1. Read the operator’s manual carefully and familiarize yourself with the proper use of your attachment. Do not allow
anyone who is not acquainted with the Safety Instructions to use your attachment.
2. Know the controls and how to stop quickly. READ THE OPERATOR’S MANUAL!
3. Do not allow children to operate the vehicle. Do not allow adults to operate it without proper instruction.
4. Be especially watchful of children and pets darting into the area while operating.
5. Keep your eyes and mind on your unit while mowing or operating your attachment. Don’t let others distract you.
6. Do not attempt to operate your unit or mower when not in the driver’s seat.
7. Always stop unit when emptying the container.
8. Stop unit, shut off deck attachment, set parking brake, shut off mower engine and remove spark plug wire before
removing clogs, removing or replacing hose, boot, blower cone, or performing any maintenance.
9. Mow across the face of slopes (not steeper than 10 degrees); never up and down the face.
10. It is recommended that the container be kept only half full when negotiating any slopes. Start mowing on slopes
when the container is empty.
11. Inspect your lawn and remove any foreign objects before mowing. Never deliberately run the mower across any
foreign object.
12. Wear ear protection if the noise level is offensive.
13. Wear eye protection to prevent debris from damaging your eyes.
2
SAFETY
WARNING! NEVER operate the mower unless the discharge guard and either the deflector assembly or the
vacuum collector adapter are fastened securely in place.
WARNING! Do not work around the mower deck boot or the blower area until you are certain that the mower
blades and the blower impeller have stopped rotating.
WARNING!To avoid serious injury, perform maintenance on the vacuum collector; ONLY AFTER
STOPPING THE MOWER’S ENGINE AND WAITING FOR ALL MOVING PARTS TO COME TO A
COMPLETE STOP. Set the parking brake. Always remove the ignition key before beginning maintenance.
WARNING!For your own personal safety, ALWAYS mow ACROSS the face of slopes and NEVER UP
and DOWN the face. NEVER attempt to mow excessively steep slopes, and use caution when turning on any slope.
Safety Alert Symbol
This Safety Alert Symbol means: “ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!”
This symbol is used to call attention to safety precautions that
Should be followed by the operator to avoid accidents. When
you see this symbol, carefully read the message that follows
and heed its advice. Failure to comply with safety precautions
could result in death or serious bodily injury.
!
Safety Signs
The signal words DANGER, WARNING, and CAUTION are used on the equipment safety signs. These words are
intended to alert the viewer to the existence and the degree of hazard seriousness.
This signal word indicates a potentially hazardous situation which, if not
DANGER
!
White letters on RED
WARNING
!
Black letters on ORANGE
CAUTION
!
Black letters on YELLOW
avoided, will result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
It may also be used to alert against unsafe practices.
This signal word indicates a potentially hazardous situation exist which, if
not avoided, will result in minor or moderate injury.
It may also be used to alert against unsafe practices.
3
DIXIE CHOPPER LIMITED WARRANTY FOR NEW PRODUCTS
A. WHAT IS UNDER WARRANTY?
Dixie Chopper extends the following warranties to the original purchaser of each new Dixie Chopper consumer
product subject to the following limitations.
1. PRODUCT WARRANTY: Any part of any consumer product, which is defective in material or workmanship as
delivered to the purchaser will be repaired or replaced, as Dixie Chopper elects, without charge for parts or
labor, if the defect appears within 12 months from the date of delivery of the product to the original purchaser.
ALL DEFECTIVE PARTS MUST BE RETURNED TO DIXIE CHOPPER FOR INSPECTION TO
DETERMINE VALIDITY OF WARRANTY CLAIMS. Freight and mailing will be borne by the customer.
2. PARTS REPLACED DURING WARRANTY: Any new Dixie Chopper part which is furnished in performance of
this warranty and is defective in material or workmanship as delivered to the purchaser will be repaired or
replaced, as Dixie Chopper elects, without charge if the defect appears within 90 days from the date of
installation of such part or before the expiration of the original warranty period, whichever is later.
B. SECURING WARRANTY ADJUSTMENTS.
All Warranty will be submitted by an Authorized Dixie Chopper Dealer directly to Dixie Chopper.
C. ITEMS NOT COVERED BY DIXIE CHOPPER WARRANTY.
Engines and batteries attached to Dixie Chopper products are covered under a separate warranty by the
respective manufacturer.
D. UNAPPROVED ALTERATION OR MODIFICATION.
All obligations of Dixie Chopper under this warranty shall be terminated if products are altered or modified in
ways not approved by Dixie Chopper.
E. ACCIDENTS AND NORMAL MAINTENANCE.
The warranty covers only defective material and workmanship. It does not cover depreciation or damage
caused by normal wear, accident, improper use or abuse of products. The cost of normal maintenance and
normal replacement of service items such as belts, cutting blades, hoses, etc., which are not defective shall be
paid for by the purchaser.
F. NO REPRESENTATIONS ADDITIONAL WARRANTIES, DISCLAIMER.
Neither Dixie Chopper nor any company affiliated with it makes any warranties, representations or promises
as to the quality of performance of its products other than those set forth herein. Except as described above,
Dixie Chopper makes no other warranties AND SPECIFICALLY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES OF FITNESS AND MERCHANTABILITY.
G. ANY MACHINE USED FOR RENTAL PURPOSES ARE GUARANTEED FOR 45 DAYS FROM
DATE OF ORIGINAL SALE ONLY.
H. REMEDIED EXCLUSIVE.
The only remedies the purchaser has in connection with the breach or performance of any warranty on
Dixie Chopper consumer products are set forth above. In no event will Dixie Chopper be liable for special
incidental or consequential damages.
1. NO SERVICE CENTER WARRANTY.
The selling Service Center makes no warranty on his own on any item warranted by Dixie Chopper unless he
delivers to purchaser a separate written warranty certificate specifically warranting the item. The dealer has no
authority to make any representation or promise on behalf of Dixie Chopper or to modify the terms of this
warranty in any way.
4
Section I - INTRODUCTION AND DESCRIPTION
1-1 Introduction
Your collection system has been designed to give you a
low maintenance, simple, and effective way to collect the
grass clippings from your mower. This manual is
provided to give you the necessary instructions to
properly mount and operate the collection system on
your mower. Please read this manual thoroughly.
Understand what each control is for and how to use it.
Observe all safety decal precautions on the machine and
noted throughout the manual.
NOTE: all references made to right, left, front, rear, top
or bottom are as viewed from the normal operator’s
position on the mower.
1-2 Description
The grass collection system is designed for turf
maintenance where there is a need to collect the grass
clippings as the mower cuts the turf. It is also used for
picking up leaves and in pre-season and post-season
clean-up. The blower, mounted on the right side of the
unit, uses a belt and gearbox system from the engine
PTO shaft. Drive train protection comes through belt
slippage. The blower draws grass clippings from the
discharge area of the cutter deck back to the (3) - 4
cubic foot collection bags P#(G0003) at the rear portion
of the mower frame. The operator can engage the
blower with a push of the over-center linkage on the right
side of the unit. Once the bags are full with clippings,
they can be released to make for easy dumping.
5
Section II - INSTALLATION FOR USE
PRESS
PRESS
2-1 Preparation Of Mower
NOTE: The mower deck PTO belt must be removed
from the electric clutch before continuing with the
installation. Refer to your Dixie Chopper mower owner’s
manual for instructions on PTO belt removal.
From the underside of the engine, disconnect the wiring
harness attached to the electric clutch. Remove the bolt
and electric clutch from the mower. Refer to Figure 2-1a.
Figure 2-1a
Remove Bolt
Remove the D-drive spacer using an arbor press or
equivalent. On removal, adjacent bearing OUTER race
must be supported or bearing damage may occur. Refer
to Figure 2-1b.
Figure 2-1b
Remove D Drive Spacer
The engine pulley assembly must be installed using an
arbor press or equivalent. During installation, opposite
bearing inner race must be supported or bearing
damage may occur. Refer to Figure 2-1c.
Upon pressing the engine pulley to the clutch, replace
the completed assembly to the mower’s engine shaft to
fasten.
Figure 2-1d
Engine Pulley
Assembly
27HP Generac & 29HP Kohler
Fasten engine pulley assembly number 18 P#(A1109) to
the electric clutch using (1) 7/16”-20 x 4” HHCS
P#(K0359) and (1) 7/16” helical spring lock washer
P#(K0140). Refer to Figure 2-d for reference.
(1) 7/16”-20 Hex Bolt
(1) 7/16” Lock Washer
Electric
Clutch
Replace Mower
Deck PTO Belt
Figure 2-1c
33HP Generac
Fasten engine pulley assembly number 23 P#(A1175) to
the electric clutch using (1) 7/16”-20 x 3-3/4” HHCS
P#(K0350) and (1) 7/16” helical spring lock washer
P#(K0140). Torque the bolt to 55ft./lbs. Refer to
Figure 2-1d for reference.
NOTE: On Classic and Xcaliber models, the PTO belt
included in the hardware bag must be positioned behind
the clutch before the engine pulley is installed. Refer to
Figure 2-1e.
Figure 2-1e
Position PTO
Belt Before
Installation of
Engine Pulley
Engine Pulley Installation
Engine Pulley
and Hardware
6
2-2 PTO Mount Plate Assembly
Installation
Position the PTO mount plate assembly P#(A1871) on
the right rear frame of the mower as shown in Figure 22a. Secure the PTO mount plate assembly R.O.P.S.
using (1) 3/8”-16 x 2-1/8” x 2-5/8” P#(K1119) and (2)
3/8”-16 nylon flange lock nuts P#(K2038). Secure the
PTO mount plate assembly to the rear frame of the
mower using (2) 3/8”-16 x 1” x 1” u-bolt P#(K1118) and
(4) 3/8”-16 nylon flange locknuts P#(K2038).
Figure 2-2a
(1) 3/8”-16 x 2-1/8” x 2-5/8” U-Bolt
(2) 3/8”-16 Nylon Flange Locknut
PTO Mount
Plate Assembly
R.O.P.S.
Mower
Rear Frame
(2) 3/8”-16 x 1” x 1” U-Bolt
(4) 3/8”-16 Nylon Flange Locknut
Refer to Figure 2-2b for Classic and Xcaliber Mounting
Hole Locations.
Xcaliber
Mount Holes
Classic
Mount Holes
Xcaliber
Mount Holes
Figure 2-2b
Classic
Mount Holes
7
2-3 PTO Assembly Installation
Insert the PTO assembly P#(A1623) into the mounting
slots on the PTO mount plate assembly. Secure the PTO
assembly with (1) PTO mount pin P#(B0274) and (1)
hair pin clip P#(K0086). Refer to Figure 2-3.
Attach the PTO handle assembly P#(A1142) to the PTO
assembly using (3) 1/4”-20 x 3/4” HHCS and P#(K1222)
(3) 1/4”-20 nylon flange locknuts P#(K2014). Refer to
Figure 2-3.
NOTE: Remove the PTO belt guard and hardware, in
preparation for the belt installation.
Figure 2-3
PTO
Mount Pin
(3) 1/4”-20 x 3/4” HHCS
(3) 1/4”-20 Locknuts
PTO Mount
Plate Assembly
Hair
Pin Clip
PTO Handle
Assembly
PTO
Assembly
8
2-4 Belt Installation and Adjustment
Loosen the (4) bolts P#(K1191), (2) on each side, that
secure the gear box assembly to the PTO assembly
P#(A1803) (Figure 2-4a and 2-4b).
Figure 2-4a
Loosen Bolts
Figure 2-4b
Connect the kevlar cord belt 78” P#(M0274) from the
engine pulley to the lower gear box pulley (Figure 2-4d).
Figure 2-4d
Connect Belt
To Both Pulleys
To tension the drive belt, turn the adjustment bolt
clockwise (Figure 2-4e) until there is 1” of deflection, with
10-11 lbs. of pressure, at the center of the belt between
the engine pulley and the gear box pulley.
Figure 2-4e
Tighten The Adjustment
Bolt To Tension The Belt
Loosen Bolts
Loosen the adjustment bolt P#(K0348) until the gear box
assembly is at its far left adjustment (the gear box is
moved toward the mower’s engine pulley). Refer to
Figure 2-4c.
Figure 2-4c
Loosen The
Adjustment Bolt
Slide Gear Box
Towards The
Engine Pulley
Once the correct tension of the belt is achieved, tighten
the (4) bolts that secure the gear box assembly. Refer to
Figures 2-4f and 2-4g. Replace the belt guard and
hardware that was removed in Section 2-3.
Figure 2-4f
Tighten Bolts
Figure 2-4g
Tighten Bolts
9
2-5 Cam Assembly Adjustment
The cam assembly P#(A0422), which controls the
blower belt tension, comes from the factory pre-adjusted.
If the belt is too tight or becomes too loose, remove the
hair pin clip P#(K0099) from the belt tension rod
P#(K0326) and pull the “L” end of the rod out of it’s hole
in the cam assembly. The tension rod may then be
screwed out to tighten the belt or screwed in to loosen
the belt. Replace the “L” end into the top hole in the cam
and replace the hair pin clip. Adjust the cam stop bolt
P#(K1159) to allow the cam to rotate slightly over center
when the blower is disengaged (Figure 2-5).
Figure 2-5
Cam Assembly
Hair Pin Clip
Cam Stop
2-6 Blower Cone Installation
Thread (1) 5/16”-18 jam nut P#(K0120) onto each end of
(2) 5/16”-18 x 2-1/2” HHCS P#(K0125). Now partially
thread the bolts into each of the two tabs located on the
blower housing. Place blower cone so the two tabs line
up with the bolts then tighten completely. See Figure 2-6.
Figure 2-6
Blower
Cone Tabs
Tension Rod
Blower
Cone
(2) 5/16”-18 x 2-1/2”
All Thread HHCS
(2) 5/16” Jam Nuts
10
2-7 Lower Main Frame and Lower
Frame Assembly Installation
Secure the lower main frame P#(B0567) to the R.O.P.S
using (2) 3/8”-16 x 2-1/8” u-bolts P#(K1119) and (4) 3/8”16 nylon flange locknuts P#(K2038) as shown in Figure
2-7a.
Figure 2-7a
Position the lower frame assembly P#(A1872) as shown
in Figure 2-7b. Secure the lower frame assembly to the
lower main frame using (2) 1/2”-13 x 1-1/4” HHCS
P#(K1232) and (2) 1/2”-13 nylon flange locknuts
P#(K2012). Secure the lower frame assembly to the rear
face of the lower main frame using (2) 3/8”-16 x 1”
HHCS P#(K1191) and (2) 3/8”-16 nylon flange locknuts
P#(K2038). Refer to Figure 2-7b.
Lower Main
Frame
Lower Frame
Assembly
Mount Here
Figure 2-7b
R.O.P.S.
(2) 3/8”-16 x 2-1/8”
U-Bolts
(4) 3/8”-16 Locknuts
(2) 1/2”-13 x 1-1/4” HHCS
(2) 1/2”-13 Locknuts
(2) 3/8”-16 x 1” HHCS
(2) 3/8”-16 Locknuts
Lower Main
Frame
Lower Frame
Assembly
11
2-8 Upper Frame Assembly
Installation
NOTE: During this step, it is suggested that two people
install the upper frame to the lower mount tube.
Lift the upper frame assembly P#(A1058) above the
lower frame assembly and lower the top assembly onto
the two vertical tubes. Secure the top assembly to the
lower mount assembly using (2) clevis pins P#(K0133)
and (2) hair pin clips P#(K0088). Refer to Figure 2-8.
Figure 2-8
Upper Frame
Assembly
Clevis
Pin
Hair Pin
Clip
Lower Frame
Assembly
Vertical
Tubes
Clevis
Pin
12
2-9 Top Assembly To Upper Frame
Assembly Installation
Position the top assembly P#(A1187) above the upper
frame assembly as shown in Figure 2-9. Fasten the top
assembly to the upper frame assembly using (2) 5/16”18 x 2-1/2” HHCS P#(K0125) and (2) 5/16”-18 nylon
flange locknuts P#(K2516). Leave the locknuts slightly
loose, to allow the top assembly to open and close
easily. Refer to Figure 2-9 for hardware location.
Figure 2-9
Top Assembly
(2) 5/16-18 x 2-1/2” HHCS
(2) 5/16”-18 Nylon Flange
Locknuts
2-10 Hinge Kit Assembly Installation
Assemble the hinge kit as shown in Figure 2-10, using
(2) 5/16”-18 x 1” HHCS P#(K1154), (3) 5/16”-18 nylon
flange locknuts P#(K2516), (5) 1/4” flat washers
P#(K0037) and (2) swing arm brackets P#(ZT-0004).
Place (1) vinyl cap P#(J0289) on the end of the hex bolts
as shown in Figure 2-10. Leave the nuts loose enough to
allow fluid movement of the top when opening and
closing. When opened, the top should rest on the middle
joint of the hinge allowing it to remain up.
Figure 2-10
K1154
Upper Frame
Assembly
J0289
K2516
K0037
ZT-0004
13
2-11 Hose Clamp Preparation
Step 3: Using a flat file or disc grinder, remove
sharp edges from clamp cut in Step 2. Refer to
Figure 2-11d.
!
CAUTION
Note: To prevent injury, wear safety gear when
cutting or grinding hose clamps.
The hose clamps P#(J1000), provided with
your collection system, will fit hose sizes 6”
through 9”. The excess should be cut from the
clamp prior to installing the hoses. Follow the
steps listed to properly install the hose clamps
to your collection system.
Step 1: Measure from hose clamp’s fastening
end (end with tension screw) to the dimension
specified for your hose diameter and mark the
clamp for cutting. Refer to Figure 2-11a.
6” Hose - Cut to 23”
7” Hose - Cut to 26”
8” Hose - Cut to 29”
9” Hose - Cut to 32”
Figure 2-11a
Figure 2-11d
Remove Sharp Edge
From Hose Clamp
Step 4: Loop previously cut hose clamp end
under and through the clamp’s tension screw.
Next, slide one finishing cap P#(V0040) over
cut end. Refer to Figure 2-11e.
Figure 2-11e
Mark
Clamp
Tension
Screw
Here
Step 2: See note on Caution above! Cut the
hose clamp at mark determined from Step 1. It
is recommended to use heavy-duty snips or a
cutting wheel. Refer to Figure 2-11b and 2-11c.
Figure 2-11b
Use Heavy-Duty Snips
Cut At
Mark
Figure 2-11c
Or Use Cutting Wheel
Cut At
Mark
Attach Finishing Cap
To Hose Clamp End
Step 5: To clamp hose, first slide completed
clamp assembly over hose end. Next, hold
tension screw up while pulling clamp end to
pre-tighten. Then, fold tension screw down
and tighten using 5/16” socket or flat-head
screw driver. See Figure 2-11f.
Figure 2-11f
Attach Hose
Tighten Clamp
14
2-12 Boot To Mower Deck Installation
NOTE: Remove all grass deflector and/or mulching
hardware from the mower deck before proceeding.
Classic Deck Plate Mounting Locations
Refer to Figure 2-12c for Classic deck plate mounting
locations.
Classic 50” & 60” Models
Position the boot plate P#(B0775) onto the top of the
aluminum boot P#(E0023) as shown in Figure 2-12a.
Secure the boot plate to the boot using (2) 3/8”-16 x 1”
carriage bolts P#(K1182) and (2) 3/8”-16 nylon flange
locknuts P#(K2038). Insert the bolts from the inside of
the boot so that the locks nuts are on top of the boot
plate. This will prevent grass clipping from collecting on
the bolt threads. Position the deck mount plate onto the
top of the mower deck as shown in Figure 2-12a. Secure
the deck mount plate to the mower deck using (2) 3/8”16 x 1” carriage bolts P#(K1182) and (2) 3/8”-16 nylon
flange locknuts P#(K2038). Insert the bolts from the
underside of the mower deck.
NOTE: Do not tighten hardware until boot has been
installed to mower deck.
Figure 2-12a
Boot Plate
Deck Mount
Plate
Figure 2-12c
Classic 50” and 60”
Mounting Holes
Classic
Deck Plate
B0774
Align the holes in the boot plate with the holes in the
deck mount plate. Insert the boot rod P#(B0333) into the
mounting holes and secure with (1) hair pin clip
P#(K0099). Refer to Figure 2-12d.
With all the carriage bolts still finger tight, use the slots in
the deck mount plate and the boot plate to position the
boot so that the front inside corner of the boot is flush to
the front outside edge of the mower deck. Also check for
clearance between the mowers blade and the bottom
edge of the boot. Once the boot is positioned correctly,
tighten all the hardware.
Aluminum
Boot
Classic Boot Plate Mounting Locations
Refer to Figure 2-12b for Classic boot plate mounting
locations.
Classic
60” Deck
Mount Holes
(4) 3/8”-16 x 1”
Carriage Bolts
(4) 3/8”-16
Locknuts
Figure 2-12b
Figure 2-12d
Boot Rod
Hair Pin
Clip
Classic
50” Deck
Mount Holes
15
2-12 Boot To Mower Deck Installation
Continued
NOTE: Remove all grass deflector and/or mulching
hardware from the mower deck before proceeding.
Xcaliber 66” Models
Position the boot plate P#(B0783) onto the top of the
aluminum boot P#(E0023) as shown in Figure 2-12e.
Secure the boot plate to the boot using (2) 3/8”-16 x 1”
carriage bolts P#(K1182) and (2) 3/8”-16 nylon flange
locknuts P#(K2038). Insert the bolts from the inside of
the boot so that the locks nuts are on top of the boot
plate. This will prevent grass clipping from collecting on
the bolt threads. Position the deck mount plate
P#(B0776) onto the top of the mower deck as shown in
Figure 2-15e. Secure the deck mount plate to the mower
deck using (2) 3/8”-16 x 1” carriage bolts P#(K1182) and
(2) 3/8”-16 nylon flange locknuts P#(K2038). Insert the
bolts from the underside of the mower deck.
NOTE: Do not tighten hardware until boot has been
installed to mower deck.
Align the holes in the boot plate with the holes in the
deck mount plate. Insert the boot rod P#(B0333) into the
mounting holes and secure with (1) hair pin clip
P#(K0099). Refer to Figure 2-12g.
With all the carriage bolts still finger tight, use the slots in
the deck mount plate and the boot plate to position the
boot so that the front inside corner of the boot is flush to
the front outside edge of the mower deck. Also check for
clearance between the mowers blade and the bottom
edge of the boot. Once the boot is positioned correctly,
tighten all the hardware.
Figure 2-12g
Hair Pin
Clip
Deck Mount
Plate
Boot Rod
Figure 2-12e
Deck Mount
Plate
Boot
Plate
Xcaliber Boot Plate Mounting Locations
Refer to Figure 2-12f for Xcaliber boot plate mounting
locations.
Xcaliber
66” Deck
Mount Holes
(2) 3/8”-16 x 1”
Carriage Bolts
(2) 3/8”-16 Locknuts
Boot
Figure 2-12f
Boot
Plate
Boot
16
2-13 Length Of Hose Adjustment
The hoses in steps 2-14 and 2-15 must be cut to fit your
machine. Follow steps 2-14 and 2-15. Do not cut the
hoses until you have tried to fit them on your machine.
Remember that the hoses have to be long enough to
adjust for the blower assembly’s movement as well as
allow for enough clamping surface between the inlet,
blower assembly, and the deck boot.
2-14 Upper Hose Installation
Fasten the inlet to the plastic top by sliding the inlet from
the inside of the top to the outside and lock into place.
Slide a pre-assembled hose clamp P#(J1000) onto both
ends of the 6” upper hose (Figure 2-16). Then slide one
end of the 6” hose onto the inlet. Make sure there is
about a two-inch overlap between the hose end and the
container inlet. Proceed to slide the opposite end of the
6” hose onto the outlet of the blower assembly. See
(Figure 2-16) for details. Make sure both ends of the
hose are clearly attached to the inlet and the blower
assembly inlet. Tighten the hose clamps.
2-15 Lower Hose To Blower Cone
Installation
Slide a pre-assembled hose clamp P#(J1000) over both
ends ofthe lower hose. Then proceed to slide the lower
hose onto the blower cone. Tighten the hose clamp. The
assembly should look like Figure 2-16.
2-16 Lower Hose To Boot Installation
Take the unattached end of the lower hose and slide it
over the circular end of the boot. Use the lower hose
clamp to secure the hose to the boot (Figure 2-16). Tip:
Before securing clamp rotate hose counter-clockwise
(away from yourself) approximately 1” to aid in retaining
boot to mower deck.
Figure 2-16
Plastic
Top
Upper
Hose
Inlet
Hose
Clamp
Hose
Clamp
Blower
Outlet
Blower
Cone
Lower
Hose
Boot
17
2-17 Impeller Blade
Removal/Replacement
To gain impeller blade (#1) access, first remove the
blower cone (#2) from the blower housing, located on
the PTO assembly P#(A1821), by removing two blower
cone bolts and nuts (#3). Next, remove the blower
housing front (#4) by removing seven bolts and nuts (#5)
around the outer housing edge. Refer to Figure 2-17.
To Remove: First, remove one 3/8”-16 x 1-1/2” HHCS
P#(K1211) (#6), one taper-lock bushing washer
P#(K0278) (#7) and one spacer bushing P#(S3242) (#8)
from the taper-lock bushing (#9). See Figure 2-17. Next,
remove two 1/4”-20 x 1” HHCS (#10) and place them
into the threaded holes (#11) of the taper-lock bushing
P#(S4302). Last, gradually thread each bolt evenly into
the taper-lock bushing, forcing the blade to break-away
from the taper-lock bushing.
Figure 2-17
4
3
Tips on removing impeller blade;
1 - Try carefully hitting the base of the impeller blade
(#1), between each vein (#12), with a rubber mallet to
loosen the taper-lock bushing hold.
2 - Spray break-free lubricant into the surrounding areas
of the taper-lock bushing (#9) and repeat Tip 1.
To Replace: First, place the impeller blade (#1) over the
drive shaft (#13). Next, slide the taper-lock bushing (#9)
on to the drive shaft and into the impeller blade, aligning
the non-threaded holes (#14) of the taper-lock bushing
to the threaded holes of the impeller blade. Then, fasten
by using two 1/4”-20 x 1” HHCS (#10), one spacer
bushing (#8) one taper lock bushing washer (#7), and
one 3/8”-16 x 1-1/2” HHCS (#6). Torque all bolts to the
specifications located in the chart towards the back of
this manual. Last, rotate the impeller blade to ensure
that the blade is clear of contact on all sides of the
blower housing.
5
5
2
3
12
9
8
13
10
7
6
Taper-Lock Bushing
9
Enlarged View
1
11
14
18
2-18 Weight Kit Installation
NOTE: It is recommended that someone assist you in
the weight kit installation procedure.
Remove the front bumper and hardware from the mower
frame. Attach the left weight bracket P#(B0383L) and
right weight bracket P#(B0383R) to the front frame of the
mower. Insert each weight bracket onto the frame tube.
Secure each weight bracket using (2) 3/8”-16 x 3-1/2”
HHCS P#(K1200), (1) 3/8” flat washers P#(K0047) and
(2) 3/8”-16 nylon flange lock nuts P#(K2038). The (2)
washers are used on the slotted holes on each weight
bracket. Leave the hardware finger tight so the position
of the weight brackets can be adjusted left or right if
necessary.
Figure 2-18a
(2) 1/2”-13 U-Bolts
(4) 1/2”-13 Locknuts
Weight
Bar
Using two people, lift the weight bar P#(B2220) into
position. Secure the weight bar to the left and right
weight brackets using (2) 1/2”-13 x 4-1/4” u-bolts
P#(K0331) and (4) 1/2”-13 nylon flange locknuts
P#K0212). Use Figure 2-19b for reference. NOTE:
Before tightening the u-bolts, make sure the weight bar
is centered between the weight brackets. Refer to
Figure 2-18a for reference.
Replace the front bumper, adding (2) 1.187 x .380 x .187
flat washers P#(K1446) as spacers to allow clearance
for the left and right weight bracket. Tighten all weight kit
hardware at this time. Refer to Figure 2-18b for
reference.
Front Bumper
Weight
Bracket
(2) 3/8”-16 x 3-1/2” HHCS
(1) 3/8” Flat Washers
(2) 3/8”-16 Locknut
Figure 2-18b
Front
Bumper
(2) 3/8”-16 x 3-1/2” HHCS
(1) 3/8” Flat Washers
(2) 3/8”-16 Locknut
Weight
Bracket
Add
Washer
19
2-19 Installation/Removal Of
Collection Bags
IMPORTANT!
To prevent bag wear, install (2) red plastic end caps
P#(J0274), as shown in Figure 2-19a, on each bag ring
before installing bags.
Figure 2-19c
Plastic Top
Figure 2-19a
Red Plastic
End Caps
To install the bag onto the bag ring, place the seam
openings of the bag onto the bag ring openings and turn
the bag one full turn (360 ) so the plastic end caps are
located opposite to the opening in the bag (Figure 219b). Do this for each of three bags.
Figure 2-19b
Bag Ring End
Caps Opposite
of Bag Opening
Bag Ring
Bag Opening
Fasten Draw
Completed Bag
Installed
To empty the bag, first unlatch and lift top, next remove
the bag and bag ring by sliding rearward, then grasp the
loop on the bottom of the bag, and last turn it upside
down to empty the collected debris (Figure 2-19d).
Repeat for the other bags. Reinstall all bags, line with
plastic bags if desired, close the plastic top and reattach
the draw latches.
Figure 2-19d
-Latch Here &
Opposite Side
For Proper Unit
Transportation
Bag
Install the completed assemblies onto the support frame
and close the plastic top. Fasten both draw-latches to
hold the plastic top closed (Figure 2-19c).
Grasp Bag
Here
Plastic lawn and leaf bags, 33 gallon size, may be used
inside the cloth bags. Be sure to leave enough plastic
bag hanging over the frame so the plastic bags can be
twist tied before emptying (Figure 2-19e).
Figure 2-19e
Plastic Bag
Cloth Bag
20
2
9
4
6
7
10
3
5
8
11
18
17
14
16
15
1
13
12
Item #Doc #TitleQty
1V0022PRO 3 BAGGER TOP1
2B0676Hinge Stop Pl.1
3K0114BLACK PLASTIC RIVET14
4C0069DUST GUARD BRACE1
5K10301/4"-20 x 1-1/4" CARRIAGE BOLT2
6J4009SHORT RUBBER STRAP W / S HOOK2
7K00371/4" FLA T WASHER .75 OD x .314 ID x .060 T2
8K11281/4"-20 NYLOC NUT2
9C0026GRASS DEFLECTOR1
10K00623/16" x 1-1/2" FENDER WASHER, Z4
11K1265BLACK PANEL RETAINER3
12V1120Black Plastic Screen1
13V1118DUST GUARD1
14R10572" x 4" Red Reflector Label2
15R1069Warning - Turn Off Blower Label1
16R1065Made In USA Label1
17R1054Important Check Hoses1
18R1051Warning - Use Hearing Protection1
Exploded Parts View
A1187 Top Assembly
21
Exploded Parts View
7
16
12
1
11
36
27
35
10
34
33
8
21
22
17
3
9
15
31
14
2
4
13
23
24
5
6
20
37
25
38
32
26
30
19
18
39
29
28
A1623 PTO Assembly
22
PTO Parts List
Item #Part #Desc.Qty.
A1623PTO ASSEMBLY
1A0429GEAR BOX ASSEMBLY1
2K03483/8"-16 x 2" ALL THREAD HHCS1
3K00473/8" Flat Washer 1.00 OD x .446 ID x .075 T5
4K03531/4"-20 x 1/2" HHSTS8
5K11595/16"-18 x 2" ALL THREAD HHCS1
6K11785/16"-18 FLANGE NUT1
7A0144BLOWER MOUNT BRACKET ASSEMBLY1
8B1755BLOWER PIVOT ROD1
9k0086.125 OD x 2.50 HAIR PIN CLIP2
10b0121BLOWER BELT GUARD1
11A0604PTO HANDLE MOUNT ASSY1
12A0422CAM BRACKET ASSEMBLY1
13K03563/8"-16 TAPERED SET SCREW1
14k0326BELT TENSION ROD 3/8"-161
15K0130.091 OD x 1.625 L HAIR PIN CLIP1
16a0306PTO SHAFT ASSEMBLY1
17J02543/16" x 3/16" x 3/4" Key1
18M0228BLOWER PULLEY1
19K14461.187 OD x .380 ID x .187 WASHER1
20K11903/8"-16 x 3/4" HHCS1
21E4004BBLOWER HSG. BACK1
22E4004FBLOWER HSG. FRONT1
23K11251/4"-20 X 1" HHCS7
24K11261/4"-20 FLANGE NUT7
25K11933/8"-16 x 1-1/2" HHCS4
26K12153/8"-16 FLANGE NUT12
27A0645SMALL 4-BLADE IMPELLER1
28S4302TAPER-LOCK BUSHING1
29S3242PLATED BUSHING1
30K12251/4"-20 X 1" HHCS GRADE 82
31K0278TAPER-LOCK BUSHING WASHER1
32K12113/8"-16 x 1-1/2" HHCS GRADE 81
33B0679Large Pulley Guard1
34B0270PTO ARM GUARD1
35A1804PTO ARM ASSY.1
36A0624BASE PLATE ASSY.1
37K11913/8"-16 x 1" HHCS6
38K11973/8"-16 X 2 1/2" HHCS1
39M0250A30K KEVLAR BELT1
A1623 PTO Assembly
23
24
25
SECTION III
OPERATING INSTRUCTIONS
3-1 General Safety
3-3 Disengagement Of The Blower
A. To disengage the blower, rotate the engagement
handle towards the mower.
Only qualified people familiar with this operator’s manual
and the mower’s operator’s manual should operate this
machine.
3-2 Operation And Tips On Mowing
A. Perform BEFORE EACH USE the maintenance list in
paragraph 4-1.
B. Start mower.
C. With the mower at high idle speed, engage the mower
deck.
D. While seated in the operator’s seat, rotate the
engagement handle of the collection system away
from the mower. Continue to rotate the handle until it
stops in an over center position. With the blower
engaged, you can proceed to operate the control
levers of the mower.
NOTE: If the collection system does not appear to be
collecting the grass clippings, disengage the deck
and blower, then, engage the parking brake and turn the
mower off. Proceed to section 3-3, and review the
section 2-4 in this manual.
To obtain the maximum effectiveness from your
collection system the tips listed below should be
followed:
WARNING: The blower will continue to spin. DO NOT
TOUCH the blower, pulleys, or the belt until the tractor is
turned off. DO NOT adjust the belt tension until the
mower is turned off. Refer to section 2-4 of the manual.
3-4 Unloading The Collection System
NOTE: To determine when the collection bags are full,
follow the following steps:
A. Stop the forward movement of the mower.
B. Disengage the mower deck.
C. Disengage the blower.
D. Engage the parking brake.
E. Once the parking brake has been engaged, then and
only then, walk behind the mower and check the
collection bags by unlatching and lifting the top
assembly. Load in bags should not exceed the height
of the installed bag.
F. To release bags, slide each bag out (towards
operator) and turn bags over to deposit clippings.
G. Return each bag to the original location, lower top
assembly and re-latch to close .
* Watch your speed- Normal conditions will allow a
speed of up to approximately 5 mph, but thick, heavy
damp conditions will require reduced ground speed.
* Mow with sharp blades- A sharp blade cuts cleaner.
* Wet grass and leaves will decrease effectiveness and
will increase horsepower requirements.
* Mow at higher cutting heights- Remove and mulch no
more than 2” of grass length with each mowing.
(Experts recommend not cutting off more than 1/3 of
the grass blade length at any given time.)
* Mow twice, at different height settings, (high, then low),
if grass is extra tall.
* Remember that horsepower requirements will vary with
the mowing conditions such as type and height of turf
grass, moisture content, amount of leaves, whether the
terrain is flat or hilly, etc.
NOTE: Do not allow collection bags to become over-
filled as potential damage may occur to your
equipment. Also, be sure to clean the hood screen as
needed.
SECTION IV
MAINTENANCE
4-1 Maintenance Checklist
NOTE: REMOVE PTO ASSEMBLY BEFORE RAISING
DECK FOR MAINTENANCE.
Before each use:
1. Check blades and spindles to be sure that no foreign
objects, such as wire or steel strapping bands, are
wrapped around them.
2. Inspect blades for wear. Replace if necessary. If it is
necessary to sharpen the blades, remove the blades
from the spindles before sharpening. DO NOT
sharpen blades while still attached to the mower.
26
3. Make sure all shields are in place and in good
condition. Repair or replace any missing or damaged
shields.
4. Perform lubrication per paragraph 4-2.
4-2 Lubrication
NOTE: Use only white lithium based grease for
lubrication of the shaft on the blower assembly.
5. Listen for abnormal sounds, which might indicate
loose parts, damaged bearings, or other damage.
Correct any deficiency before continuing operation.
6. With the engine off, engage the blower assembly.
Check the belt tension and inspect the pulley belt for
cracks or tears.
7. Check for wear or deterioration of the upper or lower
hoses. If there are any portions of the hose that have
been torn or worn through, replace with genuine
PECO parts.
After Each Use:
1. Clean all debris from machine especially from the
container, underneath the belt shields, and safety
decals. Replace any missing or illegible decals.
2. Inspect the unit for worn or damaged components.
Repair or replace before the next use. Any
replacement component installed during repair shall
include the component’s current safety decal specified
by the manufacturers to be affixed to the component.
3. Check belt for proper tension.
1. On initial use: Grease the fitting on the blower shaft.
2. Every 25 hours of use: Re-grease the grease fitting.
3. Every 200 hours of use: Check oil levels in gear box.
Oil in gear box should cover the gears. If necessary,
fill using an EP90 weight oil. 6oz. will fill the gear box
from empty.
SECTION V
PARTS AND SERVICE
5-1 Parts And Service Information
Collection system owners should record the name and
telephone number of their Dixie Chopper dealer. Your
Dixie Chopper dealer will be happy to supply
replacement parts, accessories, and do any service or
repairs to your collection system. If for any reason your
Dixie Chopper dealer is unable to service your collection
system or supply replacement parts, contact Dixie
Chopper and include the following information on the
chart below.
THE SERIAL NUMBER PLATE
IS LOCATED ON THE TOP
ASSEMBLY
WRITE THE MODEL AND
SERIAL NUMBER IN THE
BOX ABOVE FOR FUTURE
REFERENCE.
Unit Model Number: _____________________________
Unit Engine Size: _____________________________
Unit Serial Number: _____________________________
Date of purchase: _____/_____/_________
Dealer/Distributor Name: ________________________________________
Address: _____________________________________ State: __________ Zip:__________
Phone Number: ____________________________
27
SAFETY DECALS
To promote safe operation, Dixie Chopper supplies safety decals on all products manufactured. Damage can occur to
safety decals either through shipment, use or reconditioning. Contact your local Service Center for replacement decals.
Part #: R1051
Warning: Hearing Protection Label
Part #: R0012
Lrg XT3 Label
Part #: R4015
Danger: Rotating Blades Label
Part #: R1069
Warning: Turn Off Blower Label
MADE IN
MADE INMADE IN
AMERICA
AMERICAAMERICA
Part #: R1065
Made In America Label
Part #: R0013
Sml XT3 Label
Part #: R1057
Red Reflector Label
Part #: R1054
Important: Check Hoses Label
Part #: R4008
Caution: Rotating Blades Label
Part #: R4037
Warning: Hot Surface Label
Part #: R2007
Danger: Never Use Hands Label
Part #: R2008
Danger: Rotating Blades Label
28
D. Chopper
29
Contact: service@dixiechopper.com
765-246-6191 FAX 765-246-6017
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