Dixon 539 132250 Product manual

DIXON
Blower Kit
Collection System
539 132250, 539 132251
539 132252, 539 132397
Operator and
Parts Manual

©2007 HTC. All Rights Reserved.
Beatrice, NE. Printed in U.S.A.

CONTENTS
SAFETY RULES............................................................................................................................4
CARTON CONTENTS...................................................................................................................7
ASSEMBLY ...................................................................................................................................8
OPERATION................................................................................................................................15
CUSTOMER RESPONSIBILITIES..............................................................................................16
PARTS.........................................................................................................................................17
CONGRATULATIONS on your purchase of a new
collection system. It has been designed, engineered
and manufactured to give you the best possible
dependability and performance.
Should you experience any problem you can-
not easily remedy, contact the nearest authorized
service center/ department. They have competent,
well-trained technicians and the proper tools for
service and repairs.
Read and retain this manual. The instructions will
enable you to assemble and maintain your collec-
tion system properly. Always observe the SAFETY
RULES.
KNOW YOUR BLOWER SYSTEM
READ THIS OPERATION MANUALAND SAFETY
RULES BEFORE ASSEMBLING OR OPERATING
YOUR BLOWER SYSTEM. Compare the illustra-
tions 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.

4
SAFETY
DANGER !
THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEETAND THROWING OB-
JECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERI-
OUS INJURY OR DEATH.
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS
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-related injuries. 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
and tipover accidents, 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 and
gradual. 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.

5
SAFETY
DO NOT
• Do not turn on slopes unless necessary, and
then, turn slowly and gradually downhill, if
possible.
• Do not mow near drop-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 for
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.
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS

6
SAFETY
CAUTION
WARNING
Look for this symbol to point out important
safety precautions. It means CAUTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED.
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
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.
• 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.
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS

7
UNPACKING INSTRUCTIONS
• Remove all parts and packing materials from
carton.
TOOLS REQUIRED
• Drill and 11/32" drill bit - 3 bag system only
• 5/16" Wrench or ratchet and socket
• 7/16" Wrench or ratchet and socket
• ½" Wrench or ratchet and socket
• ¾" Socket
• Torque Wrench
• Phillips Head Screwdriver
• Pliers
NOTE: When right hand (RH) and left hand (LH.) are mentioned in this manual, it means when
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.•
UPPER CHUTE
BAG DUMP INDICATOR
BLOWER HOUSING
MIDDLE CHUTE
CONTAINER CONTENTS
• Blower Assembly • Drive Pulley
• Belt Shield • Belt
• Mounting Assembly • Bag of Hardware
• Weight
(not included in 50" Kit 539 132397
or 60" Kit 539 132252)
BELT COVER

8
ASSEMBLY
1. Remove the discharge chute from the deck.
(Deck configuration will vary by size and model)
2. Lower deck to the lowest cutting position.
3. Remove the right hand (discharge side) belt
cover from the deck.
4. Relieve the tension from the deck belt and
remove from the center deck pulley.
(See Operator’s Manual if necessary)
1INSTALLING DRIVE PULLEY
DISCHARGE CHUTE BELT COVER
DECK HEIGHT ADJUSTMENT
5. Remove the bolt that secures the right hand
deck pulley to the spindle.
6. Replace right blade shaft with new, longer shaft.
The existing drive pulley and key will fit on the
new shaft. Install blower drive pulley with the
raised portion of pulley hub down. Slide spacer
inside new pulley. Add key to new pulley.
7. Remove two rear bolts from spindle and place
belt shield standoff where the two bolts were
removed. Replace bolts and tighten.
8. Use heavy washer and bolt supplied in kit to
attach pulley to spindle. Torque to 55-75 ft/lbs.
9. Reinstall the deck belt.
DRIVE PULLEY
KEY
REPLACEMENT SHAFT
BELT SHIELD
STANDOFF SPINDLE
NEW HEAVY WASHER
NEW BOLT
SPACER

9
ASSEMBLY
2MOUNTING BLOWER ASSEMBLY
OUTER PULLEY COVER
PIN
HAIRPIN COTTER
3INSTALLING DRIVE BELT
REAR OF DECK IDLER PULLEYS
OUTER PULLEY
TWIST IN BELT
TENSION RELEASE LEVER
1. Install the front and rear mount brackets to the
deck with the pin and hairpin cotter supplied with
the kit.
1. Make sure the tension release lever is forward
or disengaged.
2. Place the belt over the pulley on the deck. Refer
to illustration for proper routing.
3. Move the tension release lever to the rear and
engage in the latch.

10
ASSEMBLY
BELT COVER TAB
4
INSTALLING BELT COVERS
RETAINER
KNOB
OUTER PULLEY COVER
DECK BELT SHIELD
MIDDLE CHUTE LATCH
DECK BELT SHIELD
WING
NUT
TAP SCREW
BELT SHIELD STANDOFF
1. Place deck belt shield over spindle, aligning hole
with bolt on belt shield standoff.
2. Attach with wing nut to standoff and use tap
screw from kit to attach the other side of the belt
shield to the deck.
3. Place retainer on the outer pulley cover.
4. Align the tab end of the belt cover into the slot
on the deck belt shield and the other end over
the end of the outer pulley cover.
5. Secure with knob.

11
ASSEMBLY
5INSTALLING MIDDLE CHUTE
MIDDLE CHUTE
BLOWER ASSEMBLY
Depending on model, engine guard may have
available mounting holes. If drilling is needed, use
template supplied with kit.
1. Attach template to engine guard at the
corresponding holes as shown in illustration.
With centerpunch, transfer the four 1/8" bagger
mount holes to the engine guard.
2. Remove template and drill four 11/32" holes in
engine guard at locations marked in Step 2 .
6 INSTALLING BAGGER MOUNT
3 Bin Collector
MOUNT STRAP
MOUNT TUBE
MOUNT STRAP
RAM MOUNT
1/8" DIAMETER HOLES
3. Install the bagger mount tube from the mount kit.
ENGINE GUARD
3. Remove the front carriage bolts securing the
engine guard.
4. Install kit mount straps between the mount tube
and frame as shown in the illustration. The front
side of the kit mount straps should be on the
inside of the mower frame.
5. Tighten all hardware.
KIT MOUNT STRAP
KIT MOUNT STRAP
RAM ULTRA MOUNT
1. Place middle chute over the top end of the
blower assembly.
2. Latch middle chute to blower assembly.
TEMPLATE ATTACHMENT
MOUNT TUBE

12
ASSEMBLY
7 INSTALLING CHUTE SUPPORT
3 Bin System only
1. Position upper chute support against bagger
inlet, flush at outer edges. See Illlustration.
2. Using support as a template, drill two 3/8" holes
into bagger hood.
UPPER CHUTE
SUPPORT
BAGGER INLET
NUT
BAGGER
HOOD
FLAT WASHERS
HEX BOLT
FLEX TRIM
3. Secure upper chute support to hood with hex
bolts, washers and nyloc nuts.
8 INSTALLING WEIGHT KITS
1¾ BOLT
2¾ BOLT
WEIGHT BRACKET
WEIGHT PLATES
1. Bolt weight plates to weight brackets using four
1¾" bolts and four nuts.
2. Slide both weight brackets over the front tube on
the frame, positioning the assembly in the center
of the frame.
3. Secure with four 2¾" bolts and four nuts.
2¾ BOLT
NUT
3¾ BOLT
WEIGHT BRACKET
CAST WEIGHT
1. Bolt one cast weight and two weight brackets
together using four 2¾" bolts and four nuts.
2. Slide both weight brackets over the front tube on
the frame, positioning the assembly in the center
of the frame.
3. Secure with four 3¾" bolts and four nuts.
Units with cast weight
FRONT TUBE
Units with two or more weight plates
RAM 44
RAM 50
FRONT TUBE

13
ASSEMBLY
CAUTION
DO NOT operate mower with grass
catcher, unless the front weights are
installed.
NOTE:
Ram Ultra units do not require a weight kit.
9
MOUNTING COVER ASSEMBLY
TO SUPPORT ASSEMBLY
NOTE: For ease of assembly, you may wish assis-
tance 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 the cover brackets
with support assembly tubes.
3. Slide the cover down over the support tubes
until secure.
COVER ASSEMBLY
SUPPORT
ASSEMBLY

14
TIPS FOR IMPROVED
BAGGING OPERATION
Follow the mower operation instructions in the
mower operator’s manual.
When utilizing the grass catcher on a lawn where
grass and leaf bagging equipment has not been
used, thatch and debris that has accumulated for
long periods of time will be picked up. The amount
collected and the total time of operation may be
greater than experienced with regular use of the
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.
g. Repeat for other container.
h. Reinstall containers making sure right
container overlaps left container at center
supports.
i. Close cover and secure latches over center
support tubes.
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.
• Avoid cutting wet grass or mowing 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.
- Unlatch and raise cover.
- Slide out containers and dispose of
clippings.
- Replace containers, close cover, and
latch.
b. Unlatch chutes and check for clogging.
- Remove all debris in chute.
- Reassemble and latch chutes.
OPERATION

15
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 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.
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.
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
Donotleavegrassinbaggercontainers.Empty
containers after each use and before storing.
Failure to do so may result in spontaneous
combustion which could develop into a fire.

16
PARTS
6
6
5
5
4
4
4
3
3
1
9
212
10
7
8
11

17
PARTS
ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION
539 1080811.. ....1 ....SCREW, SPEC 10-14 x ½
539 1080822.. ....1 ....BAG DUMP INDICATOR
539 1080833.. ....2 ....SCREW, 10-24 x 11/8
539 1080844.. ....3 ....WASHER, 3/16 x ¾
539 1080855.. ....2 ....SPACER, SPLIT
539 1080866.. ....2 ....NUT, ACORN 10-24
539 1080887.. ....1 ....LATCH, HOOD
539 1080898.. ....1 ....PLATED, WELD NUT
539 1081419.. ....1 ....CHUTE, UPPER
539 10955210.. ....2 ....WASHER 3/16 LOCK
539 13029411.. ....1 ....CHUTE, MIDDLE
539 97695212.. ....1 ....SCREW 10-24 x .625 MACH

18
PARTS
BAG ASSEMBLY 960 730019
9
410
7
6
1
3
8
11
12
2
3
5
12
14 13
16
15
17

19
PARTS
ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION
532 1927091.. ....1 ....SCREEN, COVER
532 1953732.. ....1 ....COVER
539 9769523.. ....6 ....SCREW, #10-24 x 5/8
539 1080964.. ....2 ....SPRING, RETAINER
539 1080975.. ....4 ....PLUG, TUBING END
539 1080986.. ....1 ....BAGGER, FRAME
532 1927867.. ....2 ....PIN, HINGE
532 1925508.. ....1 ....GASKET, COVER
532 4002269.. ....3 ....CONTAINER
532 19260310.. ...1 ....SEAL, COVER
532 13089511.. ...2 ....HANDLE, BAGGER COVER
539 97697712.. ....8 ....NUT, #10-24, CROWNLOCK
539 99062713.. ....2 ....HCS, 5/16-18 X 1¼, GR 5
539 99018814.. ....4 ....WASHER, 5/16, SAE
539 99071715.. ....2 ....NUT, 5/16-18, NYLOC
539 11023416.. ....1 ....SUPPORT, CHUTE
539 11229417.. ....1 ....FLEX TRIM
NOT SHOWN
539 108447...1 .... DECAL, CE
539 108163...1 .... DECAL, CATCHER
960 730019...1 .... COVER ASSEMBLY
(INCLUDES ITEMS 1-12)

20
PARTS
4
5
7
8
9
10
11
13
14
15
16
17
18
19
20
21
22
23
39
26
25
29
30
38
28
24
1
2
3
6
10
12
14
15
23
THIS SIDE
TOWARD BEARING
33 34
35
36
31
44
32
37
44
43
46
40
47
48
50
51
52
53
51
42
45
46
27
49
48 41
45
40
47
44
55
11
59
60
56
11
40
56
11
60
12
TORQUE TO
30 LBS
59
36 37
36 37
50" Deck
60" Deck
57
58