Dixon Lawn Mower 966004101 User Guide

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.  
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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  
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.  
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.  
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.  
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.  
DO  
Mow up and down slopes (10° Max.), not across.  
Remove obstacles such as rocks, tree limbs, etc.  
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.  
Watch for holes, ruts, or bumps. Uneven terrain  
could overturn the machine. Tall grass can hide  
obstacles.  
Slow down before turning.  
Use slow speed. Choose a low speed so that you  
will not have to stop while on the slope.  
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.  
Use extra care with grass catchers or other  
attachments. These can change the stability of the  
machine.  
Turn off blades when not mowing.  
Keep all movement on the slopes slow and  
gradual. Do not make sudden changes in speed  
or direction.  
Stop engine before removing grass catcher or  
unclogging chute.  
Mow only in daylight or good artificial light.  
Avoid starting or stopping on a slope. If tires lose  
traction, disengage the blades and proceed slowly  
straight down the slope.  
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.  
4
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SAFETY RULES  
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS  
SERVICE  
DO NOT  
Do not turn on slopes unless necessary, and then,  
The operation of any mower can result in foreign  
turn slowly and gradually downhill, if possible.  
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.  
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  
Use extra care in handling gasoline and other  
fuels. They are flammable and vapors are  
explosive.  
cause sliding.  
Do not try to stabilize the machine by putting your  
foot on the ground.  
-
Use only an approved container.  
CHILDREN  
-
Never remove gas cap or add fuel with the  
engine running.  
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.  
-
-
-
-
Allow engine to cool before refueling.  
Do not smoke.  
Never refuel the machine indoors.  
NEVER allow children to operate the machine.  
Never store the machine or fuel container  
inside where there is an open flame, such as a  
water heater.  
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.  
Never run a machine inside a closed area.  
Keep nuts and bolts, especially blade attachment  
bolts, tight and keep equipment in good condition.  
Before and when backing, look behind and down  
for small children.  
Never tamper with safety devices. Check there  
proper operation regularly.  
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.  
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
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SAFETY RULES  
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS  
Keep machine free of grass, leaves, or other  
debris buildup. Clean oil or fuel spillage. Allow  
machine to cool before storing.  
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.  
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.  
WARNING!  
Mower blades are sharp and can cut. Wrap the  
blade(s) or wear gloves, and use extra caution  
when servicing them.  
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.  
Check brake operation frequently. Adjust and  
service as shown in the Operator’s Manual.  
6
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UNPACKING INSTRUCTIONS  
CONTAINER CONTENTS  
Remove all parts and packing materials from  
carton.  
2 - Soft bag containers  
1 - Upper Chute  
1 - Bag of Hardware  
1 - Lower Chute  
Check carton contents against list. Be sure all  
parts are there.  
1 - Cover Assembly  
1 - Mounting Hardware  
TOOLS REQUIRED  
½" Wrench (2)  
7/16" Wrench (2)  
Drill  
9/16" Wrench (2)  
Ft/Lbs Torque Wrench  
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
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ASSEMBLY  
INSTALL PLATE AND HANGER  
MOUNTING COVER ASSEMBLY  
1
2TO SUPPORT ASSEMBLY  
For ease of assembly, you may wish assistance from  
another person for mounting the cover assembly to  
mower.  
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.  
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.  
Frame  
Bracket  
Hanger  
INSTALLING SPACER PLUG  
NOTE: Depending on model, rear guard hole may  
need to be drilled out to 5/16" if kit hardware is too  
large.  
3
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.  
Hex Bolt Placement  
Round Head  
Bolt Placement  
Reinforcement Plate  
Insert spacer and  
Remove center  
replace cap  
end cap  
Support Straps  
8
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ASSEMBLY  
CONTAINER INSTALLATION  
LOWER CHUTE INSTALLATION  
4
5
1. Install containers on support frame, overlapping  
containers at center tube.  
1. Raise and hold deflector shield in upright position.  
2. Fit lower chute as shown and hook rear latch to  
mower deck.  
Note: One container should always overlap the  
other container at the center tube.  
3. Align the bracket slot on lower chute with the  
deflector bracket tab on the mower deck. Slide  
chute down over tab.  
2. Close cover and lock latch handle over support  
tubes.  
Latch Handle  
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
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ASSEMBLY  
UPPER CHUTE INSTALLATION  
6
1. With ¼" drill bit, add a new hole 4¾" inches from  
the top of the chute, down along the side seam.  
3. Slide upper chute onto lower chute, lining up  
notches and channels.  
2. Attach bungee latch assembly from kit.  
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  
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ASSEMBLY  
CHUTE / HOOD INSTALLATION  
LEVELING MOWER DECK  
7
8
1. Push upper chute through the gasketed opening in  
the cover assembly.  
Be sure deck is properly leveled for best mower  
performance. See your mower operator’s manual for  
instructions.  
2. Rotate chute so the chute opening is downwards  
toward the container bags.  
Rotate upper chute to point  
downwards towards bags  
Hood Inlet  
11  
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OPERATION  
IMPROVED BAGGING TIPS  
Follow the mower operation instructions in the mower  
operator’s manual.  
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.  
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.  
a. Disengage blades, place motion control levers  
in neutral position.  
-
-
Unlatch and raise cover.  
Always run throttle at full speed when bagging.  
Slide out containers and dispose of  
clippings.  
Select a speed low enough to give good mower  
cutting performance, good quality cut and good  
bagging performance.  
-
Replace containers, close cover, and  
latch.  
NOTE: It may be necessary to overlap width of  
cut to suit your conditions.  
b. Unlatch chutes and check for clogging.  
-
-
Remove all debris in chute.  
If grass is extremely tall, it should be mowed twice.  
The first time relatively high, the second time to  
desired height.  
Reassemble and latch chutes.  
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:  
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.  
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.  
Close cover before starting.  
Disengage mower blades when crossing  
driveways or gravel surfaces and other  
areas where thrown objects could be a  
hazard.  
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  
DO NOT attempt to vacuum up cans or  
bag from the container.  
other potentially hazardous projectiles.  
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  
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CUSTOMER RESPONSIBILITIES  
GENERAL RECOMMENDATIONS  
STORAGE  
Always observe safety rules when performing any  
maintenance.  
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.  
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  
CAUTION  
BEFORE PERFORMING MAINTENANCE,  
SERVICE OR ADJUSTMENTS:  
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 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  
CAUTION  
have completely stopped.  
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.  
Disconnect spark plug wire(s) from spark  
plug(s) and place wire where it cannot  
come in contact with plug.  
13  
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PARTS  
2
1
20  
5
5
3
4
20  
20  
18  
19  
16  
14  
15  
6
8
7
12  
13  
11  
10  
17  
9
14  
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PARTS  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
ITEM PART NO.  
QTY.  
DESCRIPTION  
1.. 539 111139 ....1 ....COVER ASSM, COMPLETE  
INCLUDES ITEMS 2-4  
11.. 532 179746....1 ....BAGGER, FRAME  
12.. 532 128600....1 ....PIN, HINGE  
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  
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  
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PARTS  
1
20  
4
3
11  
15  
10  
16  
21 24  
23  
17  
18  
13  
19  
2
5
8
12  
9
14  
22  
7
8
9
6
5
16  
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PARTS  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
ITEM PART NO.  
QTY.  
DESCRIPTION  
1.. 525 497001....1 ....CHUTE, UPPER  
13.. 539 990316....4 ....RHSNB 5/16-18 x ¾  
14.. 539 112899..12 ....NUT 5/16-18 HEX FLG NYLOC  
15.. 523 112802....2 ....PLATE  
2.. 532 405455....1 ....CHUTE, LOWER  
3.. 539 108082....1 ....INDICATOR, BAG DUMP  
4.. 522 854702....1 ....BRACKET, HANGER  
5.. 539 108089....3 ....NUT #10-24 WELD PLATED  
6.. 539 108194....2 ....LATCH ASSM, CHUTE  
7.. 539 976952....3 ....SCREW #10-24 x 5/8  
8.. 539 108084....4 ....WASHER 3/16 x ¾ 16 GA  
9.. 539 109552....3 ....WASHER 3/16 LOCK  
10.. 522854402.....1 ....STRAP, SUPPORT, RT  
11.. 522 854502....1 ....STRAP, SUPPORT, LT  
12.. 522 854602....1 ....BRACKET, COLLECTION  
16.. 539 976938....2 ....HCS 5/16-18 x 2¼  
17.. 539 100472....2 ....RHSNB 5/16-18 x 1¼  
18.. 539 990209....4 ....HCS 5/16-18 x 1  
19.. 539 990188....6 ....WASHER 5/16 SAE FLAT  
20.. 539 108081....1 ....SCREW, #10-14 x ½  
21.. 539 108088....1 ....LATCH, HOOD  
22.. 539 108083....1 ....SCREW #10-24 x 11/8  
23.. 539 108085....1 ....SPACER, SPLIT  
24.. 539 108086....1 ....NUT #10-24 ACORN  
17  
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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  
Grade  
SAE Grade 5  
SAE Grade 8  
Flangelock Screw  
w/Flangelock Nut  
ft./lbs  
Nm  
ft./lbs  
12  
Nm  
13  
ft./lbs  
18  
Nm  
ft./lbs  
¼
5/16  
3/8  
9
18  
24  
28  
38  
24  
40  
33  
54  
31  
42  
46  
62  
7/16  
50  
68  
75  
108  
156  
224  
305  
502  
801  
1912  
½
75  
102  
150  
203  
339  
513  
1060  
115  
165  
225  
370  
591  
1410  
9/16  
5/8  
110  
150  
250  
378  
782  
¾
7/8  
11/8  
** Grade 5 - Minimum commercial quality (lower quality not recommended)  
Metric Standard Hardware  
Grade  
ft./lbs  
Grade 8.8  
Nm  
Grade 10.9  
Grade 12.9  
ft./lbs  
2
Nm  
2.2  
ft./lbs  
3
Nm  
2.7  
5.2  
8.2  
15  
ft./lbs  
3.6  
7
M4  
M5  
1.5  
3
4
4.5  
6
M6  
5.2  
7
7.5  
10  
11  
M7  
8.2  
11  
12  
16  
20  
M8  
13.5  
24  
18  
18.8  
35.2  
62.2  
100  
147  
202  
275  
390  
498  
474  
25  
21.8  
43.5  
75  
29  
M10  
M12  
M14  
M16  
M18  
M20  
M22  
M24  
M27  
32  
47  
58  
43.5  
70.5  
108  
142  
195  
276  
353  
530  
58  
83  
100  
159  
235  
323  
440  
628  
794  
1205  
94  
133  
196  
269  
366  
520  
664  
996  
119  
176  
242  
330  
471  
596  
904  
144  
190  
260  
368  
470  
707  
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P/N 115 137927 IR  
02/20/09  
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