TROUBLESHOOTING DIXIE CHOPPER LAWN MOWERS


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DIXIE CHOPPER
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BASIC TROUBLESHOOTING
OF DIXIE CHOPPER LAWN MOWERS.

SPECIAL NOTES TO THE READER:


Note 1-
While some of the following describes methods and techniques, the writer is not implying that all methods and techniques have been done on dixie chopper mowers.

Note 2-
While the following is somewhat basic, the writer has intentionally left out various things which one would expect the reader to know about before attempting to apply what is written. Basic understanding of electricity is a must and safety concerns must be considered before attempting to troubleshoot any mechanical or electrical system. If you do not feel you have this knowledge or training you should consult a properly trained service technician.

SPECIAL NOTE ABOUT TROUBLESHOOTING-It is up to you to not only read all the information about your problem, but it is also your responsibility to make an informed decision. If you have not properly diagnosed a problem and you just "throw parts" at your problem, don't get upset with anyone except yourself if you don't understand what you are doing or understand the complexity of the problem. You still have the choice or alternative of taking your equipment to a trained repair shop. If you buy parts and it did not fix your problem, you either improperly identified the true problem and purchased the wrong repair item or you have more than one problem.

ELECTRICAL PROBLEMS-

Customer asked,
I have a Dixie Chopper Silver Eagle.
When I start the mower and disengage the brake the engine shuts down.
As long as you leave the brake on the engine will run.
The engine dies when the brake lever is released.
What can the problem most likely be?

Answer-
The Seat Switch is there so that during operation if the occupant gets out of the seat the Engine will shut down.

There is actually two seat switches, one that is in the cushion of the seat, see wires going into the bottom of the seat.

There is a 2nd switch found on the frame rail that the seat platform rests on. The seat platform switch if not working properly won't let the machine start.
It sounds like the seat cushion switch is malfunctioning.
When you let the brake lever "down",
the electrical system is thinking the operator has come out of the seat.
The first switch to check is the seat switch.
While there are other devices that can cause this problem,
the seat switch should be the first place to check.

HYDRAULIC LEAKS--


Hydraulic leaks can happen at connectors, seals, hose lines, gear boxes and other hydraulic system components.

Hydraulic Filter leaks


Some Dixie Chopper hydraulic filters leak from the seal on the spin on filter. The sealing action must occur on the bottom of the hydraulic tank surface. Did you clean the bottom of the tank before you installed a new filter? Did you tighten the filter enough? What is enough? While most spin on filters say to tighten hand tight, it is not unusual to find DC hydraulic filters need some REAL TIGHTENING!! You should use your best judgement. Is the bottom of the hydraulic tank warped? Normally the filters are simply just not tight enough if the leak is at the filters.

PUMP RELATED LEAKS-


Hydraulic leaks at the pumps can be from leaking pump seals and connectors. On the direct drive, gearbox driven pumps, there is a seal on the pump mounting flange. In years past, Dixie chopper has used two different sizes of O-rings to seal the pump to the mounting flange on the classic mowers. Keep in mind, this is only talking about machines that are gear box driven. If your machine is belt driven, i.e. Silver Eagle series and others, then this does not apply.
The part numbers for this seal and the oversized seal are as follows- 65024 and 65024-OS (Over Sized). IF you believe you need to replace OR remove either of the pumps, it would be adviseable to order both O-rings and use the one that matches the size you remove. You will need one o-ring for each pump flange. Again, you should order one or two of each depending on the pumps you intend on removing.

Gear Box Leaks-


As for the Gear Box, there is a cork gasket on the top cover. You should inspect for fluid inside that gear box. You can remove the top cover, 4 screws holds this cover in place. If you are careful the cork gasket can be re-used. If you decide to change the gasket, be careful not to drop any of the cork inside the gearbox. 788101 IS THE CORK GASKET PART NUMBER. If you find your gear box is making noise, check the oil level. If you are hearing noise, the gear box is probably empty. This gear box is pretty tough, so don't rush out to buy a new gear box if you find it is empty. Refil the gear box and see if the noise goes away. Where did the oil go to? Was the leak a massive leak? Was it a slow leak over several years? You should determine if the gear box is cracked or has a bottom seal leak. Fille it with proper oil and test again before you assume the gearbox is bad. Again, this gearbox is pretty tough. Did the oil leak out from the pump flange o-ring? Consider all these possibilities before you remove the pumps and gearbox.

ELECTRIC DECK LIFT ACTUATOR TROUBLESHOOTING-


If the electric deck lift acutator on your Dixie Chopper will not raise or lower the deck, then something is obviously wrong. In the full up or full down position, the acutator can make a rapid and loud clicking sound. That indicates its full travel in a given direction. If you hear the rapid clicking, try to move the switch to the other direction and if the actuator does not move, it could be that you are having an electrical problem with either the actuator or its wiring or control switch or possible dead or weak battery. Try charging the battery before you go too deep into this problem. Bench test the actuator. The actuator does not have to be removed to perform a test on the actuator.

Testing of the actuator-


To test the actuator, simply connect the actuator to an alternate battery circuit. Short wire leads will be needed so that you can temporarily connect a battery with 12.0 volts to the actuator connector. No switch is required for this simple bench test. Spade type connectors that will match the connector on the actuator should be used with two separate wires. Once you have two wires connected to the actuator then simply touch the bare ends of the wires to the battery posts. The actuator, if good, will move in one direction. Keep in mind DC motors are reversable if you reverse the power input. Reverse the lead ends at the battery and the actuator should move in the opposite direction. If the actuator does pass this bench test, then your actuator is good and your problem is elsewhere. Areas to check include the connection points, switch, wiring, and battery condition. Make sure the battery is fully charged. Did the connector at the actuator make good contact? Is a wire broken? Clean up any corrosion at the connector and try again.

Is 12 volts DC going to the actuator? With a voltage tester, see if voltage is present at the wire connection for the actuator. Check with the switch placed into both directions. NOTE- You can have power going to the connector at the actuator and 12 volts indicated on the volt meter, and the switch can be bad or intermitent. If the actuator passes the previously mentioned bench test, then investigate the switch closer.

If no power is coming from the switch going to the connector at the actuator, then you should investigate the switch. Is power going to the switch? The ignition switch does not have to be on to supply power to the switch. Are the battery connections at the battery corroded? Can the engine start? If you don't have enough battery power to start the engine, the actuator probably won't work either.

ENGINE TROUBLESHOOTING

BLADES WON'T ENGAGE

Several things can cause the blades not to engage.
DID THE DECK DRIVE BELT COME OFF ?

BLADES WON'T ENGAGE MORE INFO HERE
BLADE ENGAGEMENT SWITCH IS BAD.
CLUTCH IS BAD.
FUSE IS BLOWN OR CORRODED.
ELECTRICAL CONNECTION IS LOOSE OR CORRODED.
BATTERY VOLTAGE IS LOW.

BLADE BOLTS WON'T LOOSEN FROM THE BLADE SHAFT


If you can't loosen the blade bolt,
it is probably becaue you did not use fresh FIBER WASHERS.

ALWAYS REPLACE THE FIBER WASHERS!

See the link below for more on Fiber Washers and how important they are.

CAN'T REMOVE BLADE BOLT FROM THE BLADE SHAFT-MORE INFO HERE


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AAAA Generator and Pressure Washer, Inc.
DBA: ARKANSAS OUTDOOR POWER EQUIPMENT
JACKSONVILLE ARKANSAS
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Last modified: APRIL 15, 2013

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