Dixon SpeedZTR 539 131188 User Manual

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Operator and

Parts Manual

Grass Catcher

Dixon SpeedZTR 30

Kit 539 131188

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, please contact your nearest authorized service center/ department. They have competent, well-trainedtechnicians and the proper tools for service and repairs.

Please read and retain this manual. The instructions will enable you to assemble and maintain your Grass Catcher 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.

©2007 HTC. All Rights Reserved.

Beatrice, NE. Printed in U.S.A.

2

TABLE OF CONTENTS

 

SAFETY RULES .......................................................................................................................

4-6

CARTON CONTENTS ..................................................................................................................

7

ASSEMBLY ..........................................................................................................................

8 - 12

OPERATION ...............................................................................................................................

12

CUSTOMER RESPONSIBILITIES..............................................................................................

13

PARTS ................................................................................................................................

14 - 17

TORQUE SPECIFICATIONS ......................................................................................................

18

3

SAFETY RULES

SAFE OPERATION PRACTICES FORRIDE-ONMOWERS

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

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.

Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mower-relatedinjuries. 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.

II. SLOPE OPERATION

Slopes are a major factor related to loss-of-control andtip-overaccidents, 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

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 andgradual. 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.

4

SAFETY RULES

SAFE OPERATION PRACTICES FORRIDE-ONMOWERS

DO NOT

Do not turn on slopes unless necessary, and then, turn slowly and gradually downhill, if possible.

Do not mow neardrop-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.

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 there 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 RULES

SAFE OPERATION PRACTICES FORRIDE-ONMOWERS

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

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

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.

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.

CAUTION

Look for this symbol to point out important safety precautions. It means CAUTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.

6

UNPACKING INSTRUCTIONS

CARTON 1 CONTENTS

 

 

• Remove all parts and packing materials from

1

- Upper Chute

1 - Owner’s Manual

both cartons.

1 - Flex Hose

1

- Hanger Bracket

• Check carton contents against list. Be sure all

1

- Discharge Adapter

1

- Adapter Bracket

parts are there.

1 - Guard Reinforcement

1

- Booster Ring

 

1 - Weight Kit

2

- Hi Lift Adapter

 

1

- Bag of Hardware

 

 

 

CARTON 2 CONTENTS

 

1 - Cover Assembly 2 - Soft Bag Containers

PARTS IDENTIFICATION

1 - Bag of Hardware

COVER

ASSEMBLY

FLEX HOSE

GRASS

DISCHARGE ADAPTER

CATCHER

 

CONTAINERS

 

NOTE: When right hand (R.H.) and left hand (L.H.) 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

ASSEMBLY

1BAGGER SUPPORT ASSEMBLY

1.Remove the two upper side bolts on the engine guard as illustrated. Set hardware aside for reuse.

2.Attach guard reinforcement to engine guard using hardware removed in Step 1.

3.Attach hanger bracket to guard reinforcement with two 5/16 x ¾ carriage bolts and two5/16 nyloc nuts. See illustration.

4.After the hanger bracket is attached to the guard reinforcement, two holes will need to be drilled through the engine guard for the matching bottom holes of the hanger bracket.

5.Use the bottom hanger bracket holes as a template to drill the two 11/32 holes.

2MOUNTING COVER ASSEMBLY TO

SUPPORT ASSEMBLY

NOTE: For ease of assembly, you may wish assistance from another person for mounting the cover assembly to mower.

1.Position cover assembly on ground behind mower .

2.Lift and rotate cover to align cover bracket with hanger bracket and slide down until secure.

Hanger Bracket

Frame Bracket

Guard Reinforcement

Hanger

Bracket

Engine Guard

Drill two 11/32 holes into engine guard to match these holes

Existing Hardware

8

ASSEMBLY

3CONTAINER MOUNTING

1.Install container, centering between support tubes.

NOTE: One container should always overlap the other container at supports.

2.Close cover and lock latch handles over center support tubes.

Cover Latch

Handle

Containers

Support

Tubes

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.

4BOOSTER RING

1.Remove mower deck from machine. Refer to Operator’s Manual, if necessary.

2.Install the high lift adapters to existing high lift mower blade. This combination provides the highest lift possible. Results may vary depending on mowing conditions and the type and heaviness of grass to be bagged. If desired, high lift adapters may be removed, though high lift blades must remain in the deck when using a grass catcher.

3.Position the booster ring on the bottom of the deck. Attach the booster ring to deck with the bolts and washers to the outside of the ring.

Refer to illustration. Secure with nyloc nuts.

WARNING

Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling.

4.Spin the mower blade several times to check for sufficient clearance. CONTACT WITH BLADE WILL DAMAGE BOOSTER RING AND MAY RESULT IN SERIOUS INJURY.

5.Reinstall deck to machine. Refer to Operator's Manual, if necessary.

blade rotation

Booster

Ring

9

ASSEMBLY

5LOWER CHUTE

1.Turn mower engine off.

2.Remove grass deflector on mower by pulling hair pin cotter and deflector pin. Set aside to reuse. The deflector and spring may be stored for future use when not using the bagger.

3.Attach adapter bracket to discharge adapter with bolts, washers and nuts as illustrated below.

6FLEX HOSE

1.Slide flex hose onto open end of discharge adapter.

2.Thread hose clamp around flex hose and discharge adapter. Pull tight.

¼-20Nut

Washer

¼-20x ¾ Hex

3.Align the discharge adapter into the deck’s deflector mounting bracket and insert the deflector pin. Secure with the hair pin cotter.

CAUTION

Before removing deflector shield, turn mower engine off.

Flex Hose

Hose Clamp

Discharge

Adapter

Discharge Adapter

Adapter

Mower Deflector

Bracket

 

Deflector Pin

 

Deflector

Mounting Bracket

10

ASSEMBLY

7UPPER CHUTE

1.Slide opposite flex hose end into upper chute.

2.Push upper chute through the gasketed opening in the cover assembly.

3.Rotate flex tube and upper chute so that the chute opening is downwards toward the container bags.

8FRONT WEIGHTS

1.Center the weight box on the front face of foot plate, as illustrated. Use the holes in weight box as a template to mark and drill four 11/32" diameter holes in foot plate.

2.Attach the weight box to foot plate with four 5/16-18x ½" carriage bolts and5/16" nyloc nuts.

3.Install weight in weight box.

Cover Gasket

Rotate Upper Chute

to point downwards CAUTION towards bags

DO NOT operate mower with grass catcher, unless the front weights are installed.

Weight Box

Install Weight

In Box

11

OPERATION

TIPS FOR IMPROVED BAGGING OPERATION

Follow the mower operation instructions in your mower operator’s manual.

When operating your grass catcher on a lawn where grass and leaf bagging equipment has not been used, you are picking up thatch and debris that has accumulated for long periods of time. The amount collected and the total time of operation may be greater than you will experience with regular use of your 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 (for replacement bags refer to REPLACEMENT PARTS).

g.Repeat for other containers.

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 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.

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, engage parking brake and stop engine.

-Unlatch and raise cover.

-Slide out containers and dispose of clippings.

-Replace containers, close cover, and latch.

b.Check for clogging.

-Remove all debris in chute.

-Reassemble 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.

12

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.

CAUTION

BEFORE PERFORMING ANY MAINTENANCE, SERVICE OR ADJUSTMENTS:

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 have completely stopped.

Disconnect spark plug wire(s) from spark plug(s) and place wire where it cannot come in contact with plug.

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

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

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

 

8

 

 

2

 

 

 

9

4

9

11

 

 

 

9

 

9

 

 

10

7

 

 

 

8

 

 

8

5

 

6

 

3

 

 

14

1

12

13

15

14

PARTS

ITEM P/N

QTY.

DESCRIPTION

ITEM

P/N

QTY.

DESCRIPTION

1 ..

532 124670

.... 1...

RETAINER SPRING

9 ..

539 991034

.... 8...

10-24x5/8 WASHER HD ZD

2 ..

532 127533 ....

1...

SCREEN, COVER

10 ..

532 414173

.... 1...

STRIP, REINFORCEMENT

3 ..

539 108100 ....

1...

GASKET, COVER

11 ..

532 160274

.... 1...

COVER, TOP

4 ..

532 130895 ....

1...

LATCH HANDLE, COVER

12 ..

532 174083....

3...

CAP, PLUG TUBING END

5 ..

532 132796 ....

1...

SPRING, COVER LT

13 ..

532 414172 ....

1...

FRAME ASSEMBLY, 2-BIN

6 ..

532 132983 ....

1...

SPRING, COVER RT

14 ..

532 192786....

1...

PIN, HINGE PIVOT

7 ..

532 133235 ....

1...

SPACER, COVER

15 ..

532 400226....

2...

CONTAINER BAG, SOFT

8 ..

539 976977 ....

8...

NUT, 10-24HEX W/NYLOC

 

 

 

 

15

PARTS

14

7

12

13 17

17

19

615

 

 

3

 

 

 

17

17

 

 

19

 

 

 

5

4

19

 

 

 

 

9

 

 

 

 

 

18

 

 

 

16

 

 

17

15

19 16

18

10

11

1

2

8

16

PARTS

ITEM

P/N

QTY.

DESCRIPTION

ITEM

P/N

QTY.

DESCRIPTION

1 ..

539 108397

.... 6 ...

HCS 5/16-24x7/8 GR5 ZD

11 ..

539 121399

.... 1...

WEIGHT

2 ..

539 110943

.... 6 ...

NUT 5/16-24NYLOC

12 ..

539 131153 ....

1...

BRACKET, HANGER

3 ..

539 131351

.... 1 ...

DSCHRG ADPTR W/DECAL

13 ..

539 131157 ....

1...

REINFORCEMENT, GUARD

4 ..

539 115352 ....

1 ...

DSCHRG MTNG BRKT

14 ..

539 131190 ....

1...

UPPER CHUTE

5 ..

539 115401 ....

1 ...

DECAL, WARNING

15 ..

539 976978 ..

12 ...

NUT ¼-20HEX NYLOC ZD

6 ..

539 115719 ....

1 ...

HOSE CLAMP

16 ..

539 990055 ..

12...

WASHER, ¼ FLAT SAE ZD

7 ..

539 115938 ....

1 ...

FLEX HOSE

17 ..

539 990316 ..

10 ...

RHSNB 5/16-18x ¾ GR5 ZD

8 ..

539 116336 ....

2 ...

HI LIFT ADAPTER

18 ..

539 990580 ..

12 ...

HCS ¼-20x ¾ GR5 ZD

9 ..

539 119910 ....

1 ...

BOOSTER RING

19 ..

539 990717 ..

10 ...

NUT 5/16-18HEX NYLOC ZD

10 ..

539 120206 ....

1 ...

WEIGHT BOX

 

 

 

 

17

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 in inches, fine or coar

Grade

SAE grade 5

 

SAE grade 8

 

Flangelock Screw

 

 

w/ Flangelock Nut

 

 

Nm

ft./lbs

 

 

ft./lbs

Nm

ft./lbs

Nm

1/4

9

12

13

18

 

 

 

5/16

18

24

28

38

24

33

 

3/8

31

42

46

62

40

54

 

7/16

50

68

75

108

 

 

 

1/2

75

102

115

156

 

 

 

9/16

110

150

165

224

 

 

 

5/8

150

203

225

305

 

 

 

3/4

250

339

370

502

 

 

 

7/8

378

513

591

801

 

 

 

1

583

790

893

1211

 

 

1

1/8

782

1060

1410

1912

 

 

** Grade 5 - Minimum commercial quality (Lower quality not recommended)

Metric Standard Hardware

Shank Size (Diameter in millimeters, fine or coarse

Grade

Grade 8.8

8.8

Grade 10.9

10.9

Grade 12.9

12.9

 

 

 

 

 

ft./lbs

Nm

ft./lbs

Nm

ft./lbs

Nm

M4

1.5

2

2.2

3

2.7

3.6

M5

3

4

4.5

6

5.2

7

M6

5.2

7

7.5

10

8.2

11

M7

8.2

11

12

16

15

20

M8

13.5

18

18.8

25

21.8

29

M10

24

32

35.2

47

43.5

58

M12

43.5

58

62.2

83

75

100

M14

70.5

94

100

133

119

159

M16

108

144

147

196

176

235

M18

142

190

202

269

242

323

M20

195

260

275

366

330

440

M22

276

368

390

520

471

628

M24

353

470

498

664

596

794

M27

530

707

474

996

904

1205

539-131193IR

05/07