Dixon Lawn Mower Accessory DCG 114883 User Manual

COLLECTION SYSTEM  
Operator’s Manual  
Parts List  
DCG DFS / 114883  
Please read the operator’s manual carefully and make sure you understand  
the instructions before using the machine.  
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INDEX  
Features And Controls............................................................................... 4  
General Information ................................................................................... 5  
Safety Procedures .................................................................................... 5  
Training ........................................................................................... 5  
Preparation ..................................................................................... 5  
Operation ........................................................................................ 5  
MaintenanceAnd Storage................................................................ 6  
Assembly Instructions ............................................................................... 6  
Front Weight Bar............................................................................. 6  
Collection System ........................................................................... 7  
HandleAssembly ............................................................................ 8  
Hopper Door Adjustment................................................................. 9  
Blower Kit........................................................................................ 9  
Operating The Collection System ............................................................. 9  
ServiceAnd Maintenance ........................................................................ 10  
Transport....................................................................................... 10  
Cleaning And Washing .................................................................. 10  
Preventative Maintenance Schedule ............................................. 10  
Storage ......................................................................................... 10  
Caring For Hoses...........................................................................11  
Troubleshooting Guide ...................................................................11  
Cleaning Poly Mesh .......................................................................11  
Parts Lists ............................................................................................... 12  
Hopper ......................................................................................... 12  
Drive Kit ....................................................................................... 13  
Hood Assembly............................................................................ 14  
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.  
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FEATURES  
HOOD  
INLET  
HOSE  
HOPPER  
8059-017  
4
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GENERAL INFORMATION  
General Information  
Inspect the area where the equipment is to be  
used and remove all objects such as rocks, toys  
and wire which can be thrown by the machine.  
This manual will assist you in the safe operation and  
proper maintenance of your Dixon equipment. Read it  
thoroughly before attempting to operate the machine.  
Call your dealer or Dixon if additional information is  
required.  
Use extra care when 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 engine running.  
Allow engine to cool before refueling. Do not  
smoke while fueling or operating equipment. Never  
refuel or drain the machine indoors.  
The following safety symbols are used throughout the  
manual to alert you to information about unsafe  
actions or situations:  
Check that operator’s controls, safety switches,  
hoses, and shields are securely attached  
andfunctioning properly. Do not operate unless  
they are functioning properly.  
DANGER indicates immediate hazards that  
may result in severe injury or death.  
WARNING indicates unsafe actions or  
3 - Operation  
CAUTION indicates unsafe actions or  
situations that may cause injury and/or minor  
equipment or property damage.  
Never run an engine in an enclosed area.  
Only operate in good light, keeping away from  
holes and hidden hazards.  
This equipment should not be modified without the  
manufacturer’s prior written authorization. Doing so  
may not only affect the equipments’ performance and  
durability, but also create safety hazards for the  
operator and the surroundings. Warranty will be void if  
changes are made to the equipment without the  
manufacturer’s prior written authorization.  
Slow down and use extra care on hillsides. Make  
turns gradually and at slow speed. Do not operate  
across the sides of slopes. Operate up and down  
slopes only. Do not operate on steep slopes.  
Turf conditions can affect the machine’s stability.  
Do not operate on wet grass where traction may  
be reduced.  
Safety Procedures  
Do not change the engine governor setting or  
overspeed the engine.  
1 - Training  
Stop equipment and inspect vacuum impeller and  
hoses after striking objects or if an abnormal  
vibration occurs. Make necessary repairs before  
resuming operations.  
Read the Operator’s Manual. If the operator(s) or  
mechanic(s) can not read English it is the owner’s  
responsibility to explain this material to  
them.  
Look behind and down before backing up to  
ensure a clear path.  
Become familiar with the safe operation of the  
equipment, operator’s controls, and safety signs.  
Slow down and use caution when making turns  
and crossing roads and sidewalks. Stop vacuum  
and mower blades if not mowing.  
All operators and mechanics should be trained.  
The owner is responsible for training the users.  
Never let children or untrained people operate or  
service the equipment. Local regulations may  
restrict the age of the operator.  
Do not operate machine under the influence of  
alcohol or drugs.  
Use care when loading or unloading the machine  
into a trailer or truck.  
The owner/user can prevent and is responsible for  
accidents or injuries occurring to themselves,  
other people, and/or property.  
Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
2 - Preparation  
Wear appropriate clothing including hard hat,  
safety glasses and ear protection. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
5
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SAFETY INFORMATION  
4 - Maintenance and Storage  
Assembly Instructions  
Stop engine and disconnect spark plug wire. Wait  
for all movement to stop before adjusting,  
cleaning, or repairing.  
Front Weight Bar  
Tools Required  
Clean grass and debris from muffler and engine to  
help prevent fires. Clean up oil or fuel spillage.  
Ratchet with 3/8" Socket  
3/8" Wrench  
Let engine cool before storing and do not store  
near sparks or open flame.  
Shut off fuel while storing. Do not store fuel near  
flames or drain indoors.  
Mounting Instructions  
Using the weight keepers, attach front weight bar  
to mower at the front caster arms.  
Never allow untrained personnel to service  
machine.  
Secure front weight bar to mower frame with four  
3
8" x 1¼" hex bolts, four 3/8" flat washers, and four  
8" nyloc nuts.  
Keep hands and feet away from moving parts. If  
possible, do not make adjustments with the  
engine running.  
/
/
3
Place all front weights on front weight bar.  
Keep all parts in good working condition and all  
hardware tightened. Replace all worn or damaged  
decals.  
Place hold-down bar over front weights and secure  
to front weight bar using two 3/8" x 1" clevis pins  
and two hair pins.  
WEIGHT BAR HOLD DOWN  
FRONT WEIGHT BAR  
CASTCOUNTERWEIGHT  
WEIGHTKEEPER  
8059-011  
6
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ASSEMBLY  
Collection System  
Tools Required  
Ratchet  
¾" Socket  
Torque Wrench  
½" Wrench  
½" Socket  
9/16" Wrench  
Flat Screw Driver  
5/32" Allen Wrench  
Hacksaw  
11/32" Drill Bit  
Drill  
SUPPORT BRACKET  
9/16" Socket  
5
/8" Socket  
1. Open the mounting kit box and remove all of the  
components.  
2. Place the support bracket on the frame and  
secure with (2) 539 990563, 3/8 x 1 bolts and (2)  
539 976979, 3/8 nyloc nuts.  
3. Place the hitch brackets on the frame and secure  
with (3) 990622, ½ x 1¼ bolts and (3)  
539 101331, ½ nyloc nuts.  
HITCH BRACKET  
8059-009  
4. Place the hitch assembly on the ground behind  
the mower. Place the (2) hitch pins thru the hitch  
and the hitch brackets. Secure the hitch pins with  
the (2) hairpins that are secured with the (2)  
lanyards.  
LANYARD  
HITCHASSEMBLY  
STRAP  
HITCHPIN  
LANYARD  
8059-010  
5. Install the two (2) straps on the hopper with ½"  
bolts and nuts. Install the two (2) support  
brackets on the frame.  
6. Attach hose support rod to the right side of the  
.
unit to keep the right rear tire from rubbing the  
hose.  
SUPPORT  
BRACKET  
8059-011a  
7
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ASSEMBLY  
Handle Assembly  
3. Attach threaded rod to hopper and handle. When  
connected, adjust threaded tube using adjusting  
nuts at both ends. The adjustment will be  
complete when handle is pulled forward and  
hopper door is fully closed.  
1. Attach backing plate and tube support to hopper  
using holes shown in illustration.  
2. Connect handle to tube support using pivot pin.  
4. Adjust handle stop so it goes over the center.  
HANDLE  
RODEND  
PIVOTPIN  
BACKING PLATE  
HOLES  
STOP  
TUBE  
SUPPORT  
ADJUSTMENT  
NUT  
TOHOPPER  
UNIT  
THREADEDTUBE  
BACKING  
PLATE  
ADJUSTMENT  
NUT  
HOPPERFRAME  
RODEND  
8059-008  
8
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ASSEMBLY  
Hopper Door Adjustment  
Operating the Collection System  
Adjust door rods on both sides with adjusting nut so  
door closes evenly. See illustration.  
1. NEVER USE THE COLLECTION SYSTEM  
WITHOUTTHE BLOWERASSEMBLYAND  
HOSES SECURELYATTACHED.  
2. Make sure hoses are connected at both ends.  
Inspect hoses prior to each use.  
3. Do not use the unit on slopes greater than 10  
degrees.  
HOPPER  
HOPPERDOOR  
4. The mower must be running in order to vacuum  
debris through the mower deck.  
DOOR  
RODS  
5. In heavy grass it may be necessary to mow and  
collect at a slower ground speed.  
6. Never attempt to unclog the collection system  
until the mower’s engine has been shut off and all  
moving parts have come to a complete stop.  
7. Do not stand behind the vent at the rear of the  
collection system due to the potential for small  
pieces of blowing debris to escape through the  
vent.  
ADJUSTMENT NUTS  
8059-013  
Blower Kit  
8. Wear eye and ear protection.  
Install Blower Kit per the instructions shipped with the  
blower unit. (114992 for the 52" or 130195 for the 60".)  
9
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SERVICE AND MAINTENANCE  
Storage  
Transport  
1. Clean machine.  
2. Cover all scratches with touch-up paint.  
3. Covered or indoor storage is recommended.  
WARNING  
The collection system hopper must be  
completely empty while driving forward onto a  
trailer. If the mower must be loaded onto a  
trailer while there is still debris in the  
container, the mower must be backed up onto  
the trailer to avoid tipping.  
Cleaning and Washing  
Regular cleaning, washing, and lubricating will prolong  
the service of the machine.  
NOTE: Use care with power washers to avoid damage  
to decals. Limit direct spray on these items.  
DO NOT EXCEED 1000 PSI WATER PRESSURE  
FOR CLEANING.  
For best results, clean polymesh inside hood regularly.  
Instructions for doing this can be found in the Service  
section of this manual  
Preventative Maintenance Schedule  
Item  
Before  
Each Use  
Every  
5 Hours  
Every  
25 Hours  
Every  
50 Hours  
Inspect/Clean Poly Mesh  
Check/Tighten Nuts & Bolts  
Check/Tighten Hoses  
Turn Hose End to End  
Rotate Hose  
X
X
X
X
X
X
X
Clean Machine  
10  
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SERVICE AND MAINTENANCE  
Caring For Hoses  
Cleaning Poly Mesh  
1. Inspect hoses before each use. If hoses have  
excessive wear, tears, or punctures, replace  
immediately.  
The poly mesh on the collection system is located  
inside the container hood. For best results, clean poly  
mesh regularly.  
2. To prolong the life of the hose, periodically rotate  
hose and turn hose end to end. Refer to  
Preventative Maintenance Schedule in this  
manual.  
DO NOT USE THE COLLECTION SYSTEM WITHOUT  
POLY MESH SECURELY IN PLACE.  
3. Avoid twists and sharp turns in the hoses, as they  
will increase wear on the hoses.  
4. Avoid dragging the lower hose along the sides of  
buildings or other hard surfaces.  
Troubleshooting Guide  
DANGER  
Before servicing unit, wait for all moving parts to  
come to a complete stop. Turn engine off and  
remove the spark plug wire.  
PROBLEM  
POSSIBLE CAUSE  
CORRECTION  
Remove hose and clean inlet.  
Inspect and empty.  
Loss of Vacuum.  
Blower, hose or hood inlet clogged.  
Hopper full.  
Fan blades bent or broken.  
Poly mesh plugged.  
Solid object jammed in unit.  
Replace/repair impeller.  
Clean poly mesh.  
Unusual vibration  
or noise  
Check and remove any  
obstruction.  
Loose or missing bolts on unit.  
Bent or damaged fan.  
Tighten or replace bolts.  
Replace/repair impeller.  
Clear obstructions.  
Unit difficult to close.  
Obstructions keeping door  
from completely closing.  
Hood hinge bolts too tight.  
Loosen bolts.  
11  
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HOPPER ASSEMBLY  
37  
38  
20  
2
5
23  
4
3
25  
10  
34  
44  
26  
19  
9
16  
22  
17  
24  
1
2
25  
36  
16  
12  
14  
21  
15  
13  
33  
40  
25  
23  
41  
20  
35  
14  
39  
30  
6
28  
21  
29  
31  
27  
43  
2
24  
8
7
44  
8059-014  
ITEM QTY.  
P/N  
DESCRIPTION  
1......1.... 113754....... WELDMENT - HOPPER  
2......8.... 104808....... PILLOW BLOCK  
3......1.... 113747....... WELDMENT - DOOR  
4......1.... 113755....... PLATE - BACKING  
ITEM QTY.  
P/N  
DESCRIPTION  
5......1.... 113748....... TUBE - SUPPORT, HANDLE  
6......1.... 113746....... WELDMENT - BELL CRANK  
26......1.... 101341....... HCS 3/8-16 x 3 GD 5 ZD  
27......2.... 109232....... PIN CLEVIS 3/8 x 1¼ ZD  
28......2.... 976988....... HAIRPIN COTTER  
29......2.... 990365....... PIN, COTTER 1/8 x ¾ ZD  
30......2.... 108369....... HCS ½-13 x 1¼ GR5 ZD  
31......2.... 109554....... WASHER ½ FLAT ZD  
32......2.... 990563....... HCS 3/8-16 x 1 GR 5 ZD  
33......2.... 990517....... WASHER, 3/8 FLAT STD ZD  
34......1.... 113757....... PLUG - RECTANGULAR TUBING  
35......2.... 113758....... PLUG - SQUARE TUBE  
36......1.... 113731....... BUSHING - BRONZE, 1"  
37... 17.... 200684....... RIVET,3/16 STAVEX  
38......4.... 104807....... REINFORCEMENTBAR  
39 ......2.... 102587....... GROMMET,BUMPER  
40......1.... 0033C ........ GRIP, HANDLE  
7......2.... 977465....... YOKE, 3/8  
F
8......2.... 113722....... ROD - DOOR  
9......1.... 113749....... WELDMENT-PIN, PIVOT  
10......1.... 113750....... GUARD - L.H.  
11......1.... 113751....... GUARD - R.H.  
12......1.... 113790....... HANDLE WELDMENT  
13......2.... 113739....... ROD END - 3/8 - 24 RH  
14......5.... 990122....... WASHER, 3/8 SAE FLT ZD  
15......1.... 113753....... TUBE - THREADED  
16......6.... 990613....... NUT 3/8-16 HEX WHIZLK ZD  
17......4.... 990655....... HCS 3/8-16 x 1½ GR 5 ZD  
18......2.... 107315....... SPRING,BAGGER  
19......2.... 102656....... SPACER  
20......8.... 101721....... HCS 5/16-18 x 2¾ GR 5 ZD  
21......8.... 990717....... NUT 5/16-18 HEX NYLOK ZD  
22......2.... 101572....... HCS ½-13 x 3 GR 5 ZD  
23......4.... 101331....... NUT ½ HEX NYLOK ZD  
24......4.... 108732....... NUT, 3/8-24 HEX JAM ZD  
25......4.... 976979....... NUT 3/8-16 HEX NYLOK ZD  
41......4.... 990692....... WASHER, 5/16 STD FLT ZD  
42......1.... 976978....... NUT ¼-20 HEX NYLOK ZD  
43......1.... 115392....... FLEX HOSE - 60"  
44......1.... 115719....... HOSECLAMP  
......1.... 111260....... DECAL,VENTILATION  
12  
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DRIVE KIT ASSEMBLY  
4
5
10  
9
3
6
13  
17  
12  
21  
7
11  
11  
14  
16  
8
1
10  
15  
2
11  
12  
18  
8059-015  
14  
15  
ITEM QTY.  
P/N  
DESCRIPTION  
ITEM QTY.  
P/N  
DESCRIPTION  
1.... 1 ... 111199 ...... HITCH BRKT WELDMENT, LT  
2.... 1 ... 111201 ...... HITCH BRKT WELDMENT, RT  
3.... 1 ... 20255 ........ FRONTWEIGHTBAR  
4.... 1 ... 111313 ...... HOLD DOWN, WEIGHT BAR  
5.... 2 ... 102049 ...... CLEVIS PIN  
10.... 8 ... 976979 ...... NUT 3/8-16 HEX NYLOK ZD  
11..10 ... 101331 ...... NUT ½ HEX NYLOK ZD  
12..10 ... 990622 ...... BOLT ½-13 X 1¼ WHIZLK ZD SP  
13.... 4 ... 990563 ...... HCS 3/8-16 X 1 GR 5 ZD  
14.... 2 ... 102563 ...... LANYARD  
6.... 2 ... 108096 ...... SPRING RETAINER  
7.... 2 ... 111259 ...... WEIGHT KEEPER  
8.... 4 ... 976941 ...... HCS 3/8-16 X 1¼ GR 5 ZD  
9.... 4 ... 990517 ...... WASHER, 3/8 FLAT STD. ZD  
15.... 2 ... 111206 ...... HITCH PIN  
16.... 2 ... 111192 ...... HAIRPIN  
17.... 2 ... 111215 ...... SUPPORT BRACKET  
18.... 2 ... 114674 ...... STRAP  
13  
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HOOD ASSEMBLY  
1
5
7
9
11  
9
8
3
4
8
9
10  
8059-018  
4
6
2
ITEM P/N  
QTY.  
DESCRIPTION  
ITEM P/N  
QTY.  
DESCRIPTION  
1 ... 539 111172 .... 1 ..HOOD  
7 ... 539 976978 .... 8 ..NUT, ¼-20, NYLOK  
2 ... 539 111175 .... 2 ..SUPPORT, DRAW LATCH  
3 ... 539 111182 .... 1 ..INLET TUBE  
4 ... 539 111183 .... 1 ..MESH,POLYDIAMOND  
5 ... 539 102587 .... 6 ..GROMMET,BUMPER  
6 ... 539 105408 .. 21 ..WASHER, #10  
8 ... 539 991003 .... 8 ..HCS, ¼-20 x 1¾, GR5  
9 ... 539 990598 .. 16 ..WASHER, ¼  
10 ... 539 102744 .... 7 ..RIVET, 3/16 x ¼  
11 ... 539 200684 .. 25 ..RIVET,3/16,STAVEX  
14  
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Part No. 539 130680R1  
01/07  
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