads to those you can safely control.
c. Do not turn sharply. Use care when backing.
d. Use counterweights as advised in the Owner’s Manual.
Watch out for traffic when near to or crossing roads, and obey traffic laws. Disengage blades and
wait for them to stop before crossing gravel roads.
When using any attachments, never direct discharge of materials toward bystanders, nor allow anyone
near the vehicle while it is in operation.
Keep all nuts, bolts, and screws tight to be sure equipment is in safe working condition.
Allow engine to cool before storing in any enclosure.
Never attempt to operate mower while under the influence of alcohol or drugs.
Handle gasoline with care - it s highly flammable.
Follow these guidelines:
a. Use approved gasoline container.
b. Place container out of reach of children.
c. Use gasoline only as a fuel, neveras a cleaner.
d. Never remove cap to add gasoline to a running or hot engine, or to an engine that has not been
allowed to cool for several minutes after running.
e. Never fill fuel tank indoors.
f. Wipe up spilled gasoline.
g. Positively NO SMOKING.
h. Never store equipment with gasoline in the tank inside a building where fumes may reach an
open flame or spark.
i. Always have a fire extinguisher present when using gasoline or other flammable substance.
Keep vehicle and attachments in good operating condition and keep safety devices, such as guards,
shields, and covers, in place and working.
Do not operate the mower or attachments if any guards are missing or not functioning properly.
Stop the mower and attachments, secure the mower, and inspect for damage after striking a foreign
object. Repair any damage before restarting and operating the equipment.
Do not change engine governor settings or overspeed the engine.
Disengage power to mower deck before backing up. No mower is designed to mow in reverse,
nor can it be safely operated in reverse. Dixie Chopper’s Zero Turning Radius eliminates the need for back
ing up. Simply turn the mower around within its own dimension and proceed forward.
Do not mow with mower blades that are out of balance or have eroded airlifts and/or split
ends.
Use personal protective equipment when operating mower or performing maintenance, such as (but
not limited to) protection for eyes, ears, feet, and head. Do not operate or service the mower when
barefoot or wearing open-toed sandals.
Use caution when handling mower blades during replacement or maintenance. Wear appropriate protective
gloves and clothing and cover the sharp cutting edges of the blades. Failure to comply can result in personal injury.
Operate mower only in daylight or good artificial light.
If at all possible, do not operate mower when grass is wet.
Do not make sudden turns, stops, starts, reversals, or any abrupt maneuvers, especially
when negotiating slopes. The steering speed control arms are very responsive to slight movement. Rapid,
rough, or jerky manipulation of the steering speed control arms can result in damage to equipment and
personal injury.
Do not run the engine in an enclosure without adequate ventilation to the outside. Exhaust fumes contain
carbon monoxide which is odorless and deadly poisonous to humans. Failure to comply can result in
personal injury or death.
Do not work underneath the mower unless it is supported safely by jack stands with a safe working
load capacity of 1/2 ton or more, a hoist, or blocks. Failure to comply can result in personal injury or death.
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General Safety Precautions
33.
34.
35.
36.
(Continued)
Disconnect the spark plug wires and place the wires where they cannot contact spark plugs when setting
up, adjusting, doing repairs on, or transporting your mower. Mower can accidentally start if spark plug
wires are connected. Failure to comply can result in personal injury or death.
Do not touch hot parts of the mower. Failure to comply can result in personal injury.
Give complete and undivided attention to the job at hand.
Obey all safety decals.
SAFETY INFORMATION DECALS
The following decals are intended to alert you to potential hazards and to provide you with important safety information. Should these decals become difficult to read or are missing from the mower, contact you Dixe Chopper dealer for
a replacement.
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Special Features, Capabilities, and
Specifications
Major Features
Productivity Chart
At Dixie Chopper, we believe that every machine should
pack the maximum amount of performance. We also
believe if you listen to your customers, they will tell you
what they want; and we have been listening to our customers for years!
The following is an “Acres Per Hour” productivity
chart for the Iron Eagle 2350 model Dixie Chopper
mower. Efficiency ratings of 100% and 80% are shown.
Eighty percent reflects actual mowing conditions, considering turns and overlapping.
The Iron Eagle, the newest mower in the Dixie Chopper
lineup, is a tough compact unit.
Powered by a Kohler engine (20, 23, and 25 Hp), the
new Iron Eagle is available in 44”, 50”, and 60” deck
widths.
MPH
100%
80%
4.0
2.02
1.67
4.5
2.27
1.87
5.0
2.52
2.08
5.5
2.78
2.30
6.0
3.03
2.50
6.5
3.28
2.70
7.0
3.53
2.92
Yet despite its lower price tag, it includes some of the
same rugged features that professionals use every day,
continuing to set Dixie Chopper apart from other mowers on the zero-turn landscape.
100%
(no over-lap)
80%
(over-lap cut )
MPH x cut width
= Acres per hour
99
MPH x cut width
= Acres per hour
120
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Using This Manual
Using This Manual
The general operation, adjustment, and maintenance procedures contained in this manual are meant for both the
beginner and the experienced Dixie Chopper operator. Obviously, operating conditions will vary greatly for each
person’s situation; every individual case cannot be addressed here. With experience, operators should have no
trouble developing good operating skills for the safe and effective handling of most conditions.
Unless otherwise stated, the directional references used in this manual, forward, backward, right or left, refer to an
operator orientation of being seated on the mower, facing forward.
Illustrations and photographs used in this manual were current at the time of the printing of the manual. However,
production changes may have occurred after the time of the purchase of your Dixie Chopper; therefore, your unit
may vary slightly from what is depicted in this manual.
Dixie Chopper reserves the right to change, modify, alter, or improve the design of the machine, as deemed necessary by Dixie Chopper, without notification to existing owners or purchasers of the machines. If your machine does
not appear to be configured exactly as reflected in this operation manual, or the parts manual, contact your authorized Dixie Chopper dealer for current information and parts.
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Control and Indicators
4
2
9
6
3
5
8
7
3
1
Control/Indicator Name
Control/Indicator Description
1. IGNITION SWITCH
Controls electrical power to the mower. Switch has three positions: OFF--RUN--START.
In OFF position, no power flows to the mower electrical components. In RUN position,
power flows to all mower electrical components. In START position, electrical power
flows to the engine starter.
2. DECK ENGAGING SWITCH
(PTO)
Controls operation of the mower deck blades. Pull switch up to engage the mower
blades, and push it down to disengage the mower blades.
3. FUEL CAP
Covers fill opening of the right fuel tank.
4. STEERING SPEED CONTROL Controls the speed and direction of the mower. Moving both levers forward causes the
LEVERS
mower to move forward and moving both levers backward causes the mower to back
up. Moving one lever forward will cause the mower to turn. The farther the levers are
moved forward or backward, the faster the mower will move in that direction. The levers
may be locked in neutral position by pushing both levers outward left and right to their
respective farthest points.
5. PARKING BRAKE LEVER
Applies the brakes to hold the mower in a stationary position. Pull the lever up to set the
brakes and push it down to release the brakes.
6. CHOKE CONTROL
Causes a rich fuel/air mixture in the carburetor. Used to start a cold engine and to keep
the engine running until it warms up.
7. DECK HEIGHT STOP
A pin used to set the mower deck height.
8. DECK FOOT PEDAL
Raises the mower deck when pushed with your foot.
9. THROTTLE CONTROL
Controls engine speed. Moving the throttle all the way down sets the engine speed to
maximum. Moving the throttle all the way up sets the engine speed to idle.
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Start-Up and Operation of Mower
6.
WARNING
Do not run the mower engine in
confined areas such as a closed garage. Take care
not to inhale exhaust gases as they contain carbon
7.
monoxide, which is a colorless, odorless gas that
can cause unconsciousness and is potentially lethal.
Failure to comply can result in damage to equipment
and injury to persons or death to persons.
Handle fuel with care. It is highly
WARNING
flammable. Use only approved fuel containers.
Never add fuel while the engine is running or hot.
Fill fuel tanks outdoors, never indoors. Replace fuel
tank cap securely and wipe up all spilled fuel. Failure to comply can result in damage to equipment
and injury to persons.
Before starting the engine, beWARNING
come familiar with all controls. Read and understand this Operation Manual thoroughly. Always
check for proper engine oil level before starting
engine. Failure to comply can result in damage to
equipment and injury to persons.
1.
2.
3.
4.
5.
NOTE: Mower will not start if steering speed
control levers are not in the neutral lock position
and parking brake is not set.
2.
3.
4.
5.
Place steering speed control levers in neutral
lock position.
Sit in mower seat.
Pull parking brake lever all the way up to set
parking brake.
Set throttle to 1/4-power position.
Pull out choke (if engine is cold). Choke control
activates a valve that causes a rich fuel/air mixture in the carburetor, which will assist in starting and warming up a cold engine. Insure
gas cap vents are open.
To Mow:
Set mowing deck height to desired cut height
(if different from factory setting). (Refer to
Deck Height Adjustment for detailed instructions.)
Push parking brake lever all the way down to
release parking brake.
Set throttle to 1/4-power position.
Engage mower deck by pulling up on deck
engaging switch (PTO).
Close steering speed control levers.
NOTE: Always set engine speed at fullthrottle when mowing, and maintain a minimum
of 3400 RPM and a maximum of 3600 RPM.
This engine speed will provide the necessary
airflow through the engine cowling to prevent
overheating, and will maintain blade speed for
a satisfactory quality of cut. If the engine pulls
below 3400 RPM when under load, slow down
the ground speed and allow the engine to recover up to the proper RPM.
To Start The Mower:
1.
Turn ignition switch to the START position.
Release key after engine starts. Key will
automatically return to the RUN position.
Allow engine to warm up, then slowly push
choke button in.
6.
7.
Set throttle at the full-throttle position.
Steer and accelerate mower using the steering
speed control levers.
NOTE: If the engine fails to start after 6-7
seconds of continuous cranking, turn the key to
the OFF position and allow the starter motor to
cool.
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Start-Up and Operation of Mower
To Stop The Mower:
Deck Height Adjustment
NOTE: In case of emergency, engine may
be stopped by turning the ignition key to the
OFF position.
1.
2.
3.
4.
5.
6.
7.
Move steering speed control levers to neutral
position to stop mower movement.
Push deck engaging switch (PTO) down to
disengage mower deck blades.
Pull parking brake lever all the way up to set
parking brake.
Move throttle to the idle position.
Allow engine to idle for two minutes before
turning key off.
Turn ignition key to the OFF position and remove key, even if leaving mower unattended
for only a few minutes.
Depress deck foot pedal to raise mower deck
to highest position. Engage deck lock handle.
Set the mowing deck appropriately to achieve the desired height of your cut. The recommended cutting
height is 2-3 inches (5-7 cm), though your preference
may be a higher or lower cut. Tall grasses or weeds
should be cut with the mower deck set to its highest position.
The first time you mow, set the cut height to a little higher
than normal, then adjust accordingly as follows:
1.
2.
3.
4.
Refer to the deck height indicator decal, directly
to the left of the deck height adjustment rod.
Determine the appropriate hole setting for
your desired cut height.
Depress the deck foot pedal to lift the deck.
Reposition the deck height pin to the selected
hole setting, then release the deck by slowly
releasing down pressure on deck foot
pedal to lower deck to new height setting.
Safety Interlock System
The mower has a system of safety interlock switches
that will not allow the mower to start unless these conditions are met:
•
•
•
•
(Continued)
Steering speed control levers in
neutral lock position
Parking brake set
Deck engaging switch (PTO) off
Seat is occupied
If the seat is vacated during mowing, without positioning the controls as previously outlined, the engine will
be stopped by the safety interlock system.
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Start-Up and Operation of Mower
(Continued)
Steering Speed Control Levers
To move in reverse, pull both levers backward at the
same time, slowly and evenly.
Do not move the steering speed
DANGER
control levers too rapidly, or start and stop the
mower suddenly, especially on grades. Failure to
comply will result in personal injury or death.
To speed up the backward movement, pull levers
toward you. The closer they are pulled, the faster the
mower will travel.
The mower is equipped with a separate transxles for
each rear wheel. The transaxles are controlled by
the steering speed control levers. The left lever controls the left rear wheel and the right lever controls
the right rear wheel.
To turn, slow the mower’s ground speed, then further
slow the speed of the right wheel for a right-hand
turn, or the left wheel for a left-hand turn.
Refer to illustration shown below of steering speed
control levers’ position relative to mower wheels and
the direction in which the levers turn them.
To move forward, push both levers forward at the
same time, slowly and evenly.
To speed up the forward movement, push levers
farther forward away from you. The farther they are
pushed, the faster the mower will travel.
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Start-Up and Operation of Mower
Zero Radius Turning
To execute a zero degree turn, you must put one wheel in
reverse and one wheel in forward.
Until you have practiced this procedure and acquired a feel
for the machine, it is possible to damage the turf due to
an incorrect input. Please be aware, and mindful-of, it is
possible to pull the levers back toward the operator in such
a manner that the drive wheels will spin in reverse. This is
also true for the reverse direction, that is, if the machine is
traveling in a reverse direction and the levers are suddenly,
and quickly, pushed away from the operator, it is possible
that the drive wheels will attempt to spin forward. Failure to
follow the correct procedure for zero degree turns could result in damage to the turf. When learning the zero degree
turning procedure, use reduced engine RPM and extreme
caution. During this learning procedure, keep in mind that
slightly sluggish movements may occur due to the lowered
engine RPM. The pumps perform more precisely at the
higher RPM.
(Continued)
If ground speed is too fast or blade speed is too
slow, an uneven cut will result.
Make sure that mower deck blades are sharp to
ensure the optimum quality of cut. Refer to Blade
Replacement and Blade Sharpening procedures
for detailed instructions on how to safely and
properly maintain and sharpen mower blades.
Moving the Mower Without Power
NOTE: Do not exceed a speed of 2 mph when moving the
mower without power.
In order to transport the mower without power, you must
first release the hydraulic pressure by using the bypass lever located on each transaxle. Gain access to the bypass
levers under the main chassis behind the rear wheels.
The levers are held in the front locking notch under spring
pressure. Move the levers toward the center of the mower
to release the lock, then pull the lever toward the back of
mower and move it towards the outside of the mower to
place it in the bypass notch thus enabling mower movement without power.
Optimum Performance = Best Results
The mower is designed to operate most efficiently at maximum blade speeds, which are achieved with maximum
engine speed. The ground speed of the mower should
allow the mower deck blades to maintain that maximum
efficient speed. Therefore, slow the ground speed of the
mower when cutting tall grass, grass heavy with moisture,
or mowing uphill, so as to maintain maximum blade speed.
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OPERATING THE MOWER
Operation Of The Mower With Mower Deck
Keep all shields and mower deck discharge chute, or OCDC, in place. Never attempt to clear discharge areas or mower deck blades without disengaging mower deck, setting parking brake, shutting
off engine, and removing ignition key.
For best operation on average lawns, operate engine at 3400-3600 rpm; control ground speed with
motion control levers. Average lawns usually cut at a height between two and three inches (5-7.6 cm)
Tall grass and weeds should be cut with the mower in its highest position, making a second pass cutting to height desired. Always keep mower deck blades sharp and balanced.
Mowing Speed
The mower is designed to operate most efficiently at maximum blade speed (engine 3400-3600 rpm)
The speed of the mower should allow the mower deck blades to maintain this maximum speed while
mowing across turf. Slow the mower for cutting tall grass, grass that is heavy with moisture, or when
moving uphill. If ground speed is too fast, or blade speed is too slow, mowing will be uneven because
mower blades will not be able to lift grass into cutting position as mower passes over the ground.
Mowing Height
The best cutting height for you lawn has probably been established from previous experience. The
first time you mow, set the mower to cut a little higher than you have in the past. This will help you
determine the best approach to uneven areas, to be sure a wider cut does not result in scalping the
high spots. In general, recommended cutting height is two to three inches (5-7.6 cm).
Very tall grass can be cut without difficulty by using a little care. Set mower in its highest cutting position and enter area slowly. If necessary, take a cut one half width of mower, overlapping previously
cut area on each pass. Then, with mower set to desired height, make a finish cut over entire area.
OCDC (Operator Controlled Discharge Chute) Operation
This mower is equipped with an Operator Controlled Discharge Chute. This discharge chute has a
variable adjustment from fully open to fully closed.
In the full closed position it will serve to keep some of the clipped material under the mower deck
for a longer period of time, in order to enhance the mulching capabilities, as well as functioning as a
discharge safety shield. This discharge chute should ALWAYS BE OPERATED IN THE DOWN POSITION WHEN MOWING, WHILE PEOPLE ARE PRESENT IN THE IMMEDIATE VICINITY.
OCDC Controls
1. Handle - Used to raise and lower discharge chute.
2. Slotted Adjustment - Used to adjust position of
upper screen. May also be used 2
to hold upper screen between fully
open or fully closed. To adjust the
OCDC screen, move handle to raise
or lower the screen to desired
1
position.
SAFE OPERATION OF THIS MOWER IS THE SOLE RESPONSIBILITY OF THE OPERATOR!
BE AWARE OF SURROUNDINGS AT ALL TIMES!
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Basic Mower Adjustments,
Maintenance, and Repairs
Blade Replacement
Blade Sharpening
Never work with mower blades
while mower is running. Make sure that the
ignition switch is off and key removed, PTO
switch is disengaged, motion control levers
are in neutral lock, and parking brake is on.
Failure to comply will result in personal injury
or death.
Use caution when handling
mower blades during replacement or maintenance. Wear appropriate protective gloves
and clothing and cover the sharp cutting
edges of the blades. Failure to comply can
result in personal injury.
CAUTION
CAUTION
Disconnect the spark plug
CAUTION
Newly sharpened blades
wire and place the wire where it cannot conmust be balanced using a blade balancer betact spark plug when setting up, adjusting,
doing repairs on, or transporting your mower. fore reinstalling them. Failure to comply can
Mower can accidentally start if the spark plug result in severe damage to equipment.
wire is connected. Failure to comply can result in personal injury or death
WARNING
Use caution when handling
mower blades during replacement or maintenance. Wear appropriate protective gloves
and clothing and cover the sharp cutting
edges of the blades. Failure to comply can
result in personal injury.
NOTE: Replacing the mower blades is the
preferred method of ensuring your mower
blades are sharp. Sharpening blades yourself is
not recommended. However, if you choose to
do so, the blades must be balanced after being
sharpened.
CAUTION
1.
2.
3.
4.
5.
6.
Lift front end of mower and support it with a
jack or jack stands with a sufficient safe
working load capacity.
Wedge a short piece of 2x4 lumber between
the mower blade and the mower
deck to immobilize the blade while remov
ing or attaching hardware.
Remove bolts, washers, and spacer attaching blade to blade shaft, and remove
blades.
Apply anti-seize compound to threads of
attaching bolts before installation of new or
sharpened blades.
In reverse order as removed, install
new or sharpened blade with spacer,
washers, and bolts. Make certain
to keep the air lift area, (turned -up section)
of blade, facing the underside of mower
deck. Ensure that the fiber
washer (which acts as a vibration damper)
is against the blade.
1.
2.
3.
4.
Remove blades as outlined in Blade Replacement procedure.
Sharpen the blades using a hand grinder.
Balance the blades using a cone blade balancer
following the instructions supplied with balancer.
Install newly sharpened blades as outlined in
Blade Replacement procedure.
Tighten bolts to a torque of
80-100 ft-lbs (108-135 N•m).
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Basic Mower Adjustments,
Maintenance, and Repairs (Continued)
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Under Deck Cleaning
DANGER
Never attempt to make any
adjustments to mower deck or work under it while
mower is running. Make sure that ignition switch
is off and key removed, PTO switch is disengaged,
steering speed control levers are in neutral lock, and
parking brake is on. Failure to comply will result in
personal injury or death.
4.
5.
Do not clean the underside of the
CAUTION
deck with a pressure washer. Water can get in and
under seals and cause damage to equipment.
Clean the underside of the deck frequently. Accumulation of matter clippings seriously impairs the mower’s
ability to “lift” the grass into cutting position and discharge the clippings evenly. Matted grass clogging
the underside of the mower deck is often the cause of
uneven cutting.
6.
NOTE: There can be a 1/4-inch variation
between the forward pitch of the front and back
blade measurements. For example, both front
blade tips could measure 3 inches from the
ground, and both back blade tips could measure
3-1/4 inches from the ground.
Deck Level Check
DANGER
Never attempt to make any
adjustments to mower deck or work under it while
mower is running. Make sure that ignition switch
is off and key removed, PTO switch is disengaged,
steering speed control levers are in neutral lock, and
parking brake is on. Failure to comply will result in
personal injury or death.
Make another pass with the mower to check
the evenness of cut.
If cut is still uneven, check levelness of blades.
Adjust deck height to the level for a 3-inch cut.
Refer to Controls and Indicators page 12.
Make sure deck height stop is turned so that the
wide side faces the rear.
Make sure that the blades are positioned with
the tips of blades pointing toward front and back
of mower. On right-hand side, measure the
distance from front tip of blade to ground. Note
measurement. Repeat this process for the lefthand side blade. Both front blade tips should
measure 3 inches, +/- 1/8 inch, from tip to
ground.
On the right-hand side, measure the distance
from back tip of blade to ground. Repeat this
process for the left-hand side blade. Both back
blade tips should measure 3 inches, +/- 1/8 inch
from tip to ground.
7.
If blade to ground measurements are even, but
cut is uneven, consult the Service Department
of your authorized Dixie Chopper dealer.
An uneven or lopsided cut may be caused by an outof-level mowing deck. If the quality of your cut is not
optimum, check for an out-of-level deck as follows:
1.
2.
3.
Park mower on level surface.
Check tire pressure to make sure
they are inflated to the proper pressure levels.
Both front tires should be inflated to 12 psi,
and both rear tires should be inflated to 7 psi.
If any tire’s pressure is not correct, correct the
pressure(s) to the appropriate pressure level
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Basic Mower Adjustments,
Maintenance, and Repairs (Continued)
Drive Belt Adjustment
Steering Linkage Adjustment
DANGER
Never attempt to make any
adjustments to mower deck or work under it while
mower is running. Make sure that ignition switch
is off and key removed, PTO switch is disengaged,
steering speed control levers are in neutral lock,
and parking brake is on. Failure to comply will result in personal injury or death.
1.
2.
3.
4.
There are two drive belts that can need periodic adjustment: the drive belt from the engine to the pumps, and
the drive belt from the engine to the mower deck.
5.
6.
These belts may be adjusted as follows:
7.
1.
2.
8.
9.
3.
Gain access to the underside of mower.
Adjust the drive belt from engine to pump at
the spring tensioner located near the left rear
wheel. Tighten the jamnut until spring measures 3 inches.
Adjust the drive belt from engine to mower
deck at the spring tensioner located at the back
of the mower deck. Tighten the jamnut until
spring measures 3 inches.
Place steering speed control levers in the neutral lock position.
Chock front tires.
Jack up mower enough so that back tires
are off the ground. Use a jack with a sufficient
safe working load capacity of at least 1/2 ton.
With the motor running, loosen steering linkage
jamnut.
Loosen the two bolts.
Adjust control arm until wheel stops
turning.
Tighten the two bolts on steering linkage to
align with the hole in the pump control arm.
Remove wheel chocks.
Lower mower from jack.
Drive Belt Replacement
DANGER
Never attempt to make any
adjustments to mower deck or work under it while
mower is running. Make sure that ignition switch
is off and key removed, PTO switch is disengaged,
steering speed control levers are in neutral lock,
and parking brake is on. Failure to comply will result in personal injury or death.
Replace the drive belts if they show signs of cuts,
tears, burns caused by slipping, or excessive wear.
Refer to the Routine Maintenance section of
this manual for a schedule of replacement.
1.
2.
3.
4.
Gain access to underside of mower.
Loosen the tension on the vertical/ horizontal
idler pulley by pulling it away from belt.
Roll belt off the pulley, noting the routing of belt.
Roll new belt onto pulley, routing it in the
same configuration as belt just removed.
Manipulate pulley as needed.
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Basic Mower Adjustments,
Maintenance, and Repairs (Continued)
Do not store gasoline for more
CAUTION
than 2 months. Failure to comply can cause damage to equipment or personal injury.
Tilt-Switch Replacement
1.
2.
3.
4.
5.
6.
Remove fasteners from control panel and
remove panel.
Remove tilt switch from its holder.
Cut both wires extending from the tilt
switch a few inches from switch.
Splice wires of new tilt switch onto
electrical harness wires.
Install switch into holder.
Install control panel with fasteners.
6.
7.
Battery Maintenance
Follow the instructions provided with the Kohler engine manual.
Prepare the engine for storage at the end of the
mowing season as follows:
During off-season storage, use a trickle charger to
maintain the battery.
1.
2.
3.
Mower Cleaning and Off-Season Storage
4.
After 30 days of use, painted surfaces of the mower
may be waxed to protect the luster of the original
finish. Wash the mower regularly with a mild automotive type detergent and water. Exposed bare metal
surfaces should be coated with oil, or a light coating
of grease, to prevent rust until permanent repairs can
be made. Touch-up paint is available through your
authorized Dixie Chopper dealer.
5.
6.
7.
Clean and store the mower at the end of the mowing
season as follows:
1.
2.
3.
4.
5.
Start mower and engage mower for approximately one minute to remove excess water
from belts and pulleys. Let engine run out of
gas. Gasoline forms harmful gum and varnish
deposits in the carburetor and fuel system
as it becomes old.
Fully charge battery to prevent freezing and
internal damage in weather below 32°F (0°C).
In temperatures above 40°F (4°C), check water level and trickle charge battery during storage.
8.
Perform steps as applicable under Routine
Maintenance.
Remove all grass, dirt, and debris from tractor
and mower. Wash mower and repaint all bare
metal surfaces.
Thoroughly lubricate machine according to
lubrication instructions.
Check hydraulic oil level. Add oil if necessary.
Change oil and filter if not done in last 500
hours. Refer to Routine Maintenance.
Check tires for proper inflation.
9.
10.
Run engine for 15 minutes or longer.
Drain oil while engine is still warm.
Refill crankcase with fresh oil. Refer to
Routine Maintenance for proper oil type.
Drain fuel tanks and run engine until it runs
out of gas.
Remove and replace fuel filter if not
done in the previous 100 hours of operation.
Remove spark plugs. Pour a tablespoon of
engine oil into each spark plug hole
and install plugs. Do not connect plug leads.
Crank engine with starter at least a dozen
revolutions to distribute oil over cylinder
walls and valve mechanism.
Clean exterior surfaces of engine and spread
a light coat of oil over any exposed metal surfaces of engine subject to corrosion.
Clean dirt and chaff from the cylinders, fins,
blower housing, and muffler.
Check oil filler and fuel tank caps to make
sure they’re securely in place.
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Basic Mower Adjustments,
Maintenance, and Repairs (Continued)
Mower Preparation for New Mowing Season
Prepare the stored mower for the new mowing season as
follows:
1.
2.
3.
4.
5.
6.
Clean mower and remove any debris and
dirt accumulation.
Check the hydraulic and engine oil levels.
Fill fuel tanks with fresh gasoline.
Run the engine at half speed for 5 minutes
and check the operation of the steering speed
control levers. Then, stop engine and check for
oil leaks, loose fittings, etc.
Install all safety shields (if removed) and review the General Safety Precautions listed in
the front of this manual.
Check air pressure in tires. If needed, inflate
to proper pressure: front tires 12 psi and back
tires 7 psi.
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Routine Maintenance
Daily
Checks
Every 25
Hours
Every 250
Hours or
Annually
Check
Engine Oil Level
Follow Manufacturer’s
Recommendations
Check
Transaxle Oil Level
Lucas 20/50 Plus Motor Oil
Check
Tire Pressure
Rear Tires: 7 psi
Front Tires: 12 psi
Change
Engine Oil and Filter
Follow Manufacturer’s
Recommendations
Replace
Air Filter
(DO NOT BLOW OUT WITH COMPRESSED AIR)
Check
Engine to Transaxle
Belt Tension
Tension Spring compressed to 2”
Check
Battery Fluid Level
(If applicable)
Check
Engine to Mower Deck Tension
Tension Spring compressed to 3”
Lube
Deck Spindle Assemblies
Change
Hydraulic Filters
Remove Belts and Check
Spindle Bearings, Idlers, and Pulleys.
Change
Transaxle Oil
Lucas 20/50 Plus Motor Oil
Change every 400 hours or annually
Lube
Front Caster Bearings
Clean or Replace
Spark Plugs
Check
Steering for Creep in the Neutral Position
Check
Front and Rear Tires
for Tread Wear
Replace
Engine Fuel Filter(s)
Change
Transaxle Drive Oil
DO NOT USE HYDRAULIC OIL, HYTRAN, OR AUTOMATIC TRANSMISSION FLUID.
USE Lucas 20/50 Plus Motor Oil or a HIGH-GRADE 10W50, 15W40, 15W50, OR 20W50
MOTOR OIL OF 89 SUS or BETTER AT 212 DEGREE FARENHEITi
NOTE: The recommended Transaxle oil for your Dixie Chopper machine is Lucas 20/50 Plus Motor Oil (Part Number 20500). We strongly urge that you use this oil in the event that you should need to refill or add to your hydraulic
reservoir.
Engine Oil:
Under Normal Mowing Conditions, Use Lucas 15/40.
For Cold Weather Operation, Consult Engine Manual.
Lube Grease:
Lucas X-tra H/D Grease part# 10301.
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LUBRICATION POINTS
Every 25 Hours
Right Side Deck Drive Hub
Every 25 Hours
Every 25 Hours
Center Deck Drive Hub
Left Side Deck Drive Hub
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LUBRICATION POINTS
Every 250 Hours or
annually
Front Caster Assembly
(1 each side)
Every 25 Hours
Front Wheel Bearing
1 Each Front Wheel
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Notes
Dixie Chopper • 6302 E. County Road 100 N. • Coatesville, IN • 46121 • www.dixiechopper.com
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Notes
Dixie Chopper • 6302 E. County Road 100 N. • Coatesville, IN • 46121 • www.dixiechopper.com
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Notes
Dixie Chopper • 6302 E. County Road 100 N. • Coatesville, IN • 46121 • www.dixiechopper.com
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6302 E. County Road 100 North
Coatesville, IN. 46121
Phone 1-765-CHOPPER
www.dixiechopper.com
Dixie Chopper, Magic Circle, and the Magic Circle Atom Logo are all trademarks of Magic Circle Corporation
and may not be reproduced without permission.
Printed In USA
Specifications and instructions subject to change without notice.
Print Date 3/08
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