Dixie Chopper 38131504, 38131503 Operator's Manual
DESIGNED FOR:
Classic
2960/3360
Model #: 38131504
60” Decks
Xcaliber
3366
Model #: 38131503
66” Decks
2013 - 2011
OPERATOR’S MANUAL
ASSEMBLY OPERATION MAINTENANCE
MANUAL PART#: Q0459 REV: 0
XT GRASS COLLECTION SYSTEM
TABLE OF CONTENTS
SECTION PAGE
Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Safety Alert Symbols- - - - - - - - - - - - - - - - - - - - - - 3
Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
I INTRODUCTION AND DESCRIPTION- - - - - - - - - - - - - - 5
1-1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - 5
1-2 Description - - - - - - - - - - - - - - - - - - - - - - - - - 5
II INSTALLATION FOR USE - - - - - - - - - - - - - - - - - - - - - - 6
2-1 Preparation Of Mower - - - - - - - - - - - - - - - - - - 6
2-2 PTO Mount Plate Assembly Installation - - - - - - - 7
2-3 PTO Assembly Installation - - - - - - - - - - - - - - - 8
2-4 Belt Installation - - - - - - - - - - - - - - - - - - - - - - - 9
2-5 Cam Assembly Adjustment - - - - - - - - - - - - - - - 10
2-6 Blower Cone Installation - - - - - - - - - - - - - - - - - 10
2-7 Lower Main Frame & Lower Frame
Assembly Installation - - - - - - - - - - - - - - - - - - - 11
2-8 Upper Frame Assembly Installation- - - - - - - - - - 12
2-9 Top Assembly To Upper Frame
Assembly Installation - - - - - - - - - - - - - - - - - - - 13
2-10 Hinge Kit Assembly Installation- - - - - - - - - - - - 13
2-11 Hose Clamp Preparation- - - - - - - - - - - - - - - - 14
2-12 Boot To Mower Deck Installation - - - - - - - - - 15-16
2-13 Length Of Hose Adjustment- - - - - - - - - - - - - - 17
Safety
SECTION PAGE
2-14 Upper Hose Installation - - - - - - - - - - - - - - - - 17
2-15 Lower Hose To Blower Cone Installation- - - - - - 17
2-16 Lower Hose To Boot Installation - - - - - - - - - - - 17
2-17 Impeller Blade Removal and Replacement - - - - 18
2-18 Weight Kit Installation- - - - - - - - - - - - - - - - - - 19
2-19 Installation/Removal of Collection Bags - - - - - - 20
Exploded Part Views and Assemblies- - - - - - - - - 21-25
III OPERATING INSTRUCTIONS - - - - - - - - - - - - 26
3-1 General Safety - - - - - - - - - - - - - - - - - - - - - - - 26
3-2 Operation & Tips On Mowing- - - - - - - - - - - - - - 26
3-3 Disengagement Of The Blower - - - - - - - - - - - 26
3-4 Unloading The Collection System - - - - - - - - - - - 26
IV MAINTENANCE- - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
4-1 Maintenance Checklist - - - - - - - - - - - - - - - - 26-27
4-2 Lubrication- - - - - - - - - - - - - - - - - - - - - - - - - - 27
V PARTS AND SERVICE - - - - - - - - - - - - - - - - - - - - - - - 27
5-1 Parts And Service Information - - - - - - - - - - - - - 27
Safety Decals - - - - - - - - - - - - - - - - - - - - - - - - - - 28
Torque Specifications - - - - - - - - - - - - - - - - - - - - - 29
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
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