Operating instructions | Dixon 539 131188 Lawn Mower User Manual

Operator and
Parts Manual
Grass Catcher
Dixon SpeedZTR 30
Kit 539 131188
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 for service and repairs.
Please read and retain this manual. The instructions will enable you to assemble and maintain
your Grass Catcher properly. Always observe the
"SAFETY RULES”.
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.
©2007 HTC. All Rights Reserved.
Beatrice, NE. Printed in U.S.A.
2
TABLE OF CONTENTS
SAFETY RULES ....................................................................................................................... 4-6
CARTON CONTENTS .................................................................................................................. 7
ASSEMBLY .......................................................................................................................... 8 - 12
OPERATION ............................................................................................................................... 12
CUSTOMER RESPONSIBILITIES .............................................................................................. 13
PARTS ................................................................................................................................ 14 - 17
TORQUE SPECIFICATIONS ...................................................................................................... 18
3
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
•
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•
•
•
•
•
•
•
•
•
•
•
•
•
•
4
Read, understand and follow all instructions
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 the machine unattended when
the engine is running. Always turn off the
blades, 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.
DO NOT operate mower with grass catcher,
unless the front weights are installed.
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.
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.
•
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.
5
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.
6
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.
UNPACKING INSTRUCTIONS
• Remove all parts and packing materials from
both cartons.
• Check carton contents against list. Be sure all
parts are there.
CARTON 1 CONTENTS
1 - Upper Chute
1 - Flex Hose
1 - Discharge Adapter
1 - Guard Reinforcement
1 - Weight Kit
1 - Bag of Hardware
1 - Owner’s Manual
1 - Hanger Bracket
1 - Adapter Bracket
1 - Booster Ring
2 - Hi Lift Adapter
CARTON 2 CONTENTS
2 - Soft Bag Containers
1 - Cover Assembly
1 - Bag of Hardware
PARTS IDENTIFICATION
COVER
ASSEMBLY
FLEX HOSE
DISCHARGE ADAPTER
GRASS
CATCHER
CONTAINERS
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.
7
ASSEMBLY
1
BAGGER SUPPORT ASSEMBLY
1. Remove the two upper side bolts on the
engine guard as illustrated. Set hardware
aside for reuse.
2. Attach guard reinforcement to engine guard
using hardware removed in Step 1.
3. Attach hanger bracket to guard reinforcement
with two 5/16 x ¾ carriage bolts and two 5/16
nyloc nuts. See illustration.
4. After the hanger bracket is attached to the
guard reinforcement, two holes will need to be
drilled through the engine guard for the
matching bottom holes of the hanger bracket.
5. Use the bottom hanger bracket holes as a
template to drill the two 11/32 holes.
Hanger Bracket
2
MOUNTING COVER ASSEMBLY TO
SUPPORT ASSEMBLY
NOTE: For ease of assembly, you may wish
assistance from another person for mounting the
cover assembly to mower.
1. Position cover assembly on ground behind
mower .
2. Lift and rotate cover to align cover bracket
with hanger bracket and slide down until
secure.
Frame Bracket
Guard Reinforcement
Hanger
Bracket
Engine Guard
Drill two 11/32
holes into engine
guard to match
these holes
Existing Hardware
8
ASSEMBLY
3
CONTAINER MOUNTING
4
BOOSTER RING
1. Install container, centering between support
tubes.
NOTE: One container should always
overlap the other container at supports.
2. Close cover and lock latch handles over
center support tubes.
Cover Latch
Handle
1. Remove mower deck from machine. Refer to
Operator’s Manual, if necessary.
2. Install the high lift adapters to existing high lift
mower blade. This combination provides the
highest lift possible. Results may vary depending on mowing conditions and the type
and heaviness of grass to be bagged. If
desired, high lift adapters may be removed,
though high lift blades must remain in the
deck when using a grass catcher.
3. Position the booster ring on the bottom of the
deck. Attach the booster ring to deck with the
bolts and washers to the outside of the ring.
Refer to illustration. Secure with nyloc nuts.
WARNING
Blades are sharp. Protect your
hands with gloves and/or wrap
blades with a heavy cloth when
handling.
Containers
4. Spin the mower blade several times to check
for sufficient clearance. CONTACT WITH
BLADE WILL DAMAGE BOOSTER RING
AND MAY RESULT IN SERIOUS INJURY.
5. Reinstall deck to machine. Refer to Operator's
Manual, if necessary.
Support
Tubes
blade
rotation
Booster
Ring
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.
9
ASSEMBLY
5
LOWER CHUTE
6
FLEX HOSE
1. Turn mower engine off.
2. Remove grass deflector on mower by pulling
hair pin cotter and deflector pin. Set aside to
reuse. The deflector and spring may be stored
for future use when not using the bagger.
3. Attach adapter bracket to discharge adapter
with bolts, washers and nuts as illustrated
below.
1. Slide flex hose onto open end of discharge
adapter.
2. Thread hose clamp around flex hose and
discharge adapter. Pull tight.
Flex Hose
¼-20 Nut
Washer
Hose Clamp
¼-20 x ¾ Hex
3. Align the discharge adapter into the deck’s
deflector mounting bracket and insert the
deflector pin. Secure with the hair pin cotter.
CAUTION
Before removing deflector shield, turn
mower engine off.
Discharge Adapter
Adapter
Bracket
Mower Deflector
Deflector Pin
Deflector
Mounting Bracket
10
Discharge
Adapter
ASSEMBLY
7
UPPER CHUTE
8
FRONT WEIGHTS
1. Slide opposite flex hose end into upper chute.
2. Push upper chute through the gasketed
opening in the cover assembly.
3. Rotate flex tube and upper chute so that the
chute opening is downwards toward the
container bags.
1. Center the weight box on the front face of foot
plate, as illustrated. Use the holes in weight
box as a template to mark and drill four 11/32"
diameter holes in foot plate.
2. Attach the weight box to foot plate with four
5
/16-18 x ½" carriage bolts and 5/16" nyloc nuts.
3. Install weight in weight box.
Cover Gasket
Rotate Upper Chute
to point downwards
towards bags
CAUTION
DO NOT operate mower with grass
catcher, unless the front weights are
installed.
Weight Box
Install Weight
In Box
11
OPERATION
TIPS FOR IMPROVED BAGGING
OPERATION
Follow the mower operation instructions in your
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:
a. Disengage blades, shift into neutral,
engage the parking brake and stop the
engine.
b. Unlatch and raise cover.
c. Remove one container at a time by
grasping 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 containers.
h. Reinstall containers making sure right
container overlaps left container at center
supports.
i. Close cover and secure latches over
center support tubes.
12
•
•
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, engage parking
brake and stop engine.
- Unlatch and raise cover.
- Slide out containers and dispose of
clippings.
- Replace containers, close cover, and
latch.
b. Check for clogging.
- Remove all debris in chute.
- Reassemble chutes.
CAUTION
• DO NOT operate mower with grass
catcher partially installed.
• Disengage blades and stop engine before
leaving mower seat to empty containers,
unclogging chutes, etc.
• Close cover before starting.
• Disengage mower blades when crossing
driveways or gravel surfaces and other
areas where thrown objects could be a
hazard.
• DO NOT attempt to vacuum up cans or
other potentially hazardous projectiles.
CUSTOMER RESPONSIBILITIES
GENERAL RECOMMENDATIONS
Always observe safety rules when performing any
maintenance.
• Before each use check for loose fasteners.
• Clean unit thoroughly after each use.
BLADE CARE
For best results mower blades must be kept
sharp. Replace bent or damaged blades.
• See BLADE CARE instructions in your mower
operator’s manual.
CAUTION
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.
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.
CAUTION
Grass catcher components are subject to
wear, damage and deterioration, which
could expose moving parts or allow objects
to be thrown. Frequently check components and replace with manufacturer’s
recommended parts, when necessary.
13
PARTS
8
2
9
4
11
9
9
9
10
7
8
5
8
6
3
14
1
12
13
15
14
PARTS
ITEM
1
2
3
4
5
6
7
8
P/N
QTY. DESCRIPTION
.. 532 124670 .... 1 ... RETAINER SPRING
.. 532 127533 .... 1 ... SCREEN, COVER
.. 539 108100 .... 1 ... GASKET, COVER
.. 532 130895 .... 1 ... LATCH HANDLE, COVER
.. 532 132796 .... 1 ... SPRING, COVER LT
.. 532 132983 .... 1 ... SPRING, COVER RT
.. 532 133235 .... 1 ... SPACER, COVER
.. 539 976977 .... 8 ... NUT, 10-24 HEX W/NYLOC
ITEM
9
10
11
12
13
14
15
P/N
QTY. DESCRIPTION
.. 539 991034 .... 8 ... 10-24 x 5/8 WASHER HD ZD
.. 532 414173 .... 1 ... STRIP, REINFORCEMENT
.. 532 160274 .... 1 ... COVER, TOP
.. 532 174083 .... 3 ... CAP, PLUG TUBING END
.. 532 414172 .... 1 ... FRAME ASSEMBLY, 2-BIN
.. 532 192786 .... 1 ... PIN, HINGE PIVOT
.. 532 400226 .... 2 ... CONTAINER BAG, SOFT
15
PARTS
14
12
7
13
17
17
19
6
15
3
17
5
19
4
9
18
16
17
15
19
16
18
10
11
1
2
8
16
17
19
PARTS
ITEM
1
2
3
4
5
6
7
8
9
10
P/N
QTY. DESCRIPTION
.. 539 108397 .... 6 ... HCS 5/16-24 x 7/8 GR5 ZD
.. 539 110943 .... 6 ... NUT 5/16-24 NYLOC
.. 539 131351 .... 1 ... DSCHRG ADPTR W/DECAL
.. 539 115352 .... 1 ... DSCHRG MTNG BRKT
.. 539 115401 .... 1 ... DECAL, WARNING
.. 539 115719 .... 1 ... HOSE CLAMP
.. 539 115938 .... 1 ... FLEX HOSE
.. 539 116336 .... 2 ... HI LIFT ADAPTER
.. 539 119910 .... 1 ... BOOSTER RING
.. 539 120206 .... 1 ... WEIGHT BOX
ITEM
11
12
13
14
15
16
17
18
19
P/N
QTY. DESCRIPTION
.. 539 121399 .... 1 ... WEIGHT
.. 539 131153 .... 1 ... BRACKET, HANGER
.. 539 131157 .... 1 ... REINFORCEMENT, GUARD
.. 539 131190 .... 1 ... UPPER CHUTE
.. 539 976978 .. 12 ... NUT ¼-20 HEX NYLOC ZD
.. 539 990055 .. 12 ... WASHER, ¼ FLAT SAE ZD
.. 539 990316 .. 10 ... RHSNB 5/16-18 x ¾ GR5 ZD
.. 539 990580 .. 12 ... HCS ¼-20 x ¾ GR5 ZD
.. 539 990717 .. 10 ... NUT 5/16-18 HEX NYLOC ZD
17
TORQUE SPECIFICATIONS
HEX HEAD CAP SCREWS
The torque values shown should be used as a general guideline when specific torque values are not given.
U.S. Standard Hardware
Shank Size (Diameter in inches, fine or coars
Grade
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
SAE grade 5
ft./lbs
9
18
31
50
75
110
150
250
378
583
782
Flangelock Screw
w/ Flangelock Nut
ft./lbs
Nm
SAE grade 8
Nm
12
24
42
68
102
150
203
339
513
790
1060
ft./lbs
13
28
46
75
115
165
225
370
591
893
1410
Nm
18
38
62
108
156
224
305
502
801
1211
1912
24
40
33
54
** Grade 5 - Minimum commercial quality (Lower quality not recommended)
Metric Standard Hardware
Shank Size (Diameter in millimeters, fine or coarse
Grade
M4
M5
M6
M7
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
Grade 8.8
ft./lbs
1.5
3
5.2
8.2
13.5
24
43.5
70.5
108
142
195
276
353
530
8.8
Nm
2
4
7
11
18
32
58
94
144
190
260
368
470
707
Grade 10.9
ft./lbs
2.2
4.5
7.5
12
18.8
35.2
62.2
100
147
202
275
390
498
474
10.9
Nm
3
6
10
16
25
47
83
133
196
269
366
520
664
996
Grade 12.9
ft./lbs
2.7
5.2
8.2
15
21.8
43.5
75
119
176
242
330
471
596
904
12.9
Nm
3.6
7
11
20
29
58
100
159
235
323
440
628
794
1205
539-131193 IR
05/07
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