Dixon Lawn Mower Accessory 539130211 User Manual

Collection System  
Operators Manual  
539130211 - DCKC  
539130212 - DCRC  
Models:  
Parts Manual  
Please read these instructions carefully and make  
sure you understand them before using the machine.  
MANUAL NO. 539 130679 REV IR (02/06/07)  
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SAFETY RULES  
Safety Procedures  
General Information  
This manual will assist you in the safe operation  
and proper maintenance of your Husqvarna  
equipment. Read it thoroughly before attempting  
to operate the machine. Call your dealer or Dixon  
if additional information is required.  
1 - Training:  
• 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.  
• Become familiar with the safe operation of the  
equipment, operator’s controls, and safety  
signs.  
The following safety symbols are used throughout  
the manual to alert you to information about unsafe  
actions or situations:  
• 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.  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to themselves,  
other people, and/or property.  
DANGER indicates immediate hazards that  
may result in severe injury or death.  
WARNING indicates unsafe actions or  
situations that may cause severe injury,  
death, and/or major equipment or property  
damage.  
2 - Preparation:  
CAUTION indicates unsafe actions or  
situations that may cause injury and/or  
minor equipment or property damage.  
• Wear appropriate clothing including hard hat,  
safety glasses and ear protection. Long hair,  
loose clothing or jewelry may get tangled in  
moving parts.  
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.  
• 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.  
• 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.  
• Check that operator’s controls, safety switches,  
hoses, and shields are securely attached and  
functioning properly. Do not operate unless  
they are functioning properly.  
5
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SAFETY RULES  
3 - Operation  
Use care when loading or unloading the machine  
into a trailer or truck.  
Use care when approaching blind corners,  
shrubs, trees, or other objects that may obscure  
vision.  
Never run an engine in an enclosed area.  
• Only operate in good light, keeping away from  
holes and hidden hazards.  
• 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.  
• Do not change the engine governor setting or  
overspeed the engine.  
• Stop equipment and inspect vacuum impeller  
and hoses after striking objects or if an abnormal  
vibration occurs. Make necessary repairs before  
resuming operations.  
• Look behind and down before backing up to  
ensure a clear path.  
• Slow down and use caution when making turns  
and crossing roads and sidewalks. Stop vacuum  
and mower blades if not mowing.  
Do not operate machine under the influence of  
alcohol or drugs.  
4 - Maintenance and Storage:  
Stop engine and disconnect spark plug wire.  
Wait for all movement to stop before adjusting,  
cleaning, or repairing.  
Clean grass and debris from muffler and engine  
to help prevent fires. Clean up oil or fuel  
spillage.  
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.  
Never allow untrained personnel to service  
machine.  
Keep hands and feet away from moving parts.  
If possible, do not make adjustments with the  
engine running.  
Keep all parts in good working condition and all  
hardware tightened. Replace all worn or  
damaged decals.  
6
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ASSEMBLY  
Assembly Instructions  
Tools Required:  
Ratchet  
(2) 3/4" Wrench  
3/4" Socket  
Flat Screw Driver  
Torque Wrench  
1/2" Wrench  
1/2" Socket  
9/16" Wrench  
9/16" Socket  
(2) 1” Wrench - open end  
RAM/RAM MAG  
REAR GUARD  
1. Remove clamshell from crate.  
2. Remove two 5/16 x 3/4 carriage bolts from  
the lower flange of the rear guard on the  
mower.  
3. Place (539 114781) Mount Bracket, Lower  
in place and secure using four (539 111785)  
3/8 x 3/4 carriage bolts, four (539 976979) 3/  
8 nyloc hex nut and two (539 107271) 5/16 x  
1 carriage bolts. Reuse the two 5/16 nyloc  
hex nuts previously removed from the 5/16 x  
3/4 carriage bolts. See Figure 1.  
LOWER FLANGE  
539 114781 MOUNT BRACKET, LOWER  
FIGURE 1  
539 114786 PLATE,  
SUPPORT, LINKAGE  
4. Lift seat and latch with seat latch.  
5. Remove seat springs.  
6. Place (539 114786) Plate, Support, Linkage  
on frame.  
7. Reposition springs and secure with (990209)  
5/16 x 1 hex bolts and hex nut previously  
removed from seat springs. See Figure 2.  
8. Attach two (539 114783) Linkage, Support  
to the clamshell assembly as shown in Fig-  
ure 2.  
9. Secure with two (539 100476) 5/8 hex jam  
nut and two (539 115591) 5/8 nyloc hex nut  
as shown. Do not tighten nuts.  
FIGURE 2  
7
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ASSEMBLY  
10. Lift Clamshell assembly onto (539 114781)  
Mount Bracket, Lower. Position tubes on  
bottom of clamshell on out side of the tubes  
on (539 114781) Mount Bracket, Lower.  
539 114782  
BRACKET  
11. Secure with (539 119372) Hinge Pin and (539  
115501) Cotter Pin.  
12. Hook both (539 114783) Linkage, Support  
into (539 114786) Plate, Support, Linkage  
and secure with two remaining (539 115501)  
Cotter Pins.  
CLAMSHELL  
ASSEMBLY  
13. Tighten (539 100476) 5/8 Jam nut and (539  
115591) 5/8 Nyloc nut so that the clamshell  
is sitting straight on unit.  
539 114812 LINKAGE,  
SUPPORT  
FIGURE 3  
14. Tighten (539 114782) Brackets on front of  
clamshell.  
8
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ASSEMBLY  
KODIAK  
1. Remove clamshell from crate.  
REAR GUARD  
2. Remove two 5/16 x 3/4 carriage bolts from  
the lower flange of the rear guard on the  
mower.  
3. Place (539 114815) Mount Bracket, Lower  
in place and secure using four (539 111785)  
3/8 x 3/4 carriage bolts, four (539 976979) 3/  
8 nyloc hex nut and two (539 107271) 5/16 x  
1 carriage bolts. Reuse the two 5/16 nyloc  
hex nuts previously removed from the 5/16 x  
3/4 carriage bolts. See Figure 4.  
LOWER FLANGE  
539 114815 MOUNT BRACKET, LOWER  
FIGURE 4  
539 114811 BRACKET, SUPPORT  
4. Secure two (539 114811) Bracket, Support  
to frame as shown in Figure 5. Secure us-  
ing (539 103433) 1/2 x 3 1/4 hex bolt and  
(539 101331) 1/2 hex nyloc nut.  
FIGURE 5  
FIGURE 3  
9
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ASSEMBLY  
5. Attach two (539 114812) Linkage, Support  
to the clamshell assembly as shown in Fig-  
ure 6.  
6. Secure with two (539 100476) 5/8 hex jam  
nut and two (539 115591) 5/8 nyloc hex nut  
as shown. Do not tighten nuts.  
539 114782  
BRACKET  
7. Lift Clamshell assembly onto (539 114815)  
Mount Bracket, Lower. Position tubes on  
bottom of clamshell on out side of the tubes  
on (539 114781).  
8. Secure with (539 119372) Hinge Pin and (539  
115501) Cotter Pin.  
CLAMSHELL  
ASSEMBLY  
9. Hook both (539 114812) Linkage, Support  
into (539 114811) Bracket, Support and se-  
cure with two remaining (539 115501) Cot-  
ter Pins.  
539 114812 LINKAGE,  
SUPPORT  
FIGURE 6  
10. Tighten (539 100476) 5/8 Jam nut and  
(115591) 5/8 Nyloc nut so that the clamshell  
is sitting straight on unit.  
11. Tighten (539 114782) Brackets on front of  
clamshell.  
10  
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ASSEMBLY  
FRONT WEIGHTS - RAM  
CAUTION  
1. Bolt cast weight and two weight brackets to-  
gether using four bolts (539 106492, 3/8 x 2  
3/4”) and four nuts (539 976979, 3/8” nyloc).  
2. Slide both weight brackets over the front tube  
on the frame. Be sure to position in the cen-  
ter of the frame.  
DO NOT operate mower with grass catcher,  
unless the front weights are installed.  
3. Secure with four bolts (539 991126, 3/8 x 3  
3/4”) and four nuts (539 976979, 3/8”  
nyloc).  
BRACKET  
539 976979  
539 991126  
539 106492  
CAST WEIGHT  
539 976979  
11  
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ASSEMBLY  
FRONT WEIGHTS - KODIAK  
1. Remove mower foot plate and floor pan.  
2. Align weight bar to the front of the frame.  
See diagram.  
3. Secure weight bar to mower frame with four  
5/16-18 x 1 1/4” hex bolts from kit, reuse the  
four 5-16” washers and four 5/16” nyloc nuts  
that were removed from the foot plate.  
4. Place all front weights on front weight bar.  
5. Place holddown bar over front weights and  
secure to front weight bar using two 3/8” x 1”  
clevis pins and two hair pins.  
6. Reinstall floor pan.  
WEIGHT BAR HOLD DOWN  
CAST COUNTERWEIGHT  
FRONT WEIGHT BAR  
12  
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OPERATION  
Operating the Collection System  
1. NEVER USE THE COLLECTION SYSTEM  
WITHOUT THE BLOWER ASSEMBLY  
AND HOSES SECURELY ATTACHED.  
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.  
4. The mower must be running in order to  
vacuum debris through the mower deck.  
5. In heavy grass it may be necessary to mow  
and collect at a slower ground speed.  
6. Never attempt to unclog the collection sys-  
tem until the mower’s engine 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.  
8. Wear eye and ear protection.  
13  
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SERVICE AND MAINTENANCE  
Transport  
For best results, clean poly mesh inside hood regu-  
larly. Instructions for doing this can be found in  
the Service section of this manual.  
WARNING  
The collection system must be completely  
empty or removed while driving forward onto  
a trailer. If the mower must be loaded onto  
a trailer while there is still debris in the con-  
tainer, the mower must be backed up onto  
the trailer to avoid tipping.  
Storage  
Cleaning and Washing  
1. Clean machine.  
Regular cleaning, washing, and lubricating will  
prolong the service of the machine.  
2. Cover all scratches with touch-up paint.  
3. Covered or indoor storage is recommended.  
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.  
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  
14  
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SERVICE AND MAINTENANCE  
Caring For Hoses  
1. Inspect hoses before each use. If hoses have  
excessive wear, tears, or punctures, replace  
immediately.  
2. To prolong the life of the hose, periodically ro-  
tate hose and turn hose end to end. Refer to  
Preventative Maintenance Schedule in this  
manual.  
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.  
Cleaning Poly Mesh  
The poly mesh on the collection system is located  
inside the container hood. For best results, clean  
poly mesh regularly.  
Cleaning Instructions  
1. Shut off engine.  
2. Release the two (2) rubber latches under the  
rear of the hood. Open hood and brush debris  
off of both sides.  
3. Close hood and re-latch.  
DO NOT USE THE COLLECTION SYSTEM  
WITHOUT POLY MESH SECURELY IN PLACE.  
15  
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SERVICE AND MAINTENANCE  
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  
Loss of Vacuum.  
1. Hose or hood inlet clogged.  
2. Container full.  
1. Remove hose and clean inlet.  
2. Inspect and empty.  
3. Poly mesh plugged.  
3. Clean poly mesh.  
Unusual vibration  
or noise.  
1. Solid object jammed in unit.  
2. Loose or missing bolts on unit.  
1. Check and remove any  
obstruction.  
2. Tighten or replace bolts.  
Unit difficult to close.  
1. Obstructions keeping door from  
completely closing.  
2. Hood hinge bolts too tight.  
1. Clear obstructions.  
2. Loosen bolts.  
16  
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PARTS  
ILLUSTRATIONS  
17  
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CLAMSHELL ASSEMBLY  
4
REF.  
1
3
3
2
7
REF.  
8
9
5
6
10  
18  
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CLAMSHELL ASSEMBLY  
ITEM PART NO.  
QTY.  
DESCRIPTION  
1.. 539 990629 ... 2... HCS 3/8-16 X 2 1/4, GR5  
2.. 539 200282 ... 2... NUT, 3/8-16, HAM, NYLOC  
3.. 539 990122 ... 3... WASHER, 3/8, SAE  
4...539 115972 ... 2... BUSHING  
5.. 539 990717 ... 1... NUT, 5/16-18, NYLOC  
6...539 119414 ... 1... BUSHING, PLASTIC  
7...539 117244 ... 1... ROD END  
8...539 115609 ... 1... NUT, 1/2-13, THIN, NYLOC  
9.. 539 990625 ... 1... NUT, 1/2-13, JAM  
10...539 119371 ... 1... LIFT LINK  
19  
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CLAMSHELL REAR ASSEMBLY  
1
12  
16  
3
13  
17  
7
18  
15  
10  
11  
10  
2
9
19  
12  
8
6
5
4
10  
18  
14  
18  
10  
20  
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CLAMSHELL REAR ASSEMBLY  
ITEM PART NO.  
QTY.  
DESCRIPTION  
1...539 117967 ... 1... REAR FRAME  
2...539 119396 ... 2... STRAP  
3...539 119367 ... 1... HOOK LATCH  
4...539 119377 ... 1... CLAMSHELL BACK  
5...539 119458 ... 1... STRAP  
6...539 117543 ... 1... CHAMSHELL VENT  
7...539 115677 ... 2... CLIP NUT, 5/16-18  
8...539 119412 ... 1... VENT SCHREEN  
9...539 115789 ... 3... NYLON WASHER  
10.. 539 990188 . 17... WASHER, 5/16, SAE  
11.. 539 107271 ... 6... RHSSNB, 5/16C X 1.0  
12.. 539 100472 ... 7... RHSNB, 5/16-18 X 1 1/4, GR5  
13.. 539 990254 ... 1... LOCKWASHER, 1/2  
14.. 539 990316 ... 2... RHSNB, 5/16-18 X 3/4, GR5  
15.. 539 990206 ... 2... HCS, 5/16-18 X 3/4, GR5  
16...539 115609 ... 1... NUT, 1/2-13, THIN, NYLOC  
17.. 539 990625 ... 1... NUT, 1/2-13, JAM  
18.. 539 990717 . 15... NUT, 5/16-18, NYLOC  
19...539 119413 ... 6... LARGE DOME RIVET  
21  
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CLAMSHELL FRONT ASSEMBLY  
6
8
16  
16  
23  
13  
23  
7
5
18  
17  
18  
27  
18  
24  
23  
2
18  
23  
19  
10  
4
3
22  
18  
14  
1
19  
20  
11  
15  
20  
25  
26  
25  
28  
12  
9
21  
21  
22  
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CLAMSHELL FRONT ASSEMBLY  
ITEM PART NO.  
QTY.  
DESCRIPTION  
1...539 119410 ... 1... FRONT FRAME  
2...539 119409 ... 2... STRAP  
3...539 119368 ... 2... STRAP  
4...539 117986 ... 1... LIFT SHAFT  
5...539 119376 ... 1... CLAMSHELL, FRONT  
6...539 115596 ... 2... CLEVIS PIN, 5/16  
7...539 115489 ... 2... RETAINING RING  
8...539 119433 ... 1... DEFLECTOR  
9...539 114779 ... 1... MOUNT, LOWER, CLAMSHELL  
10...539 119458 ... 1... STRAP  
11...539 121194 ... 1... CLAMSHELL SPACER  
12...539 114782 ... 2... BRACKET, SUPPORT  
13...539 115441 ... 1... WINDOW  
14...539 114785 ... 2... BRACKET, SUPPORT, UPPER  
15...539 117988 ... 2... SPACER PLATE  
16...539 115495 ... 4... WASHER, 11/32  
17...539 115560 . 10... WASHER  
18.. 539 990188 . 23... WASHER, 5/16, SAE  
19.. 539 107271 ... 6... RHSSNB, 5/16C X 1.0  
20.. 539 100472 ... 6... RHSNB, 5/16-18 X 1 1/4, GR5  
21.. 539 102933 ... 9... RHSNB, 5/16-18 X 1 1/2, GR5  
22.. 539 990316 ... 2... RHSNB, 5/16-18 X 3/4, GR5  
23.. 539 990717 . 23... NUT, 5/16-18, NYLOC  
24...539 115661 . 10... POP RIVE, 5/32  
25.. 539 990563 ... 4... HCS, 3/8-16 X 1, GR5  
26.. 539 990517 ... 2... WASHER, 3/8  
27...539 119413 ... 6... LARGE DOME RIVET  
28.. 539 976979 ... 4... NUT, 3/8-16, NYLOC  
23  
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CLAMSHELL LINKAGE - RAM  
17  
18  
8
10  
9
10  
12  
11  
4
5
16  
7
6
13  
15  
1
5
2
14  
3
24  
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CLAMSHELL LINKAGE - RAM  
ITEM PART NO.  
QTY.  
DESCRIPTION  
1...539 116443 ... 1... BAR SLEEVE  
2...539 119372 ... 1... HINGE PIN  
3...539 114781 ... 1... BRACKET, MOUNT, LOWER  
4...539 114783 ... 2... LINKAGE, SUPPORT  
5...539 115501 ... 3... HAIR PIN COTTER, 1/8 DIA. X 1 3/4  
6...539 114786 ... 1... BRACKET, SUPPORT, LINKAGE  
7...539 114824 ... 1... LINKAGE, ARM, DUMP  
8...539 114816 ... 1... LINKAGE, LATCH  
9.. 539 990188 ... 1... WASHER, 5/16, SAE  
10.. 539 990717 ... 3... NUT, 5/16-18, NYLOC  
11...539 110340 ... 1... NUT, 5/8-11C, NYLOC  
12.. 539 100476 ... 2... NUT, 5/8-11, JAM  
13... 539 111785 ... 4... RHSNB, 3/8-16 X 3/4, GR5  
14.. 539 976979 ... 4... NUT, 3/8-16, NYLOC  
15.. 539 107271 ... 2... RHSSNB, 5/16C X 1  
16.. 539 990209 ... 3... HCS, 5/16-18 X 1, GR5  
17...539 115392 ... 1... FLEX HOSE - 60"  
18...539 115719 ... 1... HOSE CLAMP  
25  
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CLAMSHELL LINKAGE - KODIAK  
15  
13  
1
12  
6
5
6
10  
8
16  
18  
4
14  
3
7
3
19  
11  
9
17  
2
10  
26  
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CLAMSHELL LINKAGE - KODIAK  
ITEM PART NO.  
QTY.  
DESCRIPTION  
1...539 116443 ... 1... BAR SLEEVE  
2...539 119372 ... 1... HINGE PIN  
3...539 115501 ... 3... HAIR PIN COTTER, 1/8 DIA. X 1 3/4  
4...539 114816 ... 1... LINKAGE, LATCH  
5.. 539 990188 ... 1... WASHER, 5/16, SAE  
6.. 539 990717 ... 3... NUT, 5/16-18, NYLOC  
7...539 110340 ... 1... NUT, 5/8-11C, NYLOC  
8.. 539 100476 ... 2... NUT, 5/8-11, JAM  
9... 539 111785 ... 4... RHSNB, 3/8-16 X 3/4, GR5  
10.. 539 976979 ... 4... NUT, 3/8-16, NYLOC  
11.. 539 107271 ... 2... RHSSNB, 5/16C X 1  
12...539 115392 ... 1... FLEX HOSE - 60"  
13...539 115719 ... 1... HOSE CLAMP  
14... 539 114811 ... 2... BRACKET, SUPPORT  
15...539 114813 ... 1... DUMP ARM, KODIAK  
16...539 114812 ... 2... LINKAGE SUPPORT  
17...539 114815 ... 1... PLATE MOUNT, SUPPORT  
18.. 539 101331 ... 2... NUT, 1/2, NYLOC  
19.. 539 103433 ... 2... HCS, 1/2-13 X 3 1/4, GR5  
27  
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WEIGHT KIT - RAM  
4
5
3
4
2
1
5
ITEM PART NO.  
QTY.  
DESCRIPTION  
1... 539 111587 ... 1... CAST WEIGHT  
2...539 114898 ... 2... BRACKET, WEIGHT  
3.. 539 106492 ... 4... HCS, 3/8-16 X 2 3/4, GR5  
4...539 991126 ... 4... HCS, 3/8-16 X 3 3/4, GR5  
5.. 539 976979 ... 8... NUT, 3/8-16, NYLOC  
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WEIGHT KIT - KODIAK  
2
1
5
6
3
8
7
4
ITEM PART NO.  
QTY.  
DESCRIPTION  
1... 539 111313 ... 1... HOLD DOWN, WEIGHT BAR  
2.. 539 102049 ... 2... CLEVIS PIN  
3.. 539 108096 ... 2... SPRING RETAINER  
4...539 114858 ... 1... WEIGHT BAR  
5.. 539 990627 ... 4... HCS, 5/16-18 X 1 1/4, GR5  
6.. 539 977778 ... 1... ABRASIVE PAD  
7.. 539 102587 ... 3... GROMMET, BUMPER  
8.. 539 000019 ... 3... WEIGHT CAST, FRONT  
...539 102115 ... 4... PLASTIC TIE (NOT SHOWN)  
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