Dixon 130211 - DCKC Product manual

Operators Manual 130211 - DCKC
130212 - DCRC
Models:
Please read these instructions carefully and make
sure you understand them before using the machine.
MANUAL NO. 539 130679 REV IR (02/06/07)
Parts Manual
Collection System

2

3
©2007 Dixon.All Rights Reserved.
Beatrice, NE. Printed in U.S.A.

4
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
General Information ................................................................. 5
Safety Procedures.................................................................... 5
Assembly Instructions .............................................................. 7
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
Troubleshooting Guide ........................................................... 16
Replacement Parts
ClamshellAssembly ............................................................... 18
Clamshell RearAssembly ...................................................... 20
Clamshell Front Assembly...................................................... 22
Clamshell Linkage - Ram ....................................................... 24
Clamshell Linkage - Kodiak.................................................... 26
Weight Kit Ram ...................................................................... 28
Weight Kit Kodaik................................................................... 30

5
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’sresponsibilitytoexplainthismaterialto
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 theequipment.Local regulations may
restrict the age of the operator.
• The owner/user can prevent and is responsible
foraccidentsorinjuriesoccurringto themselves,
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
usedandremove all objectssuch as rocks, 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. Useonly 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.
• Checkthatoperator’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.
Thefollowingsafetysymbolsare used throughout
themanual toalertyou toinformationabout unsafe
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.
Thisequipmentshould not bemodifiedwithout the
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
equipmentwithoutthe manufacturer’sprior written
authorization.

6
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
notoperateacross the sidesofslopes. Operate
up and down slopes only. Do not operate on
steep slopes.
• Turfconditions canaffectthemachine’sstability.
Donotoperate on wetgrasswheretraction 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. Make necessaryrepairsbefore
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.
•Usecarewhenloadingorunloadingthe machine
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.
•Cleangrassand debris frommufflerandengine
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.

7
ASSEMBLY
Assembly Instructions
Tools Required:
Ratchet
Torque Wrench
1/2" Wrench
1/2" Socket
9/16" Wrench
9/16" Socket
(2) 3/4" Wrench
3/4" Socket
Flat Screw Driver
(2) 1” Wrench - open end
RAM/RAM MAG
1. Remove clamshell from crate.
2. Remove two 5/16 x 3/4 carriage bolts from
the lower flange of the rear guard on the
mower.
3. Place (539 114781) Mount Bracket, Lower
in place and secure using four (539 111785)
3/8 x 3/4 carriage bolts, four (539 976979) 3/
8 nyloc hex nut and two (539 107271) 5/16 x
1 carriage bolts. Reuse the two 5/16 nyloc
hex nuts previously removed from the 5/16 x
3/4 carriage bolts. See Figure 1.
4. Lift seat and latch with seat latch.
5. Remove seat springs.
6. Place (539 114786) Plate, Support, Linkage
on frame.
7. Reposition springsandsecurewith (990209)
5/16 x 1 hex bolts and hex nut previously
removed from seat springs. See Figure 2.
8. Attach two (539 114783) Linkage, Support
to the clamshell assembly as shown in Fig-
ure 2.
9. Secure with two (539 100476) 5/8 hex jam
nut and two (539 115591) 5/8 nyloc hex nut
as shown. Do not tighten nuts.
REAR GUARD
539 114781 MOUNT BRACKET, LOWER
LOWER FLANGE
FIGURE 1
FIGURE 2
539 114786 PLATE,
SUPPORT, LINKAGE

8
ASSEMBLY
10. Lift Clamshell assembly onto (539 114781)
Mount Bracket, Lower. Position tubes on
bottom of clamshell on out side of the tubes
on (539 114781) Mount Bracket, Lower.
11. Securewith (539119372) HingePinand(539
115501) Cotter Pin.
12. Hook both (539 114783) Linkage, Support
into (539 114786) Plate, Support, Linkage
andsecurewithtwo remaining (539 115501)
Cotter Pins.
13. Tighten (539 100476) 5/8 Jam nut and (539
115591) 5/8 Nyloc nut so that the clamshell
is sitting straight on unit.
14. Tighten (539 114782) Brackets on front of
clamshell.
539 114782
BRACKET
CLAMSHELL
ASSEMBLY
539 114812 LINKAGE,
SUPPORT
FIGURE 3

9
ASSEMBLY
FIGURE 3
KODIAK
1. Remove clamshell from crate.
2. Remove two 5/16 x 3/4 carriage bolts from
the lower flange of the rear guard on the
mower.
3. Place (539 114815) Mount Bracket, Lower
in place and secure using four (539 111785)
3/8 x 3/4 carriage bolts, four (539 976979) 3/
8 nyloc hex nut and two (539 107271) 5/16 x
1 carriage bolts. Reuse the two 5/16 nyloc
hex nuts previously removed from the 5/16 x
3/4 carriage bolts. See Figure 4.
4. Secure two (539 114811) Bracket, Support
to frame as shown in Figure 5. Secure us-
ing (539 103433) 1/2 x 3 1/4 hex bolt and
(539 101331) 1/2 hex nyloc nut.
REAR GUARD
539 114815 MOUNT BRACKET, LOWER
LOWER FLANGE
FIGURE 4
FIGURE 5
539 114811 BRACKET, SUPPORT

10
ASSEMBLY
5. Attach two (539 114812) Linkage, Support
to the clamshell assembly as shown in Fig-
ure 6.
6. Secure with two (539 100476) 5/8 hex jam
nut and two (539 115591) 5/8 nyloc hex nut
as shown. Do not tighten nuts.
7. Lift Clamshell assembly onto (539 114815)
Mount Bracket, Lower. Position tubes on
bottom of clamshell on out side of the tubes
on (539 114781).
8. Secure with(539119372)HingePinand(539
115501) Cotter Pin.
9. Hook both (539 114812) Linkage, Support
into (539 114811) Bracket, Support and se-
cure with two remaining (539 115501) Cot-
ter Pins.
10. Tighten (539 100476) 5/8 Jam nut and
(115591) 5/8 Nyloc nut so that the clamshell
is sitting straight on unit.
11. Tighten (539 114782) Brackets on front of
clamshell.
CLAMSHELL
ASSEMBLY
539 114812 LINKAGE,
SUPPORT
FIGURE 6
539 114782
BRACKET

11
ASSEMBLY
FRONT WEIGHTS - RAM
1. Bolt cast weight and two weight brackets to-
gether using four bolts (539 106492, 3/8 x 2
3/4”) and four nuts (539 976979, 3/8” nyloc).
2. Slideboth weight bracketsover thefronttube
on the frame. Be sure to position in the cen-
ter of the frame.
3. Secure with four bolts (539 991126, 3/8 x 3
3/4”) and four nuts (539 976979, 3/8”
nyloc).
CAUTION
DO NOT operate mower with grass catcher,
unless the front weights are installed.
CAST WEIGHT
BRACKET
539 976979
539 106492
539 991126
539 976979

12
ASSEMBLY
FRONT WEIGHTS - KODIAK
CAST COUNTERWEIGHT
WEIGHT BAR HOLD DOWN
FRONT WEIGHT BAR
1. Remove mower foot plate and floor pan.
2. Align weight bar to the front of the frame.
See diagram.
3. Secure weight bar to mower frame with four
5/16-18 x 1 1/4” hex bolts from kit, reuse the
four 5-16” washers and four 5/16” nyloc nuts
that were removed from the foot plate.
4. Place all front weights on front weight bar.
5. Place holddown bar over front weights and
secure to front weight bar using two 3/8” x 1”
clevis pins and two hair pins.
6. Reinstall floor pan.

13
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 movingpartshavecome
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.

14
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
WARNING
The collection system must be completely
emptyor removedwhile drivingforward onto
a trailer. If the mower must be loaded onto
a trailer while there is still debris in the con-
tainer, 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.

15
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 thesides
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.

16
SERVICE AND MAINTENANCE
PROBLEM POSSIBLE CAUSE CORRECTION
Loss of Vacuum. 1. Hose or hood inlet clogged. 1. Remove hose and clean inlet.
2. Container full. 2. Inspect and empty.
3. Poly mesh plugged. 3. 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.
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.

17
PARTS
ILLUSTRATIONS

18
CLAMSHELL ASSEMBLY
1
2
3
4
5
6
7
8
9
10
REF.
REF.
3

19
CLAMSHELL ASSEMBLY
1.. 539 990629 ...2...HCS 3/8-16 X 2 1/4, GR5
2.. 539 200282 ...2...NUT, 3/8-16, HAM, NYLOC
3.. 539 990122 ...3...WASHER, 3/8, SAE
4...539 115972 ...2...BUSHING
5.. 539 990717 ...1...NUT, 5/16-18, NYLOC
6...539 119414 ...1...BUSHING, PLASTIC
7...539 117244 ...1...ROD END
8...539 115609 ...1...NUT, 1/2-13, THIN, NYLOC
9.. 539 990625 ...1...NUT, 1/2-13, JAM
10...539 119371 ...1...LIFT LINK
ITEM PART NO. QTY. DESCRIPTION

20
CLAMSHELL REAR ASSEMBLY
1
2
3
4
5
6
7
89
10
11
12
13
14
15
16
17
18
19
18 10
10
18
10
12