Dixon 966 004201 Lawn Mower User Manual

Operator and
Parts Manual
Grass Catcher
54"
Model 966 004201
CONTENTS
Safety..........................................................................................................................................4
Container Contents..............................................................................................................7
Assembly....................................................................................................................................8
Operation.................................................................................................................................12
Customer Responsibilities...............................................................................................13
Parts..........................................................................................................................................14
TORQUE CHART.........................................................................................................................18
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
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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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.
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•
•
II. SLOPE OPERATION
Slopes are a major factor related to loss-of-control and
tipover 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
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4
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.
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
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS
DO NOT
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•
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•
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.
•
•
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•
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 for
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
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS
•
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•
•
•
•
•
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•
•
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•
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
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
carton.
Check carton contents against list. Be sure all
parts are there.
TOOLS REQUIRED
CONTAINER CONTENTS
3 - Soft bag containers
1 - Upper chute
1 - Lower chute
1 - Catcher mount
1 - Cover Assembly
4 - Bolts 3/8-16 x 3¾
8 - Nuts 3/8-16, Nyloc
8 - Bolts 5/16-18 x 1
4 - Bolts 3/8-16 x 3½
• ½" Wrench (2)
• 9/16" Wrench
• 9/16" Socket wrench
• Drill and 5/16" bit
PARTS IDENTIFICATION
DUMP BAG
INDICATOR
COVER ASSEMBLY
UPPER CHUTE
CHUTE LATCH
BAG CONTAINERS
LOWER CHUTE
LOWER CHUTE
ATTACHING
STRAPS
NOTE: When right hand (RH) and left hand (LH.) are mentioned in this manual, it means when seated
on the mower in the operator’s position.
CAUTION
BEFORE ASSEMBLING GRASS CATCHER TO MOWER:
• Place motion control levers in “NEUTRAL” position.
• Set parking brake.
• 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
INSTALLING BAGGER MOUNT
1. Install the bagger mount tube to the rear guard
with 5/16-18 x 3¼ bolts and flange nuts from kit.
NOTE: Depending on model, rear guard hole may
need to be drilled out to 5/16" if kit hardware is too
large.
2. Install kit support straps on the outside of the
mount tube as shown in the illustration. Using a
5
/16-18 x 1¼ bolt, attach the front side of the strap
to the fender support. Do not add flange nut at this
time. Place the reinforcement plate to the outside
of the fender support. Secure with additional 1¼
bolt and fasten both bolts with flange nuts. Repeat
steps on opposite side.
NOTE: The front side of the kit support straps
should be on the inside of the mower frame.
3. Tighten all hardware.
2
INSTALLING CHUTE SUPPORT
1. Position upper chute support against bagger inlet,
flush at outer edges. See Illustration.
2. Using support as a template, drill two 3/8 holes into
bagger hood.
Upper Chute Support
Bagger Hood
Bagger Inlet
Drill rear
guard hole to
5
/16" if needed
3. Secure upper chute support to hood with hex
bolts, washers and nyloc nuts.
Flex Trim
Mount Tube
Reinforcement Plate
Support Strap
Nut
Flat Washers
Hex Bolt
8
ASSEMBLY
3
CONTAINER MOUNTING
1. Remove plastic end caps from the center two bag
support arms. Fully insert spacer plugs into the
ends of the support tubes. It may be necessary
to tap the spacers 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.
5
CONTAINER MOUNTING
1. Install containers on supports, overlapping at
center supports.
2. Close cover and lock latch handles over center
support tubes.
Center
Support
Tubes
Remove center
end caps
4
Insert spacers
and replace caps
MOUNTING COVER ASSEMBLY
NOTE: Assistance from another person may ease
mounting the cover assembly to mower.
1. Lift and rotate cover to align the cover brackets
with support assembly tubes.
2. Slide the cover down over the support tubes until
secure.
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
6
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.
7
UPPER CHUTE INSTALLATION
1. Attach bungee latch assembly from kit as
illustrated.
Deflector
Shield
Deflector
Bracket Tab
Front Latch
Rear Latch
CAUTION
Before raising deflector shield, turn mower
engine off. DO NOT remove deflector shield
from mower. Raise and hold shield when
attaching lower chute and allow it to rest on
chute while in operation.
10
2. Slide upper chute onto lower chute, lining up
notches and channels.
3. Stretch bungee latch up onto acorn nut on upper
chute to secure.
8
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
9
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
TIPS FOR IMPROVED
BAGGING OPERATION
Follow the mower operation instructions in the mower
operator’s manual.
When utilizing 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 containers.
h. Reinstall containers making sure containers
overlap left 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.
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
CAUTION
BEFORE PERFORMING MAINTENANCE,
SERVICE OR ADJUSTMENTS:
• Place motion control levers in “NEUTRAL”
position.
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.
• Set parking brake.
• 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
3
12
1
12
11
8
3
2
6
5
7
4
10
7
9
14
PARTS
ITEM
PART NO.
QTY.
DESCRIPTION
ITEM PART NO.
QTY.
DESCRIPTION
1.. 532 192709����1���� SCREEN, COVER
7.. 532 192786����2���� PIN, HINGE
2.. 532 195373����1���� COVER
8.. 532 192550����1���� SEAL, COVER
3.. 539 976952����4���� SCREW #10-24 x /8
5
9.. 532 400226����3���� CONTAINER, SOFT BAG
4.. 539 108096����2���� HAIR PIN
10.. 532 192603����1���� GASKET, COVER
5.. 539 108097����4���� PLUG, TUBING END
11.. 532 130895����2���� HANDLE, BAGGER COVER
6.. 539 108098����1���� BAGGER, FRAME
12.. 539 976977��14���� NUT #10-24 CROWNLOCK
NOTE: ALL FASTENERS ARE GRADE 5 UNLESS OTHERWISE SPECIFIED.
15
PARTS
25
21
26
22
24
21
18
17
22
3
20
15
22
19
16
23
14
13
18
21
2
22
12
8
6
10
11
7 9
6
1
5
4
6
8
16
PARTS
ITEM
PART NO.
QTY.
DESCRIPTION
ITEM PART NO.
QTY.
DESCRIPTION
1.. 539 113204����1���� CHUTE, LOWER
14.. 539 131091����1���� TUBE MOUNT
2.. 539 108141����1���� CHUTE, UPPER
15.. 522 854502����1���� STRAP, SUPPORT, LT
3.. 539 108082����1���� DUMP BAG INDICATOR
16.. 522 854402����1���� STRAP, SUPPORT, RT
4.. 539 108194����2���� LATCH
17.. 539 976937����2���� HCS 5/16-18 x 2
5.. 539 976952����3���� SCREW #10-24 x 5/8
18.. 539 990627����4���� HCS 5/16-18 x 1¼
6.. 539 108084����4���� WASHER 3/16 x ¾ 16GA
19.. 539 110472����2���� RHSNB 5/16-18 x 1¼
7.. 539 108088����1���� LATCH, HOOD
20.. 539 101520����2���� HCS 5/16-18 x 3¼
8.. 539 108089����3���� PLATED, WELD NUT
21.. 539 990188��10���� WASHER 5/16 SAE
9.. 539 109552����1���� LOCKWASHER 3/16
22.. 539 112899��10���� NUT 5/16-18 FLANGE NYLOC
10.. 539 108083����1���� SCREW #10-24 x 11/8
23.. 523 112802����2���� REINFORCE PLATE
11.. 539 108085����1���� SPACER, SPLIT
24.. 539 110281����1���� SUPPORT, CHUTE
12.. 539 108086����1���� NUT, ACORN #10-24
25.. 539 112294����1���� FLEX TRIM
13.. 539 108081����1���� SCREW #10-14 x ½
26.. 522 801301����2���� SPACER PLUG
NOTE: ALL FASTENERS ARE GRADE 5 UNLESS OTHERWISE SPECIFIED.
17
TORQUE CHART
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 ininches,fineorcoarsethread)
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
SAE grade 8
ft./lbs
Nm
ft./lbs
Nm
9
18
31
50
75
110
150
250
378
583
782
12
24
42
68
102
150
203
339
513
790
1060
13
28
46
75
115
165
225
370
591
893
1410
18
38
62
108
156
224
305
502
801
1211
1912
FlangelockScrew
w/ FlangelockNut
ft./lbs
Nm
24
40
33
54
** Grade 5 - Minimum commercial quality (Lower quality not recommended)
Metric Standard Hardware
Shank Size (Diameter inmillimeters,fineorcoarsethread)
Grade
18
M4
M5
M6
M7
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
Grade 8.8
8.8
ft./lbs
1.5
3
5.2
8.2
13.5
24
43.5
70.5
108
142
195
276
353
530
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
P/N 115 149927 IR
02/12/09