Dixon 114863 - DCK3 Product manual

Operators Manual 114863 - DCK3
114873 - DCG3
Models:
Please read these instructions carefully and make
sure you understand them before using the machine.
MANUAL NO. 539 114865 REV IR (01/30/07)
Parts Manual
Collection System

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

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WARNING: Engine exhaust, some of its constituents, and certain vehicle components con-
tain or emit chemicals known to the State of California to cause cancer and birth defects or
other reproductive harm.
INDEX
Operators Guide
Features and Controls.............................................................. 4
General Information ................................................................. 5
Safety Procedures.................................................................... 5
Unpacking Instructions............................................................. 7
Assembly Instructions .............................................................. 7
Collection System.............................................................. 7
Blower/Drive Kit ............................................................... 11
Operating the Collection System........................................ 13
Maintenance and Service Instructions
Transport ................................................................................ 14
Cleaning and Washing ........................................................... 14
Storage................................................................................... 14
Preventative Maintenance Schedule...................................... 14
Caring for Vacuum Hoses ...................................................... 15
Cleaning Poly Mesh ............................................................... 15
Caring for Bags ...................................................................... 15
Troubleshooting Guide ........................................................... 16
Replacement Parts
HoodAssembly ...................................................................... 20
HitchAssembly....................................................................... 22
Blower Kit 52”......................................................................... 24
Blower Kit 60”......................................................................... 26
BlowerAssembly.................................................................... 28
Weight Kit (Model DCG3)....................................................... 30
Weight Kit (Model DCK3) ....................................................... 31
Mounting Kit (Model DCG3) ................................................... 32
Mounting Kit (Model DCK3) ................................................... 34
BagAssembly ........................................................................ 36

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FEATURES & CONTROLS
NOTE: Your Front Weight Bar may look different from those shown in this diagram.
HOOD
SUPPORT STRAP
SUPPORT BRACKET
HITCH BRACKET
WEIGHT BAR
CAST WEIGHT
HOSE
BAG
INLET
BLOWER

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SAFETY RULES
Safety Procedures
1 - Training:
• Read the Operator’s manual. If the operator(s)
or mechanic(s) can not read English it is the
owner’sresponsibilityto explain this material to
them.
• Become familiar with the safe operation of the
equipment, operator’s controls, and safety
signs.
• All operators and mechanics should be trained.
The owner is responsible for training the users.
• Never let children or untrained people operate
orservice the equipment.Localregulations may
restrict the age of the operator.
• The owner/user can prevent and is responsible
foraccidents orinjuries occurringtothemselves,
other people, and/or property.
2 - Preparation:
• Wear appropriate clothing including hard hat,
safety glasses and ear protection. Long hair,
loose clothing or jewelry may get tangled in
moving parts.
• Inspect the area where the equipment is to be
usedand remove all objectssuchasrocks, toys
and wire which can be thrown by the machine.
• Use extra care when handling gasoline and
other fuels. They are flammable and vapors
areexplosive. Use only an approved container.
Never remove gas cap or add fuel with engine
running. Allow engine to cool before refueling.
Do not smoke while fueling or operating
equipment. Never refuel or drain the machine
indoors.
• Checkthat operator’scontrols, safety switches,
hoses, and shields are securely attached and
functioning properly. Do not operate unless
they are functioning properly.
General Information
This manual will assist you in the safe operation
and proper maintenance of your Husqvarna
equipment. Read it thoroughly before attempting
to operate the machine. Call your dealer or Dixon
if additional information is required.
Thefollowingsafetysymbols are used throughout
themanual toalertyou to informationaboutunsafe
actions or situations:
DANGER indicates immediate hazards that
may result in severe injury or death.
WARNING indicates unsafe actions or
situations that may cause severe injury,
death, and/or major equipment or property
damage.
CAUTION indicates unsafe actions or
situations that may cause injury and/or
minor equipment or property damage.
Thisequipment should not be modified withoutthe
manufacturer’s prior written authorization. Doing
so may not only affect the equipments’
performance and durability, but also create safety
hazards for the operator and the surroundings.
Warranty will be void if changes are made to the
equipmentwithout the manufacturer’sprior written
authorization.

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SAFETY RULES
3 - Operation
•Never run an engine in an enclosed area.
• Only operate in good light, keeping away from
holes and hidden hazards.
• Slow down and use extra care on hillsides.
Make turns gradually and at slow speed. Do
notoperate across the sides of slopes. Operate
up and down slopes only. Do not operate on
steep slopes.
• Turf conditions canaffectthemachine’sstability.
Donot operate on wet grass where traction may
be reduced.
• Do not change the engine governor setting or
overspeed the engine.
• Stop equipment and inspect vacuum impeller
andhoses afterstriking objectsorifan abnormal
vibrationoccurs. Makenecessaryrepairsbefore
resuming operations.
• Look behind and down before backing up to
ensure a clear path.
• Slow down and use caution when making turns
andcrossingroadsandsidewalks. Stopvacuum
and mower blades if not mowing.
•Do not operate machine under the influence of
alcohol or drugs.
•Usecarewhen loadingor unloadingthemachine
into a trailer or truck.
•Use care when approaching blind corners,
shrubs,trees, or other objectsthatmayobscure
vision.
4 - Maintenance and Storage:
•Stop engine and disconnect spark plug wire.
Wait for all movement to stop before adjusting,
cleaning, or repairing.
•Cleangrass and debris from mufflerand engine
to help prevent fires. Clean up oil or fuel
spillage.
•Let engine cool before storing and do not store
near sparks or open flame.
•Shut off fuel while storing. Do not store fuel
near flames or drain indoors.
•Never allow untrained personnel to service
machine.
•Keep hands and feet away from moving parts.
If possible, do not make adjustments with the
engine running.
•Keep all parts in good working condition and all
hardware tightened. Replace all worn or
damaged decals.

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ASSEMBLY
Unpacking Instructions
Assembly Instructions
Collection System
Tools Required:
Ratchet
Torque Wrench
1/2" Wrench
1/2" Socket
9/16" Wrench
9/16" Socket
5/8" Socket
1. Cut plastic tie securing the hitch to the crate top.
2. Remove the top of the crate.
3. Remove the plastic bag.
4. Remove the hose.
5. Remove the sides and ends of the crate.
6. Remove the mounting kit box from the corner of the crate.
7. Cut the two plastic ties that secure the hitch assembly to the pallet. Remove the hitch assembly.
8. Cut the two plastic ties that secure the back of the hood, and the two that secure the front of the
hood. Remove the hood assembly.
9. Cut and two plastic ties that secure the weight bar to the pallet. Remove the weight bar.
10. Cutthetwo plastic tiesthatsecure the blowerassemblyto the pallet. Removetheblower assembly.
11. Remove the 1 x 4 that secures the cast weights to the pallet. Remove the weights.
(2) 3/4" Wrench
3/4" Socket
Flat Screw Driver
5/32" Allen Wrench
Hacksaw
11/32" Drill Bit
Drill
1. Open the mounting kit box and remove all of
the components.
2. Place the support bracket on the frame and
secure with (2) 990563, 3/8 x 1 bolts and (2)
976979, 3/8 nyloc nuts. Figure 1.
3. Place the hitch brackets on the frame and
secure with (3) 990622, 1/2 x 1 1/4 bolts and
(3) 101331, 1/2 nyloc nuts. Figure 1.
FIGURE 1
SUPPORT BRACKET
HITCH BRACKET
HITCH BRACKET
SUPPORT BRACKET

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ASSEMBLY
HITCHASSEMBLY
LANYARD
HITCH PIN
4. Place the hitch assembly on the ground
behind the mower. Place the (2) hitch pins
thruthe hitch and the hitch brackets. Secure
the hitch pins with the (2) hairpins that are
secured with the (2) lanyards. Figure 3.
5. Move to the rear of the hitch assembly and
pick it up towards the rear guard. Secure
using straps. Figure 2.
FIGURE 2

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ASSEMBLY
6. Place the hood assembly on to the hitch
assembly. Place both hood hinges between
theupperhitchmountsonthe hitchassembly.
Be sure that the rubber seal is on the inside
of the hood. Place the (2) friction washers
between the hood hinge and the upper hitch
mount. Place(2)990563, 3/8 x1bolt thru the
hinge and mount. Secure with (2) 976979,
3/8 nyloc nut. Figure 3.
FIGURE 3
HOODASSEMBLY
HOOD HINGE
3/8 NYLOC NUT
3/8 X 1 BOLT
RUBBER SEAL UPPER HITCH MOUNT
HITCH PIN
7. Open the hood and secure the (2) springs
to the bolts on the hood assembly and the
hitch assembly. Figure 3.
SPRING

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ASSEMBLY
8. With the hood open, secure the (3) bags in
place. The back of the bags will hook over
the mounting tabs on the hitch assembly.
Figure 4.
9. Close thehood,and latchthedraw latch over
thedraw latch keeper on the hitch assembly.
Figure 4.
10. Install the (2) straps to the (2) support
brackets on hitch assembly and the (2)
support brackets on the frame. Figure 5.
FIGURE 4
HOODASSEMBLY
DRAW
LATCH
MOUNT
TABS
DRAW LATCH
KEEPER
BAG
FIGURE 5
SUPPORT BRACKET
STRAP
LANYARD
SUPPORT BRACKET

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ASSEMBLY
Blower/Drive Kit
1. Open the blower/drive kit box and remove
all of the components.
2. Place the deck in the lowest cutting
height.
3. Remove the right side belt shield from the
deck.
4. Remove the deck belt from the right side
pulley.
5. Remove the deck pulley and spindle, but
keepthe hardware at handforre-installation.
6. Installnew spindle. Useexisting deck pulley
and key.Add new pulley, with raised portion
of pulley hub on the bottom. Secure with
existing hardware and tighten to 70 - 80 ft./
lbs.
7. Attach blower housing assembly to mower
deck. First, insert the stud at rear of blower
housing into tube at rear of deck discharge
opening. See Figure 7.
Rotate blower housing around toward the
front.The eyelbolt atfront of blower housing
will nest into slot in deck bracket. Tighten
with knob on eyeblot. See Figure 7.
8. Install blower drive belt so that blower
rotation is clockwise when viewed from the
operator’s position. Belt will be easiest to
install if it goes on the flat idler pulley last.
Pull lever in Figure 8 to assist in routing belt
around flat idler.After belt is installed, make
certain the bolts are tight on the bracket
supporting the rear “V” idler pulley. Refer to
Figure 8.
FIGURE 7
FIGURE 8

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ASSEMBLY
FIGURE 9
9. Install belt guard to blower assembly using
three1/4” washers and three 1/4” wing nuts.
See Figure 9.
10. Install hose on the blower housing and
secure with hose clamp.
BELT GUARD
WING NUT
WASHER

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OPERATION
Operating the Collection System
1. NEVER USE THE COLLECTION SYSTEM
WITHOUT THE BLOWER ASSEMBLY
AND HOSES SECURELYATTACHED.
2. Make sure hoses are connected at both
ends. Inspect hoses prior to each use.
3. Do not use the unit on slopes greater than
10 degrees.
4. The mower must be running in order to
vacuum debris through the mower deck.
5. In heavy grass it may be necessary to mow
and collect at a slower ground speed.
6. Never attempt to unclog the collection sys-
tem until the mower’s engine engine has
beenshut offand all moving partshavecome
to a complete stop.
7. Do not stand behind the vent at the rear of
the collection system due to the potential for
small pieces of blowing debris to escape
through the vent.
8. Wear eye and ear protection.

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SERVICE AND MAINTENANCE
Preventative Maintenance Schedule
Item Before Every Every Every
Each Use 5 Hours 25 Hours 50 Hours
Inspect/Clean Poly Mesh X X
Check/Tighten Nuts & Bolts X
Check/Tighten Hoses X
Turn Hose End to End X
Rotate Hose X
Clean Machine X
Inspect Bags X
WARNING
The collection system bags must be com-
pletely empty or removed while driving for-
ward onto a trailer. If the mower must be
loaded onto a trailer while there is still de-
bris in the container, the mower must be
backed up onto the trailer to avoid tipping.
Cleaning and Washing
Regular cleaning, washing, and lubricating will
prolong the service of the machine.
NOTE: Use care with power washers to avoid
damage to decals. Limit direct spray on these
items.
DONOTEXCEED 1000PSIWATERPRESSURE
FOR CLEANING.
Transport
Storage
1. Clean machine.
2. Cover all scratches with touch-up paint.
3. Covered or indoor storage is recommended.
Forbest results,cleanpolymesh insidehood regu-
larly. Instructions for doing this can be found in
the Service section of this manual.

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SERVICE AND MAINTENANCE
Caring For Hoses
1. Inspect hoses before each use. If hoses have
excessive wear, tears, or punctures, replace
immediately.
2. To prolong the life of the hose, periodically ro-
tate hose and turn hose end to end. Refer to
Preventative Maintenance Schedule in this
manual.
3. Avoid twists and sharp turns in the hoses, as
they will increase wear on the hoses.
4. Avoiddragging the lower hose along the sides
of buildings or other hard surfaces.
Cleaning Poly Mesh
The poly mesh on the collection system is located
inside the container hood. For best results, clean
poly mesh regularly.
Cleaning Instructions
1. Shut off engine.
2. Release the two (2) rubber latches under the
rear of the hood. Open hood and brush debris
off of both sides.
3. Close hood and re-latch.
DO NOT USE THE COLLECTION SYSTEM
WITHOUT POLY MESH SECURELY IN PLACE.
Caring For Bags
Inspect the bags before each use. If bags have
excessive wear, tears or punctures, replace im-
mediately.
Cleaning Instructions
NOTE: Under normal usage the bag material is
subject to deterioration and wear.

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SERVICE AND MAINTENANCE
PROBLEM POSSIBLE CAUSE CORRECTION
Loss of Vacuum. 1. Blower, hose or hood inlet clogged. 1. Remove hose and clean inlet.
2. Bags full. 2. Inspect and empty.
3. Fan blades bent or broken. 3. Replace/repair impeller.
4. Poly mesh plugged. 4. Clean poly mesh.
Unusual vibration 1. Solid object jammed in unit. 1. Check and remove any
or noise. obstruction.
2. Loose or missing bolts on unit. 2. Tighten or replace bolts.
3. Bent or damaged fan. 3. Replace/repair impleller.
Unit difficult to close. 1. Obstructions keeping door from 1. Clear obstructions.
completely closing.
2. Hood hinge bolts too tight. 2. Loosen bolts.
Troubleshooting Guide
DANGER
Before servicing unit, wait for all moving parts
to come to a complete stop. Turn engine off
and remove the spark plug wire.

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NOTE: Your Front Weight Bar may look different from those shown in this diagram.
SPINDLE DRIVE ASSEMBLY

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PARTS
ILLUSTRATIONS

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HOOD ASSEMBLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
22
10
20
5
23
19
23
23
21
23
20
14
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