Dixon Lawn Mower 966 004201 User Manual

Operator and  
Parts Manual  
Grass Catcher  
54"  
Model 966 004201  
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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.  
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.  
I. GENERAL OPERATION  
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.  
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.  
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.  
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.  
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.  
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.  
Turn off blades when not mowing.  
Stop engine before removing grass catcher or  
unclogging chute.  
Use slow speed. Choose a low speed so that you  
will not have to stop while on the slope.  
Mow only in daylight or good artificial light.  
Do not operate the machine while under the  
influence of alcohol or drugs.  
Use extra care with grass catchers or other  
attachments. These can change the stability of the  
machine.  
Watch out for traffic when operating near or  
crossing roadways.  
Keep all movement on the slopes slow and  
gradual. Do not make sudden changes in speed or  
direction.  
Use extra care when loading and unloading the  
machine onto a trailer or truck.  
Avoid starting or stopping on a slope. If tires lose  
traction, disengage the blades and proceed slowly  
straight down the slope.  
4
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SAFETY  
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS  
Use extra care in handling gasoline and other  
fuels. They are flammable and vapors are  
explosive.  
DO NOT  
Do not turn on slopes unless necessary, and then,  
turn slowly and gradually downhill, if possible.  
-
Use only an approved container.  
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.  
-
Never remove gas cap or add fuel with the  
engine running.  
-
-
-
-
Allow engine to cool before refueling.  
Do not smoke.  
Do not mow on wet grass. Reduced traction  
could cause sliding.  
Never refuel the machine indoors.  
Do not try to stabilize the machine by putting your  
foot on the ground.  
Never store the machine or fuel container  
inside where there is an open flame, such as a  
water heater.  
III. CHILDREN  
Never run a machine inside a closed area.  
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.  
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.  
NEVER allow children to operate the machine.  
Keep machine free of grass, leaves, or other  
debris buildup. Clean oil or fuel spillage. Allow  
machine to cool before storing.  
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.  
Stop and inspect the equipment if you strike an  
object. Repair, if necessary, before restarting.  
Before and when backing, look behind and down  
for small children.  
Never make adjustments or repairs with the  
engine running.  
Never carry children. They may fall off and be  
seriously injured or interfere with safe machine  
operation.  
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.  
Use extra care when approaching blind corners,  
shrubs, trees, or other objects that may obscure  
vision.  
IV. SERVICE  
Mower blades are sharp and can cut. Wrap the  
blade(s) or wear gloves, and use extra caution  
when servicing them.  
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.  
Check brake operation frequently. Adjust and  
service as shown in the Operator’s Manual.  
5
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SAFETY  
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.  
CAUTION  
Never carry passengers or children even with the  
blades off.  
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.  
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.  
WARNING  
Mow up and down slopes (10° Max), not across.  
Remove obstacles such as rocks, tree limbs, etc.  
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.  
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.  
WARNING  
CAUTION  
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.  
Look for this symbol to point out important  
safety precautions. It means CAUTION!  
BECOME ALERT! YOUR SAFETY IS  
INVOLVED.  
6
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UNPACKING INSTRUCTIONS  
CONTAINER CONTENTS  
Remove all parts and packing materials from  
3 - Soft bag containers  
1 - Upper chute  
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  
carton.  
Check carton contents against list. Be sure all  
1 - Lower chute  
parts are there.  
1 - Catcher mount  
1 - Cover Assembly  
TOOLS REQUIRED  
½" Wrench (2)  
9/16" Wrench  
9/16" Socket wrench  
Drill and 5/16" bit  
PARTS IDENTIFICATION  
COVER ASSEMBLY  
DUMP BAG  
INDICATOR  
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
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ASSEMBLY  
INSTALLING BAGGER MOUNT  
INSTALLING CHUTE SUPPORT  
1
2
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.  
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  
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.  
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  
Reinforcement Plate  
Mount Tube  
Support Strap  
Nut  
Flat Washers  
Hex Bolt  
8
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ASSEMBLY  
CONTAINER MOUNTING  
CONTAINER MOUNTING  
3
5
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.  
1. Install containers on supports, overlapping at  
center supports.  
2. Close cover and lock latch handles over center  
support tubes.  
Center  
Support  
Tubes  
Insert spacers  
and replace caps  
Remove center  
end caps  
MOUNTING COVER ASSEMBLY  
4
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
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ASSEMBLY  
LOWER CHUTE INSTALLATION  
UPPER CHUTE INSTALLATION  
6
7
1. Raise and hold deflector shield in upright position.  
1. Attach bungee latch assembly from kit as  
illustrated.  
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  
2. Slide upper chute onto lower chute, lining up  
notches and channels.  
Deflector  
Bracket Tab  
3. Stretch bungee latch up onto acorn nut on upper  
chute to secure.  
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  
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CHUTE / HOOD INSTALLATION  
LEVELING MOWER DECK  
8
9
1. Push upper chute through the gasketed opening in  
Be sure deck is properly leveled for best mower  
performance. See your mower operator’s manual for  
instructions.  
the cover assembly.  
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  
TIPS FOR IMPROVED  
BAGGING OPERATION  
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.  
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.  
a. Disengage blades, place motion control levers  
in neutral position.  
-
-
Unlatch and raise cover.  
Slide out containers and dispose of  
clippings.  
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.  
-
Replace containers, close cover, and  
latch.  
b. Unlatch chutes and check for clogging.  
NOTE: It may be necessary to overlap width of  
cut to suit your conditions.  
-
-
Remove all debris in chute.  
Reassemble and latch chutes.  
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.  
CAUTION  
b. Unlatch and raise cover.  
DO NOT operate mower with grass catcher  
c. Remove one container at a time by grasping  
container handles and pulling toward the rear,  
off of the tube rails.  
partially installed.  
Disengage blades and stop engine before  
leaving mower seat to empty containers,  
unclogging chutes, etc.  
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  
Close cover before starting.  
bag from the container.  
Disengage mower blades when crossing  
driveways or gravel surfaces and other  
areas where thrown objects could be a  
hazard.  
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  
DO NOT attempt to vacuum up cans or  
overlap left at center supports.  
other potentially hazardous projectiles.  
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  
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.  
CAUTION  
BEFORE PERFORMING MAINTENANCE,  
SERVICE OR ADJUSTMENTS:  
Place motion control levers in “NEUTRAL”  
position.  
Set parking brake.  
Place clutch control in “DISENGAGED”  
position.  
CAUTION  
Turn ignition key to “OFF” position.  
Make sure blades and all moving parts have  
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.  
completely stopped.  
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  
3
12  
1
12  
11  
8
3
2
7
6
5
4
10  
7
9
14  
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PARTS  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
ITEM PART NO.  
QTY.  
DESCRIPTION  
1.. 532 192709....1 ....SCREEN, COVER  
2.. 532 195373....1 ....COVER  
7.. 532 192786....2 ....PIN, HINGE  
8.. 532 192550....1 ....SEAL, COVER  
3.. 539 976952....4 ....SCREW #10-24 x 5/8  
9.. 532 400226....3 ....CONTAINER, SOFT BAG  
10.. 532 192603....1 ....GASKET, COVER  
11.. 532 130895....2 ....HANDLE, BAGGER COVER  
12.. 539 976977..14 ....NUT #10-24 CROWNLOCK  
4.. 539 108096....2 ....HAIR PIN  
5.. 539 108097....4 ....PLUG, TUBING END  
6.. 539 108098....1 ....BAGGER, FRAME  
NOTE: ALL FASTENERS ARE GRADE 5 UNLESS OTHERWISE SPECIFIED.  
15  
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PARTS  
25  
21  
26  
17  
22  
24  
21  
18  
22  
15  
19  
3
22  
20  
16  
23  
14  
13  
18  
21  
2
22  
6
10  
12  
11  
1
6
7
8
9
5
4
6
8
16  
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PARTS  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
ITEM PART NO.  
QTY.  
DESCRIPTION  
1.. 539 113204....1 ....CHUTE, LOWER  
2.. 539 108141....1 ....CHUTE, UPPER  
3.. 539 108082....1 ....DUMP BAG INDICATOR  
4.. 539 108194....2 ....LATCH  
5.. 539 976952....3 ....SCREW #10-24 x 5/8  
6.. 539 108084....4 ....WASHER 3/16 x ¾ 16GA  
7.. 539 108088....1 ....LATCH, HOOD  
14.. 539 131091....1 ....TUBE MOUNT  
15.. 522 854502....1 ....STRAP, SUPPORT, LT  
16.. 522 854402....1 ....STRAP, SUPPORT, RT  
17.. 539 976937....2 ....HCS 5/16-18 x 2  
18.. 539 990627....4 ....HCS 5/16-18 x 1¼  
19.. 539 110472....2 ....RHSNB 5/16-18 x 1¼  
20.. 539 101520....2 ....HCS 5/16-18 x 3¼  
21.. 539 990188..10 ....WASHER 5/16 SAE  
22.. 539 112899..10 ....NUT 5/16-18 FLANGE NYLOC  
23.. 523 112802....2 ....REINFORCE PLATE  
24.. 539 110281....1 ....SUPPORT, CHUTE  
25.. 539 112294....1 ....FLEX TRIM  
8.. 539 108089....3 ....PLATED, WELD NUT  
9.. 539 109552....1 ....LOCKWASHER 3/16  
10.. 539 108083....1 ....SCREW #10-24 x 11/8  
11.. 539 108085....1 ....SPACER, SPLIT  
12.. 539 108086....1 ....NUT, ACORN #10-24  
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  
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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  
Flangelock Screw  
w/ Flangelock Nut  
Grade  
SAE grade 5  
SAE grade 8  
ft./lbs  
9
Nm  
12  
ft./lbs  
13  
Nm  
18  
ft./lbs  
Nm  
1/4  
5/16  
3/8  
18  
24  
28  
38  
24  
40  
33  
54  
31  
42  
46  
62  
7/16  
1/2  
50  
68  
75  
108  
156  
224  
305  
502  
801  
1211  
1912  
75  
102  
150  
203  
339  
513  
790  
1060  
115  
165  
225  
370  
591  
893  
1410  
9/16  
5/8  
110  
150  
250  
378  
583  
782  
3/4  
7/8  
1
1 1/8  
** Grade 5 - Minimum commercial quality (Lower quality not recommended)  
Metric Standard Hardware  
Grade  
Grade 8.8  
Grade 10.9  
Grade 12.9  
10.9  
12.9  
8.8  
Nm  
2
ft./lbs  
2.2  
ft./lbs  
1.5  
Nm  
ft./lbs  
2.7  
Nm  
3.6  
7
M4  
3
M5  
M6  
3
4
4.5  
6
5.2  
5.2  
7
7.5  
10  
8.2  
11  
M7  
8.2  
11  
12  
16  
15  
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  
18  
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P/N 115 149927 IR  
02/12/09  
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