Dixon 966004101 Lawn Mower User Manual

OPERATOR AND PARTS MANUAL
Grass Catcher
966004101
Please read the operator’s manual
carefully and make sure you
understand the instructions before
using the machine.
CONTENTS
SAFETY RULES................................................ 4
OPERATION.................................................... 12
GENERAL OPERATION.............................. 4
IMPROVED BAGGING TIPS..................... 12
SLOPE OPERATION................................... 4
CUSTOMER RESPONSIBILITIES.................. 13
CHILDREN.................................................. 5
GENERAL RECOMMENDATIONS........... 13
SERVICE..................................................... 5
STORAGE................................................. 13
CONTAINER CONTENTS................................. 7
PARTS............................................................. 14
ASSEMBLY....................................................... 8
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, contact the nearest authorized service
center/ department. They have competent, well-trained
technicians and the proper tools for service and
repairs.
Read and retain this manual. The instructions will
enable you to assemble and maintain your collection
system 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.
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.
GENERAL OPERATION
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
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.
SLOPE OPERATION
Slopes are a major factor related to loss-of-control 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.
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.
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.
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.
5
SAFETY RULES
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS
•
•
•
•
•
•
6
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.
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.
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.
UNPACKING INSTRUCTIONS
•
•
Remove all parts and packing materials from
carton.
Check carton contents against list. Be sure all
parts are there.
CONTAINER CONTENTS
2 - Soft bag containers
1 - Upper Chute
1 - Cover Assembly
1 - Bag of Hardware
1 - Lower Chute
1 - Mounting Hardware
TOOLS REQUIRED
• ½" Wrench (2) • 9/16" Wrench (2)
• 7/16" Wrench (2)
• Ft/Lbs Torque Wrench
• Drill
• ¼" and 5/16" Drill Bits
• 9/16" Socket and Ratchet
• Standard Screwdriver
PARTS IDENTIFICATION
UPPER CHUTE
COVER ASSEMBLY
LOWER CHUTE
BAG CONTAINERS
NOTE: When right hand (RH) and left hand (LH. 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
INSTALL PLATE AND HANGER
1. Using hardware provided in kit, attach support
mount to unit.
2. Attach hanger bracket to support mount. Do not
fully tighten nuts at this time.
2
MOUNTING COVER ASSEMBLY
TO SUPPORT ASSEMBLY
For ease of assembly, you may wish assistance from
another person for mounting the cover assembly to
mower.
1. Position cover assembly on the ground behind the
mower.
2. Lift and rotate cover to align the frame bracket with
the hanger and slide the cover down until secure.
Cover Assembly
Support Mount
Hanger Bracket
3. Secure rear end of support straps to outside of
hanger assembly. Set reinforcement plates to the
outside of the tank brackets and fasten front end
of support strap to tank bracket and reinforcment
plate with round head bolt. Secure front end
of reinforcement plate to tank bracket with hex
bolt. Fully secure all mounting hardware. See
illustration.
NOTE: Depending on model, rear guard hole may
need to be drilled out to 5/16" if kit hardware is too
large.
Hex Bolt Placement
Round Head
Bolt Placement
Reinforcement Plate
Support Straps
8
Frame
Bracket
Hanger
3
INSTALLING SPACER PLUG
Remove plastic end cap from the center bag
support arm. Fully insert spacer plugs into the
ends of the support tube. It may be necessary
to tap the spacer into place with a hammer or
mallet. Replace the plastic end cap back over
the spacer. The additional extension will hold the
hood more securely when latched.
Remove center
end cap
Insert spacer and
replace cap
ASSEMBLY
4
CONTAINER INSTALLATION
1. Install containers on support frame, overlapping
containers at center tube.
Note: One container should always overlap the
other container at the center tube.
2. Close cover and lock latch handle over support
tubes.
Latch Handle
5
LOWER CHUTE INSTALLATION
1. Raise and hold deflector shield in upright position.
2. Fit lower chute as shown and hook rear latch to
mower deck.
3. Align the bracket slot on lower chute with the
deflector bracket tab on the mower deck. Slide
chute down over tab.
4. With the lower chute in proper position, hold the
chute securely while hooking the front latch to the
mower deck.
NOTE: While hooking the latches, the deflector
shield may try to push the chute away from the
mower deck opening. It is important to hold the
chute in position while hooking the latches to
the mower deck.
Deflector
Shield
Deflector
Bracket Tab
Support Frame
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.
Front Latch
Rear Latch
Attach Rear Latch here
9
ASSEMBLY
6
UPPER CHUTE INSTALLATION
1. With ¼" drill bit, add a new hole 4¾" inches from
the top of the chute, down along the side seam.
2. Attach bungee latch assembly from kit.
3. Slide upper chute onto lower chute, lining up
notches and channels.
4. Stretch bungee latch up onto acorn nut on upper
chute to secure.
New Bungee
Latch Hole
Before continuing to Step 7, locate the seal
fastening kit (packed separately) and install the
top cover grommet.
10
ASSEMBLY
7
CHUTE / HOOD INSTALLATION
1. Push upper chute through the gasketed opening in
the cover assembly.
2. Rotate chute so the chute opening is downwards
toward the container bags.
Hood Inlet
8
LEVELING MOWER DECK
Be sure deck is properly leveled for best mower
performance. See your mower operator’s manual for
instructions.
Rotate upper chute to point
downwards towards bags
11
OPERATION
IMPROVED BAGGING TIPS
Follow the mower operation instructions in the mower
operator’s manual.
When using the grass catcher on a lawn where grass
and leaf bagging equipment has not been used, thatch
and debris that has accumulated for long periods
of time will be picked up. The amount collected
and the total time of operation may be greater than
experienced with regular use of the 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.
g. Repeat for other container.
h. Reinstall containers making sure right
container overlaps left container at center
supports.
i. Close cover and secure latches over center
support tubes.
• Avoid cutting wet grass or mowing 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.
12
•
If the grass catcher fails to pick up cut grass
or leaves, it is an indication that clogging has
occurred in the system or that the grass catcher
containers are full.
a. Disengage blades, place motion control levers
in neutral position.
- Unlatch and raise cover.
- Slide out containers and dispose of
clippings.
- Replace containers, close cover, and
latch.
b. Unlatch chutes and check for clogging.
- Remove all debris in chute.
- Reassemble and latch chutes.
CAUTION
• 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
BEFORE PERFORMING MAINTENANCE,
SERVICE OR ADJUSTMENTS:
• Set parking brake.
• Place motion control levers in “NEUTRAL”
position.
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.
• 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
2
1
20
5
5
3
4
20
20
18
19
16
14
15
6
12
8
7
13
11
10
17
9
14
PARTS
ITEM PART NO.
QTY.
DESCRIPTION
1.. 539 111139����1���� COVER ASSM, COMPLETE
INCLUDES ITEMs 2-4
2.. 532 127533����1���� SCREEN, COVER
3.. 532 155042����1���� STRIP, REINFORCEMENT
4.. 532 130895����1���� LATCH HANDLE, COVER
5.. 539 976952����4���� SCREW #10-24 x 5/8
6.. 532 132796����1���� SPRING, COVER, LH
7.. 532 132983����1���� SPRING, COVER RH
8.. 532 133235����1���� SPACER, COVER
9.. 532 085902����1���� SPRING, RETAINER
10.. 532 174083����3���� CAP, TUBING END
ITEM PART NO.
QTY.
DESCRIPTION
11.. 532 179746����1���� BAGGER, FRAME
12.. 532 128600����1���� PIN, HINGE
13.. 532 400226����2���� container, soft bag
14.. 539 105408����8���� WASHER #10 FLAT
15.. 539 976977����4���� NUT #10-24 HEX NYLOC
16.. 539 106312����4���� HMS #10-24 x ¾
17.. 522 801301����1���� spacer, plug
18.. 532 127534����1���� GASKET
19.. 539 108081����4���� SCREW #10-24 x ½
20.. 539 108086����9���� NUT #10-24 ACORN
NOTE: ALL FASTENERS ARE GRADE 5 UNLESS OTHERWISE SPECIFIED.
15
PARTS
1
20
4
3
11
15
10
21
24
16
23
17
18
13
19
5
9
2
8
12
22
7
8
9
5
16
6
14
PARTS
ITEM PART NO.
QTY.
DESCRIPTION
1.. 525 497001����1���� CHUTE, UPPER
ITEM PART NO.
QTY.
DESCRIPTION
13.. 539 990316����4���� RHSNB 5/16-18 x ¾
2.. 532 405455����1���� CHUTE, LOWER
14.. 539 112899��12���� NUT 5/16-18 HEX FLG NYLOC
3.. 539 108082����1���� INDICATOR, BAG DUMP
15.. 523 112802����2���� PLATE
4.. 522 854702����1���� BRACKET, HANGER
16.. 539 976938����2���� HCS 5/16-18 x 2¼
5.. 539 108089����3���� NUT #10-24 WELD PLATED
17.. 539 100472����2���� RHSNB 5/16-18 x 1¼
6.. 539 108194����2���� LATCH assm, CHUTE
18.. 539 990209����4���� HCS 5/16-18 x 1
7.. 539 976952����3���� SCREW #10-24 x 5/8
19.. 539 990188����6���� WASHER 5/16 SAE FLAT
8.. 539 108084����4���� WASHER 3/16 x ¾ 16 GA
20.. 539 108081����1���� SCREW, #10-14 x ½
9.. 539 109552����3���� WASHER /16 LOCK
21.. 539 108088����1���� LATCH, HOOD
3
10.. 522854402�����1���� STRAP, SUPPORT, RT
22.. 539 108083����1���� SCREW #10-24 x 11/8
11.. 522 854502����1���� STRAP, SUPPORT, LT
23.. 539 108085����1���� SPACER, SPLIT
12.. 522 854602����1���� BRACKET, COLLECTION
24.. 539 108086����1���� NUT #10-24 ACORN
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 coarse thread)
Grade
SAE Grade 5
SAE Grade 8
Flangelock Screw
w/Flangelock Nut
ft./lbs
Nm
ft./lbs
Nm
ft./lbs
Nm
ft./lbs
¼
9
12
13
18
/16
18
24
28
38
24
33
/8
31
42
46
62
40
54
/16
50
68
75
108
½
75
/16
110
102
115
156
150
165
224
/8
150
203
225
305
¾
250
339
370
502
/8
378
513
591
801
1 /8
782
1060
1410
1912
5
3
7
9
5
7
1
** Grade 5 - Minimum commercial quality (lower quality not recommended)
Metric Standard Hardware
Shank Size (Diameter in millimeters, fine or coarse thread)
Grade
Grade 8.8
Grade 10.9
Grade 12.9
ft./lbs
Nm
ft./lbs
Nm
ft./lbs
Nm
ft./lbs
M4
1.5
2
2.2
3
2.7
3.6
M5
3
4
4.5
6
5.2
7
M6
5.2
7
7.5
10
8.2
11
M7
8.2
11
12
16
15
20
M8
13.5
18
18.8
25
21.8
29
M10
24
32
35.2
47
43.5
58
M12
43.5
58
62.2
83
75
100
M14
70.5
94
100
133
119
159
M16
108
144
147
196
176
235
M18
142
190
202
269
242
323
M20
195
260
275
366
330
440
M22
276
368
390
520
471
628
M24
353
470
498
664
596
794
M27
530
707
474
996
904
1205
P/N 115 137927 IR
02/20/09