Chain Drive to 2002

Parts Information
 Table of Contents

Chain Drive___________________________________3
Operation Manual and Saftey Information_________51
Standard Production Manual 11/1997_____________71
Standard Production Manual 11/12/1998__________135
XW Manual 05/01_____________________________195
LX-X-XF Manual04/02_________________________229
XW-XF-60 Manual 04/02_______________________277
XXW-72 Manual 04/02_________________________315
XXWD-5000 Manual__________________________ 361
Diesel Wiring and Parts________________________ 424
XXWD26-60-72 Updrive Parts Breakdown________ 425
XXWD-5000 and XXWD-2600 Motor Mounts_____ 428
Front Weight_________________________________ 430
Roll Cage____________________________________ 433
Noram Clutch Parts Breakdown_________________436
Generac Repower Information__________________ 437
Hydro-Gear Serial Number Informantion_________445
Hydro-Gear Service and Part ID Informantion____ 446
Hydro-Gear BDP 10L Breakdown & Parts Info.___ 490
Hydro-Gear BDP 10A Breakdown & Parts Info.___ 492
Hydro-Gear BDP 16A Breakdown & Parts Info.___ 494
White Wheel Motor ID and Part Number_________ 498
Kohler Engine Part Numbers for 2002 Model yr.___ 499
Kohler Engine Part Numbers for 2001 and Older __ 516
72” Snow Blade_______________________________ 566
Zebra Kit (strip kit for all models)_______________ 573
 20206 Left Pump

20205 Right Pump

18
17

21
23

59
 For Serial Numbers 0024500 and Higher

Model # ____________________ Engine Model # ____________________

Serial # ____________________ Engine Serial # ____________________

Date Purchased ____________________ Engine Spec. # ____________________

OPERATION MANUAL
700003 May, 2001
Congratulations on your purchase of a DIXIE CHOPPER lawn
mower. We believe you have exercised excellent judgement, and are most
appreciative of your patronage.

We recommend that you read this entire manual before operating this unit.
Time spent in becoming fully aquainted with its performance will add a longer
and more satisfactory life to your DIXIE CHOPPER.

To obtain the latest information on your Dixie Chopper lawn mower, and receive the highest quality
service, please call or visit your nearest authorized Dixie Chopper Dealer.

AUTHORIZED DEALER

Dixie Chopper reserves the right to make changes or add improvements to its products at any time without
incurring any obligation to make such changes to products previously manufactured. Neither Dixie Chopper, nor
its dealers, accept responsiblility for variations which may be evident in the actual specifications of its products and
the statements and descriptions contained in this publication.
 CONTENTS

Introduction....................................................................................................1
Warranty.........................................................................................................1
General Safety................................................................................................4
Mower Controls.............................................................................................6
Operating your Mower...................................................................................8
OCDC...........................................................................................................10
Mower Deck Adjustments............................................................................11
Mower Cleaning and Storage......................................................................13
Routine Maintenance...................................................................................14
Lubrication Points........................................................................................15
Twin Engine Load Balancing.......................................................................17
Diesel Engine Maintenance..........................................................................19
Notes.............................................................................................................22
 Introduction
Prior to operating the Dixie Chopper lawn mower you
should be trained in its proper use and warned of its dan-
gers before operating, adjusting, or servicing it.
You should also read and understand this entire manual.
DANGER This symbol if used warns immedi-
ate hazards which will result in se-
vere personal injury or death.
WARNING This symbol refers to a hazard or un-
safe practice which can result in se-
vere personal injury or death.
CAUTION This symbol refers to a hazard or
unsafe practice which can result in
severe personal injury or product or property damage.
Familiarize yourself with the controls and
know how to stop the mower quickly.
Inspect your work area carefully. Remove
debris from the turf area to be cut.
Avoid contact with moving parts. Keep away
from whirling blades. Keep feet and hands
from underneath mower deck.
Never direct discharge of material toward by
standers nor allow anyone near the machine
while in operation.
This machine is not meant for highway or
street use. It is not a recreational vehicle and
you should not carry passengers.
Never tamper with safety devices or guards.
If a guard or safety device is damaged, or re-
moved, replace before operating mower.
Handle gasoline carefully. Never add fuel to
tank while the engine is running or hot.

WARRANTY
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES EXPRESSED OR IMPLIED
(INCLUDING BUT NOT LIMITED TO ANY REGARDING THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE), NOT SPECIFIED HEREIN, REGARDING THE EQUIPMENT WHICH IS THE SUBJECT OF THIS WARRANTY.

Owner/Operator Knowledge Responsibility

As a condition of the Dixie Chopper warranty, the owner and operator(s) are fully responsible for
having read, and reasonably understanding the proper operation and care of the Dixie Chopper unit Before At-
tempting to Operate the Machine.

Through the terms and conditions contained herein, Magic Circle Corporation (Dixie Chopper)
warrants that it will adjust, repair, or replace, any factory original part used in the manufacturing
of a Dixie Chopper complete unit, found to be defective in material or workmanship.

Complete Unit
The warranty period is limited to one year from the date of retail purchase on behalf of the original owner of
a Dixie Chopper complete unit. This warranty will provide the cost of repair or replacement
(at the discretion of Dixie Chopper) of the defective part, including labor. This warranty applies in like form
to the original retail purchaser of a Dixie Chopper complete unit used commercially, or for income
producing purposes. Additionally, Dixie Chopper will provide to the original purchaser beyond the initial
one year warranty as stated above, any main-frame due to breakage, or any stainless steel body due to rust, for the
useful life period of the machine. This additional “lifetime warranty” covers stated parts ONLY… NO LABOR.
 WARRANTY
Drive Train
The hydrostatic drive components (pumps, wheel motors, and T-box), of the Dixie Chopper complete unit will be warranted
for two years from the retail purchase date on behalf of the original owner against defects
in materials or workmanship. Labor required to repair or replace components of the hydrostatic drive
system will be covered by Dixie Chopper for the 1st year, and at the unit owners expense during the 2nd year
from the original purchase date.

Drive Train 3-Year Extended Warranty {Optional}

Dixie Chopper offers for an additional fee (to be paid at the time of the unit purchase), a 3-year extended
warranty covering the hydrostatic drive system components of the standard warranty… plus all drive
linkages, bushings, hoses, fittings, filter bases, oil reservoir, input pulley assembly, wheel hubs, and
wheel rims that require replacement due to a defect in materials or workmanship.
{This extended warranty covers stated parts only… no labor.}

Engine
Engine warranty is provided by the engine manufacturer. Please refer to the engine manufacturer warranty
statement included within the ownership materials provided with the unit. Dixie Chopper is not authorized
to handle warranty adjustments on engines. Engine warranty claims must be filed with the appropriate
engine manufacturer (Kohler, Kawasaki, Honda etc.) for necessary warranty repairs. In general, engines
used on Dixie Chopper units are warranted by the respective engine manufacturer for a period of two years
from the retail purchase date on behalf of the original owner.

Tires Blades and Belts

Tires blades and belts are considered to be consumable-wear items, and are therefore warranted for a period of 90
days against materials or workmanship defects, not for wear or abuse.

Transportation for Warranty Repairs

A Dixie Chopper complete unit (including any defective part(s)) requiring warranty repair, must be returned
to an authorized Dixie Chopper Service Dealer within the warranty period. The expense of transporting the
unit to and from the dealer for warranty work will be the responsibility of the unit owner.

Limitation of Warranty
The Product Registration Card must be submitted to Dixie Chopper within 3-days of the original retail
purchase date to enable validation of the warranty period provided. Proof of purchase may be required
of the unit owner to substantiate any warranty claim.

All warranty work must be performed by an authorized Dixie Chopper Servicing Dealer.
This warranty covers only Dixie Chopper complete units which are properly serviced, maintained, and operated under
conditions considered normal for commercial turf equipment.
 WARRANTY
Expressly Not Covered
a.) Replacement of service items, such as oil, lubricants, spark plugs, belts, rubber hoses or other
items subject to normal service replacement.
b.) Maintenance services such as cleaning, lubrication, oil change, blade sharpening etc.
c.) Damage, defects or deterioration due to normal use, wear, or exposure to elements.
d.) Damage or defects resulting from misuse, neglect, alteration, accident or negligence.
e.) Use of fuels, oils, or lubricants other than as specified.
f.) Damage or defects resulting from repairs by person(s) other than an authorized Dixie Chopper
service dealer or installation of parts other than genuine Dixie Chopper parts or parts recom-
mended by Dixie Chopper.
g.) Repairs, alterations or installations of accessories which have an adverse affect on the operation,
performance or durability of the Dixie Chopper complete unit.
h.) Repair or replacements resulting from operations of Dixie Chopper equipment that has been
modified, altered, or affected with respect to the intended use of the product.
i.) Repair or replacement as a result of Dixie Chopper equipment operated in a manner which is not
in accord with the instructions as specified in the operators manual or other instructions pro-
vided by Dixie Chopper.

Dixie Chopper Is Not Responsible for… (nor limited to the following)

j.) Travel time, overtime, after hours time or other extraordinary repair charges or charge relating to
repairs or replacements outside of normal business hours at the place of business of the autho-
rized Dixie Chopper service dealer.
k.) Loss, cost or expense relating to transportation of Dixie Chopper equipment from the location of
owner or location where used by owner to or from any authorized Dixie Chopper service
dealer.
l.) Expenses relating to gasoline, oil, or lubricants.
m.) Rental of like or similar equipment during the time of any warranty, or replacement work.
n.) Any claims for lost revenue, lost profit or additional cost or expense incurred as a result of a
claim of breach of warranty.
o.) Loss or damage to person or property other than that covered by the terms of this warranty.
p.) Any telephone, telegram, travel charges, or attorney’s fees.

Disclaimer
Any and all statements or representations made by seller of this equipment, including those set forth in any sales
literature or made orally by any sales representative, are superceded by the terms of this warranty. There are no
representations or warranties, which have been authorized and provided to the buyer of Dixie Chopper equipment,
other than as set forth in this warranty. Any affirmation of fact or promise made by Dixie Chopper or any of its
representatives to the buyer which relates to the goods that are the subject of this warranty shall not be regarded as
part of the basis of the bargain and shall not be deemed to create any express warranty that such goods shall
conform to the affirmation or promise.
 GENERAL SAFETY
1. The Dixie Chopper mower is designed for high productivity. Operators should understand its proper usage
before operating the mower.
2. Carefully read and understand this Operator’s Manual before operating the mower.
3. NEVER allow individuals who have not read this Operator’s Manual to operate the mower. Operators less
than 14 years of age are not recommended.
4. Absolutely NO passengers. Avoid mowing while children and others are nearby. The operator is responsible
for accidents or hazards occurring during operation.
5. Always use personal protection equipment, such as, but not limited to, protection for the eyes, ears, feet and
head.
6. NEVER operate the mower when barefoot or when wearing open sandals.
7. Thoroughly clear the work area of objects (wire, stones, sticks, bones, etc.) which may damage the mower
or cause personal injury to the operator or bystanders.
8. Before attempting to start the engine, disengage the deck and all attachment clutches and position the steering
levers into the neutral lock position.
9. Give complete, undivided attention to the job at hand.
10. Whenever the deck is engaged, NEVER direct the discharge of material toward bystanders nor allow anyone
near the mower while in operation.
11. Whenever possible, avoid operating the mower in wet grass.
12. Mow only in well-lit area.
13. Use EXTREME CAUTION when mowing and/or turning on hill sides.
14. Reduce speed and exercise EXTREME CAUTION on slopes to prevent tipping over or loss of control.
15. This mower is not recommended for use on slopes exceeding 15 degrees.
16. To avoid tipping over, avoid sudden starts when mowing up hill.
17. When mowing downhill, loss of traction may occur. Weight transfer to the front wheels may cause drive wheels
to slip and result in loss of braking. To help re-gain control, increase ground speed and gradually turn left or
right followed by a decrease in ground speed to re-gain directional control.
18. DO NOT mow slopes when grass is wet.
19. Be especially cautious when changing directions on slopes.
20. Stay alert for holes, rocks and roots in the terrain, which may cause the vehicle to upset.
21. Keep away from drop-offs (ponds, lakes, river banks, etc.).
22. When backing up make sure the area behind you is clear. Dixie Chopper’s zero turning radius nearly eliminates
the need for backing up. Simply turn the mower around within its own dimension and proceed forward.
23. Disengage power to attachments, set parking brake, and stop engine before leaving the operator position.
24. Disengage power to attachments, set parking brake, and stop engine before making any repairs or adjustments.
25. Disengage power to deck and other attachments when the mower is being transported or not in use.
26. Take all possible precautions when leaving vehicle unattended; such as disengaging deck, engaging parking
brake, lowering attachments, placing steering levers into neutral lock position, stopping the engine, and
removing the key.
27. NEVER operate the mower with defective guards, shields, or covers. Always have safety shields, guards,
switches, and other devices in place and in proper working condition.
28. Keep hands, feet and clothing away from rotating parts anytime the units engine is running.
29. DO NOT mow with mower blades that are out of balance or have eroded airlifts and/or split ends.
30. Keep mower and attachments in good operating condition, keep safety devices in place and working.
31. Keep all nuts, bolts, and screws tight to be sure equipment is in safe working condition.
 GENERAL SAFETY
32. Stop the engine, set parking brake, and remove the key:
- After striking a foreign object (inspect the mower for damage and make any repairs before starting
and operating the mower).
- Before making any adjustments or repairs.
- Before unclogging chute.
- Before refueling.
33. DO NOT change the engine governor settings or overspeed the engine.
34. Handle gasoline with care – it is highly flammable.
- Use approved gasoline container and place out of reach of children.
- Use gasoline as a fuel ONLY. Never use as a cleaner.
- Never remove fuel cap or add gasoline to a running or hot engine or
an engine that has not been allowed to cool for at least minutes after
running.
- Never fill fuel tanks inside of buildings.
- Always wipe up spilled fuel.
- Absolutely, positively NO SMOKING around fuel.
- Never store equipment, with gasoline in the tank, inside a building
where fumes may reach an open flame or spark.
- To reduce fire hazard, keep engine free of grass, leaves, or excessive
grease.
- Allow engine to cool before storing in any enclosure.
35. Use care when pulling loads or using heavy equipment.
- Use only approved drawbar hitch points.
- Limit loads to those you can safely control.
- Do not turn sharply.
- Use care when backing.
- Use counterweights when suggested in the Owner’s Manual.
- Use extreme caution on slopes.
36. Watch out for traffic when near or crossing driveways, parking lots, and roads.
37. Always run engine at idle for at least one minute for each hour of previous running, before shutting-down
engine.
 MOWER CONTROLS

1. Ignition Switch
2. Choke
3. Throttle
4. Parking Brake (if so equipped)
5. Deck Lift Pedal 7 4
6. Fuel Cap (1 each side)
7. Steering Control Levers
8. Deck Engaging Handle 3
2
5
6

Note* - Always set engine speed to full throttle when

mowing and maintain a minimum of 3600 RPM and a
maximum of 3750 RPM as it provides necessary airflow
through the engine cowling to prevent overheating as
well as maintaining blade speed for a satisfactory
quality of cut. If engine pulls below 3500 when under
load slow down the ground speed and allow the engine
to recover up to proper RPM.
 MOWER CONTROLS
1. THROTTLE CONTROL
Throttle is located on top of right fuel tank just ahead of the
fuel cap. Move throttle forward all the way to operate
machine. Move throttle all the way to the rear before shut-
ting engine off.
2. IGNITION SWITCH
The ignition switch is located on the right side of front panel
just below the seat. The ignition switch has three positions:
(1) OFF, (2) RUN, (3) START. To start the engine, turn
the key all the way to START. Release the key when en-
gine starts and it will automatically return to the RUN posi-
tion. Turn the switch to the OFF position to stop the en-
gine.
3. CHOKE CONTROL
The choke control is located on the right side of the front
panel next to the ignition switch. Pull the choke knob out
when starting the engine. Slowly push the knob in after
engine starts. If the engine is warm and has been running,
choking may not be necessary to restart engine.
4. MOWER LIFT PEDAL
The mower foot lift pedal is located on the left side of the
floor pan. To lower the mower deck, first push up on the
foot pedal lock, then, push down and rotate foot to move
bottom of the pedal down. Remove foot from peal when
desired height is obtained. Lastly, push down on the foot
pedal lock to lock the pedal into position.
5. RIGHT AND LEFT MOTION CONTROL
LEVERS
To ener the seat, move the levers all the way left and right
into the neutral lock position. Enter the seat and move the
levers in toward the center of the machine. Left lever con-
trols the left rear wheel and the right lever controls the right
rear wheel. To go forward, push both levers forward evenly;
the further forward the levers are pushed, the faster the
machine will travel. To go in reverse, pull both levers to the
rear evenly; the further the levers are pulled towards you,
the faster the machine will travel. To turn, slow the machine
down and slow speed of wheel in the direction you want to
turn.
6. FUEL TANK VALVES
Fuel tank valves are located at the bottom of each fuel tank.
Fuel tank valves are normally left open except when service
on the fuel system becomes necessary.
SAFETY INTERLOCK SYSTEM
Each machine has safety interlock switches. Switches
are actuated by the seat. The seat switch will stop engine
when seat is vacated with the engine running.
Seat must be occupied.
If the machine will not start, check that the seat is occupied.
The safety interlock system must be tested periodically.
To test operation, the following functions must be performed
by an Authorized Dixie Chopper Dealer for your pro-
tection:
1. Engine should NOT start if seat is not occup-
pied.
2. With engine running, test operate seat switch
by rising off seat. Engine should shut off.
CORRECT ENGINE OPERATION
CAUTION
Before starting the engine, become familiar
with all controls. Read this Operator’s Man-
ual thoroughly. Always check engine oil level
before starting the engine.
WARNING
Care should be taken to avoid inhaling ex-
haust gases as they contain carbon monoxide
gas, which is colorless and odorless. Carbon
monoxide is a dangerous gas that can cause un-
consciousness and is potentially lethal. Do not
run the engine in confined areas such as a
closed garage.
 OPERATING YOUR MOWER
STARTING ENGINE
To start the engine, occupy the seat. Move throttle control
lever halfway to operate position. Pull choke control all the
way out to cold position. Turn ignition key to start position
to engage the starter. When engine starts, release key.
Switch is spring-loaded and will return to the run posi-
tion automatically.
If the engine fails to start after 10 seconds of
continuous cranking, turn the key to the OFF
position and allow the starter motor to cool.
Check for the cause of hard starting; consult
the Troubleshooting Checklist.
Once the engine has started, slowly return the choke con-
trol to its normal position. If the engine stalls at low
speeds, or hesitates during acceleration, choke should
be applied as necessary until engine reaches normal op-
erating temperature.
STOPPING ENGINE
To stop the engine, move the throttle lever to the idle posi-
tion and turn ignition key to the OFF postion. If the
engine has been working hard or the engine is hot, allow
the engine to idle for one minute for each hour of running
before turning the key off. This practice will help cool
the engine before stopping.
Note: In case of emergency, engine may be stopped by
turning the ignition key to the OFF position.
CAUTION
Always remove the key when leaving
the machine unattended, even if for just
a few minutes. Prevent accidents; don’t
give children or unauthorized persons an
oppotunity to operate this machine.
THROTTLE CONTROL
Throttle control regulates the speed of the engine as mea-
sured in RPM (Revolutions Per Minute). This control
should not be used to regulate the ground speed.
The engine has been designed with a special governor
that limits engine RPM. Unlike an automobile, this
governor allows the engine to operate most efficiently
at a set speed and protects it from damage caused by
excessive RPM. Always operate the machine with the
throttle control set at 3/4 to full speed.
CHOKE CONTROL
The choke control activates a “butterfly” valve in the
carbureator. When the choke is partially or completely
closed, less air is admitted to the engine. This results in a
higher fuel-to-air (richer) mixture that is required when the
engine is started cold. Warm engines may not need chok-
ing.
CAUTION
Handle fuel with care. It is highly flammable.
Use only approved fuel containers. Never add
fuel while the engine is running. Fill fuel tanks
outdoors with extreme care. Never fill fuel
tanks indoors. Replace fuel tank cap securely
and wipe up all spilled fuel.
CORRECT PUMP OPERATION TO GO FOR-
WARD OR REVERSE
The machine is equipped with a separate pump for each
rear wheel. The pumps are controlled by the motion con-
trol levers, one for each wheel.
CAUTION
Sudden starts can be damaging to the equip-
ment and could cause loss of operator con-
trol. For safe operation, never move the mo-
tion conrol levers too rapidly, especially on
grades.
To go forward, push both levers forward evenly.
To go in reverse, pull back on both levers evenly.
 OPERATING YOUR MOWER
CORRECT PUMP OPERATION TO CHANGE
SPEED OR DIRECTION
To change direction of the machine, slowly move lever to
nuetral and move levers in the direction you want to
go. The further the levers are moved away from neutral
position, the faster the machine will travel. To turn the
machine left or right, slow the speed of the wheel in the
direction you want to turn.
CORRECT PUMP OPERATION TO STOP
To stop the machine, return both levers evenly to the neutral
position.
CAUTION
Read the manuals provided with attachments
before operating. These manuals give a more
detailed description of operation and point out
other areas of caution. Familiarize yourself
thoroughly with equipment before attempting
to use it.
OPERATION OF THE MACHINE WITH MOWER
DECK
IMPORTANT
Keep all shields and mower deck dis-
charge chute, or OCDC, in place. Never
attempt to clear discharge areas or
mower deck blades without disengaging
mower deck, setting parking brake, and
removing ignition key.
For best operation on average lawns, operate engine at
full throttle; control ground speed with motion control
levers. Average lawns usually cut at a height between 2
and 3 inches (5-7.6cm). Tall grass and weeds should be
cut with the mower in its highest position, making a
second pass cutting to height desired. Always keep
mower deck blades sharp.
MOWING SPEED
The mower is designed to operate most efficiently at
maximum blade speeds. The speed of the machine
should allow the mower deck blades to maintain this
maximum speed while mowing across turf. Slow the ma-
chine for cutting tall grass, grass that is heavy with
moisture, or when moving uphill. If ground speed is too
fast, or blade speed is too slow, mowing will be uneven
because mower blades will not be able to lift grass into
cutting position as mower passes over ground.
MOWING HEIGHT
The best cutting height for your lawn has probably been
established from previous experience. The first time you
mow, set the mower to cut a little higher than you have in
the past. This will help you determine the best approach to
uneven areas, to be sure a wider cut does not result in scalp-
ing the high spots. In general, recommended cutting height
is 2 to 3 inches (5-7.6cm).
Very tall grass can be cut without difficulty by using a
little care. Set mower in its highest cutting position and
enter area slowly. If necessary, take a cut one half width
of mower, overlapping previously cut area on each
pass. Then, with mower set to desired height, make a
finish cut over entire area.
 OCDC
OPERATOR CONTROLLED DISCHARGE CHUTE

OPERATION
This machine may be equipped with an Operator Con-
trolled Discharge Chute. This discharge chute has a
variable adjustment from full open to full closed.
In the full closed position it will serve to keep some
of the clipping materials under the mower deck for a
longer period of time in order to enhance the mulching
capabilities as well as functioning as a discharge
safety shield. This discharge chute should ALWAYS
BE OPERATED IN THE DOWN POSITION
WHEN MOWING WHILE PEOPLE ARE
PRESENT IN THE IMMEDIATE VICINITY.
Mulching may not be possible in some cutting condi-
tions. In extremely wet conditions you may have to
run the OCDC in the open position to facilitate
proper material discharge and avoid wind-rowing.
CONTROLS
1. Handle - Used to raise and lower discharge chute.
2. Friction Nut - Used to adjust friction drag. May also
be used to hold upper screen between full open or
full closed.
3. Upper Screen with bolt on lower screen.
NOTE: SAFE OPERATION OF THIS VEHICLE IS
THE SOLE RESPONSIBILITY OF THE OPERA-
TOR. SAFETY IS AN ATTITUDE AND IT STARTS
WITH YOU !

3
 MOWER DECK ADJUSTMENTS
GENERAL DECK ADJUSTMENTS
Drive and spindle belts
- Check that all belts seat in pulleys
- Check that connecting arm spring height is 2 inches
in the “engaged” position. Adjust turnbuckle
if necessary.
Mower Deck Drive and Spindle Belts
LEVEL MOWER DECK
Side-to-side leveling of the mower deck is accomplished
by lowering the mower deck and adjusting the threaded
eyebolts, at the front of the deck. Park mower on level a
surface and place a level across the front of the mower
deck or position the mower blade tips side-to-side.
Adjust the eyebolts, so that the mower deck is level or
the distance between the right and left blade tip ends and
surface is the same.
Side-to-Side Level Adjustment
Mower level front-to-rear is adjusted by changing the
stabilizer bar positions. Always adjust each side evenly.
Adjust at rear or middle of stabilizer bar by removing
the hairpin cotters and clevis pins and raising or low-
ering the stabilizer bar position, changing the mower
deck pitch.
To mow in the 2.5” to 4.0” cutting height range, leave
as shipped. For cutting below 2.5”, it may be neces-
sary to lower the rear of the deck.
Note: NEVER allow rear of deck to be lower than
the front unless cutting height is in the fully raised
position (6”), and you are mowing tall weeds. This is
the ONLY exception and will happen automatically
with the deck at the fully raised position.
Front-to-Back Level Adjustment
CAUTION
Sharp edges of mower deck blades can cut
you during blade maintenance or adjust-
ment. Use suitable covering over cutting
edges of blade to prevent bodily harm.
To obtain optimum mower results, mower blades should
be kept sharp and well balanced. To sharpen blades,
simply lift front of machine and support it with jack
stands or floor jack. Remove blade attaching bolts and
washers from end of spindles and remove blades. A
short piece of 2x4 lumber may be placed between side
of mower deck and blade to “lock” it in position when
loosening attaching hardware.
 MOWER DECK ADJUSTMENTS
BLADE MAINTENANCE (Cont’d) MOWER SPINDLE BELT REPLACEMENT
Re-install the blades with air lift area, (turned up sec- Be sure to purchase genuine Dixie Chopper belts for re-
tion), facing the underside of the mower deck. Tighten placement purposes as these belts are designed specifi-
blade attaching bolts to a torque of 80-100 ft. lbs. cally for each application.
(112-140 nm).
Mower Deck Spindle Belt Removal
UNDERSIDE CLEANING
It is of vital importance to clean the underside of the deck Please thoroughly read the safety section of this
frequently. Accumulation of matter clippings seriously manual before attempting any reparis or service.
impairs the mower’s ability to “lift” the grass into the - Remove connecting arm bracket at the triangle
cutting position and discharge the clippings evenly. plate
Matted grass clogging the underside of the mower deck - Remove the engine to deck belt from top sheave
is often the cause of uneven cutting. of the center deck spindle.
- Make note of wrapping procedure of the belt to
MOWER DECK DRIVE BELT REPLACEMENT insure proper placement of new belt.
Be sure to purchase genuine Dixie Chopper belts for re- - Grasp belts on both sides of either outboard deck
placement purposes, as these blets are designed specifi- spindle and pull belt away from pulley until it is
cally for each application. possible to remove the belt. Once this is done
remove from remaining pulleys and discard.
Mower Deck Drive Belt Removal
For mower deck spindle belt installation, reverse the se-
Please thoroughly read the safety section of this quence of removal procedures.
manual before attempting any repairs or service.
- Remove connecting arm bracket at the triangle
plate. This is done by removing the hairpin
cotter and the washer pin on the triangle plate.
- Remove the belt from the top pulley of the center
deck spindle.
- Remove the triangle plate from its stand at the
rear of the mower deck.
- Loosen the engine belt guides by loosing the nuts
on the all-thread near the engine between the
wheel motor boxes and letting the belt guides
swing down.
- Remove the belt from the double sheaved engine
pulley.
- Remove the flat idler pulley from the triangle
plate, allowing belt removal. Note the loca
tion of shim under pulley.

For mower deck drive belt installation, reverse the sequence

of removal procedures.
 MOWER CLEANING AND STORAGE
CLEANING AND STORAGE
After 30 days, painted surfaces may be waxed to
protect the luster of the original finish. The machine
should be washed regularly with a mild automotive
type detergent and water. Exposed bare metal surfaces
should be coated with oil, or a light coating of grease,
to prevent rust until permanent repairs can be made.
Aerosol cans of touch-up paint are available through
your Authorized Dixie Chopper Dealer.

When the machine will not be used for an extended period

of time, the following steps will help insure minimum diffi-
culty when unit is returned to service:
- Perform required maintenance steps called for
in the “Routine Maintenance” section of this
manual.
- Check tires for proper inflation.
- Wash machine and re-paint all bare metal sur-
faces.
- Start machine and engage mower for approxi-
mately one minute, to remove excess water
from belts and pulleys. Let engine run out of
gas. As gasoline grows old, it becomes less
volatile and forms harmful gum and varnish
deposits in the carbureator and fuel system.
DO NOT STORE GASOLINE FOR
MORE THAN 2 MONTHS.
- If applicable, charge battery. In temperatures
above 40 degrees Fahrenheit (4 C) water level
should be checked and battery “trickle charge”
every 30 days (more often in higher tempera-
tures). Battery must be fully charged to prevent
freezing and internal damage in weather below
32 degrees Fahrenheit (0 C).
- Remove key from machine.
- Cover seat relay and solenoid from direct
water spray.
 Routine Maintenance

Check Engine Oil Level Check Hydraulic Oil Level Check Tire Pressure
Daily Checks Use oil in accordance with engine Dixie Chopper VTC Hydraulic Rear 5-7 psi - 6 preferred
manufacturers recommendations Oil Front 12-18 psi

Change Engine Oil Clean Kohler Air Filter Check Engine to Transmission
Every 100 Hours Normal - 10W30
(DO NOT BLOW OUT WITH Belt Tension
Cold - Consult Engine Manual
COMPRESSED AIR) 1" from idler to frame
Check Battery Fluid
Check Engine Idler Spring Tension Lube Deck Spindle Assemblies
Level (XXW4000 only)
(If applicable)

Lube Center Drive Shaft Clean Donaldson Air Filter End Cap
Every 200 Hours (3 pumps max) (DO NOT BLOW OUT WITH COM- Lube Steering Levers
(XXW4000 only) PRESSED AIR)

Every 1000 Hours Remove Belts and Check Spindle Bearings,

Change Hydraulic Filters Change Amsoil Filter
or Annually Idlers, and Pulleys.

Lube Front Clean or Replace Check Steering for Creep

Caster Bearings Spark Plugs in the Neutral Position

Check Front and Rear Replace Engine Change Hydraulic Drive Oil
Tires for Tread Wear Fuel Filter(s) Dixie Chopper VTC Hydraulic Oil

Change Hydraulic Drive Oil

DO NOT USE HYDRAULIC OIL, HYTRAN, OR AUTOMATIC TRANSMISSION FLUID. USE
ONLY A HIGH GRADE 10W50, 15w40, 15W50, 20W50 MOTOR OIL THAT MEETS THE MINI-
MUM VISCOSITY REQUIREMENTS OF: 89 SUS or BETTER @ 212 DEGREES FAHRENHEIT.

Note: The recommended Hydraulic Drive oil for your Dixie Chopper Machine is D/C VTC
Hydraulic Oil (Part# 4940002106). We strongly urge that you use this oil in the
event that you should need to refill or add to your hydraulic reservoir.

Engine Oil : Normal Mowing Conditions - 10W30

Cold Weather Operation - Consult Engine Manual
Lube Grease: High Temp. Lithium Grease
LUBRICATION POINTS

Every 1000
Front Caster Assembly
Hours or
(1 each side)
annually

Every 200 Steering Lever Pivots

Hours (Under Seat)

Every 100 Right Side Deck Drive

Hours Hub
LUBRICATION POINTS

Every 100 Idler Arm Pivot

Hours Left Side Deck Drive Hub

Every 100 Front Wheel Bearing

Hours 1 Each Front Wheel

Deck Engaging Swing Arm

Every 100 Scissor Linkage Pivot
Hours Center Deck Drive Hub
Deck Engaging Rod
 6302 E. County Road 100 North
Coatesville, IN. 46121
Phone 1-765-CHOPPER
www.dixiechopper.com

Dixie Chopper, Magic Circle, and the Magic Circle Atom Logo are all trademarks of Magic Circle Corporation and
may not be reproduced without permission.
Printed In USA
Specifications and instructions subject to change without notice.
Print Date 3/01
P arts/Operator’s Manual

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STANDARD PRODUCTION
MANUAL

MODELS COVERED: LX, X, XF, XW, AND XWF

',;,(&+233(5

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',;,(&+233(5
)54:+4:9
SECTION 1
Introduction……………………………………………… 4
General Safety Suggestions………………………….. 5
SECTION 2
Vehicle Identification Number Location………………. 6
Owner Registration…………………………………….. 6
SECTION 3
Warranty………………………………………………… 7
Maintenance and Service……………………………… 8
Deck Pitch Adjustment……………………………. 8
Transmission Drive Belt Adjustment…………….. 8
Recommended Hydro Filter Change……………… 8
Nuetral Adjustment………………………………….. 8
Forward Lever Stop Adjustment………………….. 8
Sundstrand Pump Start Up Procedure………….. 9
Engine To Deck Belt Adjustment………………… 9
SECTION 4
Mowing Machine Controls……………………………. 10
Throttle Control……………………………………... 10
Ignition Switch………………………………………….10
Choke Control………………………………………. 10
Mower Lift Pedal……………………………………. 10
Right and Left Motion Control Levers…………………10
Fuel Tank Valves…………………………………… 10
SECTION 5
Operating Your Mowing Machine…………………….. 10
Safety Interlock System…………………………… 10
Starting Engine…………………………………….. 11
Stopping Engine……………………………………. 11
Throttle Control……………………………………... 11
Choke Control………………………………………. 11
Correct Transmission Operation………………….. 11
Mowing Speed………………………………………. 12
Mowing Height………………………………………. 12
SECTION 6
Mower……………………………………………………. 13
Mower Adjustments………………………………… 13
Level Mower…………………………………………. 13
Blade Maintenance………………………………… 13
Underside Cleaning………………………………… 13
Mower Drive Belt Replacement……………………. 14
Mower Spindle Belt Replacement………………… 14
Cleaning and Storage………………………………. 14
SECTION 7
Decal Pictures………………………………………………15
SECTION 8
Decal Part Numbers…………………………………… 17
SECTION 9
Part Drawings and Numbers…………………………… 18


',;,(&+233(5
)54:+4:9

SECTION 9 (cont’d)
Main Frame…………………………………………….. 18
Kohler Command 20 Hp Engine……………………… 20
Kohler Command 22 Hp Engine……………………… 22
Kohler Command 25 Hp Engine……………………… 24
Seat……………………………………………………… 26
Electrical System………………………………………. 28
42" Mower Deck…………………………………………30
50" Mower Deck…………………………………………32
60" Mower Deck…………………………………………34
Hubs and Belts…………………………………………. 36
Fenders and Covers……………………………………. 38
T Gear Box……………………………………………… 40
Foot Pedal………………………………………………. 42
Tires and Wheels………………………………………. 44
Hydraulic Wheel Motors………………………………. 46
Throttle Assembly……………………………………… 48
Fuel Tank……………………………………………….. 48
Transmission and Drive…………………………………50
Transmission Drive Linkage…………………………… 52
Parking Brake……………………………………………54
Hydraulic System………………………………………. 56
SECTION 10
Index…………………………………………………….. 58
Notes……………………………………………………. 59


',;,(&+233(5
INTRODUCTION
Prior to operating the Dixie Chopper Mowing Machine,
you should be trained in its proper use and warned of its
dangers before operating, adjusting, or servicing it. You
should also read and understand this entire manual.
DANGER This symbol, if used, warns of
immediate hazards which will result in
severe personal injury or death.
WARNING This symbol refers to a hazard
or unsafe practice which can result in severe
personal injury or death.
CAUTION This symbol refers to a hazard
or unsafe practice which can result in
personal injury or product or property damage.
The customer is responsible for filling out the
warranty registration card. Within ten (10)
days, the customer MUST mail card to
Magic Circle Corporation
6302 E. County Road 100 North
Coatesville, Indiana 46121
Any extended warranties expressed or implied are
null and void unless proper documentation has been
sent to Magic Circle Corporation by the original
purchaser of the machine.
SECTION 1
* Familiarize yourself with the controls and
know how to stop the mower quickly.
* Inspect your work area carefully. Remove
debris from the turf area to be cut.
* Avoid contact with moving parts. Keep
away from whirling blades. Keep feet and
hands from underneath mower deck.
* Never direct the discharge of material
toward bystanders, nor allow anyone near
the machine while in operation.
* This machine is not meant for highway or
street use. It is not a recreational vehicle
and you should never carry passengers.
* Never tamper with safety devices or
guards. If a guard or safety device is
damaged, or removed, replace before
operating the mower
* Handle gasoline carefully. Never add fuel
to tank while the engine is running or hot.

',;,(&+233(5
Routine Maintenance

Check Engine Oil Level Check Hydraulic Oil Level Check Tire Pressure
Daily Checks Use oil in accordance 15W40 Synthetic or full synthetic Rear 5-7 psi - 6 preferred
manufacturers recommendations Front 10-14 psi

Lube Deck Spindles, Idler Arm

Every 50 Hours Pivots, Front Wheel Bearings,
(3-5 pumps)

Check engine to Transmission

Every 100 Hours Change Engine Oil Check Battery Fluid Level Belt Tension
(If applicable) 1-1/2" from idler to frame

Lube Steering Clean Donaldson Air Filter End Cap

Every 250 Hours Levers (DO NOT BLOW OUT WITH COMPRESSED AIR)

Every 500 Hours

Change Hydraulic Filters
or Annually
Lube Front
Caster Bearings
Check Front and Rear
Tires for Tread Wear
Change Amsoil Filter Remove Belts and Check Spindle
Bearings, Idlers, and Pulleys
Clean or Replace Check Steering for Creep
Spark Plugs in the Neutral Position
Replace Engine
Fuel Filter(s)

Change Hydraulic Drive Oil

Every 2000 Hours DO NOT USE HYDRAULIC OIL, HYTRAN, OR AUTOMATIC TRANSMISSION FLUID.
USE ONLY A HIGH GRADE 10W50,15W40,20W50 MOTOR OIL THAT MEETS THE
MINIMUM VISCOSITY REQUIREMENTS OF: 89 SUS or BETTER @ 212 DEGREES
FAHRENHEIT.

Note: The recommended Hydraulic Drive oil for your Dixie Chopper machine is D/C
Part#60106. We strongly urge that you use this oil in the event that you should need
to refill or add to your hydraulic reservoir. However, if this oil is unavailable to you,
any premium grade 10W40, 15W50, 20W50 synthetic or synthetic blend may be used
PROVIDING IT MEETS THE ABOVE REQUIREMENTS.

'
',;,(&+233(5
SECTION 1
GENERAL SAFETY SUGGESTIONS
Recommended by Outdoor Power Equipment Institute
SAFE OPERATION PRACTICE - RIDING VEHICLES
1. Know the controls and how to stop quickly - READ
THIS OWNERS MANUAL and instructions furnished
w ith attachments.
2. Do not allow children to operate machine. Do not
allow adults to operate machine w ithout proper
instruction.
3. Do not carry passengers. Do not m ow w hen
children and others are present.
4. Clear w ork area of objects (w ire, rocks, etc.)
w hich might be picked up and throw n.
5. Disengage all attachment clutches and shift into
neutral before attempting to start engine (motor).
6. Disengage pow er to attatchments and stop engine
(motor) before leaving operator position.
7. Disengage pow er to attachments and stop engine
(motor) before making any repairs or adjustments.
8. Disengage pow er to attachments w hen transporting
or not in use.
9. Take all possible precautions w hen leaving vehicle
unattended; such as disengaging pow er-take-off,
low ering attachments, shifting into neutral, stopping
engine and removing key.
10. Do not stop or start suddenly w hen going uphill or
dow nhill. Mow up and dow n the face of steep
slopes; never across the face. If a steep hill must
be asdended, back up the hill; drive forw ard w hen
descending.
11. Reduce speed and exercise extreme caution on
slopes and in sharp turns to prevent tipping or loss
of control. Be especially cautious w hen changing
directions on slopes.
12. Stay alert for holes, rocks and roots in the terrain
w hich may cause the vehicle to upset. Keep aw ay
from dropoffs.
13. Use care w hen pulling loads or using heavy
equipment.
a. Use only approved draw bar hitch points.
b. Limit loads to those you can safely control.
c. Do not turn sharply. Use care w hen backing.
d. Use counterw eights w hen suggested in ow ner’s
manual.
14. Watch out for traffic w hen crossing or near roadw ays.
15. When using any attachments never direct discharge
of material tow ard bystanders nor allow anyone near
vehicle w hile in operation.
16. Handle gasoline w ith care - it is highly flammable.
A. Use approved gasoline container. Place container
out of reach of children.
B. Use gasoline only as fuel - never as a cleaner.
Never remove cap or add gasoline to a running or
hot engine or an engine that has not been allow ed
to cool for several minutes after running. Never fill
fuel tank indoors. Wipe up spilled gasoline. And
positively NO SMOKING.
C. Open doors if engine is run in garage - exhaust
fumes are dangerous. Do not run engine (motor)
indoors.
17. Keep vehicle and attachments in good operating
condition and keep safety devices in place and
w orking.
18. Keep all nuts, bolts and screw s tight to be sure
equipment is in safe w orking condition.
19. Never store equipment w ith gasoline in the tank
inside a building w here fumes may reach an open
flame or spark
20. Allow engine to cool before storing in any enclosure
21. To reduce fire hazard keep engine free of grass,
leaves or excessive grease.
22. Vehicle and attachments should be stopped and
inspected for damage after striking a foreign object
and the damage should be repaired before restarting
and operating the equipment.
23. Do not change engine governor settings or over-
speed engine.
24. When using vehicle w ith mow er:
1. Mow only in daylight or in good artificial light.
2. Never make a cutting height adjustment w hile
engine (motor) is running if operator must
dismount to do so.
3. Shut engine (motor) off w hen unclogging chute.
4. Check blade mounting bolts for proper tightness at
frequent intervals.
25. Under normal usuage, grass catcher bag material is
subject to deterioration and w ear. It should be
checked frequently for bag replacement. Replacement
bags should be checked to ensure compliance w ith
original manufacturers recommendations or
specifications.
26. Disengage pow er to mow er before backing up. Do
not mow in reverse unless absolutely necessary
and then only after careful observation of the entire
area behind the mow er.
27. Use personal protective equipment w hen operating
or performing maintenance such as (but not limited
to) protection for eyes, ears, feet & head.

',;,(&+233(5
VEHICLE INDENTIFICATION NUMBER
(VIN) LOCATIONS
Vehicle identification numbers are used to
identify your new mowing machine and
attachments. These numbers should always be
referred to when consulting your dealer or the
factory concerning service, parts, or other
information you may require, if these plates are
removed during repair operations, they should
always be replaced.
The mowing machine vehicle indentification
number plate is located on frame under seat. This
number identifies both the chassis and mower.
Engine identification number is located on engine
shrouding, and indicates model, type number and
serial number of your mowing machines engine.
For your convenience and ready reference, enter
mowing machine and engine numbers below.

Mowing Machine Identification Number

Dixie Chopper VIN Plate

Model_________________________________ Model Spec.____________________________

VIN___________________________________ Serial No._______________________________

OWNER REGISTRATION
Service and warranty assurance are as important
to Dixie Chopper as they are to you, the owner.
Magic Circle Corp. requires factory registration to
facilitate warranty service at an authorized Dixie
Chopper Dealer. A registration card is supplied
with each new machine and attachment. You must
fill in the required information and mail the card
to Magic Circle Corp.
The Dixie Chopper Limited Warranty Statement is
described on page _. This statement describes
what items are covered by the Dixie Chopper
Limited Warranty, your rights and obligations and
the procedure to follow to obtain warranty service.
Please familiarize yourself with the warranty
statement. All of us at Dixie Chopper want you to
be satisfied with your Dixie Chopper mowing
machine. Please don’t hesitate to contact us for
assistance.

* Warranty void unless registration card is returned
within 10 days from purchase. Warranty to be used only
to cover correction of manufacturing defects, it will not
be used to cover lack of maintenance, operator mis-use,
normal wear, accidents, customer dissastisfaction,
transportation charges to and from the servicing dealer
or loss of revenue.
This commercial mower has safety features that exceeded
the national specifcations; however, the user is ultimately
responsible for the safe operations of the mower.
THESE ARE NLY A FEW RECOMMENDATIONS,
BE SURE TO COMPLETELY READ ENGINE
MANUFACTURER’S OPERATOR’S MANUAL BEFORE
OPERATION OF THIS MACHINE.
FAILURE TO PERFORM ROUTINE DAILY
MAINTENANCE AS DESCRIBED WILL RESULT IN
PREMATURE ENGINE FAILURE, AND WILL VOID
ENGINE MANUFACTURER’S WARRANTY.


',;,(&+233(5
SECTION 3
WARRANTY
INTRODUCTION
Congratulations on your purchase of a DIXIE CHOPPER
law n mow er. We believe you have exercised excellent
judgement, and are most appreciative of you patronage.
We recommend you read this entire manual before
operating this unit.Time spent in becoming fully aquainted
w ith its performance features, adjustments and main-
tenance w ill add a longer and more satisfactory life to
your DIXIE CHOPPER. The manufacturer reserves the
right to make changes or add improvements to its product
at any time w ithout incurring any obligation to make such
changes to its product manufactured previously.As w ith
all law n mow ers, if handled carelessly, it is a dangerous
piece of equipment. If incorrectly used, this machine can
cause severe injury. YOU THE OPERATOR ARE
RESPONSIBLE WHEN OPERATING IT. Therefore, safety
is of the utmost importance.
WARRANTY
This mow er is w arranted for one year from date of
purchase against all defects in material and w orkman-
ship. Under normal use and service our obligation, under
this w arranty,shall be limited to the replacement or repair,
to the original retail purchaser,of any part or parts,w hich,
w ithin the w arranty period, shall be show n to be defect-
ive due to faulty w orkmanship at the factory. All parts
SAFETY PRECAUTION
Those w ho come in contact w ith the DIXIE CHOPPER
should be trained in its proper use and w arned of its
danger before operating, adjusting, or servicing it. They
should also read and understand this entire manual, and
the engine ow ners manual.
Familiarize yourself w ith the controls and learn how to
stop the mow er quckly.
Inspect your w ork area carefully. Remove debris from
the turf area to be cut.
Avoid contact w ith moving parts. Keep aw ay from
w hirling blades. Keep feet and hands from underneath
STARTING INSTRUCTIONS
To start machine observe the follow ing procedure: Sw ing
control levers out to neutral position.
Check to be sure the
deck engaging handle is in the disengaged position. Set
throttle handle to half-throttle position. Turn key to start
position and release w hen engine fires.
CUTTING HEIGHT ADJUSTMENT
Mow er deck height is adjustable from 1" to 6" in 3/4"
increments w ith a foot actuated lever.
Mow er deck may be leveled side to side by adjusting
eye bolts at the front of the deck.
Mow er deck pitch, front to rear, may be adjusted by
changing stabilizer arm position at front or rear (in 1/2"
increments). Adjustment at the rear of the deck or in the
middle stabilizer arm w ill result in 1" change in pitch
*NOTE -- To mow in the 2 1/2" range, leave as
claimed defective must be returned to the factory for in-
spection, repair or replacement w ith transportation
charges prepaid.This w arranty does not apply to damage
in transit or damage caused by misuse negligence, or
accident,to alterations or repairs done outside the factory
or authorized service center, nor does it obligate us to
assume any transportation charges in connection w ith the
replacement of the parts claimed to be defective.
OUR WARRANTY DOES NOT APPLY TO THE
BLADES OR BELTS ON OUR MOWERS DUE TO THE
VERY NATURE OF THE FUNCTION THEY PERFORM AND
THE ELEMENTS THEY ARE EXPOSED TO. NOR LOST
REVENUE.
The w arranty specifically excludes engines, tires and
batteries w hich are w arranted separately by their
respective manufacturers. All claims for defective engines
or engine parts must be made in accordance w ith the
engine manufacturers w arranty. This w arranty is null and
void if any parts other than the original manufacturers
mow er deck. Never direct the discharge of material tow ard
bystanders, nor allow anyone near the machine w hile in
operation. This machine is not meant for highw ay or street
use. It is not a recreational vehicle and you should never
carry passengers. Never tamper w ith safety devices or
guards. If a guard or safety device is damaged, or
removed, replace before operating mow er. Handle
gasoline carefully. Never add fuel to fuel tank w hile the
engine is running or hot
shipped -- stabilizer arm one hole dow n from top front
and middle and top hole in the rear. For cutting below
2 1/2", it m ay be necessary to low er the rear of the deck.
*NOTE -- Never allow the rear of the deck to be low er than
the front: unless the cutting height is in full up
position (6"), and you are mow ing tall w eeds. This is the
only exception and w ill happen automatically w ith
the deck in the full up position.
MOWING INSTRUCTIONS
Always cut grass with the engine at full throttle.
This engine speed allow s the cutting blades to
operate at optimum cutting speed. Control ground speed
w ith steering levers.
*NOTE -- Operating engine at less than 3/4 throttle w ill
result in decreased air flow through the cow ling causing
engine overheat.
',;,(&+233(5
MAINTENANCE & SERVICE
DECK PITCH ADJUSTMENT
The mower deck is set to mow level at 3 ½” from the
factory, using these settings: MOWER DECK FRONT
nd
– 2 hole from the top. MOWER DECK REAR –top
nd
hole. AXLE MOUNT – 2 hole from the top. When
mowing at a lower height, with the factory setting it is
possible to leave a streaking appearance. This is
easily remedied by pitch adjustment of the deck.
Dropping the rear of the deck one hole will result in a
1” change in pitch. However, dropping the front AND
the rear will result in only a ½” change pitch. Which
should provide satisfactory results when mowing at a
lower height.
TRANSMISSION DRIVE BELT ADJUSTMENT
(vertical shaft engines only)
1. Loosen engine mounting nuts and bolts.
2. Loosen drive belt tensioning jam nut, and tighten
drive belt tensioning bolt until ½” to ¾” deflection
exists midway between the double engine and
transmission pulleys.
3. Re-tighten engine mounting bolts and locknuts.
4. Re-tighten jam nut.
RECOMMENDED HYDRO FILTER CHANGE
Change filter at 500 hours or annually.
1. Clean area around filters so it’s free of any
dirt and debris.
2. Fill replacement filter with 15W40 Schaeffers oil,
Part #60106. Filter will absorb oil, so fill until it
takes no more. Pinch line to stop oil from leaking.
3. Remove old filter on unit and replace with new.
4. You may want to loosen the charge line at the
pump and pressurize the reservoir to purge
air from the line, purge the line until no air is
present (tighten fitting).
5. With handles in neutral crank engine over with the
starter and observe oil movement in clear line
from filter base to the charge pump (flashlight
may be necessary).
6. Oil should be flowing from the filter to the
pump when you are cranking the engine. DO
NOT START THE ENGINE UNLESS OIL IS
FLOWING FROM FILTER TO PUMP.
7. If step 6 is not accomplished, check for air
leaks between charge pump port and
reservoir. Note: You must have pump primed
before starting the engine, if it is not primed it
will self-destruct in 16 seconds or less.
8. With above steps accomplished, leave handles in
neutral and throttle at idle speed. You may now
start the unit. Let idle in neutral and observe oil flow
in clear line from filter mount to pump. It should be
flowing toward the pump. You may see a few air
pockets shoot through the line. This is ok as
long as you have movement toward the pump.
If oil stops flowing toward the pump shut down
immediately (check for air leaks between
charge pump and inlet to reservoir).
9. Let unit idle in neutral for at least 2 minutes
and until no more air is observed. Bring engine up
to 2000 r.p.m.
10. Then gently stroke levers for an additional 2
minutes. At this point unit can be put back in
service.
SECTION 3
NOTES:
1. Failure to observe this procedure will
destroy pumps in 16 seconds or less.
2. Pump failure due to charge pump
loosing its prime is not a warranty
item.
3.Read instructions carefully.
4. You may benefit by reading instructions
twice.
LUBRICATION
See service intervals.
NEUTRAL ADJUSTMENT
THE FOLLOWING PROCEDURE SHOULD BE DONE
WITH THE REAR WHEELS OFF THE GROUND AND
THE ENGINE ON.
1. Remove clevis pin from neutral adjustment yoke at
right side pump control arm and at steering pivot
on left side drive linkage.
2. Loosen neutral spring mounting bolt, located on oil
filter mounting bracket, adjust neutral spring
assembly to the front or rear until the pump is in
neutral and there is no motion at drive wheels.
Once this is achieved, tighten neutral spring
mounting bolt.
3. Loosen jam nut on adjustment yoke and turn yoke
so that clevis can be inserted without force. When
control lever is in neutral lock position, the wheel
should continue to sit still.
4. Start engine, operate tires in forward and reverse
and return lever to the neutral lock position, tires
should not move, if tires move repeat above
procedure.
FORWARD LEVER STOP ADJUSTMENT
THIS PROCEDURE DONE WITH THE ENGINE OFF!
1. Move control lever to the full forward position,
applying gentle pressure.
2. With control lever in full forward position, turn
forward lever, stop bolt down, until it contacts
steering lever pivot block arm. Once contact is
made, give additional ¼ to ½ turn. Re-tighten jam
nut.
3. Test drive machine and observe operation at full
forward on level surface. If machine does not go
straight, correct by slowing fast wheel, (lengthen
lever stop bolt). Adjust lever stop until machine
travels in a straight path with both control levers at
full forward.
4. Align control levers by swinging into neutral
position and bending levers until handles are
parallel. Both controls should be spaced
evenly at rest and should travel together and
reach full forward uniformly.
*Lubricate between the transmission frame mounting
point and steering lever pivot block.
*NOTE – Late model machines are equipped with a
greaseable mounting bolt. These mounting bolts utilize
a compression spring for positive steering resistance.
Although this assembly does not require adjustment, it
should be lubricated every 100 hours.
',;,(&+233(5
SECTON 3
MAINTENANCE & SERVICE
(CONTINUED)

SUNDSTRAND PUMP START UP

PROCEDURE
ighten bolt to compress spring. Proper tension has
1. With new pump installed and charge pump return
been achieved when spring height reaches 2” in the
disconnected, pitch hose together to seal off
hose 1” behind swivel fitting. Note: Vice grips will engaged position, which should allow ½” to ¾”
distance between the double jam nut and the
work to pinch hose, it must be sealed off
tensioner assembly. A visual check can be made by
completely.
simply engaging the mower deck. During this action
2. Remove reservoir overflow tube from plastic
the last 1/4 turn should be spring compression.
overflow nipple.
3. The system is now ready to pressurize. Note:
This is done to purge air from the lines on the
inlet side of the pump and to assure the pump
has an immediate oil supply to the inlet side of
the pump. Maximum 5 lbs.
4. Using an air regulator, pressurize the system until
clear line is full of oil down to pump inlet 90º
fitting (Page 60, Fig.10) and oil comes out of
charge pump return 90º fitting. Note: maintain
pressure on the reservoir through step 5.
5. With handles in neutral position (Note: Brake
must be in off position) crank engine over and
observe oil in clear tube. The oil should be
traveling towards the pump and coming out of the
charge pump return 90º fitting. Do not start
engine unless you have determined you have oil
flowing to the pump while cranking engine with
the starter. Note: If this condition does not exist,
check for air leaks from 90º inlet fitting to
reservoir.
6. Remove pressure from reservoir and install
overflow tube back onto overflow nipple, and
remove vise grips from charge pump return line
and connect line back onto charge pump return
90º fitting. With throttle in idle position, and
handle in neutral, start engine, let idle for no less
than 60 seconds, then lightly stroke the levers.
After 2 minutes of lightly stroking the levers and
achieving steady movement of the wheel hub,
you may stroke the levers fully.
7. Reinstall rear wheel and lug nuts.
8. Check fluid level in hydraulic reservoir and fill if
necessary.

NOTES:
1. You must follow this procedure.
2. Failure to observe above procedure will destroy
this pump in 16 seconds or less.
3. Pump failure due to a dry start up is not a
warranty item.
4. You may profit from reading your instructions
twice.

ENGINE TO DECK BELT ADJUSTMENT

This belt only requires 40lbs. Of tension to achieve
satisfactory results. New machines equipped with the
30209-1 connecting arm may be adjusted using this
procedure: With engine off, engage mower deck,


',;,(&+233(5 SECTION 4
MOWING MACHINE CONTROLS
1. THROTTLE CONTROL
Throttle is located on top of right fuel tank just
ahead of fuel cap. Move throttle forward all the way to
operate machine. Move throttle all the way to rear
before shutting engine off.
2. IGNITION SWITCH
Ignition switch is located on right side of front panel
below seat. Ignition switch has three positions: (1) Off,
(2) Run, (3) Start. To start engine turn key all the way
to start. Release key when engine starts and it will
automatically return to Run position. Turn switch to
Off position to stop engine.
3. CHOKE CONTROL
Choke control is located on right side of front panel
next to ignition switch. Pull choke knob out when
starting engine. Slowly push knob in after engine
starts. If engine is warm and has been running,
choking may not be necessary to restart engine.
4. MOWER LIFT PEDAL
Mower foot lift pedal is located on left side of foot
platform. To raise mower, push down on front of OPERATING YOUR MOWING
pedal. To lower mower, push down and rotate foot to
move bottom of pedal down, remove foot from pedal MACHINE
when desired height is obtained.

SAFETY INTERLOCK SYSTEM

Each machine has interlock switches. Switches

are actuated by the seat. Seat switch will stop
engine when seat is vacated with engine running.
Seat must be occupied.
If machine will not start, check that seat is
occupied.
Safety interlock system must be tested
periodically.
To test operation, the following functions must
be performed by an Authorized Dixie Chopper
Dealer for your protection.
1. Engine should NOT start if seat is not occupied.
2. With engine running, test operate seat switch
by rising off seat. Engine should shut off.
5. RIGHT AND LEFT MOTION CONTROL
LEVERS
To enter seat, move levers all the way left and right
into neutral lock position. Enter seat and move levers
in toward center of machine. Left lever controls left
CORRECT ENGINE OPERATION
rear wheel and right lever controls right rear wheel. To
go forward, push both levers forward evenly; the
further levers are pushed forward, the faster the
CAUTION
machine will travel. To go in reverse, pull both levers
Before starting engine, become familiar
to rear evenly; the further levers are pulled, the faster
with
the machine will travel. To turn, slow machine down
all controls. Read this Operator’s Manual
and slow speed of wheel in direction you want to turn.
thoroughly. Always check engine oil level
6. FUEL TANK VALVES before starting engine.
Fuel tank valves are located at bottom of each
tank. Fuel valves are normally left open except when
service on fuel system becomes necessary.


',;,(&+233(5
SECTION 5
OPERATING YOUR
WARNING
Care should be taken to avoid inhaling exhaust
gases as they contain carbon monoxide gas, which
is colorless and odorless. Carbon monoxide is a
dangerous gas that can cause unconsciousness and
is potentially lethal. Do not run engine in confined
areas such as a closed garage.
STARTING ENGINE
To start engine, occupy seat. Move throttle control
lever halfway to operate position. Pull choke control
all the way out to cold position. Turn ignition key to
start position to engage starter. When engine starts,
release key. Switch is spring-loaded
and will return to run position automatically.
If the engine fails to start after 10 seconds of
continuous cranking, turn the key to the OFF
position and allow the starter motor to cool.
Check for the cause of hard starting; consult the
Troubleshooting Checklist.
Once engine has started, slowly return choke
control to its normal position. If engine stalls at low
speeds, or hesitates during acceleration, choke
should be applied as necessary until engine reaches
normal operating temperature.
STOPPING ENGINE
To stop engine, move throttle lever to idle position
and turn ignition key to OFF position. If engine has
been working hard or engine is hot, allow engine to
idle a short time before turning key off, This practice
will help cool engine before stopping.
Note: In case of emergency, engine may be
stopped by turning ignition key to OFF position.
CAUTION
Always remove key when leaving machine
unattended, even if for just a few minutes.
Prevent accidents; don’t give children or
unauthorized persons an opportunity to
operate this machine.
MOWING MACHINE
THROTTLE CONTROL
Throttle control regulates speed of engine as
measured in RPM (Revolutions Per Minute). This
control should not be used to regulate the ground
speed.
Engine has been designed with a special governor
that limits engine RPM. Unlike an automobile, this
governor allows engine to operate most efficiently at a
set speed and protects it from damage caused by
excessive RPM. Always operate machine with throttle
control set at ¾ to full speed.
CHOKE CONTROL
Choke control activates a “butterfly” valve in
carburetor. When choke is partially or completely
closed, less air is admitted to engine. This results in a
higher fuel-to-air (richer) mixture that is required when
engine is started cold. Warm engines may not need
choking.
CAUTION
Handle fuel with care – it is highly flammable.
Use only approved fuel container. Never add fuel
while engine is running. Fill fuel tanks outdoors with
extreme care. Never fill fuel tanks indoors. Replace
gasoline cap securely and wipe up all spilled fuel.
CORRECT TRANSMISSION OPERATION TO
GO FORWARD OR REVERSE
Machine is equipped with a separate transmission
for each rear wheel. Transmissions are controlled with
“Motion Control Levers,” one for each wheel.
CAUTION
Sudden starts can be damaging to equipment and
could cause loss of operator control.
For safe operation, never move the motion
control lever too rapidly, especially on grades.
To go forward, push both levers forward evenly.
To go in reverse, pull back on both levers evenly.

',;,(&+233(5
OPERATING YOUR
TO CHANGE SPEED OR DIRECTION
To change direction of machine, slowly move levers
to neutral and move levers in direction you want to go.
The further levers are moved away from neutral
position, the faster machine will travel. To turn
machine left or right, slow speed of wheel in direction
you want to turn.
TO STOP
To stop machine, return both levers evenly to
neutral position.
CORRECT MACHINE USAGE
CAUTION
Read manuals provided with attachments
before operating. These manuals give a more
detailed description of operation and point out
other areas of caution. Familiarize yourself
thoroughly with equipment before attempting to
use it.
SECTION 5
MOWING MACHINE
MOWING SPEED
Mower is designed to operate most efficiently at
maximum blade speeds. Speed of machine should
allow mower blades to maintain this maximum speed
while mowing across turf. Slow machine for cutting tall
grass, grass that is heavy with moisture, or when
moving uphill. If ground speed is too fast, or blade
speed is too slow, mowing will be uneven because
mower blades will not be able to lift grass into cutting
position as mower passes over ground.
MOWING HEIGHT
Best cutting height for your lawn has probably been
established from previous experience. First time you
mow, set mower to cut a little higher than you have in
past. This will help you determine the best approach
to uneven areas, to be sure wider cut does not result
in scalping high spots, in general, recommended
cutting height is 2 to 3 in. (5-7.6cm).
Very tall grass can be cut without difficulty by using
a little care. Set mower in its highest cutting position
and enter area slowly. If necessary, take a cut one
half width of mower, overlapping previously cut area
on each pass. Then, with mower set to desired height,
make a finish cut over entire area.

OPERATION OF THE MACHINE WITH

MOWER

IMPORTANT

Keep all shields and mower discharge chute in

place. Never attempt to clear discharge areas or
mower blades without disengaging mower and
removing ignition key.

For best operation on average lawns, operate

engine at full throttle; control ground speed with
transmission. Average lawns ate usually cut at a
height between 2 and 3 in. (5-7.6cm). Tall grass and
weeds should be cut with the mower in its highest
position, making a second pass cutting to height
desired. Always keep mower blades sharp.


',;,(&+233(5
SECTION 6
MOWER
GENERAL
Refer to Usage Section of this manual for basic
mowing information.
MOWER ADJUSTMENTS
Drive and Spindle Belts
• Check that all belts seats in pulleys.
• Check that connecting arm spring height is 2
inches in the “engaged” position. Adjust
turnbuckle if necessary.
Mower Drive and Spindle Belts
LEVEL MOWER
Side-to-side leveling of mower deck is
accomplished by lowering mower and adjusting
threaded eyebolts, at front of deck. Park mower on
Level surface and place a level across front of mower
deck or position mower blade tips side-to-side. Adjust
eyebolts, so that mower is level or distance between
right and left blade tip ends and surface is the same.
Side-To-Side Level Adjustment
Mower level front-to-rear is adjusted by changing
stabilizer bar positions. Always adjust each side
evenly. Adjust at rear or middle of stabilizer bar by
removing hairpin cotters and clevis pins and raising or
lowering stabilizer bar position, changing mower
deck pitch.
To Mow in 2 ½” to 4” cutting height range, leave as
shipped. For cutting below 2 ½”, it may be necessary
to lower rear deck.
NOTE: NEVER allow rear of deck to be lower than
front unless cutting height is in fully raised position
(6”). And you are mowing tall weeds. This is the
ONLY exception and will happen automatically with
deck at fully raised position.
Front-To-Back Level Adjustment
BLADE MAINTENANCE
CAUTION
Sharp edges of mower blades can cut you during
blade maintenance or adjustment. Use suitable
covering over cutting edges of blade to prevent
bodily harm.
To obtain optimum mower results, mower blades
should be kept sharp and well balanced. To sharpen
blades, simply lift front of machine and support it with
jack stands or floor jack. Remove blade attaching
bolts and washers from end of spindles and remove
blades. A short piece of 2 x 4 lumber may be placed
between side of mower deck and blade to “lock” it in
position when loosening attaching hardware.
File or grind blades evenly. Take care to retain
angle of original cutting edge. Blade balance can be
checked on an inexpensive blade balancer, available
at most hardware stores.
Reinstall blades with lift area (turned up section)
facing mower deck. Tighten blade attaching bolts to a
torque of 80-100 ft. lbs. (112-140nm).
UNDERSIDE CLEANING
It is of vital importance to clean the underside of
deck frequently. Accumulation of matter clippings
seriously impairs mower’s ability to “lift” grass blades
into cutting position and discharge clippings evenly.
Matted grass clogging underside of mower is often
cause of uneven cutting.

',;,(&+233(5 SECTION 6
MOWER
(CONTINUED)
MOWER DRIVE BELT When the machine will not be used for an extended
REPLACEMENT period of time, the following steps will help insure
Be sure to purchase genuine Dixie Chopper belts minimum difficulty when unit is returned to service:
for replacement purposes as these belts are designed • Perform required maintenance steps called for in
specifically for each application. the “Maintenance Checklist”.
• Check tires for proper inflation
TO REMOVE MOWER DRIVE BELT: • Wash machine and repaint all bare metal
surfaces.
• Remove connecting arm bracket at triangle plate.
This is done by removing hairpin cotter and • Start machine and engage mower for
washer pin on triangle plate. approximately 1 minute to remove excess water
from belts and pulleys. Let engine run out of gas.
• Remove belt from top groove of center deck
pulley. As gasoline grows old, it becomes less volatile
and forms harmful gum and varnish deposits in
• Remove triangle plate from its stand at the rear of
the mower deck. carburetor and fuel system. DO NOT STORE
GASOLINE FOR MORE THAN 2 MONTHS.
• Loosen engine belt guard at mounting bolts near
the engine at the rear of the machine, and • If applicable, charge battery. In temperatures
remove belt from double groove engine pulley. lower 40ºF (4ºC) a battery will maintain a charge
for about 60 days. In temperatures above 40ºF
• Remove flat idler pulley from triangle plate
(4ºC) water level should be checked and battery
allowing belt removal. Note location of shim
“trickle charge” every 30 days (more often In
under pulley.
higher temperatures). Battery must be fully
charged to prevent freezing and internal damage
MOWER SPINDLE BELT in weather below 32ºF (0ºC).
REPLACEMENT
• Remove key from machine.
Be sure to purchase genuine Dixie Chopper belts
for replacement purposes as these belts are designed
specifically for each application. • Cover seat switch and solenoid from direct water
spray.
TO REMOVE MOWER SPINDLE BELT:
• Remove connecting arm bracket at triangle plate.
• Remove engine to deck belt from top groove of
center spindle.
• Make note of wrapping procedure of belt to
insure placement of new belt.
• Grasp belts on both sides of either outboard deck
spindle and pull belt away from pulley until it is
possible to remove belt. Once this is done
remove from remaining pulleys and discard.

(FOR MOWER BELT INSTALLATION,

REVERSE SEQUENCE OF REMOVAL
PROCEDURES.)

CLEANING AND STORAGE

After 30 days, painted surfaces may be waxed to
protect the luster of the original finish. Machine should
be washed regularly with a mild automotive type
detergent and water.* Exposed bare metal surfaces
should be coated with oil, or a light coating of grease,
to prevent rust until permanent repairs can be made.
Aerosol cans of touch up paint are available through
your Authorized Dealer.


',;,(&+233(5

  

 

  

 



  

 
 

  


 



 


  




',;,(&+233(5

 













',;,(&+233(5
*+)'299+):/54
ITEM PART
NO. DESCRIPTION NO.

1 LX2002 Front Panel………65439

2 X2002 Front Panel…………65440
3 X2000 Front Panel…………65403
4 X2202 Front Panel…………65443
5 X2200 Front Panel…………65404-22
6 X2502 Front Panel…………97068
7 X2500 Front Panel…………97066
8 XF2200 Front Panel………65445
9 XF2500 Front Panel………65446
10 XW2002 Front Panel………65441
11 XW2000 Front Panel………65417
12 XW2202 Front Panel………65444
13 XW2200 Front Panel………65419
14 XW2502 Front Panel………97067
15 XW2500 Front Panel………65428
16 42 Inch Cut…………………65407
17 50 Inch Cut…………………65408
18 60 Inch Cut…………………65409
19 Flatlander………………… 65430
20 Belt Info……………………65423
21 Choke………………………65412-C
22 Ignition………………………65412-I
23 Check Oil………………… 65431
24 Idler Position………………97014
25 Tractor Buster……………… 30586
26 No Smart Spark……………97126
27 Brake and Steering……… 40202-87
28 Throttle……………………… 40203-87
29 Air Filter……………………30589
30 Hillside Caution……………30588
31 Parking Brake……………… 65406
32 Motor Oil Caution…………97013
33 Deck Danger………………30229
34 Fender Caution……………30585
35 Fuel Caution………………40118
36 Belt Route…………………65422
37 Patent Pending……………65413
38 OCDC Safety………………97072
39 Fender………………………30571
40 Floor Pan…………………… 30573
41 Warranty Notice…………… 30591
42 USA…………………………30590
43 RPM Decal…………………97160


',;,(&+233(5
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',;,(&+233(5
3'/4,8'3+9+):/54
2>>>,GTJ>=35*+29
ITEM
No. DESCRIPTION PART NO.
1a. LX Main Frame…………………………67100
1b. X, XF-50 Main Frame…………………65100
1c. XF-60, XW Main Frame………………65100-W
2. Hydraulic Line Right (Long Rubber)
LX-Model……………………………. 67010
X,XF,and XW-Models………………… 65010
Hydraulic Line Left (Short Rubber)
LX, and XF-Models…………………… 67011
X,and XW-Models……………………65011
3. Fitting 45o LX-Model……………………87103
Fitting - Straight X,XF,XW-Model……87104
4. LX,X,XW Wheel Motor Axle (14ci)……67114
XF Wheel Motor Axle (12ci)………… 67112
5. Wheel Hub …………………………… 67002
6. Cupped Washer 11/4" Axle……………W-137
7. Solid Nut 11/4" Axle……………………PB339303P
8. 3/8" Barbed Fitting…………………… 67014
o
9. 3/8" 90 Swivel…………………………67017
10. 3/8" Straight Nipple……………………67016
11. Wheel Motor Bolt………………………B-183
12. Wheel Motor Square Washer………… W-138
13. Wheel Motor Nut………………………N-127
14. 1/4" Key………………………………. PB339101
15. Stud 1/2"-20x2.0"……………………. B-226
16. Lug Nut…………………………………N-113
17. Wheel Motor Faceplate………………65019


',;,(&+233(5
15.2+8)533'4*.V+4-/4+9+):/54
35*+29
2> 
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',;,(&+233(5
15.2+8)533'4*.V+4-/4+9+):/54

ITEM
NO. DESCRIPTION PART NO.
1. Kohler Engine CV20 40215-C20V
2. Engine Pulley 97009
1/4" Key K-100
3. Engine Guard 70100-20
4. Low Oil Horn 60117
5. 90o Fitting 1/8" MP-3/8" 45o MS 60113
6. Amsoil One Micron Filter 60119
7. Filter Mounting Base 60122
8. 90o Fitting 1/4" MP x 3/8" Barb 67019
9. 1/4" Street "T" 67022
10. Plenum Cover 72120
11. Plenum Cover Knob 12-341-01
12. Muffler 24-068-20
13. Muffler Guard
Wire Screen 40136-OS
Solid (HOT) 24-281-06
Stainless (DIXIE CHOPPER - HOT) 97069
14. Hydro Cooler 60103-L
15. Wiring Harness (not shown) 65522
16. Spark Plug RC12YC
17. Turbo Pre-Cleaner 90115
18. Belt Guide Assembly 72220 (2-72217, 1-72222, 4-N110)
Belt Guide Weldment 72217
19. 1/2" Thread All (not shown) 72222
20. 1/2"-13 Hex Nut (not shown) N-110
21. Pull Stop 72216
22. 1/2" Thread All w/ welded nut 40221

Kohler Oil Filter………………………………12-050-01

Air Filter Cartridge…………………………..24-083-03
Air Filter Foam………………………………24-083-05
Fuel Filter…………………………………… 25-050-03
Spark Plug……………………………………RC12YC


',;,(&+233(5
15.2+8)533'4*.V+4-/4+ 9+):/54

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',;,(&+233(5
15.2+8)533'4*+4-/4+9+):/54

ITEM
NO. DESCRIPTION PART NO.
1. Kohler Command 22 HP Engine………………40215-K22V
2. Muffler Guard
Wire Screen………………………………. 40136-OS
Solid (HOT)…………………………………24-281-06
Stainless Steel(DIXIE CHOPPER - HOT).97069
3. Muffler………………………………………….. 24-068-20
4. Engine Pulley…………………………………. 97009
1/4" Key……………………………………. K-100
5. Belt Guide Assembly (includes items below)72220 (2-72217,1-72222, 4-N110)
Belt Guide Welment……………………… 72217
1/2" Thread All (not shown)……………… 72222
1/2"-13 Hex Nut (not shown)……………. N-110
6. Turbo Pre-Cleaner…………………………….. 90115
7. 2" Hose Clamp…………………………………90125
8. Low Oil Horn……………………………………60117
9. Donaldson Air Cleaner (Complete)……………90121
Donaldson Filter Element…………………90122
10. Donaldson Band………………………………. 90123
11. #4 Micro Hose Clamp 68231
12. 3/8"id Black Rubber Hose (sold per inch)….. 60109
13. 3/8" Brass Barb "T" Fitting………………….. 67008
14. Amsoil Filter…………………………………… 60119
15. Amsoil Filter Base……………………………. 60122
o
16. 3/8"MPx 3/8" Barb 90 Brass Fitting……….. 60113
3/8"FP x 3/8" Barb Brass Fitting……………. 60116
17. 2"idx4.0"Black Rubber Hose………………… 72126-T
18. Oil & Transmission Cooler…………………… 60103-L
19. 2"id 90o Black Rubber Hose…………………. 90124
20. 3/8"id MP x 3.0" Steel Pipe………………….. 72230
21. 3/8"MPx 3/8" Barb 90o Brass Fitting……….. 60125
22. 3/8" FP Zinc Coated Steel "T" Fitting……………60102
23. 3/8"MP Oil Drain Hose……………………….. 68230
24. 3/8" Female Hex Pipe Cap…………………… 10231
25. Pull Stop……………………………………….. 72216
26. 1/2" Thread All w/ welded nut……………….. 40221
27. Cooler Bracket………………………………… 70100-22
Kohler Oil Filter…………………………………277233
Air Filter Cartridge………………………………24-083-03
Air Filter Foam………………………………… 24-083-05
Fuel Filter……………………………………… 25-050-03
Spark Plug………………………………………RC12YC


',;,(&+233(5
15.2+8)533'4*.V+4-/4+ 9+):/54

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',;,(&+233(5
15.2+8)533'4*.V+4-/4+9+):/54
ITEM
NO. DESCRIPTION PART NO.
1. Kohler Command 22 HP Engine………………40215-K25CV
2. Muffler Guard
Solid (HOT)…………………………………24-281-06
Stainless Steel(DIXIE CHOPPER - HOT) 97070
3. Muffler………………………………………….. 24-068-28
4. Engine Pulley…………………………………. 97009
Fan Spacer…………………………………97154
Fan…………………………………………. 97107
1/4" Key……………………………………. K-100
5. Belt Guide Assembly (includes items below)72220 (2-72217,1-72222, 4-N110)
Belt Guide Welment……………………… 72217
1/2" Thread All (not shown)……………… 72222
1/2"-13 Hex Nut (not shown)……………. N-110
6. Turbo Pre-Cleaner…………………………….. 90115
7. 2" Hose Clamp…………………………………90125
8. Low Oil Horn……………………………………60117
9. Donaldson Air Cleaner (Complete)……………90121
Donaldson Filter Element…………………90122
10. Donaldson Band………………………………. 90123
11. #4 Micro Hose Clamp 68231
12. 3/8"id Black Rubber Hose (sold per inch)….. 60109
13. 3/8" Brass Barb "T" Fitting………………….. 67008
14. Amsoil Filter…………………………………… 60119
15. Amsoil Filter Base……………………………. 60122
o
16. 3/8" MP x 1/8" MP 90 Brass Fitting………. 60113
3/8" FP x 3/8" Barb Brass Fitting…………… 60116
17. 2"idx4.0"Black Rubber Hose………………… 72126-T
18. Oil & Transmission Cooler…………………… 60103-L
19. 2"id 90o Black Rubber Hose…………………. 90124
20. 3/8"id MP x 4.0" Steel Pipe………………….. 10230
21. 3/8"MPx 3/8" Barb 90o Brass Fitting……….. 60125
22. 3/8"FP Zinc Coated Steel "T" Fitting……….. 60102
23. 3/8"MP Oil Drain Hose……………………….. 68230
24. 3/8" Female Hex Pipe Cap…………………… 10231
25. Pull Stop……………………………………….. 72216
26. 1/2" Thread All w/ welded nut……………….. 40221
27. Cooler Bracket………………………………… 70100-22
Kohler Oil Filter…………………………………277233
Air Filter Cartridge………………………………24-083-03
Air Filter Foam………………………………… 24-083-05
Fuel Filter……………………………………… 25-050-03
Spark Plug………………………………………RC12YC


',;,(&+233(5






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',;,(&+233(5
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Item Description Part Number

1 Arm Rest Cover 40097
2 RH Armrest Kit 40095
3 LH Armrest Kit 40096
4 Low Back Seat Top Cover 40099
5 Low Back Seat Bottom Cover 40100
6 High Back Seat Top Cover 40098
7 High Back Seat Bottom Cover 64100
8 Right Lumbar Adjustment Knob 64098
9 Left Back Adjustment Knob 64099
10 Vertical Adjustment Detent Guide 64096
11 4-Way Lumbar Vertical Adjustment Knob 64097
12 Self Tapping Screw 64095

Low Back Seat Complete 40100-W

High Back Seat Complete 64100-W


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ITEM PART
NO. DESCRIPTION NO.
1. Hour Meter/Tach……………………………… 20246-T
2. Ignition Switch…………………………………20245
3. Seat Relay………………………………………65510
4. 3/8" Hose Clamp (For Tilt Switch)……………60124
5. Battery……………………………………………20225
6. Battery Strap……………………………………20228
7. Battery Cable Boot…………………………… 20225-B
8. Fuse Holder……………………………………20254
9. 20,22,and 25 Hp Dixie Chopper Wiring
Harness………………………………. 65522
10. Battery Cable Grd (12")……………………… 20226-B
11. Battery Cable Positive…………………………20227-72
12. Tach Bracket……………………………………68247
13. Tilt Switch…………………………………. 40229-Z
14. Mini Fuse………………………………….. 65509


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ITEM PART ITEM PART

NO. DESCRIPTION NO. NO. DESCRIPTION NO.
1. Clevis Pin 3/8"x2-1/4" Long……………P-103 31. Hex Bolt 1/2"-13 x 3/4"……………….. B-115
2. Clevis Pin 3/8"x1-1/2" Long……………P-102 32. Hex Bolt 5/8"-11 x 1"………………… B-120
3. Hairpin Cotter…………………………… 20224 33. "V"-Idler Pulley…………………………30234
4. Rod End Stud………………………… S-114 (#50) 34. Bronze Bushing………………………. 30206
Nut…………………………………. N-157 35. Flat Idler Pulley………………………..30224
Deck Lift Chain #50……………….68217 36. 3/8" Flat Washer……………………… W-104
Master Link #50……………………10232 37. Ser. Flange Hex Nut 3/8"-16………… N-108
5. Clevis Pin 5/16"x1"……………………… P-101 38. Bronze Bushing………………………. 20276
6. L.H. Scissor Link Arm…………………30232 39. Shoulder Bolt 1/2"-13 x 1-3/4"………. B-118-G
7. 42" Blow-Out Baffle……………………50315-42 40. Clevis Pin 3/8" x 1-1/4"………………. P-102
8. R.H. Scissor Link Arm…………………30231 41. Stabilizer Bar…………………………. 30214-86
9. Clevis Pin 3/8"x1-1/2" Long……………P-102 42. Hex Bolt 1/2"-13 x 1-1/4"………………B-117
10. Clevis Pin 3/8"x2-1/4" Long……………P-103 43. 1/2" Flat Washer……………………… W-109
11. 42" Mower Deck Complete……………30200-42 44. Long Tensioning Spring……………… 10222
42" Mower Deck Shell…………… 67350 45. Tower Assembly Weldment………….67131
12. Mulch Plate…………………………… 50122-42 Deck Spindle Belt (A-89)………………63203
13. Cam Weldment………………………..30210
14. Engaging Shaft……………………….. 30211
15. Hairpin Cotter…………………………… 30213
16. Engaging Handle………………………30212
17. Handle Grip…………………………….67258-R
18. Engaging Rod………………………….68209
19. Return Spring…………………………. 20217-25
20. L Bracket……………………………… 30209-B
21. Engaging Spring……………………… 30207-S
22. Engaging Rod Assembly………………30209-1
23. Hex Nut 1/4"-20 ………………………. N-102
24. Hex Bolt 1/4"-20 x 3/4"…………………B-102
25. Belt Tensioning Pivot………………… 30235
26. 5/8" Shim (4)………………………….. 30112
27. Grease Fitting………………………… F-100
28. Belt Tensioning Swing Arm…………. 30236
29. 1/2" Lock Washer……………………. W-111-V
30. Flat Idler Pulley………………………..30224


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ITEM PART ITEM PART

NO. DESCRIPTION NO. NO. DESCRIPTION NO.
1. Clevis Pin 3/8"x2-1/4" Long……………P-103 31. Hex Bolt 5/8"-11 x 1"………………… B-120
2. 50" Top Plate Weldment…………….. 32. "V"-Idler Pulley…………………………30234
3. Hairpin Cotter…………………………… 20224 33. Bronze Bushing………………………. 30206
4. Clevis Pin 3/8"x1-1/2" Long……………P-102 34. Flat Idler Pulley………………………..30224
5. Clevis Pin 5/16"x1"……………………… P-101 35. Belt Idler Arm…………………………. 30223
6. L.H. Scissor Link Arm…………………30232 36. 3/8" Flat Washer……………………… W-104
7. 50" Stamped Mower Deck Complete… 30200-50 37. Ser. Flange Hex Nut 3/8"-16………… N-108
50" Stamped Mower Deck Shell…30100 38. Bronze Bushing………………………. 20276
8. Rod End Stud………………………… S-114 (#50) 39. Shoulder Bolt 1/2"-13 x 1-3/4"………. B-118-G
Nut…………………………………. N-157 40. Clevis Pin 3/8" x 1-1/4"………………. P-102
Deck Lift Chain #50……………….68217 41. Stabilizer Bar…………………………. 30214-86
Master Link #50……………………10232 42. Hex Bolt 1/2"-13 x 1-1/4"………………B-117
9. R.H. Scissor Link Arm…………………30231 43. 1/2" Flat Washer……………………… W-109
10. 50" H.D. Mower Deck Complete.. 30200-H50 44. Long Tensioning Spring……………… 10222
50" H.D. Mower Deck Shell………30100-H50 45. Spring Tab………………………………65308
11. 50" Blow-Out Baffle (Stamped Deck)50315-50 46. Tower Assembly Weldment………… 67131
50" Baffle (H.D. Deck)…………… 50315-H50
12. Cam Weldment………………………..30210
13. Engaging Shaft……………………….. 30211 Deck Spindle Belt (B-103)……………30203
14. Hairpin Cotter…………………………… 30213
15. Engaging Handle………………………30212
16. Handle Grip…………………………….67258-R
17. Engaging Rod………………………….68209
18. Return Spring…………………………. 20217-25
19. L Bracket……………………………… 30209-B
20. Engaging Spring……………………… 30207-S
21. Engaging Rod Assembly………………30209-1
22. Hex Nut 1/4"-20 ………………………. N-102
23. Hex Bolt 1/4"-20 x 3/4"…………………B-102
24. Belt Tensioning Pivot………………… 30235
25. 5/8" Shim (4)………………………….. 30112
26. Grease Fitting………………………… F-100
27. Belt Tensioning Swing Arm…………. 30236
28. 1/2" Lock Washer……………………. W-111-V
29. Flat Idler Pulley………………………..30224
30. Hex Bolt 1/2"-13 x 3/4"……………….. B-115


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ITEM ITEM
NO. DESCRIPTION PART NO. NO. DESCRIPTION PART NO.
1. Clevis Pin 3/8" x 2-1/4" Long…P-103 41. Spring Tab……………………………………65308
2. Clevis Pin 3/8" x 1-1/2"……… P-102 42. 1/2" Flat Washer…………………………… W-109
3. Hairpin Cotter…………………20224 43. Hex Bolt 1/2"-13 x 1-1/4"……………………B-117
4. 60" Top Plate Weldment……30127-60 44. Clevis Pin 3/8" x 1-1/4"………………………P-102
5. L.H. Scissor Link Arm………30232 45. Long Tensioning Spring……………………10222
6. Clevis Pin 5/16" x 1……………P-101 46. Pulley Guard (QTY. 2)…………………… 67317
7. 60" Mower Deck Complete.. 30200-60 47. Rod End Stud……………………………… S-114 #50
60" Mower Deck Shell…. 30100-60 48. Nut (Not Shown)…………………………… N-157
8. Hex Bolt 5/8" x 9-1/2" (Long)…B-146 49. Deck Skid (50,60)…………………………. 30135
9. Roller (Long)………………… 30240-0 50 Roller Cap (50,60)………………………… 65130
10. 5/8"-11Hex Nut……………… N-115 51. Short Roller Tab (50,60)……………………65131
5/8" Flat Washer……….. W-135 52. Long Roller Tab (50,60)……………………65141-L
11. Blow Out Baffle………………50315-60 53. Tower Assembly Weldment……………… 67131
12. R.H. Scissor Link Arm………30231
13. Roller (Short)…………………67240 Deck Spindle Belt B128…………………. 30236-o
5/8"-11Bolt (Short)………… B-122
5/8"-11 Hex Nut…………… N-115
5/8" Flat Washer……….. W-135
Roller Spacer…………… 10203
14. Cam Weldment………………30210
15. Engaging Shaft 14"………… 30211
16. Hairpin Cotter…………………30213
17. Engaging Handle…………… 30212
Handle Grip (Plastic)……67258-R
18. Engaging Rod…………………68209
19. Return Spring…………………20217-25
Engaging Spring…………30207-S
20. L. Bracket…………………… 30209-B
21. Engaging Rod Assembly……30209-1
22. Belt Tensioning Pivot…………30235
23. Hex Bolt 1/4"-20 x 3/4"……… B-102
24. Hex Nut 1/4"-20………………N-102
25. 5/8" Shim (QTY. 4)………… 30112
26. Belt Tensioning Swing Arm…30236
27. 1/2" Lock Washer……………W-111-V
28. Flat Idler Pulley………………30224
29. Hex Bolt 1/2"-13 x 3/4"……… B-115
30. Grease Fitting…………………F-100
31. Hex Bolt 5/8"-11 x 1"…………B-120
32. "V"-Idler Pulley……………… 30234
33. Bronze Bushing………………30206
34. Belt Idler Arm…………………30223
35. 3/8" Flat Washer……………… W-104
36. Ser. Flange Hex Nut 3/8"-16…N-108
37. Stabilizer Bar…………………30214-86
38. Bronze Bushing………………20276
39. Shoulder Bolt 1/2"-13 x 1-3/4" B-118-G
40. Flat Idler………………………30224


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Item Part
No. Description No.
1. Engine-Deck Belt
42" Deck B-80…………………………. 65080
50" Deck B-78………………………….. 30204
60" Deck B-80………………………….. 65080
2. Deck Spindle Belt
42" Deck A-89………………………….. 63203
50" Deck B-103………………………… 30203
60" Deck B-128………………………… 30236-0
3. Slotted Hex Nut 1"……………………….... N-142
4. Belleville Washer 1"…………………………W-137
5. Center Spindle Top Pulley
42" Deck (Steel) (All Machines)………63221
50" Deck (Cast) (Stainless Machines). 30220-50V
50" Deck (Steel) (Painted Machines)…63221
60" Deck (Cast) (Stainless Machines). 30220-60V
60" Deck (Steel) (Painted Machines)…62265
6. Washer 1"x1.5"x 1/8"……………………….. W-131
7. 5-1/2" Spacer………………………………... W-136
8. All Spindle Bottom Pulley
42" Deck (Steel) (All Machines)……… 63221
50" Deck (Cast) (Stainless Machines). 30220-50
50" Deck (Steel) (Painted Machines)…63221
60" Deck (Cast) (Stainless Machines). 30220-60
60" Deck (Steel) (Painted Machines)…62265
9. Washer 1"x1.75"x 1/4"……………………… W-146
10. Sealed Bearing 1"………………………….. 30218
11. Grease Fitting………………………………. F-102
12. Inner Deck Hub Spacer……………………. 30219
13. Deck Hub Casting………………………….. 30241
14. Long Blade Shaft (Center Only)……………30217L
15. Short Blade Shaft (Outboard)………………30217
16. 1/2" Blade Spacer………………………….. 30242
17. Fiber Washer……………………………….. W-101
18. Mower Blade
42" Deck 14"x2.5" Standard…………….. 63227-H
42" Deck 14"x3" High Lift………………63227-N
50" Deck 17"x2.5" Standard………………30227-H
50" Deck 17"x3" High Lift………………30227-N
60" Deck 20.5"x2.5" Standard…………… 30227-60H
60" Deck 20.5"x3" High Lift……………30227-60N
19. 5/8" Belleville Washer………………………. W-100
20. Blade Shaft Bolt …………………………… B-121L (Use with Blade Spacer)
Short Blade Shaft Bolt…………………….. B-121 (Use without Blade Spacer)
21. Triangle Plate Rear "V" Idler Pulley
42",50", and 60" Decks……………….. 30234
22. Triangle Plate Front Flat Idler Pulley
42",50", and 60" Decks……………….. 30224
23. Deck Flat Idler Pulley
42",50", and 60" Decks……………….. 30224
24. Transmission Pulley(not shown)………….. 20265
25. Transmission "V" Idler Pulley(not shown).. 30234
26. Engine-Transmission Belt B-38 20256


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STAINLESS POWDER
COATED
ITEM PART.
NO. DESCRIPTION NO.
1. 1/4"-20 Whiz Nut………………. N-102
2. Rear Fender Bracket R.H……. 20266-R 67272
3. Rear Fender R.H………………. 20270-R1 67270
4. Rear Fender Bracket L.H………20266-L 67273
5. Rear Fender L.H………………. 20269-L1 67269
6. Hex Nut 1/2"-13…………………N-110
7. Carpet……………………………20275
8. Wing Nut 5/16"-18………………N-106
9. Fender Washer 3/8"…………… W-106
10. Floor Pan………………………. 67268 67271
11. Rubber Washer……………….. W-103
12. Fender Washer 3/8"…………… W-106
13. Hex Nut 5/16"-18…………………N-103
14. Full Thread Bolt 5/16"-18x1.5"…B-105
15. Front Panel LX………………… 67267
Front Panel X,XF,XW……………82267
16. Hex Bolt 1/4"-20x 1/2"……………B-101
17. Flat Washer 1/4"…………………W-102
18. Front Fender Bracket L.H………20275-L 67274
19. Front Fender Bracket R.H……. 20275-R 67275
20. Flat Washer 1/4"………………. W-102
21. Hex Bolt 1/4"-20x 1/2"……………B-101


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35*+245

ITEM
NO. DESCRIPTION PART NO.
1. Screw, Pan Head, Self Tap 10-24x 1/2"…………792025
2. Pipe Plug, Hex Countersunk Headless 1/8"-27 28534
3. Cover Plate……………………………………….. 772067
4. Cover Plate Gasket……………………………… 788028
5. Snap Ring………………………………………… 788018
6. Miter Gear (Downshaft)………………………… 778101
7. Downshaft Bearing………………………………. 780174
8. Downshaft……………………………………… 776360
9. Cross-Shaft (9 teeth)………………………………776305
10. Miter Gear (Cross-shaft)…………………………778210
11. Screw, Hex Head, 1/4"-20x1/2"…………………. 792026
12. Bell Housing Gasket…………………………….. 788030
13. Cross-Shaft Bearing………………………………780034
14. T-Gearbox Housing……………………………… N/A
15. Snap Ring………………………………………… 792119
16. Snap Ring………………………………………… 788019
17. Vicon Oil Seal……………………………………. 788099
18. 1/8"MPx 3/8"Barb Fitting…………………………. 65033
19. Hose Clamp………………………………………. 67013
20. 3/8" Hose…………………………………………. 65108
21. Pop-Off Valve…………………………………….. 792118
22. Fill Top Cap (Cap Only) (Optional)…………… 40117-C
23. Fill Top Cover (Cap and Lid) (Optional)…………68204
24. Bell Housing O-Ring………………………………65024
25. Aluminum Bell Housing…………………………. 65001

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PARTS LIST
ITEM PART
NO. DESCRIPTION NO.

1 Lever Arm and Sprocket Assembly…………………10225-1

2 Height Control Sprocket………………………………10226-1
3 Lift Arm Pawl……………………………………………10224-2 (#50)
4 Foot Pedal………………………………………………10218-1
5 Pivot Link……………………………………………… 10223-1
6 Pin………………………………………………………10228-1
7 Long Foot Spring………………………………………10222
8 Short Foot Spring………………………………………20217-25
9 Foot Pedal Chain………………………………………68219 (#50)
10 5/16"-18 x 1 1/2" Full Thread Hex Head Bolt………B-105
11 5/16"-18 x 1" Full Thread Hex Head Bolt……………B-131
12 5/16" Standard Flat Washer…………………………W-113
13 5/16"-18 Nyloc Nut……………………………………N-103
14 5/16"-18 x 3/4" Coupling Hex Nut……………………N-130
15 Clevis Pin………………………………………………P-101
16 Nylon Spacer…………………………………………… N/A
17 Clip………………………………………………………30213
18 Grease Fitting………………………………………… F-100
19 Hairpin Cotter…………………………………………… N/A

Complete Foot Pedal Assembly………………… 10107-2 (#50)

Contains 1,2,3,5,7,8,9,10,13,17,19


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PARTS LIST
ITEM PART
NO. DESCRIPTION NO.

1 Front Tire Assembly……………………………………………… 97166

(Contains 2,3,31,32)
2 Front Rim (Rim Only)…………………………………………… 10239
Hairpin Cotter…………………………………………………N/A
3 Front Tire (Tire Only)……………………………………………97165
4 Front Fork…………………………………………………………97170
5 Outer Front Wheel Spacer………………………………………10203
6 Outer Front Wheel Bearing………………………………………10205
7 Inner Front Wheel Bearing………………………………………67205
8 Inner Front Wheel Spacer………………………………………67204
9 5/8"-11 X 7" Hex Head Bolt………………………………………B-122
10 5/8"-11 Hex Nut……………………………………………………N-115
11 Grease Fitting……………………………………………………… F-100
12 Dust Cap…………………………………………………………… 10220
13 1" Slotted Hex Nut……………………………………………… N-142
14 Top Bearing………………………………………………………10207
15 Outer Bearing Race………………………………………………10206
16 Bottom Bearing……………………………………………………97171
17 Seal…………………………………………………………………10208
18a Back Right Tire Assembly………………………………………10214-RB
(Contains 19,20,33,34)
18b Back Left Tire Assembly…………………………………………10214-LB
(Contains 19,20,33,34)
19 Rear Rim (Rim Only
LX Models (8" x 7")………………………………………61238
X, XF, XW Models (8" x 9")………………………………10238
20a Rear Tire Turf Boss II (Tire Only)………………………………10156-BII
20b Rear Tire CTR (Tire Only)……………………………………… 10156-C
21 Wheel Motor (14 Cu In)…………………………………………67114
22 Thrust Washers………………………………………………… PB018054
23 Thrust Bearings…………………………………………………… PB018052
24 Dust/Shaft Seal……………………………………………………PB018069
25 Snap Ring…………………………………………………………PB018073
26 Wheel Stud……………………………………………………… B-226
27 Wheel Flange……………………………………………………… N/A
Wheel Flange Assembly (Contains 26,27)…………………67002
28 Lug Nuts…………………………………………………………… N-113
29 Shaft Nut………………………………………………………….PB339303P
30 Shaft Key…………………………………………………………PW72546
31 Brake Drum
LX Models……………………………………………………97159
X, XF, XW, XXW Models……………………………………67266
32 CTR Tire Assembly………………………………………………10214-C

NOT SHOWN
33 Valve Stem…………………………………………………………10127-S
34 Tire Sealant (32 Fluid Ounce Bottle)……………………………68211


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ITEM PART
NO. DESCRIPTION NO.
1. Dust/Shaft Seal…………PB018069
2. Body Seal (4)……………In Kit
3. Commutator Seal……… In Kit
4. O-ring Seal………………In Kit
5. Teflon Back-up Seal…… In Kit
Seal Kit………………… PB333700
(Contains:1-5)
6. Snap Ring………………. PB018073
7. Thrust Washers…………PB018054
8. Thrust Bearing…………. PB018052
9. Housing Bearing…………PB018053
10. Housing…………………. PB130015
11. Drive Link
12 cu.in…………………. PB014030
14 cu.in…………………. PB014027
12. Rotor Assembly
12 cu.in……………….... PB332012
14 cu.in…………………. PB332014
13. Manifold…………………. PB015008
14. Commutator Assembly PB012011
15. Endcover Piston…………PB018056
16. Piston Spring……………PB018059
17. Endcover………………... PB160007G
18. ID Tag…………………… N/A
19. Assembly Bolts
12 cu.in…………………. PB334012
14 cu.in……………………PB334014
20. Shaft…………………….. PW72545
21. Shaft Key……………….. PB339101
22. Shaft Nut…………………PB339303P
12 cu.in Wheel Motor…67112
14 cu.in. Wheel Motor…67114


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ITEM PART ITEM PART

NO. DESCRIPTION NO. NO. DESCRIPTION NO.
1. Handle Grip (Black)…………67258 13. Lower Throttle Mounting Bracket……… 97011
2. Handle Weldment……………97012 14. Throttle Cable (with nuts and washers) 68249
3. 5/16" Flat Washer………… W-102 15. Hex Nut……………………………………N/A
4. 5/16"x1"Hex Head Bolt………B-159 16. Washer……………………………………N/A
5. Hairpin Cotter………………. 20224 17. "C" Clip……………………………………C-105
6. Stainless Flat Washer, 1/4" W-153 18. Upper StainlessThrottle Bracket………… 65270
7. 3/8" Flat Washer…………… W-104 19. 5/16" Whiz Flange Nut……………………N-134
8. 3/8"-16 Nyloc Nut……………N-107 20. 3/8" Nylon Washer………………………… W-125
9. 3/8" Nylon Washer…………… W-125 21. Stainless #10 Washer……………………W-152
10. Hex Nut………………………N/A 22. Stainless 10-32x3/4" Bolt………………… B-203
11. Washer……………………… N/A 23 3/8" Flat Washer………………………… W-104
12. 3/8" Nylon Washer……………. W-125 24 3/8"x1" Hex Head Bolt……………………B-108

,;+2:'41

ITEM PART
NO. DESCRIPTION NO.
1. Fuel Gas Cap…………40117-1
2. Fuel Tank………………40204-1
3. Rubber Bushing………40220
4. 1/4"id Fuel Line Hose…40211 Sold per foot
5. Hose Clamp…………. 40213
6. Gas Line Y……………40230
7. 1/4"id Fuel Line Hose…40211 Sold per foot
8. Hose Clamp……………40213
9. 1/4"id Fuel Line Hose.. 40211 Sold per foot
10. Hose Clamp…………. 40213
11. Tank Valve…………… 40219
12. Engine Clip………….. 45-083-01


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ITEM PART
NO. DESCRIPTION NO.
1. Dump Valve
With .031" Hole………. 25-130-31
With No Hole……………25-130-30
2. Case Bleed Fitting…………67015
3. Sundstrand Pump Left…… 65015
Sundstrand Pump Right… 65016
4. Bell Housing Bolt…………… 792026
5. Bearing Plate Gasket………3046 or 788030
6. T Box Gasket…………….. 3045 or 788028
7. T Box Cover Plate…………N/A
8. T Box Cover Plate Bolt……792025
9. T Box Vent Fitting…………65033
10. High Pressure Port Fitting. 65004
11. Charge Pump Inlet Fitting…67016
12. Hex Nut 3/8"-24…………... N-150
13. Flat Washer 3/8"……………W-113
14. Pump O-ring………………. 65024
15. Small Bell Housing…………65001
16. Threaded Rod 3/8"…………65206
17. Woodruff Key 3/16"x 3/4"……K-102
18. T Gear Box…………………65201
19. Hex Nut 3/8"-24…………… N-150
20. Fan…………………………. 97106
21. Transmission Pulley………20265
22. I/8"x 3/4" Flat Washer………W-131
23. 3/4" Belleville Washer……. W-132
24. Hex Nut 3/4"-16…………… N-114


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ITEM PART
NO. DESCRIPTION NO.
1. Seat Relay…………………………65510
2. Self Tap 3/16"x 1/2" Screw………… S-100
3. Clevis Pin 5/16"x1"………………… P-101
4. 5/16"-18 Hex Nut………………… N-103
5. Transmission Frame Weldment
LX Model………………………67250
X,XF,XW Models………………65250
6. Hydraulic Oil Tank……………… 68018
7. 3/8"-16x2.5" HH Bolt……………… B-179
8. Hair Pin……………………………20224
9. Jam Nut 1/4"-13 Hex……………… N-111
10. Bolt 5/16"-18x1.25"……………… B-174
11. Nylon Washer 3/8"………………… W-125
12. Wafer Washer 3/8"(3)…………… W-126
13. Nyloc Nut 3/8"…………………… N-107
14. Bolt 5/16"-18x1"…………………. B-131
15. Bolt 1/2"x4.5" Grease Fitting……B-143-G
16. Steering Lever Left
LX Model………………………67231
X,XF,XW Models………………20231
17. Steering Lever Spring……………20252
18. Eye Bolt 5/16"……………………… B-150
19. Pump Control Arm……………… 65207
20. Steering Lever Right
LX Model………………………67232
X,XF,XW Models………………20232
21. Nut 1/2"-13…………………………N-110
22. Rod Linkage………………………65241
23. Yoke 5/16"…………………………20214
24. Jam Nut 1/2"-13 Hex……………… N-111
25. Machinery Bushing 1/2"…………W-110
26. Idler Arm
LX Model………………………65209
X,XF,XW Models………………65209
27. Steering Block Weldment………65205
28. Nylon Washer 5/8"……………… W-139
29. Idler Spring………………………… 10222
30. Foam Grip…………………………67259
Plastic Grip……………………… 20257


',;,(&+233(5
6'81/4-(8'1+9+):/54

Item Part
No. Description No.
1. Brake Cable (Long)……………… 65247
2. Brake Cable (Short)………………65246
3. Plate……………………………… 65060
4. Pin Clevis 5/16"x 3/4"………………P-112
5. Roll Pin 3/16" x1.5"……………… P-118
6. Roll Pin 3/16" x 1"…………………P-100
7. Brake Band…………………………65244
8. Spacer 5/8"id x 7/8"od x 3/4"………65227 (Weld onto Wheel Motor Box on Frame)
Spacers for #9
1/4" Spacer (Need 1)………30111
1/8" Spacer (Need 3)………65278
9. Brake Pin………………………… 65243
10. Spacer (short) (retainer clamps). 65063
11. Clevis Pin 5/16" x 1.25"…………… P-107
12. Flat Washer 5/16"x 5/8"……………W-113
13. Flat Washer 5/16"x 5/8"……………W-113
14. Brake Handle Assembly…………65245
15. Flat Washer 5/16"…………………W-113
16. Hex Nut 5/16"-18………………… N-103
17. Lock Flange Nut 5/16"-24…………N-121
18. Bolt 5/16"-18x1.5" HH GR5………B-171
19. Clamps Cable Retainer……………65061
20. Fender Washer 5/16" thick………W-118
21. Spacer (Long)………………………65062
22. Bolt 5/16"-18x2.0"" HH GR5……… B-156
23. Cotter Pin 3/32"x1.5"………………P-108


',;,(&+233(5
6'81/4-(8'1+9+):/54


',;,(&+233(5
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',;,(&+233(5
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ITEM PART
NO. DESCRIPTION NO.
1. Hydraulic Oil Resevoir/Tank………………68018
2. Oil Tank Outlet Fitting……………………… 87113
3. Hydro Filter Fitting…………………………60125
4. Hydro Filter Top…………………………… 60104
5. Hydro Filter…………………………………68140
6. Vent Tube Fitting……………………………65033
7. Case Bleed Fitting…………………………67015
8. Dump Valve
With .031" Hole……………………….. 25-130-31
With No Hole………………………….. 25-130-30
9. Sundstrand Pump Left…………………… 65015
10. High Pressure Port Fitting……………….. 65004
11. Charge Pump Inlet Fitting…………………67015
12. Hydraulic Hose L.F.
LX Model………………………………. 67011
X,XF,XW Models……………………… 65011
13. Hydraulic Hose L.R.
LX Model………………………………. 67011
X,XF,XW Models……………………… 65011
14. High Pressure Wheel Motor Fitting L.R.
LX Model………………………………. 87103
X,XF,XW Models……………………… 87104
15. High Pressure Wheel Motor Fitting L.F.
LX Model………………………………. 87104
X,XF,XW Models……………………… 87104
16. Wheel Motor
LX,X,XW Models………………………. 67114
XF Model………………………………. 67112
17. Hydro Cooler………………………………. 60103-L
18. Sundstrand Pump Right……………………65016
19. Flush Line Bottom Barb
LX Model………………………………. 67019
X,XF,XW Models……………………… 67014
20. Flush Line Bottom Coupling………………67017
21. High Pressure Wheel Motor Fitting R.R.
LX Model………………………………. 87103
X,XF,XW Models……………………… 87104
22. High Pressure Wheel Motor Fitting R.F.
LX Model………………………………. 87103
X,XF,XW Models……………………… 87104
23. Flush Line Top Fitting Barb……………… 67016
24. Hydraulic Hose R.R.
LX Model………………………………. 67010
X,XF,XW Models……………………… 65010
25. Hydraulic Hose R.F.
LX Model………………………………. 67010
X,XF,XW Models……………………… 65010
26. Clear Hose (sold per foot)…………………65108


',;,(&+233(5
SECTION 9 9+):54

GENERAL MANUAL INDEX

Adjustments……………………………………...…… 13
Mower……………………………………….……..… 13,14
Cleaning and Storage…………………………….… 14
Decals……………………………………………….. 15-17
Maintenance………………………………...………… 8,9
Motion Control Levers…………………………...…… 10
Mower Lift Pedal………………………………...…… 10
Parts……………………………………………..…… 18
Registration……………………………………..…… 6
Safety Interlock System…………………………...… 10
Safety suggestions……………………………...…… 5
Starting Engine…………………….……………..… 11
Stopping Engine………………………………..…… 11
Throttle………………………………………….……… 11
Transmission Operation……………………………… 11
Vehicle Identifications Number
(VIN) Locations……………………………..…..… 6
Warranty……………………………………..……… 7
Wiring Diagram……………………………….……… 28


 For Serial Numbers 2034000 and Higher

Model # ____________________ Engine Model # ____________________

Serial # ____________________ Engine Serial # ____________________

Date Purchased ____________________ Engine Spec. # ____________________

XW MODEL PARTS MANUAL

May, 2001
Congratulations on your purchase of a DIXIE CHOPPER lawn
mower. We believe you have exercised excellent judgement, and are most
appreciative of your patronage.

We recommend that you read this entire manual before operating this unit.
Time spent in becoming fully aquainted with its performance will add a longer
and more satisfactory life to your DIXIE CHOPPER.

To obtain the latest information on your Dixie Chopper lawn mower, and receive the highest quality
service, please call or visit your nearest authorized Dixie Chopper Dealer.

AUTHORIZED DEALER

Dixie Chopper reserves the right to make changes or add improvements to its products at any time without
incurring any obligation to make such changes to products previously manufactured. Neither Dixie Chopper, nor
its dealers, accept responsiblility for variations which may be evident in the actual specifications of its products and
the statements and descriptions contained in this publication.
 CONTENTS

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 XW MODEL
QUICK REFERENCE PARTS

MODEL XW2400 XW2500 XWK2501 XWK2503

Engine Honda 24Hp Kohler 25Hp Kaw asaki 25Hp Kohler 25Hp
Deck 60" 60" 60" 60"
Rear Tires Turf Boss III Turf Boss III Turf CTR Turf Boss III

Pulleys
Engine 9907500X600D 9907500X600D 9907500X600D 9907500X600D
Transmission 9907500X750S 9907500X750S 9907500X750S 9907500X750S
Outer Spindle 9907525X100S 9907525X100S 9907525X100S 9907525X100S
Center Spindle Top 9907675X100S 9907675X100S 9907675X100S 9907675X100S
Center Spindle Bottom 9907525X100S 9907525X100S 9907525X100S 9907525X100S

Belts
Engine-Transmission 9907B41 9907B41 9907B41 9907B41
Engine-Deck 9907B85 9907B85 9907B85 9907B85
Deck 9907B130 9907B130 9907B130 9907B130

Filters
Fuel 97392 97392 97392 97392
Donaldson 90122
Amsoil 60119
Zinga-Hydro 68140 68140 68140 68140

Blades
Standard 30227-60H 30227-60H 30227-60H 30227-60H
Heavy-Duty 30227-60N 30227-60N 30227-60N 30227-60N
 DECALS

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 WHEELS & TIRES
1
2
3

5
6
9
7 11
10 25
8 13
12
15
16
17 27
14
26
18
24
23
19 22 REF # PART # DESCRIPTION QTY.
21
20 18 10214-C L. & R. Tire Assembly (XWK2501) 2
10156-C Turf CTR Tire 2
61238 Rim 2
10127-S Valve Stem 2
REF # PART # DESCRIPTION QTY. 400019 Left Tire Assembly
1 N-142 1" Slotted Hex Nut 2 (XW2400, XW2500, XWK2503) 1
2 10220 Dust Cap 2 97200 Turf Boss III Tire 1
3 10207 Top Bearing 2 400014 Rim 1
4 10206 Outer Bearing Race 4 10127-S Valve Stem 1
5 97171 Bottom Bearing 2 400020 Right Tire Assembly
6 10208 Oil Seal 2 (XW2400, XW2500, XWK2503) 1
7 97170 Front Fork Weldment 2 97200 Turf Boss III Tire 1
8 B-122 Bolt - 5/8"-11x7" Hex Head 2 400014 Rim 1
9 N-115 Nut - 5/8"-11 Nyloc 2 10127-S Valve Stem 1
10 67205 Inner Front Wheel Bearing 2 19 N-113 Lug Nut 8
11 10205 Outer Front Wheel Bearing 2 20 PB339303P Wheel Motor Axle Nut 2
12 10203 Outer Front Wheel Spacer 2 21 67266 Brake Drum 2
13 97166 Front Tire Assembly 2 22 67002 Wheel Flange w/studs 2
N/A Front Tire 2 23 B-183 Wheel Motor Bolt 8
10239 Rim 2 24 W-138 Wheel Motor Square Washer 8
10127-S Valve Stem 2 25 PW72546 1/4" Key 2
14 67205 Inner Front Wheel Bearing 2 26 67114 Wheel Motor 14Cu.In. (XWK2501) 2
15 67204 Inner Front Wheel Spacer 2 67118-W Wheel Motor 18Cu.In.
16 10205 Outer Front Wheel Bearing 2 (XW2400, XW2500, XWK2503) 2
17 10203 Outer Front Wheel Spacer 2 27 N-127 Wheel Motor Nut 8
 FOOT PEDAL ASSEMBLY
2
20
15
18 19
17
7

16
4 5 6

8
9

14
13 10
3
1
11
12

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 10107-1/2 Kit - Foot Pedal (excl. #7,#9) 1 11 10228-1 Pin 1
2 10225-2 Assembly - Foot Pedal 1 12 F-100 Grease Fitting 1
3 10224-1 Pawl 1 13 Bolt 1
4 990735020 Foot Pedal Lock 1 14 Washer 1
5 W-164 Washer 1 15 68219 #50 Chain 1
6 N-144 Nut 1 16 10233 #50 Half Link 1
7 300008 Deck Height Pointer 1 17 10232 #50 Master Link 1
8 Coupling Nut 1 18 10222 Spring 1
9 300007 Deck Height Indicator 1 19 20217-25 Spring 1
10 10226-1 Lift Sprocket 1 20 30213 Cotter Pin 1
 DECK LIFT SYSTEM
6

2
1 1 3 1
4 5
7

8
11

19
12
8
10 13
10 9

9 14
15

20
8

16
8
15 18
15
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REF # PART # DESCRIPTION QTY.
1 68112 1" Bushing 3
2 68106 1.1875" Bushing 1
3 S-114 1/2"-13 Stud 4
4 N-157 1/2"-13 Whiz Flange Nut 4
5 68105 1/4" Bushing 1
6 68104 #50 Small Sprocket 1 REF # PART # DESCRIPTION QTY.
7 N-143 1/2"-13 Nyloc Nut 2 14 N-108 3/8"-16 Whiz Flange Nut 1
8 68103 Deck Lift Sprocket #50 7 15 W-154 3/4" Flat Washer 4
9 990710004 #50 Rear Deck Lift Chain 2 16 B-239 3/4"-10x10" Bolt 1
10 68217 #50 Front Deck Lift Chain 2 17 B-238 3/4"-10x8.5" Bolt 1
11 990710002 #50 Return Spring Chain 1 18 N-158 3/4"-10 Nyloc Nut 2
12 97455 200 lb. Return Spring 1 19 68113 3/4"x31.5" Rod 1
13 B-241 3/8"-16 Eye Bolt 1 20 10232 #50 Master Link 10
 60” DECK

 
 
 
 
 
 
 
    

 

   
   
 

 

 
  
 
 
 
 
 
 





  

 

  
 

 

 

 



 60” DECK (CONT’D)

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REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

68122-60 Assembly - 60" OCDC 9 97122 Control Rod 1
1 B-179 3/8"-16 x2.5" Bolt 1 10 N-157 1/2"-13 Whiz Flange Nut 2
2 W-113 5/16" Standard Flat Washer 2 11 68121 3/8"-24 Yoke 1
3 20252 Spring 1 12 W-104 3/8" Standard Flat Washer 2
4 97044 Handle 1 13 B-138 1/2"-13x1" Bolt 2
5 68142 1"x1" Plastic Plug 1 14 W-109 1/2" Standard Flat Washer 2
6 N-107 3/8"-16 Nyloc Nut 1 15 68136 Lower Screen 1
7 20224 Clip 2 16 N-150 3/8"-24 Nut 1
8 67258 Handle Grip 1 17 P-102 3/8"x1.25" Clevis Pin 1
 ENGINE - HONDA 24 Hp




 

   










  


 

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 ENGINE - KOHLER 25 Hp





  









  

 






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 HONDA ELECTRICAL DIAGRAM

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 KOHLER ELECTRICAL DIAGRAM

1 1.
2.
White (kill wire)
Red (charge wire)
Kohler Wiring 3 2 3.
4.
Blue (start wire)
Fused wire (to hot post o n starter)
Harness 5. Green (from oil sending unit)

5 4
Connect to Kohler Dixie Chopper Wiring Harness Co nnect to Ignition
Wiring Harn ess Switch

1 W W
1 BLU
OR
R
4 3 BLU
BLK
2 3
2 5 4
BLK GR R
BLK

R R

GR

BLK
HORN OR
R
R
Starter
So leno id
1
BLK
2 3 4 R

Starter B LK
+ -
Battery
SEAT
SWITCH
Conne ct to Seat Relay
R BLK
Ground to
All connectors are viewed Transmission
Fram e BLK
from wire e nd.

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 65522 Kohler Wiring Harness 1 9 20227-72 Battery Cable Positive (72") 1
2 20246-T Ignition Switch 1 10 20226-B Battery Cable Ground (12") 1
3 20245 Hour Meter/Tach 1 11 40229 Mercury Switch 1
4 68247 Tach Bracket 1 12 60124 Clamp for Mercury Switch 1
5 20225 Battery 1 13 65510 Seat Relay 1
6 20228 Battery Strap 1 14 97191 Seat Relay Pigtail 1
7 14078 Battery Box 1 15 65509 Fuse 1
8 20225-B Red Rubber Boot 1 16 20254 Fuse Holder 1
 KAWASAKI ELECTRICAL DIAGRAM

BK Mercury
BK
M BK
Seat BK Switch
B S
R or BR BK
G L
Seat Engine
BL Relay Ignition BK W (Charging Coil)
R Coil
Br W W
W W

R
Fuse So Fuel
Gn

BK
l Solenoid
e R
n Regulator
o Starter
i
d
Abbr. Color
Red Battery Cable W White
Battery Red Battery Cable R Red
BK Black
Description Part Number BL Blue
Keyswitch 20245
Br Brown
Seat 64100-S
25 HP Engine 600000 Gn Green
Regulator 210667003
Battery 20225
Seat Relay Connector
Starter 211637001
Solenoid 20253 White
Seat Relay 65510 Brown
Fuse 65509
Fuse Holder 20254
16" Battery Cable 20226-R
72" Battery Cable 20227-72 86 87A 85
Wiring Harness 364000168205
Ground Cable 20226-B
Fuel Solenoid 21188-7001 30 Black
Mercury Switch 40229
Big Red
Red Rubber Boot 20225-B
 TRANSMISSION FRAME ASSEMBLY


 
 
  
 
  
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 TRANSMISSION FRAME ASSEMBLY (CONT’D)


    
 





 





 



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 TRANSMISSION & DRIVE

23
19 20 21 22
2

18 3
4 5 6
7
17 8
9
16
10
15
11
14

REF # PART # DESCRIPTION QTY. 12

1 65070 Sundstrand 10A Pump - Right 1
2 N-150 Nut - 3/8"-24 8
13
3 W-169 Washer - 5/16" Grade 8 Flat 4
4 365201 T Gear Box 1
5 788101 T Box Gasket 1
6 772150 T Box Cover Plate 1
7 792025 T Box Cover Plate Bolt 4 REF # PART # DESCRIPTION QTY.
8 65206 3/8" Threaded Rod 2 16 67015 Case Bleed Fitting 2
9 K-102 Woodruff Key 3/16"x 3/4" 1 17 65072 Charge Pump Inlet Fitting 2
10 W-131 1/8"x 3/4" Flat Washer 1 18 25-130-30 Dump Valve - no cross port 2
11 9907500X750S Transmission Pulley 1 19 65001 Small Bell Housing 2
12 W-132 3/4" Belleville Washer 1 20 788030B Bearing Plate Gasket 2
13 N-114 Nut - 3/4"-16 1 21 792026 Bell Housing Bolt 8
14 65004 High Pressure Port Fitting 4 22 65024 Pump O-Ring 2
15 65071 Sundstrand 10A Pump - Left 1 23 68031 T Box Vent Fitting 2
 HYDRAULIC HOSE DIAGRAM
1
2 7
7
9

3
17
4
16

5 15
16 14
6 13
7 12
8 11

7
10
9

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 990468018 Hydraulic Tank 1 67118-W Wheel Motor - 18 Cubic Inch
2 40117-T T-Handle Cap w/ Dipstick 1 (XW2400,XW2500,XWK2503) 1
3 60115 Fitting - 3/8" Close Nipple 2 10 60103-L Oil Cooler 1
4 60104 Head - Filter Mounting Zinga 2 11 67014 3/8" barb x 1/4" MPT Fitting 2
5 60125 90 3/8" NPT x 3/8" Barb 2 12 67017 90 degree fitting 2
6 68140 Filter - Hydro Zinga 40 Micron 2 13 87104 Steel Fitting 2
7 65108 5/8" Clear Hose /ft. 14 87104 Steel Fitting 2
8 65073 High Pressure Black Hydro Hose 2 15 67016 1/4" O-ring x 3/8" Barb 90 2
9 67114 Wheel Motor - 14 Cu.In. (XWK2501) 2 16 65074 High Pressure Black Hydro Hose 2
17 67008 3/8" Tee 1
 WHEEL MOTOR

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 BRAKE ASSEMBLY
5 4 3
2

7
8

9
10

11

12
15
13
16 14

18

17

20

1
28 19
27

24 26
25

21

23 22

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 65242 Complete Brake Kit (Inc. #2,#17-#28) 1 16 W-102 Flat Washer 2
2 97094 Brake Handle Assembly (Inc. #2-#18) 1 17 65247 Right Brake Cable 1
3 N/A Bolt 1 18 65246 Left Brake Cable 1
4 N-134 Nut 2 19 65277 Bushing (Welded on Frame) 2
5 W-106 Washer 4 20 65244 Brake Band 2
6 65061 RClip 2 21 P-108 Hairpin Cotter 2
7 65063 Spacer 1 22 P-102 Pin 2
8 65060 Pivot Plate 2 23 P-100 Roll Pin 2
9 N/A Nut 1 24 67266 Brake Drum 2
10 65062 Spacer 2 25 991100025 Brake Cable Retainer 2
11 B-156 Bolt 2 26 65284 Spacer Use #65284 and #30112 to
12 N/A Hairpin Cotter 2 30112 place brake band fully onto brake drum.
13 P-129 Pin 1 27 65243 Brake Pin 2
14 P-112 Pin 2 28 P-118 Roll Pin 2
15 N/A Hairpin Cotter 1
 FUEL SYSTEM

  










   
 




XW2400,XW2500,XWK2503 XWK2501
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 THROTTLE ASSEMBLY













 

 




  
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17 18
12 13 2 4

BODY
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34 36 39 43 8 9
35
38
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 6302 E. County Road 100 North
Coatesville, IN. 46121
Phone 1-765-CHOPPER
www.dixiechopper.com

Dixie Chopper, Magic Circle, and the Magic Circle Atom Logo are all trademarks of Magic Circle Corporation and
may not be reproduced without permission.
Printed In USA
Specifications and instructions subject to change without notice.
Print Date 3/01
 Serial Numbers
2037200
and Higher

Model # ____________________ Engine Model # ____________________

Serial # ____________________ Engine Serial # ____________________

Date Purchased ____________________ Engine Spec. # ____________________

LX, X, XF-50 PARTS MANUAL

700004 April , 2002
Congratulations on your purchase of a DIXIE CHOPPER lawn
mower. We believe you have exercised excellent judgement, and are most
appreciative of your patronage.

Your DIXIE CHOPPER Dealer is your #1 SOURCE for

DIXIE CHOPPER parts and service !

Please call or visit your nearest authorized Dixie Chopper Dealer for
additional service information.

AUTHORIZED DEALER

Let us know how you are getting along with your new CHOPPER!
www.dixiechopper.com

Dixie Chopper reserves the right to make changes or add improvements to its products at any time without
incurring any obligation to make such changes to products previously manufactured. Neither Dixie
Chopper, nor its dealers, accept responsiblility for variations which may be evident in the actual
specifications of its products and the statements and descriptions contained in this publication.
 CONTENTS

Quick Reference Parts 1

Decals 2
Decal Placement 4
Frame 5
Wheels & Tires 8
Foot Pedal 11
Deck Lift System 13
Deck 15
Hubs & Belts 21
50" OCDC 22
Transmission Frame 23
Transmission & Drive 27
Wheel Motor 28
Hydraulic Hose Diagram 29
Fuel/Throttle 32
Body 33
Brake Assembly 39
Engine - Kohler 41
Electrical Diagram - Kohler 44
 LX, X, XF-50 MODEL
QUICK REFERENCE PARTS
MODEL LX2001-42 X1701-50 X2001 XF2300-50
Engine Kohler 20Hp Kohler 17Hp Kohler 20Hp Kohler 23Hp
Deck 42" 50" 50" 50"
Rear Tires 97452 97452 97452 97200
Rear Rims 97450 97450 61238 400014
Front Tires 10157 10157 10157 T/R - #97166
Front Rims 10239 10239 10239 10239

Belts
Engine-Transmission 9907B41 9907B41 9907B41 9907B41
Engine-Deck 68081 9910B84 9910B84 68082
Deck 63203 9907B112 9907B112 9907B112

Filters
Fuel Filter 24-050-02 24-050-02 24-050-02 97392
Donaldson Air Filter 90122
Amsoil Oil Filter 60119
Zinga-Hydro Filter 68140 68140 68140 68140

Blades
Standard 63227H 30227-50H 30227-50H 30227-50H
Heavy-Duty 63227H 30227-50N 30227-50N 30227-50N

Various Parts ALL MODELS

Fiber Washer W-101
Spindle Bearing 30218
Deck Roller (Ctr) 30240-O
Choke Control 20248
Throttle Cable 68249
Brake Cable 89991210001
Parking Brake Band 65244
Fuel Cap 40117-1
Control Lever Grip 20257
 DECALS

R EF # PAR T # D E S C R IP T IO N Q TY . REF # PA RT # D E S C R IP T IO N Q TY .
1 67404 L X2 0 0 1 1 8 800015 C hok e 1
2 97515 X1 7 0 1 1 9 40118 F u e l C a u t io n 2
3 65415 X2 0 0 1 F ro n t P a n e l 1 10 800014 Ig n it io n 1
4 97510 XF 2 3 0 0 1 11 97160 R P M N o t ic e 1
5 65406 P a rk in g B ra k e C a u t io n 1 12 30588 H ills id e D a n g e r 1
6 30591 W a rra n t y N o t ic e 1 13 97013 V T C O n ly 1
7 65413 P a t e n t P e n d in g 1 14 264000200210 V TC 1
 DECALS (CONT’D)

R EF # PA R T # D E S C R IP T IO N Q TY . R EF # PA R T # D E SC R IP TIO N Q TY .
15 63401 Throttle 1 21 30229 D ec k D anger Dec al 2
16 63402 B rak e & S teering 1 22 65407 42" Cut (LX O nly ) 2
17 990765438 B elt Inform ation 1 23 30573 F loor P an D ec al 1
18 97514 Low O il W arning (XF O nly ) 1 24 30571 F ender D ec al 2
19 65408 50" C ut 2 25 30586 Trac tor B us ter D ec al 1
20 30585 F ender C aution 2 26 30590 U S A D ec al 1
27 65422 B elt R oute D ec al 1
 DECAL PLACEMENT
7 T-Box
13 Oil Tank
25 Rear Left
Fender
26 Rear Right 5 12
Fender
16
15 18
Side Left
24 Fender

11 6 1 2 3 4

20 9
24
14
10 8
23

17

21

19
22

19
27
22
 LX FRAME

12

14
15 22 13
14 15 14 14
16 15
21 16
3 16 17
15
18
18
19
20
2 18
18

1 4
5
5
7 6
8 5 6
10
11 4 5

4
5
5
6
6
5
5
4
7
8
9

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 67100 W eldment - LX Frame 1 12 N-103W 5/16"-18 W hiz Flange Nut 4
2 67250 W eldment - LX Transmission 13 72216 Pull Stop W eldment 1
Frame 1 14 W -113 5/16" Standard Flat W asher 4
3 67401 LX Seat Pan 1 15 B-156 5/16"-18x2" Bolt 4
4 B-199 7/16"-20 x 2" Bolt 4 16 N-110 1/2"-13 Nut 9
5 W -168 7/16" Hardened Flat W asher 8 17 40221 Engine Adjustment Bolt 1
6 N-135 7/16"-20 Nyloc Nut 4 18 N-111 1/2"-13 Jam Nut 4
7 B-131 5/16"-18 x1" Bolt 2 19 98218 W eldment - Right LX Belt Guide 1
8 W -160 10mm Flat W asher 2 20 98217 W eldment - Left LX Belt Guide 1
9 N-103W 5/16"-18 W hiz Flange Nut 2 21 72222 All Thread 2
10 67045 LX Round Bumper W eldment 1 22 W -107 Shark-Tooth Belleville W asher 1
11 67255 Plastic Bumper Cap 2
 X1701 FRAME
X2001 FRAME
2
3
9
4
15
10
11
17 12

13
16 14
18
19

5
22 1 8
20 7
7
22 6
21 20 6
7
23 8 7
21

8
7
19A 6 7
6
7
8 7

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 65100 Weldment - X Frame 1 12 40221 Engine Adjustment Bolt 1
2 400026 Weldment - Low Ride Seat Pan 13 W-113 5/16" Standard Flat Washer 4
w/ Hinge 1 14 B-156 5/16"-18x2" Bolt 4
3 100007 Weldment - Low Ride 15 W-107 Shark-Tooth Belleville Washer 1
Transmission Frame 1 16 72220 Belt Guide Assembly 1
4 B-229 3/8"-16 x 5" Bolt 2 17 72217 Belt Guide Weldment 2
5 N-107 3/8"-16 Nyloc Nut 2 18 72222 All Thread 2
6 N-135 7/16"-20 Nyloc Nut 4 19 N-110 Nut 12
7 W-168 7/16" Hardened Flat Washer 8 19A 400008 Mount - Floor Pan Hinge Frame 2
8 B-199 7/16"-20 x 2" Bolt 4 Standard on X2001. Optional on X1701.
9 N-103W 5/16"-18 Whiz Flange Nut 4 20 97169 Plastic Cap 2
10 72216 Pull Stop Weldment 1 21 N-108 3/8"-16 Standard Flat Washer 8
11 N-110 1/2"-13 Nut 1 22 B-247 3/8"-16x2.375" U Bolt 4
23 222001020428 Standard Duty Bumper Weldment 1
 XF2300 FRAME

7 8
6 6 7
7 7
9 8
10
11

12

19 13
14
15
21 16

17
20 18
22
23

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 65100-F W eldment - XF Frame 1 11 67045-X Bumper - Square 1
2 400026 W eldment - Low Ride Seat Pan 12 N-108 3/8"-16 W hiz Flange Nut 2
w/ Hinge 1 13 N-103W 5/16"-18 W hiz Flange Nut 4
3 100007 W eldment - Low Ride 14 72216 Pull Stop W eldment 1
Transmission Frame 1 15 N-110 1/2"-13 Nut 1
4 B-229 3/8"-16 x 5" Bolt 2 16 40221 Engine Adjustment Bolt 1
5 N-107 3/8"-16 Nyloc Nut 2 17 W -113 5/16" Standard Flat W asher 4
6 N-135 7/16"-20 Nyloc Nut 4 18 B-156 5/16"-18x2" Bolt 4
7 W -168 7/16" Hardened Flat W asher 8 19 W -107 Shark-Tooth Belleville W asher 1
8 B-199 7/16"-20 x 2" Bolt 4 20 72220 Belt Guide Assembly 1
9 B-165 3/8"-16x2" Bolt 2 21 72217 Belt Guide W eldment 2
W -113 5/16" Standard Flat W asher 2 22 72222 All Thread 2
10 97169 Plastic Cap 2 23 N-110 1/2"-13 Nut 12
 LX WHEELS & TIRES
2A
1
2
3
4
5
4
6
10
7
8 11 14
9
15
12
13 13
14
15
25
16 24
23
22
21
20

19 Tire Sealant - Part#68211 1 Liter Bottle

Front Tire @ 1 Liter
Rear Tire @ 2 Liter (Optional)
17 18

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 10220 Dust Cap 2 13 67205 Inner Front Wheel Bearing 4
2 N-142 1" Slotted Hex Nut 2 14 10205 Outer Front Wheel Bearing 4
2A P-108 Cotter Pin 2 15 10203 Outer Front Wheel Spacer 4
3 10207 Top Bearing 2 16 97451 L. & R. CTR Tire Assembly 2
4 10206 Outer Bearing Race 4 97452 Titan CTR Tire 2
5 F-100 Grease Fitting 2 97450 Titan Rim 2
6 97171 Bottom Bearing 2 10127-S Valve Stem 2
7 10208 Oil Seal 2 17 PB339303P Wheel Motor Axle Nut 2
8 97170 Front Fork Weldment 2 18 N-113 Lug Nut 8
9 B-122 Bolt - 5/8"-11x7" Hex Head 2 19 97159 Brake Drum 1
10 N-115 Nut - 5/8"-11 Nyloc 2 20 67002 Wheel Flange w/studs 2
11 N/A Front Tire Assembly 2 21 B-183 Wheel Motor Bolt 8
10157 Front Tire 2 22 W-138 Wheel Motor Square Washer 8
10239 Rim 2 23 PW72546 1/4" Key 2
10127-S Valve Stem 2 24 67114 Wheel Motor 14Cu.In. 2
12 67204 Inner Front Wheel Spacer 2 25 N-127 Wheel Motor Nut 8
 X1701 WHEELS & TIRES
X2001 WHEELS & TIRES
2A
1
2
3
4
5
4
6
10
7
8 11 14
9
15
12
13 13
14
15
24
16 23
22
21
20
Tire Sealant - Part#68211 1 Liter Bottle
19 Front Tire @ 1 Liter
Rear Tire @ 2 Liter (Optional)
17 18
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 10220 Dust Cap 2 16 X1701
2 N-142 1" Slotted Hex Nut 2 97451 L/R Titan CTR Tire Assembly 2
2A P-108 Cotter Pin 2 97452 Titan CTR Tire 2
3 10207 Top Bearing 2 97450 Titan Rim 2
4 10206 Outer Bearing Race 4 10127-S Valve Stem 2
5 F-100 Grease Fitting 2 X2001
6 97171 Bottom Bearing 2 97457 L/R Titan CTR Tire Assembly 2
7 10208 Oil Seal 2 97452 Titan CTR Tire 2
8 97170 Front Fork W eldment 2 61238 Rim 2
9 B-122 Bolt - 5/8"-11x7" Hex Head 2 10127-S Valve Stem 2
10 N-115 Nut - 5/8"-11 Nyloc 2 17 PB339303P W heel Motor Axle Nut 2
11 N/A Front Tire Assembly 2 18 N-113 Lug Nut 8
10157 Front Tire 2 19 67266 Brake Drum 1
10239 Rim 2 20 67002 W heel Flange w/studs 2
10127-S Valve Stem 2 21 B-183 W heel Motor Bolt 8
12 67204 Inner Front W heel Spacer 2 22 W -138 W heel Motor Square W asher 8
13 67205 Inner Front W heel Bearing 4 23 PW 72546 1/4" Key 2
14 10205 Outer Front W heel Bearing 4 24 67114 W heel Motor 14Cu.In. 2
15 10203 Outer Front W heel Spacer 4 25 N-127 W heel Motor Nut 8
 XF2300 WHEELS & TIRES
2A
1
2
3
4
5
4
6
7
8
9 10 11
13

24
12
15
12 14
13 26
11
25
16 23
22
18 21
20
17 19
Tire Sealant - Part#68211 1 Liter Bottle
Front Tire @ 1 Liter
Rear Tire @ 2 Liter (Optional)
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 10220 Dust Cap 2 15 67204 Inner Front Wheel Spacer 2
2 N-142 1" Slotted Hex Nut 2 16 400019 Left Turf Boss III Assembly 1
2A P-108 Cotter Pin 2 400020 Right Turf Boss III Assembly 1
3 10207 Top Bearing 2 97200 Turf Boss III Tire 2
4 10206 Outer Bearing Race 4 400014 Non-Reinforced Rim 2
5 F-100 Grease Fitting 2 10127-S Valve Stem 2
6 97171 Bottom Bearing 2 68211 Tire Sealant (1 liter) 4
7 10208 Oil Seal 2 17 PB339303P Wheel Motor Axle Nut 2
8 97170 Front Fork Weldment 2 18 N-113 Lug Nut 8
9 B-122 Bolt - 5/8"-11x7" Hex Head 2 19 W-142 Spacer - Wheel Motor (left side) 1
10 N-115 Nut - 5/8"-11 Nyloc 2 20 67266 Brake Drum 2
11 67205 Inner Front Wheel Bearing 4 21 67002 Wheel Flange w/studs 2
12 10205 Outer Front Wheel Bearing 4 22 B-183 Wheel Motor Bolt 8
13 10203 Outer Front Wheel Spacer 4 23 W-138 Wheel Motor Square Washer 8
14 97166 Front Tire Assembly 2 24 PW72546 1/4" Key 2
68211 Tire Sealant (1 liter) 2 25 67114 Wheel Motor 14Cu.In. 2
10239 Rim 2 26 N-127 Wheel Motor Nut 8
 LX2001 FOOT PEDAL ASSEMBLY
X1701 FOOT PEDAL ASSEMBLY
X2001 FOOT PEDAL ASSEMBLY
18
13
16 17 1

15

14
4 5 6

12 3
11 2

8
9
10

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 10107-1/2 Kit - Foot Pedal 1 10 F-100 Grease Fitting 1
2 10225-2 Weldment - #50 Foot Lift Arm 1 11 B-131 Bolt 1
3 10224-1 Pawl 1 12 W-113 Washer 1
4 990735020 Foot Pedal Lock 1 13 68219 #50 Chain 1
5 W-164 Washer 1 14 10233 #50 Half Link 1
6 N-144 Nut 1 15 10232 #50 Master Link 1
7 N-130 Coupling Nut 1 16 10222 Spring 1
8 10226-1 Lift Sprocket 1 17 20217-25 Spring 1
9 10228-1 Pin 1 18 30213 Cotter Pin 1
 XF2300 FOOT PEDAL ASSEMBLY
19
15 1
18

17
7

16
4 5 6

8
9

14 3
13 2

10
11
12

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 10107-1/2 Kit - Foot Pedal 1 11 10228-1 Pin 1
2 10225-2 Weldment - #50 Foot Lift Arm 1 12 F-100 Grease Fitting 1
3 10224-1 Pawl 1 13 B-131 Bolt 1
4 990735020 Foot Pedal Lock 1 14 W-113 Washer 1
5 W-164 Washer 1 15 68219 #50 Chain 1
6 N-144 Nut 1 16 10233 #50 Half Link 1
7 300008 Deck Height Pointer 1 17 10232 #50 Master Link 1
8 N-130 Coupling Nut 1 18 20217-25 Spring 1
9 300007 Deck Height Indicator 1 19 30213 Cotter Pin 1
10 10226-1 Lift Sprocket 1
 LX2001 DECK LIFT SYSTEM
X1701 DECK LIFT SYSTEM
X2001 DECK LIFT SYSTEM

2
5
6
3 4 7 7
8
2 9
9
1
6
7 7
8
9
9

REF # PART # DESCRIPTION QTY.

1 68107 3/4"x20" Lift Shaft 1
2 68103 #50x18T Sprocket 2
3 68104 #50x10T Sprocket 1
4 68105 Spacer 3/4"idx1"odx.1/4" 1
5 68106 Spacer 3/4"idx1"odx1.125" 1
6 68217 #50 Deck Hang Chain 2
7 10232 #50 Master Link 4
8 S-114 1/2"-13 Stud 2
9 N-157 1/2"-13 Whiz Flange Nut 4
 XF2300 DECK LIFT SYSTEM
6

1 2
3 1
5 4
4
3
View from front of mower
7
10

18
11
9 12
7 9 8

8 13
14

19
7

15
7
14 17
14
16
REF # PART # DESCRIPTION QTY.
1 68112 1" Bushing 2
2 68106 1.1875" Bushing 1
3 S-114 1/2"-13 Stud 4
4 N-157 1/2"-13 Whiz Flange Nut 8
5 68105 1/4" Bushing 1
6 68104 #50 Small Sprocket 1
7 68103 Deck Lift Sprocket #50 7 REF # PART # DESCRIPTION QTY.
8 990710003 #50 Rear Deck Lift Chain 2 14 W-154 3/4" Flat Washer 4
9 68217 #50 Front Deck Lift Chain 2 15 B-237 3/4"-10x7.5" Bolt 1
10 990710002 #50 Return Spring Chain 1 16 B-237 3/4"-10x7.5" Bolt 1
11 97455 200 lb. Return Spring 1 17 N-158 3/4"-10 Nyloc Nut 2
12 B-241 3/8"-16 Eye Bolt 1 18 68114 3/4"x28" Rod 1
13 N-108 3/8"-16 Whiz Flange Nut 1 19 10232 #50 Master Link 10
 LX2001 42” DECK

31 32 33
3
33 34
22
34
30 35 36
37
28 22
27 38
26 29 4
39 3
22 25
24 34A
3 18 36 40 41
3
23 17
16 4 3
21 42
3 20 15
14 4
19
4 13
13 14
3
11 4
12
43
6b 10
1

9
3 2
3
8 4

3
7 6b 6a 2
5
 LX2001 42” DECK (CONT’D)

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

31200-36-42 42" Deck Assembly 1 24 30212 Enguaging Handle 1
1 30100-36 42" Deck Weldment 1 25 N-173 #10 Nyloc Nut 1
2 N-134 5/16" -18 Large Flange Nut 2 30209-1 Enguaging Rod Assembly
3 20224 Hairpin Clip 10 (inc. #22,26,28,29,30) 1
4 P-102 3/8"x1.25" Clevis Pin 6 26 97343 Enguaging Rod 1
5 30232 Left Scissor Arm 1 27 20217-25 Return Spring 1
6a B-110 3/8"-16x3/4" Carriage Bolt 2 28 30207-S Enguaging Spring 1
6b N-108 3/8"-16 Whiz Flange Nut 17 29 30209-B Connecting Arm Bracket 1
7 50315-42 42" Deck Blow-Out Baffle 1 30 N-107 3/8"-16 Nyloc Nut 1
8 67131 Scissor Link Tower Weldment 1 300012 Triangle Plate Assembly
9 Enguaging Tower Weldment 1 (inc. #31,32,33,34,34A,F-102 1
10 B-136 3/8"-16x1.25" Carriage Bolt 12 31 30206 5/8"x1/2" Bushing 1
11 30231 Right Scissor Arm 1 32 300011 Weldment - Triangle Plate 1
12 F-100 3/16" Drive in Grease Fitting 1 33 B-185 5/8"-11 X 2" Bolt 2
13 P-103 3/8"x2.25" Clevis Pin 2 34 N-180 5/8"-11 Jam Lock Nut 2
14 C-104 Ring Clip 2 34A N-181 5/8-11 Lock Nut 2
15 30235 Pivot Stand 1 35 30234 V Pulley 1
16
17
18
65278
30112
N-102
1/2" Shim (if needed)
1/8" Shim (if needed)
1/4"-20 Whiz Flange Nut
**
4
36
37
38
30224
B-117
B-118G
Flat Idler Pulley
1/2"-13x1.25" Bolt
1/2"x1.5" Shoulder Bolt (inc. F-101)
2
1
1
19 30210 Cam Weldment 1 39 30223 Idler Arm (inc. F-102) 1
20 P-113 Roll Pin 1 40 10222 Spring 1
21 30211 Enguaging Shaft 1 41 65308 Idler Spring Tab 1
22 W-104 3/8" Flat Washer 3 42 30214-86 Stabilizer Bar 2
23 B-245 #10-24 Carriage Bolt 1 43 B-172 1/4"-20x1" Bolt 4

*
Use individually or a combination of 65278 and 30112 to achieve proper belt alignment
between the triangle plate and the top center deck spindle pulley.
 X1701 50” STANDARD DUTY DECK
X2001 50” STANDARD DUTY DECK

33 7 40 41 42 41 43
39
38
37 43
36
44
45
43A
49
35 43A 7
30 46 44 6
34 29
28 47 7
7 6
26 27 48
33 49
25
32
31 23 7
22 6 7
19
20
21
21 20 6
6 19
18 7
7 8
17
1
16 5
7 2
3
7 4
15 6
24

9
10 11
14 11 12
13 2
14 11
 X1701 50” STANDARD DUTY DECK (CONT’D)
X2001 50” STANDARD DUTY DECK (CONT’D)

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1
30200-H50
30201
50" Heavy Duty Deck Assembly
50" Top Plate Weldment
1
1
25 65278
26 30211
1/2" Shim (if needed)
Enguaging Shaft *1
2
3
4
N-103-W
65308-L
10222
5/16"-18 Whiz Flange Nut
Idler Spring Tab
Spring
6
1
1
27
28
29
30112
P-113
N-107
1/8" Shim (if needed)
Roll Pin
3/8"-16 Nyloc Nut
*1
1
5 30232 Left Scissor Arm 1 30 W-104 3/8" Flat Washer 1
6 P-102 3/8"x1.25" Clevis Pin 6 31 30210 Cam Weldment 1
7 20224 Hairpin Clip 10 30209-1 Enguaging Rod Assembly
8 334000130111 Left 3-Hole Tab 1 (inc.#40,41,42,43,43A,F-102) 1
9 B-104 5/16"-18x3/4" Carriage Bolt 5 32 97343 Enguaging Rod 1
10 B-136 3/8"-16x1.25" Carriage Bolt 12 33 W-104 3/8" Flat Washer 1
11 N-108 3/8"-16 Whiz Flange Nut 15 34 30207-S Enguaging Spring 1
12 30100-H50 Deck Shell w/Blow out Baffle 1 35 20217-25 Return Spring 1
13 B-259 5/16"-18x1" Carriage Bolt 1 36 N-173 #10 Nyloc Nut 1
14 B-110 3/8"-16x3/4" Carriage Bolt 2 37 30212 Enguaging Handle 1
15 F-100 3/16" Drive in Grease Fitting 1 38 B-245 #10-24 Carriage Bolt 1
16 67131 Scissor Link Tower Weldment 1 39 30209-B Connecting Arm Bracket 1
Enguaging Tower Weldment 1 40 30206 5/8"x1/2" Bushing 1
17 30231 Right Scissor Arm 1 41 B-185 5/8"-11x 2 " Bolt 2
18 334000130110 Right 3-Hole Tab 1 300012 Triangle Plate Assembly
19 C-104 Ring Clip 2 (inc.#40,41,42,43,43A,F-102) 1
20 334000130109 2-Hole Tab 2 42 300011 Weldment - Triangle Plate 1
21 P-103 3/8"x2.25" Clevis Pin 2 43 N-180 5/8"-11 Jam Lock Nut 2
22 30235 Pivot Stand 1 43A N-181 5/8"-11 Lock Nut 2
23 N-102 1/4"-20 Whiz Flange Nut 4 44 30224 Flat Idler Pulley 2
24 B-172 1/4"-20x1" Bolt 4 45 30234 V Pulley 1
46 B-117 1/2"-13x1.25" Bolt 1
47 B-118G 1/2"x1.5" Shoulder Bolt (inc. F-101) 1
48 30223 Idler Arm (inc. F-102) 1

*
Use individually or a combination of 65278 and 30112 to achieve proper belt alignment
between the triangle plate and the top center deck spindle pulley.
 XF2300 50” HEAVY DUTY DECK
7 40
31 41
39 42
38 42
37 43
36 43
44 45
46
45 7
47 6
35 31 32 43A 48
49
34 30 6
29 6
7 28 7 7
27
31 26 49
24
33 6
23 7
20 21 22
6 22
7 7 21
20
19 7 8 5
1
18 2
3
17
16 4

25
6
7

9
10 11
15 12
14 13 2
11 11
11
14
 XF2300 50” HEAVY DUTY DECK (CONT’D)

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1
30200-H50
30201
50" Heavy Duty Deck Assembly
50" Top Plate Weldment
1
1
27 65278
28 30211
1/2" Shim (if needed)
Enguaging Shaft *1
2
3
4
N-103-W
10222
65308-L
5/16"-18 Whiz Flange Nut
Spring
Idler Spring Tab
6
1
1
29
30
31
30112
P-113
W-104
1/8" Shim (if needed)
Roll Pin
3/8" Flat Washer
*1
1
5 334000130111 Left 3-Hole Tab 1 32 N-107 3/8"-16 Nyloc Nut 1
334000130110 Right 3-Hole Tab 1 30209-1 Enguaging Rod Assembly
6 P-102 3/8"x1.25" Clevis Pin 6 (inc. #31,32,33,34,39) 1
7 20224 Hairpin Clip 10 33 97343 Enguaging Rod 1
8 30232 Left Scissor Arm 1 34 30207-S Enguaging Spring 1
9 B-104 5/16"-18x3/4" Carriage Bolt 5 35 20217-25 Return Spring 1
10 B-136 3/8"-16x1.25" Carriage Bolt 12 36 N-173 #10 Nyloc Nut 1
11 N-108 3/8"-16 Whiz Flange Nut 19 37 30212 Enguaging Handle 1
12 30100-H50 50" Heavy DutyDeck Weldment 1 38 B-245 #10-24 Carriage Bolt 1
13 B-259 5/16"-18x1" Carriage Bolt 1 39 30209-B Connecting Arm Bracket 1
14 B-110 3/8"-16x3/4" Carriage Bolt 6 40 30206 5/8"x1/2" Bushing 1
15 50315-50 50" Deck Blow-out Baffle 1 41 300011 Weldment - Triangle Plate 1
16 F-100 3/16" Drive in Grease Fitting 1 42 B-185 5/8"-11x2" Bolt 2
17 67131 Scissor Link Tower Weldment 1 300012 Triangle Plate Assembly
18 Enguaging Tower Weldment 1 (inc.#40,41,42,43,43A,F-102) 1
19 30231 Right Scissor Arm 1 43 N-180 5/8"-11 Jam Lock Nut 2
20 C-104 Ring Clip 2 43A N-181 5/8"-11 Lock Nut 2
21 334000130109 2-Hole Tab 2 44 30224 Flat Idler Pulley 2
22 P-103 3/8"x2.25" Clevis Pin 2 45 30234 V Pulley 1
23 30235 Pivot Stand 1 46 B-117 1/2"-13x1.25" Bolt 1
24 N-102 1/4"-20 Whiz Flange Nut 4 47 B-118G 1/2"x1.5" Shoulder Bolt (inc. F-101) 1
25 B-172 1/4"-20x1" Bolt 4 48 30223 Idler Arm (inc. F-102) 1
26 30210 Cam Weldment 1 49 30214-86 Stabilizer Bar 2

*
Use individually or a combination of 65278 and 30112 to achieve proper belt alignment
between the triangle plate and the top center deck spindle pulley.
 HUBS AND BELTS 1

20
16

2
1
2
2
4
19 18 3

4
5

6
5
7
6
8
7 9
8 6

9 2
17
6
11
2
12
Complete Spindle Assembly 10
13
11
Outside--10161 12 14
Center---10161-L 13
15

14
Optional-- Whiz-Mow #30302
15

REF # MODEL PART # DESCRIPTION QTY. REF # MODEL PART # DESCRIPTION QTY.
1 ALL N-167 1" Nut 3 14 ALL W-100 5/8" Belleville Washer 3
2 ALL W-146 1/4" Washer 11 15 ALL B-121 2.5" Blade Bolt (use w/o blade spacer) 3
3 ALL W-137 1" Belleville Washer 6 B-121-L 3" Blade Bolt (use with blade spacer) 3
4 LX2001 63221 4.25" Pulley 3 B-121-LL 3.25" Blade Bolt (use with Whiz-Mow) 3
X1701 9907475X100S 4.75" Pulley 3 16 LX2001 9907475X100S 4.75" Pulley 1
X2001 9907475X100S 4.75" Pulley 3 X1701 9907600X100S 6.00" Pulley 1
XF2300 9907475X100S 4.75" Pulley 3 X2001 9907600X100S 6.00" Pulley 1
5 ALL W-131 1/8" Washer 3 XF2300 9907525X100S 5.25" Pulley 1
6 ALL 30218 Sealed Bearing 6 17 ALL 30217-L Long Blade Shaft 1
7 ALL 30241 Deck Hub 3 18 LX2001 68081 Engine - Deck Belt 1
8 ALL F-102 Grease Fitting 3 X1701 9910B84 Engine - Deck Belt 1
9 ALL 30219 Inner Deck Hub Spacer 3 X2001 9910B84 Engine - Deck Belt 1
10 ALL 30217 Short Blade Shaft 2 XF2300 68082 Engine - Deck Belt 1
11 ALL 30242 1/2" Blade Spacer 3 19 LX2001 63203 Deck Belt 1
12 ALL W-101 Fiber Washer 3 X1701 9907B112 Deck Belt 1
13 LX2001 63227-H 42" Standard High Lift Blade 3 X2001 9907B112 Deck Belt 1
63227-N 42" Heavy Duty High Lift Blade 3 XF2300 9907B112 Deck Belt 1
X1701 30227-50H 50" Standard High Lift Blade 3 20 LX2001 9907B41 Engine-Trans. Belt (not shown) 1
30227-50N 50" Heavy Duty High Lift Blade 3 X1701 9907B41 Engine-Trans. Belt (not shown) 1
X2001 30227-50H 50" Standard High Lift Blade 3 X2001 9907B41 Engine-Trans. Belt (not shown) 1
30227-50N 50" Heavy Duty High Lift Blade 3 XF2300 9907B41 Engine-Trans. Belt (not shown) 1
XF2300 30227-50H 50" Standard High Lift Blade 3
30227-50N 50" Heavy Duty High Lift Blade 3
 XF2300 50” OCDC

18
4
17

16
1
15 2

4 3

14 7
8
9

10

11

14 13
12

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

68122-50 Assembly - 50" OCDC 10 W-104 3/8" Standard Flat Washer 1
1 67258 Handle Grip 1 11 68135 Lower Screen 1
2 900014 Handle 1 12 B-138 1/2"-13x1" Bolt 2
3 N-107 3/8"-16 Nyloc Nut 1 13 W-109 1/2" Standard Flat Washer 2
4 W-104 3/8" Standard Flat Washer 4 14 N-157 1/2"-13 Whiz Flange Nut 2
5 20252 Spring 1 15 B-179 3/8"-16 x2.5" Bolt 1
6 N-150 3/8"-24 Nut 1 16 68142 1"x1" Plastic Plug 1
7 68121 3/8"-24 Yoke 1 17 97122 Control Rod (Inc. #6,7,17) 1
8 P-102 3/8"x1.25" Clevis Pin 1 18 20224 Clip 1
9 20224 Clip 1
 LX2001 TRANSMISSION FRAME ASSEMBLY

28 32
29 30
34
27 31 35 36 1
33 7A
2
3 4 5

24 6 7
23 22 8
26
25 21 20 9
11
10
12
19 18
14 11
13
17
15 16

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 67250 LX Transmission Frame Weldment 1 19 N-103-W Nut 1
2 B-150 Eye Bolt 1 20 W-113 Washer 1
3 N-103W Nut 2 21 N-117 3/8"-16 Large Flange Lock Nut 1
4 W-171 Teflon Washer 2 22 W-124 3/8" Machine Washer .120" 1
5 65205 Steering Block Weldment 2 23 W-123 3/8" Machine Washer .060" 1
6 20257 Rubber Handle 2 24 W-176 3/8" Machine Washer .031" 1
7 67259 Foam Handle Grip 2 25 30234 Pulley 1
7A 400037 Foam Lever Sleeve 2 26 61250 Spacer 1
8 62231 Left Steering Lever 1 27 B-165 3/8"-16x2" Bolt 1
9 62232 Right Steering Lever 1 28 B-124 Bolt 1
10 W-170 Teflon Washer 2 29 W-104 3/8" Standard Flat Washer 1
11 W-110 Machine Washer 8 30 65209 Idler Arm 1
12 20252 Spring 2 31 N-103W Nut 4
13 N-110 Hex Nut 2 32 200008 Hydraulic Tank 1
14 N-111 Jam Nut 2 33 W-125 Washer 1
15 F-101 Grease Fitting 90 degree 2 34 W-126 Washer 3
16 B-131 Bolt 4 35 N-107 Nut 1
17 B-143G Bolt 2 36 10222 Spring 1
 LX2001 TRANSMISSION FRAME ASSEMBLY (CONT’D)

17
15 16 18
14 19
20
13
11 23
12
9
12 8 10
4
5
7 17 18
8
14
19
20
16 15
9
10 6
23
5

21
22
3 2

1
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 B-105 Bolt 2 13 65207-L Left Pump Control Arm 1
2 W-113 Washer 4 14 20221 Plastic Bushing 2
3 N-103 Nut 4 15 P-101 Pin 2
4 20224 Hairpin Clip 2 16 20224 Hairpin Clip 2
5 20222 Plastic Bushing 2 17 B-138 Bolt 2
6 200002 Right Pump Rod (#6,9,10) 1 18 N-175 Coupling Nut 2
7 65207-R Right Pump Control Arm 1 19 20252 Spring 2
8 P-118 Roll Pin 2 20 W-110 Washer 10
9 20214 Yoke 2 21 68142 Plastic Plug 1"x1" 4
10 N-105 Nut 2 22 67256 Plastic Plug 1"x2" 2
11 200001 Left Pump Rod (#9,10,11) 1 23 20223 Backing Clip 2
12 B-131 Bolt 2
 X1701 TRANSMISSION FRAME ASSEMBLY
X2001 TRANSMISSION FRAME ASSEMBLY
XF2300 TRANSMISSION FRAME ASSEMBLY
29
28
30 1
31 3
33 32
35 2
27 5 7A 6 7
34 4
36

26
25 8
2 4 23

22 20 9
10
21 19
18
17 13 12
15 16 11 11
14

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 100007 Low Ride Transmission Frame 1 19 N-103-W Nut (2 only X1701 & X2001 ) 4
2 B-150 Eye Bolt 1 20 W-113 Washer (2 only X1701 & X2001 4
3 N-103W Nut 2 21 N-117 3/8"-16 Large Flange Lock Nut 1
4 W-171 Plastic Washer 2 22 30234 Pulley 1
5 65205 Steering Block Weldment 2 23 W-124 3/8" Machine Washer .120" 1
6 20257 Rubber Handle 2 24 W-123 3/8" Machine Washer .060" 1
7 400037 Foam Lever Sleeve 2 25 W-176 3/8" Machine Washer .031" 1
7A 67259 Foam Handle Grip 2 26 61250 Spacer 1
8 20231-L Left Steering Lever 1 27 B-165 3/8"-16x2" Bolt 1
9 20232-L Right Steering Lever 1 28 B-124 Bolt 1
10 W-170 Teflon Washer 2 29 W-104 3/8 Standard Flat Washer 1
11 W-110 Machine Washer 8 30 100011 Idler Arm 1
12 20252 Spring 2 31 N-103W Nut 4
13 N-110 Hex Nut 2 32 200008 Hydraulic Tank 1
14 N-111 Jam Nut 2 33 W-125 Washer 1
15 F-101 Grease Fitting 90 degree 2 34 W-126 Washer 3
16 B-131 Bolt 4 35 N-107 Nut 1
17 B-143G Bolt 2 36 10222 Spring 1
 X1701 TRANSMISSION FRAME ASSEMBLY (CONT’D)
X2001 TRANSMISSION FRAME ASSEMBLY (CONT’D)
XF2300 TRANSMISSION FRAME ASSEMBLY (CONT’D)

17
14 15 16 18 20
12
13 19

7 23
9
10
8 11

6
23
5
4
22 21
3
2
1
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 B-105 Bolt 2 13 65207-L Left Pump Control Arm 1
2 W -113 W asher 2 14 20221 Plastic Bushing 2
3 N-103 Nut 2 15 P-101 Pin 2
4 20224 Hairpin Clip 2 16 20224 Hairpin Clip 2
5 20222 Plastic Bushing 2 17 B-138 Bolt 2
6 200001 Right Pump Control Rod (#6,9,10 1 18 N-175 Coupling Nut 2
7 65207-R Right Pump Control Arm 1 19 20252 Spring 2
8 P-118 Roll Pin 2 20 W -110 W asher 10
9 20214 Yoke 2 21 68142 Plastic Plug 1"x 1" 2
10 N-105 Nut 2 22 67256 Plastic Plug 1"x 2" 2
11 200002 Left Pump Control Rod (#9,10,11 1 23 20223 Backing Clip 2
12 B-131 Bolt 2
 TRANSMISSION & DRIVE

23
19 20 21 22
2

18 3
4 5 6
7
17 2A 8
9
16
10
15
11
14

REF # PART # DESCRIPTION QTY.

1 65070 Sundstrand 10A Pump - Right 1 12
2 N-168 3/8"-24 Whiz Flange Nut 4
2A N-184 Nut - 3/8"-24 Harden 4
3 W-169 Washer - 5/16" Grade 8 Flat 4
4 000365201 T Gear Box 1
5 788101 T Box Gasket 1
6 772150 T Box Cover Plate 1 REF # PART # DESCRIPTION QTY.
7 792025 T Box Cover Plate Bolt 4 16 67015 Case Bleed Fitting 2
8 65206 3/8" Threaded Rod 2 17 65072 Charge Pump Inlet Fitting 2
9 K-102 Woodruff Key 3/16"x 3/4" 1 18 25-130-30 Dump Valve - no cross port 2
10 W-167 Flat Washer Hardened 1 19 65001 Small Bell Housing 2
11 9907500X750S Transmission Pulley 1 20 788030B Bearing Plate Gasket 2
12 W-132 3/4" Belleville Washer 1 21 792026 Bell Housing Bolt 8
13 N-114 Nut - 3/4"-16 1 22 65024 Pump O-Ring 2
14 65004 High Pressure Port Fitting 4 23 68031 T Box Fitting 2
 WHEEL MOTOR

WHEEL MOTOR IDENTIFICATION #18

14 Cu. In. W80379

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 PB018069 Dust/Shaft Seal 1 12 PB332014 Rotor Assembly (14 cu.in.) 1
2 IN KIT Body Seal 4 13 PB015008 Manifold 1
3 IN KIT Commutator Seal 1 14 PB012013 Commutator Assembly 1
4 IN KIT O-ring Seal 1 15 PB018056 Endcover Piston 1
5 IN KIT Teflon Back-up Seal 1 16 PB018059 Piston Spring 1
PB333700 Seal Kit (Contains item 1-5) 17 PB160007G Endcover 1
6 PB018073 Snap Ring 1 18 N/A ID Tag 1
7 PB018054 Thrust Washer 3 19 PB334014 Assembly Bolts (14 cu.in.) 4
8 PB018052 Thrust Bearing 1 20 PW72545 Shaft 1
9 PB018053 Housing Bearing 2 21 PW72546 Shaft Key 1
10 PB130015 Housing 1 22 PB339303P Shaft Nut 1
11 PB014027 Drive Link (14 cu.in.) 1 67114 Wheel Motor 14 Cu. In. 2
 LX2001 HYDRAULIC HOSE DIAGRAM
1 2 16 6
14 16 3 18
16
6
5
16
6
4 6
15 17 13 8
6
3 16
16
16
16 7
18 9
5 16
6 4 6 17 16 11
16 6 12
16 7 10 6
8 6

12
11
10
9
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 200008 Hydraulic Tank (3-1-02) 1 10 67017 90 degree fitting 2
2 40117-T T-Handle Cap w/ Dipstick 1 67019 90 degree Brass Fitting 2
3 60125 90 3/8" NPT x 3/8" Barb 2 11 87103 Steel Fitting 2
4 65072 Charge Pump Inlet Fitting 2 12 87104 Steel Fitting 2
5 68140 Filter - Hydro Zinga 40 Micron 2 13 67008 3/8" Tee 1
6 65108 5/8" Clear Hose /ft. 14 67014 3/8" barb x 1/4" MPT Fitting 1
7 65076 High Pressure Black Hydro Hose 4 15 65009 Plug 1
8 67016 1/4" O-ring x 3/8" Barb Straight 2 16 67013 Hose Clamp 20
9 67114 Wheel Motor - 14 Cu.In. 2 17 65004 High Pressure Port Fitting 4
18 67015 90 degree fitting 2
 X1701 HYDRAULIC HOSE DIAGRAM
X2001 HYDRAULIC HOSE DIAGRAM
1 2 16 6
14 16 3
16 18
6
5
16
6
4
15 17 13 6
8
6
3 16
16
16
16 7
18 9
5 16
6 4 6 17 16 11
16 6 12
16 7 10 6
8 6

12
11
10 16
9
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 200008 Hydraulic Tank (3-1-02) 1 10 67017 90 degree fitting 2
2 40117-T T-Handle Cap w/ Dipstick 1 67014 Brass Fitting 2
3 60125 90 3/8" NPT x 3/8" Barb 2 11 87104 Steel Fitting 2
4 65072 Charge Pump Inlet Fitting 2 12 87104 Steel Fitting 2
5 68140 Filter - Hydro Zinga 40 Micron 2 13 67008 3/8" Tee 1
6 65108 5/8" Clear Hose /ft. 14 67014 3/8" barb x 1/4" MPT Fitting 1
7 65073 High Pressure Black Hydro Hose 4 15 65009 Plug 1
8 67016 1/4" O-ring x 3/8" Barb Straight 2 16 67013 Hose Clamp 20
9 67114 Wheel Motor - 14 Cu.In. 2 17 65004 High Pressure Port Fitting 4
18 67015 90 degree fitting 2
 XF2300 HYDRAULIC HOSE DIAGRAM
1 2 16 6
14 16 3
16 20
6
5
16
6
4
15 17 13 6
8

3 16
16
16
16 7
20 9
5 16 6
6 4 6 17 16 11
16 19 12
16 6 7 10 6
6
8

12
11
10 19 18
9
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 200008 Hydraulic Tank (3-1-02) 1 11 87104 Steel Fitting 2
2 40117-T T-Handle Cap w/ Dipstick 1 12 87104 Steel Fitting 2
3 60125 90 3/8" NPT x 3/8" Barb 2 13 67008 3/8" Tee 1
4 65072 Charge Pump Inlet Fitting 2 14 67014 3/8" barb x 1/4" MPT Fitting 1
5 68140 Filter - Hydro Zinga 40 Micron 2 15 65009 Plug 1
6 65108 5/8" Clear Hose /ft. 16 67013 Hose Clamp 20
7 65073 High Pressure Black Hydro Hose 4 17 65004 High Pressure Port Fitting 4
8 67016 1/4" O-ring x 3/8" Barb Straight 2 18 60103-L Oil Cooler 1
9 67114 Wheel Motor - 14 Cu.In. 2 19 68231 #4 Worm Clamp 2
10 67017 90 degree fitting 2 20 67015 90 degree fitting 2
67014 Brass Fitting 2
 FUEL SYSTEM
1 2 9
2

To Kohler Filter
8
3

4 7
6 4 3
5 7
5

7
5

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 40204-1 3 Gal. Fuel Tank (LX,X Both)(XF Left) 2 6 97369 Gas Line "Y" - 5/16" 1
2 40117-1 Fuel Cap - Manual Vent w/Guage 2 7 72012 Spring Clamp (Black) 5
3 40220 Fuel Tank Bushing 2 8 60124 Hose Clamp 1
4 400016 Valve - Fuel Tank Shut-Off 2 9 400015 7 Gal. Fuel Tank (XF Right) 1
5 97374 Gas Line - 5/16" /ft.

THROTTLE ASSEMBLY
1

2
16

17 15 3
18
14 4

REF # PART # DESCRIPTIO N QTY. 7

5
1 67258 Handle Grip (Black ) 1 13
6
2 97012 Handle W eldm ent 1 12
7
8
3 N-134 5/16" Flange Lock Nut 1
4 20224 Hairpin Cotter 1 9
5 N-107 3/8" -16 Ny loc Nut 1
11 6 10
6 W -104 3/8" Standard Flat W as her 2
7 W -125 3/8" Ny lon W as her 3 REF # PART # DESCRIPTIO N Q TY.
8 C-105 C Clip 2 12 B-107 5/16"-18 x 3/4" Bolt 1
9 68249 Throttle Cable 1 13 W -113 5/16" Flat W as her 1
W as her 2 14 65270 Upper Stainles s Throttle Brac k e 1
Hex Nut 2 15 W -152 #10 Stainless W as her 2
Cable and Liner 1 16 B-203 10-32x 3/4" Stainles s B olt 2
10 97011 Lower Throttle M ounting B rac k et 1 17 B-209 1/4"-20x3/4" Bolt 1
11 B-108 3/8"-16 x 1" Bolt 1 18 W -153 1/4" Stainles s Flat W as her 1
 20
19

18

6 7 8

11 12 16 17

36 37 14 15
13
4 15
6 7 8 14 6 7 8
2
9 10
LX2001 BODY

5
21
22
23
36 37
24
26 25 9 10 1
27 9 10 3
6 7 8
28 35
34
29
30 31 33

32
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 82269 Fender - 3Gal. Left 1 20 64100-S Seat 1
2 68278 Left Fender Mounting Tab 1 176200 Armrest Kit (optional) 1 pair
3 20275-L Left Front 3 Gal. Fuel Tank Support Bracket 1 21 20275 Grey Carpet 1
4 20275-R Right Front 3Gal. Fuel Tank Support Bracket 1 22 N-106 Wing Nut 2
5 20266-L Left Rear 3 Gal. Fuel Tank Support Bracket 1 23 W-106 Washer 2
6 B-103 1/4"-20 Stainless Bolt 10 24 67268 Floor Pan 1
7 W-153 1/4" Stainless Flat Washer 10 25 W-103 Rubber Washer 2
8 N-101 1/4"-20 Stainless Whiz Flange Nut 10 26 W-106 Washer 2
9 B-102 1/4"-20 Bolt 7 27 N-103-W Whiz Nut 2
10 W-102 1/4" Flat Washer 7 28 B-131 5/16 Bolt 2
11 82270 Fender - 3 Gal. Right 1 29 B-105 5/16 Bolt 2
12 20266-R Right Rear 3Gal. Fuel Tank Support Bracket 1 30 400022 Floor Pan Adapter Bracket - Right 1
13 68279 Right Fender Mounting Tab 1 31 N-131 5/16 Lock Nut 2
14 B-105 5/16"-18x1.75" Bolt 2 32 400023 Floor Pan Adapter Bracket-Left 1
15 W-113 5/16" Flat Washer 4 33 20245 Ignition Switch 1
LX2001 BODY (CONT’D)

16 B-174 5/16"-18 Bolt- 4 34 20248 Choke 1

17 W-104 5/16"x1.5" Fender Washer 4 35 67267 Front Panel 1
18 400028 Plastic spacer 2 36 B-209 Bolt Stainless 1/4 x 20 x 3/4 2
19 67401 Seat Pan 1 37 W-153 Washer Flat 1/4 Stainless 2
 20

18 19

12 17
6 7 8
16
11
36 37 13 14 15 6 7 8
15 14
4 2
6 7 8 5

9 10
21
22
23 36 37
X2001 BODY
X1701 BODY

25 24
26
28 9 10 1
35 6 7 8 3
29 27 33
30 31 34 9 10
31 25
32 27 26
29 28
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 400001 Fender - 3Gal. Low Ride Left 1 20 64100-S Seat 1
2 400035 Left Fender Mounting Tab 1 176200 Armrests (optional) 1 pair
3 400029 Left Front 3 Gal. Fuel Tank Support Bracket 1 21 20275 Grey Carpet 1
4 400030 Right Front 3Gal. Fuel Tank Support Bracket 1 22 N-106 Wing Nut 2
5 400031 Left Rear 3 Gal. Fuel Tank Support Bracket 1 23 W-106 Washer 2
6 B-103 1/4"-20 Stainless Bolt 10 24 67268 Floor Pan 1
7 W-153 1/4" Stainless Flat Washer 10 25 W-103 Rubber Washer 2
8 N-101 1/4"-20 Stainless Whiz Flange Nut 10 26 W-106 Washer 2
9 B-102 1/4"-20 Bolt 6 27 N-103-W Nut 2
10 W-102 1/4" Flat Washer 6 28 B-131 Bolt 2
11 400002 Fender - 3 Gal. Low Ride Right 1 29 B-105 Bolt 2
12 400032 Right Rear 3Gal. Fuel Tank Support Bracket 1 30 400022 Floor Pan Adapter Bracket-Right 1
400036 Right Fender Mounting Tab 1 N-131 Nut 2
X2001 BODY
X1701 BODY

13 31
14 B-105 5/16"-18x1.75" Bolt 2 32 400023 Floor Pan Adapter Bracket-Left 1
15 W-113 5/16" Flat Washer 4 33 20248 Choke 1
16 B-107 Bolt 4 34 20245 Ignition Switch 1
17 W-113 Washer 4 35 400011 Front Panel 1
18 W-113 Washer 4 36 B-209 Bolt Stainless 1/4 x 20 x 3/4 2
19 400026 Seat Pan 1 37 W-153 Washer 1/4 Stainless 2
 B-165
W-113 97021

N-108
22

5 6 21
13 17 18
5 6 7
12 18 19 20

10 11 14 15 16 15 16 5 6 7
28
29 5 6 2 4
30
XF2300 BODY

8 9
31 23
24 40
32 25 10 11
33 26
34
27
8 9 1
37 5 6 7 3
40 38
36 39 8 9

35
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 400001 Fender - 3Gal. Low Ride Left 1 176801 Armrest Kit (L &R) 1
2 400035 Left Fender Mounting Tab 1 176803 Left Arm 1
3 400029 Left Front 3 Gal. Fuel Tank Support Bracket 1 176802 Right Arm 1
4 400031 Left Rear 3 Gal. Fuel Tank Support Bracket 1 176201 Arm Pad (L & R) BLACK 1
5 B-103 1/4"-20 Stainless Bolt 17 306025 Back Cover 1
6 W-153 1/4" Stainless Flat Washer 17 305839 Cushion Cover 1
7 N-101 1/4"-20 Stainless Whiz Flange Nut 9 177827PS Spring Kit - For Seat 40100-W 1
8 B-102 1/4"-20 Bolt 6 23 20275 Grey Carpet 1
9 W-102 1/4" Flat Washer 6 24 N-106 Wing Nut 2
10 B-209 1/4"-20X3/4" Stainless Bolt 2 25 W-106 Washer 2
11 W-153 1/4" Stainless Flat Washer 2 26 67268 Floor Pan 1
12 400004 Fender - 7 Gal. Low Ride Right 1 27 B-104 Carriage Bolt 2
13 400034 Right Rear 7Gal. Fuel Tank Support Bracket 1 28 B-131 5/16"-18x1" Bolt 2
14 400036 Right Fender Mounting Tab 1 29 B-171 5/16"-18x1.5" Bolt 2
15 B-105 5/16"-18x1.75" Bolt 2 30 400007 Connecting Arm 2
16 W-113 5/16" Flat Washer 4 31 W-125 3/8" Plastic Washer 4
17 B-131 5/16"-18x1 Bolt 2 32 400006 Floor Pan Mounting Bracket (Right) 1
18 W-118 5/16"x1.5" Fender Washer 4 33 N-176 1/4"-20 Nylon Lock Nut 4
XF2300 BODY (CONT’D)

19 S-115 5/16"-18x1.75" Stud 2 34 N-131 5/16"-18 Nylon Lock Nut 4

20 N-103W 5/16"-18 Hex Nut 4 35 400005 Floor Pan Mounting Bracket (Left) 1
21 400026 Seat Pan 1 36 B-157 1/4"-20x1/2" Carriage Bolt 4
22 40100-W Seat (Complete) 1 37 400011 Front Panel 1
38 20248 Choke 1
39 20245 Ignition Switch 1
40 C-111 Plastic cap For Floor Pan 2
 LX2001 BRAKE ASSEMBLY
X1701 BRAKE ASSEMBLY
X2001 BRAKE ASSEMBLY
2

4 3

5
6

7
10

12 13
8
11
9
10

15

19
22 20 14

16
18 17
21

23

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 89991210000 Brake Handle Assembly (Inc. #2 - #13) 1 14 65277 Bushing (Welded on Frame) 1
2 N/A Brake Handle 1 15 65244 Brake Band 1
3 N-134 Nut 2 16 P-108 Hairpin Cotter 1
4 W-106 Washer 4 17 P-107 Pin 1
5 65062 Spacer 2 18 P-118 Roll Pin 1
6 B-156 Bolt 2 19 P-118 Roll Pin 1
7 N/A Bolt 1 20 65243 Brake Pin 1
8 65063 Spacer 2 21 65278 Spacer Use #65278 and #30112 or
9 N/A U Clip 1 65284 #65284 to
10 N/A Nut 2 30112 place brak e band fully onto brak e drum.
11 N/A Pin 1 22 991100025 Brake Cable Retainer 1
12 N/A Hairpin Cotter 1 23 97159 Brake Drum (LX Only) 1
13 89991210001 Brake Cable 1 67266 Brake Drum (All other models) 1
 XF2300 BRAKE ASSEMBLY

2 5 4 3
6
7
8
10 9
11 12
15 13
16 14

18
17

20
1

28 19
27
24 26
25
21
23 22

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 N/A Complete Brake Kit (Inc. #2,#17-#28) 1 16 W-102 Flat Washer 2
2 97094 Brake Handle Assembly (Inc. #2-#18) 1 17 65247 Right Brake Cable 1
3 N/A Bolt 1 18 65246 Left Brake Cable 1
4 N-134 Nut 2 19 65277 Bushing (Welded on Frame) 2
5 W-106 Washer 4 20 65244 Brake Band 2
6 65061 R Clip 2 21 P-108 Hairpin Cotter 2
7 65063 Spacer 1 22 P-107 Pin 2
8 65060 Pivot Plate 2 23 P-118 Roll Pin 2
9 N/A Nut 1 24 67266 Brake Drum 2
10 65062 Spacer 2 25 991100025 Brake Cable Retainer 2
11 B-156 Bolt 2 26 65278 Spacer Use #65278 and #30112 or
12 N/A Hairpin Cotter 2 65284 #65284 to
13 P-129 Pin 1 30112 place brake band fully onto brake drum.
14 P-112 Pin 2 27 65243 Brake Pin 2
15 N/A Hairpin Cotter 1 28 P-118 Roll Pin 2
 X1701 ENGINE - Kohler 17 Hp

1
2
3
4
5
6

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 K-100 1/4" Key 1 4 W-144 7/16" Belleville Washer 1
2 W-145 1-1/8" x 1-3/4" x 1/8" Washer 1 5 W-108 7/16" Lock Washer 1
3 9907500X600D Split Pulley 5" x 6" 1 6 B-114 7/16"-20 x 3/4" Bolt 1
 LX2001 ENGINE - Kohler 20 Hp
X2001 ENGINE - Kohler 20 Hp

2
3
4
5
6
7

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 364001168218 Muffler Guard 1 5 W-144 7/16" Belleville Washer 1
2 K-100 1/4" Key 1 6 W-108 7/16" Lock Washer 1
3 W-145 1-1/8" x 1-3/4" x 1/8" Washer 1 7 B-114 7/16"-20 x 3/4" Bolt 1
4 9907500X600D Split Pulley 5" x 6" 1
 XF2300 ENGINE - Kohler 23 Hp

15
18 19 20 21
14
16
17

22

13
12
11 1
23
10 24
2
9 25
8
5 26
3
7
28
4 27
6

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 70100-22 Oil Cooler Bracket 1 13 72120 Air Plenum Cover 1
2 B-165 3/8"-16x2" Bolt 3 14 72126 2" Rubber Hose 90 Degree 1
3 W-104 3/8" Standard Flat Washer 3 15 90125 2" Worm Clamp 4
4 N-107 3/8"-16 Nyloc Nut 3 16 60103-L Oil Cooler 2
5 90121 Donaldson Air Cleaner Complete 1 17 72126-T 2" Rubber Hose Straight 1
P103007 End Cap 1 18 90115 Turbo Pre-Cleaner 1
P002904 Clamp 1 19 B-107 5/16"-18x3/4" Bolt 4
P102523 Rubber Baffle 1 20 W-102 1/4" Standard Flat Washer 4
P101870 Internal Wing Nut 1 21 N-103-W 5/16"-18 Whiz Flange Nut 4
90122 Filter Element 1 22 90123 Donaldson Mounting Bracket 2
6 60119 Amsoil Filter 1 23 K-100 1/4" Key 1
7 B-172 1/4"-20x1" Bolt 3 24 W-145 1-1/8" x 1-3/4" x 1/8" Washer 1
8 W-102 1/4" Standard Flat Washer 3 25 9907500X600D Split Pulley 5" x 6" 1
9 60113 1/8"x3/8" 90 degree fitting 2 26 W-144 7/16" Belleville Washer 1
10 N-102 1/4"-20 Whiz Flange Nut 3 27 W-108 7/16" Lock Washer 1
11 W-102 1/4" Standard Flat Washer 8 28 B-114 7/16" -20 x 3/4 Bolt 1
12 B-102 1/4"-20x3/4" Bolt 8
 KOHLER ELECTRICAL DIAGRAM
1 1.
2.
White (kill wire)
Red (charge wire)
Kohler Wiring 3 2 3.
4.
Blue (start wire)
Fused wire (to hot post on starter)
Harness 5. Gre en (from oil sending unit)

5 4
Connect to Ko hler Dixie Chopper Wiring Harness Connect to Ignition
Wiring Harness Switch

1 W W
1 BLU
OR
R
4 3 BLU
BLK
2 3
2 5 4
BLK GR R
BLK

R R

GR

BLK
HORN OR
R
R
Starter
Solenoid
1
BLK
2 3 4 R

Starter BLK
+ -
Battery
SEAT
SWITCH
Conne ct to Seat Relay
Gro und to R BL K
All connectors are viewe d Transmission
Fram e BLK
from wire end.

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 65522 Kohler Wiring Harness 1 9 20227-72 Battery Cable Positive (72") 1
2 20245 Ignition Switch 1 10 20226-B Battery Cable Ground (12") 1
3 20246-T Hour Meter/Tach 1 11 40229 Mercury Switch 1
4 68247 Tach Bracket 1 12 60124 Clamp for Mercury Switch 1
5 N/A Battery 1 13 65510 Seat Relay 1
6 20228 Battery Strap 1 14 97191 Seat Relay Pigtail 1
7 14078 Battery Box 1 15 65509 Fuse 1
8 20225-B Red Rubber Boot 1 16 20254 Fuse Holder 1
 6302 E. County Road 100 North
Coatesville, IN. 46121
Phone 1-765-CHOPPER
www.dixiechopper.com

Dixie Chopper, Magic Circle, and the Magic Circle Atom Logo are all trademarks of Magic Circle Corporation
and may not be reproduced without permission.
Printed In USA
Specifications and instructions subject to change without notice.
Print Date 11/01
 Serial Numbers
2037200
and Higher

Model # ____________________ Engine Model # ____________________

Serial # ____________________ Engine Serial # ____________________

Date Purchased ____________________ Engine Spec. # ____________________

X W,XF-60 PARTS MANUAL

700005 April, 2002
Congratulations on your purchase of a DIXIE CHOPPER lawn
mower. We believe you have exercised excellent judgement, and are most
appreciative of your patronage.

Your DIXIE CHOPPER Dealer is your #1 SOURCE for

DIXIE CHOPPER parts and service !

Please call or visit your nearest authorized Dixie Chopper Dealer for
additional service information.

AUTHORIZED DEALER

Let us know how you are getting along with your new CHOPPER!
www.dixiechopper.com

Dixie Chopper reserves the right to make changes or add improvements to its products at any time without
incurring any obligation to make such changes to products previously manufactured. Neither Dixie Chopper, nor
its dealers, accept responsiblility for variations which may be evident in the actual specifications of its products and
the statements and descriptions contained in this publication.
 CONTENTS

Quick Reference Parts 1

Decals 2
Decal Placement 5
Frame 6
Wheels & Tires 7
Foot Pedal 8
Deck Lift System 9
OCDC 10
Deck 11
Hubs & Belts 13
Transmission Frame 14
Transmission & Drive 17
Wheel Motor 18
Hydraulic Hose Diagram 19
Fuel System 20
Body 21
Throttle 23
Brake Assembly 24
Engine - Kohler 23Hp 26
Engine - Honda 24Hp 27
Engint - Kohler 25Hp 28
Engine - Kawasaki 25Hp 29
Engine - Kohler 26Hp EFI 30
Electrical Diagram - Honda 31
Electrical Diagram - Kohler 32
Electrical Diagram - Kawasaki 33
Electrical Diagram - Kohler EFI 34
 XW MODEL
QUICK REFERENCE PARTS
MODEL XW2300 XW2400 XF/XW2500 XWK2501 XWK2503 XW2600-EFI
Engine Kohler 23 Hp Honda 24Hp Kohler 25Hp Kawasaki 25Hp Kawasaki 25Hp Kohler 26Hp
Deck 60" 60" 60" 60" 60" 60"
Rear Tires 97200 97200 97200 97452 97200 97200
Rear Rims 400014 400014 400014 61238 400014 400014
Front Tires 97165 97165 97165 97165 97165 97165
Front Rims 10239 10239 10239 10239 10239 10239

Belts
Engine-Transmission 9907B41 9907B41 9907B41 9907B41 9907B41 9907B41
Engine-Deck 9907B85 9907B85 9907B85 9907B85 9907B85 9907B85
Deck 9907B130 9907B130 9907B130 9907B130 9907B130 9907B130

Filters
Fuel Filter 97392 97392 97392 97392 97392 97392
Nelson Air Filter 90122 90122
Amsoil Oil Filter 60119 60119
Zinga-Hydro Filter 68140 68140 68140 68140 68140 68140

Blades
Standard 30227-60H 30227-60H 30227-60H 30227-60H 30227-60H 30227-60H
Heavy-Duty 30227-60N 30227-60N 30227-60N 30227-60N 30227-60N 30227-60N

Various Parts ALL MODELS

Fiber Washer W-101
Spindle Bearing 30218
Deck Roller (Ctr) 30240-O
Choke Control 20248 Kawasaki & Honda ONLY 600002
Throttle Cable 68249 Kawasaki & Honda ONLY 364000668211
Brake Cable 65246 (Left) 65247 (Right)
Parking Brake Band 65244
Fuel Cap 40117-1
Control Lever Grip 20257
 DECALS

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 97507 XW2300 Front Panel 1 9 65413 Patent Pending 1
2 65419 XW2400 Front Panel 1 10 800014 Ignition 1
3 65462 XFW2500 Front Panel 1 11 800015 Choke 1
4 65428 XW2500 Front Panel 1 12 65406 Parking Brake Caution 1
5 800006 XWK2501 Front Panel 1 13 97013 VTC Only 1
6 800011 XWK2503 Front Panel 1 14 30591 Warranty Notice 1
7 800016 XW2600 Front Panel 1 15 800010 Flex-Deck Ready Decal 1
8 800003 Big Wheel Decal 1 16 97160 RPM Notice 1
 DECALS (CONT’D)

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

17 30588 Hillside Danger 1 23 990765438 Belt Information 1
18 264000200210 VTC 1 24 30585 Fender Caution 1
19 30586 Tractor Buster 1 25 63401 Throttle 1
20 30590 USA Decal 1 26 63402 Brake & Steering 1
21 65409 60 Inch Cut 2 27 97514 Horn Warning 1
22 40118 Fuel Caution 1 28 97008 Cross Member Decal 1
 DECALS (CONT’D)

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

28 30573 Floor Pan Decal 1 31 97072 OCDC Safety Decal 1
29 30571 Fender Decal 2 32 65430 Flatlander Decal 1
30 30229 Deck Danger Decal 2 33 65422 Belt Route Decal 1
 DECAL PLACEMENT
9 T-Box
13 Oil Tank
19 Rear Left
Fender
20 Rear Right 12 17
Fender
25 26
27

Side Left
Fender

31 8 32
1 2 3 4 5 6 7
16 14
24 22
28
29
18
10 11
28

23

30

21

15
21
33
 FRAME

32 6
30
29
31 400000 XW2400
7

14 9
13 10
11
12

XF2500
XW2500
1
XWK2501
15 33
400027 XWK2503
XW2600 EFI

22 16
17
18
27 24 19 XW2300
28
20
23
25
21 70100-22
26

REF # PART # D E S C R IP T IO N Q TY. REF # PART # D E S C R IP T IO N Q TY.

1 100000 W e ld m e n t - XW F ra m e 1 15 N -1 0 8 3 / 8 " -1 6 W h iz F la n g e N u t 2
2 B -2 0 4 3 / 8 " -1 6 U -B o lt 4 16 N -1 0 3 -W 5 / 1 6 " -1 8 W h iz F la n g e N u t 4
3 N -1 6 0 3 / 8 " -1 6 C o u p lin g N u t 8 17 72216 P u ll S t o p W e ld m e n t 1
4 400000 V S t y le R e a r G u a rd 1 18 N -1 1 0 1 / 2 " -1 3 N u t 1
400027 H S t y le R e a r G u a rd 1 19 4 0 2 2 1 -6 0 B o lt 1 4 " x 1 / 2 " 1
7 0 1 0 0 -2 2 2 2 / 2 3 H p R e a r G u a rd 1 20 W -1 1 3 5 / 1 6 " S t a n d a rd F la t W a s h e r 4
5 400026 W e ld m e n t - L o w R id e S e a t P a n 21 B -1 5 6 5 / 1 6 " -1 8 x 2 " B o lt 4
w / H in g e 1 22 W -1 0 7 S h a rk -To o t h B e lle ville W a s h e r 1
6 100007 W e ld m e n t - L o w R id e 23 72220 B e lt G u id e A s s e m b ly 1
Tra n s m is s io n F ra m e 1 24 72217 B e lt G u id e W e ld m e n t 2
7 B -2 2 9 3 / 8 " -1 6 x 5 " B o lt 2 25 72222 A ll Th re a d 1
8 N -1 0 7 3 / 8 " -1 6 N y lo c N u t 2 26 N -1 1 0 N ut 6
9 N -1 3 5 7 / 1 6 " -2 0 N y lo c N u t 4 27 72222 A ll Th re a d 1
10 W -1 6 8 7 / 1 6 " S t a n d a rd F la t W a s h e r 8 28 N -1 1 0 N ut 6
11 B -1 9 9 7 / 1 6 " -2 0 x 2 " B o lt 4 29 B -1 2 3 1 / 2 " -1 3 x 1 1 / 2 " B o lt 4
12 1 0 1 0 0 -S T B u m p e r - XW / XF 1 30 W -1 0 9 1 / 2 " F la t W a s h e r 4
13 W -1 6 0 1 0 m m F la t W a s h e r 2 31 97124 C ro s s m e m b e r 1
14 B -1 7 9 3/8 - 16 X 2 1/2 2 32 N -1 5 7 1 / 2 " -1 3 W h iz F la n g e N u t 4
33 400008 M o u n t - F lo o r P a n H in g e F ra m e 2
 WHEELS & TIRES

1A 1
2
3

5
6
7 9
13 11
10
25
8

15 12
17 16 27
14
26
18
24
23
19 22
21
20

R EF # PA R T # D ESC R IPTIO N Q TY .
18 97451 L/R Titan CTR A s s em bly (X W K2501) 2
97452 Titan CTR Tire 2
61238 Rim 2
10127-S V alve S tem 2
R EF # PA R T # D ESC R IPTIO N Q TY . 400019 Left Tire A s s em bly (X F 2400,2500,2600)
1 10220 Dus t Cap 2 (X W 2300, 2400, 2500, 2503, 2600) 1
1A P -108 Cotter P in 2 97200 Turf B os s III Tire 1
2 N-142 1" S lotted Hex Nut 2 400014 Rim 1
3 10207 Top B earing 2 10127-S V alve S tem 1
4 10206 O uter B earing Rac e 4 400020 Right Tire A s s em bly (X F2400,2500,2600)
5 97171 B ottom B earing 2 (X W 2300, 2400, 2500, 2503, 2600) 1
6 10208 O il S eal 2 97200 Turf B os s III Tire 1
7 97170 F ront F ork W eldm ent 2 400014 Rim 1
8 B -122 B olt - 5/8" -11x 7" Hex Head 2 10127-S V alve S tem 1
9 N-115 Nut - 5/8"-11 Ny loc 2 19 N-113 Lug Nut 8
10 67205 Inner F ront W heel B earing 2 20 P B 339303P W heel M otor A x le Nut 2
11 10203 O uter Front W heel S pac er 2 21 67266 B rak e Drum 2
12 10205 O uter Front W heel B earing 2 22 67002 W heel F lange w/s tuds 2
13 97166 F ront Tire A s s em bly 2 23 B -183 W heel M otor B olt 8
N/A Front Tire 2 24 W -138 W heel M otor S quare W as her 8
10239 Rim 2 25 P W 72546 1/4" K ey 2
10127-S V alve S tem 2 26 67114 W heel M otor 14Cu.In. 2
14 67205 Inner F ront W heel B earing 2 (X F 2400,X W K2501,X F 2500,X F 2600)
15 67204 Inner F ront W heel S pac er 2 67118-W W heel M otor 18Cu.In.
16 10205 O uter Front W heel B earing 2 (X W 2300, 2400, 2500, 2503,2600) 2
17 10203 O uter Front W heel S pac er 2 27 N-127 W heel M otor Nut 8
 FOOT PEDAL ASSEMBLY
19
15 1
18

17
7

16
4 5 6

8
9

14 3
13 2

10
11
12

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 10107-1/2 Kit - Foot Pedal 1 11 10228-1 Pin 1
2 10225-2 Weldment - #50 Foot Lift Arm 1 12 F-100 Grease Fitting 1
3 10224-1 Pawl 1 13 B-131 Bolt 1
4 990735020 Foot Pedal Lock ( Incl. #5 - #6 ) 1 14 W-113 Washer 1
5 W-164 Washer 1 15 68219 #50 Chain 1
6 N-144 Nut 1 16 10233 #50 Half Link 1
7 300008 Deck Height Pointer 1 17 10232 #50 Master Link 1
8 N-130 Coupling Nut 1 18 20217-25 Spring 1
9 300007 Deck Height Indicator 1 19 30213 Cotter Pin 1
10 10226-1 Lift Sprocket 1
 DECK LIFT SYSTEM
6

2 5
1 1 3 1
4 7

8
11

19
12
10 13
8 10 9

9 14
15

20
8

16
8
15 18
15
REF # PART # DESCRIPTION QTY. 17
1 68112 1" Bushing 3
2 68106 1.1875" Bushing 1
3 S-114 1/2"-13 Stud 4
4 N-157 1/2"-13 Whiz Flange Nut 4
5 68105 1/4" Bushing 1
6 68104 #50 Small Sprocket 1 REF # PART # DESCRIPTION QTY.
7 N-157 1/2"-13 Whiz Flange Nut 4 14 N-108 3/8"-16 Whiz Flange Nut 1
8 68103 Deck Lift Sprocket #50 7 15 W-154 3/4" Flat Washer 4
9 990710004 #50 Rear Deck Lift Chain 2 16 B-239 3/4"-10x10" Bolt 1
10 68217 #50 Front Deck Lift Chain 2 17 B-238 3/4"-10x8.5" Bolt 1
11 990710002 #50 Return Spring Chain 1 18 N-158 3/4"-10 Nyloc Nut 2
12 97455 200 lb. Return Spring 1 19 68113 3/4"x31.5" Rod 1
13 B-241 3/8"-16 Eye Bolt 1 20 10232 #50 Master Link 10
 60” OCDC
4 5
7
6 3
1
2

2 2 8
12

17 11 10

7 16
12

10

15

14
13

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

68122-60 Assembly - 60" OCDC 9 97122 Control Rod (Inc. #9,11,16) 1
1 B-179 3/8"-16 x2.5" Bolt 1 10 N-157 1/2"-13 W hiz Flange Nut 2
2 W -104 3/8" Standard Flat W asher 3 11 68121 3/8"-24 Yoke 1
3 20252 Spring 1 12 W -104 3/8" Standard Flat W asher 2
4 900014 Handle 1 13 B-138 1/2"-13x1" Bolt 2
5 68142 1"x1" Plastic Plug 1 14 W -109 1/2" Standard Flat W asher 2
6 N-107 3/8"-16 Nyloc Nut 1 15 68136 Lower Screen 1
7 20224 Clip 2 16 N-150 3/8"-24 Nut 1
8 67258 Handle Grip 1 17 P-102 3/8"x1.25" Clevis Pin 1
 60” DECK
50
49 51
7 52
38 53
48 54
47 60
46 55
45 56
57
44 38 58 7
43
37 53 8
7 38 59
36
38 39 8
7
42 40 35 8
41 34
33 31 7
1 30 59
32 8
8 32
29 31 7
7 30
1
28 7
27 6 2
7 7
26 3
8
9 4
24 25 5
10
23 11
10 12
13 13
3
18 14 3
19 15
22 13
21
3 16
13 3
17
10 11
3 13
12 20
3 13 10 19 18
 60” DECK (CONT’D)
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
300006 60" Deck Assembly 1 33 30235 Pivot Stand 1
1 300261 Pulley Guard 2 34 N-102 1/4"-20 Whiz Flange Nut 4
2
3
10222
N-108
Spring
3/8" Whiz Flange Nut
1
33
35
36
10203
65278
1" Shim (if needed)
1/2" Shim (if needed) **
4
5
65308-L
300002
Idler Spring Tab
60" Top Plate Weldment
1
1 37
30112
N-107
1/8" Shim (if needed)
3/8 -16 Nylon Lock Nut *
1
6 334000130111 Left 3-Hole Tab 1 38 W-104 3/8" Flat Washer 1
7 20224 Hairpin Clip 10 39 P-113 Roll Pin 1
8 P-102 3/8"x1.25" Clevis Pin 6 40 30211 Enguaging Shaft 1
9 30232 Left Scissor Arm 1 41 30210 Cam Weldment 1
10 N-156 5/8"-11 Nyloc Jam Nut 4 30209-1 Enguaging Rod Assembly
11 30240-0 Long Roller 2 (Inc. #37,38,42,43,44)
12 B-255 5/8"-11x9" Carriage Bolt 2 42 97343 Enguaging Rod 1
13 B-110 3/8"-16x3/4" Carriage Bolt 16 43 30209-B Connecting Arm Bracket 1
14 B-136 3/8"-16x1.25" Carriage Bolt 12 44 30207-S Enguaging Spring 1
15 300000 60" Deck Weldment 1 45 20217-25 Return Spring 1
16 300003 Weldment - Roller Bracket 1 46 N-173 #10 Nyloc Nut 1
17 B-253 5/8"-11x6" Carriage Bolt 1 47 30212 Enguaging Handle 1
18 67240 Short Roller 2 48 B-245 #10-24 Carriage Bolt 1
19 W-135 5/8" Flat Washer 2 49 30206 5/8"x1/2" Bushing 1
20 300005 Left 60" Blow Out Baffle 1 300012 Triangle Plate Assembly
21 300004 Right 60" Blow Out Baffle 1 (Inc.#49,50,51,52,60,F-102) 1
22 10203 Spacer 1 50 300011 Weldment - Triangle Plate 1
23 B-254 5/8"-11x7" Carriage Bolt 1 51 B-185 5/8"-11 x 2" Bolt 2
24 B-172 1/4"-20x1" Bolt 4 52 N-180 5/8"-11 Jam Lock Nut 2
25 F-100 3/16" Drive in Grease Fitting 1 53 30224 Flat Idler Pulley 2
26 67131 Scissor Link Tower Weldment 1 54 30234 V Pulley 1
27 Enguaging Tower Weldment 1 55 B-117 1/2"-13x1.25" Bolt 1
28 30231 Right Scissor Arm 1 56 F-101 1/4"-28 90 Grease Fitting 1
29 334000130110 Right 3-Hole Tab 1 57 B-118G 1/2 x 1 1/2 Shoulder Bolt 1
30 C-104 Ring Clip 2 58 30223 Idler Arm 1
31 334000130109 2-Hole Tab 2 59 30214-86 Stabilizer Bar 2
32 P-103 3/8" x 2" Clevis Pin 2 60 N-181 5/8 - 11 Lock nut 2

Use individually or a combination of 10203, 65278 and 30112 to achieve proper belt

*
alignment between the triangle plate and the top center deck spindle pulley.
 HUBS AND BELTS

20 1
3

16

19 18
1 2

2
4
3

4
5

6
5
Complete Spindle Assembly 7
6
Outside--10161 8
Center---10161-L 7 9
8 6
OPTIONAL 9 2
Whiz-Mow #30302 17
Hard-Faced 60” Blades #98124 6
11
Offset 60” Blades #98005 2
12
10
11 13

12 14
13
15

14

15

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 N-167 1" Nut 3 13 30227-60H 60" Standard High Lift Blade 3
2 W-146 1/4" Washer 11 30227-60N 60" Heavy Duty High Lift Blade 3
3 W-137 1" Belleville Washer 6 14 W-100 5/8" Belleville Washer 3
4 9907525X100S 5.25" Pulley 3 15 B-121 2.5" Blade Bolt (use w/o blade spacer) 3
5 W-131 1/8" Washer 3 B-121-L 3" Blade Bolt (use with blade spacer) 3
6 30218 Sealed Bearing 6 B-121-LL 3.25" Blade Bolt (use with Whiz-Mow) 3
7 30241 Deck Hub 3 16 9907675X100S 6.75" Pulley 1
8 F-102 Grease Fitting 3 17 30217-L Long Blade Shaft 1
9 30219 Inner Deck Hub Spacer 3 18 9907B85 Engine - Deck Belt 1
10 30217 Short Blade Shaft 2 19 9907B130 Deck Belt 1
11 30242 1/2" Blade Spacer 3 20 9907B41 Engine-Trans. Belt (not shown) 1
12 W-101 Fiber Washer 3
 XW2300,XW2400,XF2500,XW2500,
XWK2501,XWK2503,XF2600,XW2600
TRANSMISSION FRAME ASSEMBLY
29
28
30 1
31 3
33 32
35 2
27 5 7A 6 7
34 4
36

26
25 8
2 4 23

22 20 9
10
21 19
18
17 13 12
15 16 11 11
14

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 100007 Low Ride Transmission Frame 1 19 N-103-W Nut 4
2 B-150 Eye Bolt 1 20 W -113 W asher 4
3 N-103W Nut 2 21 N-117 3/8"-16 Large Flange Lock Nut 1
4 W -171 Plastic W asher 2 22 30234 Pulley 1
5 65205 Steering Block W eldment 2 23 W -124 3/8" Machine W asher .120" 1
6 20257 Rubber Handle 2 24 W -123 3/8" Machine W asher .060" 1
7 400037 Foam Lever Sleeve 2 25 W -176 3/8" Machine W asher .031" 1
7A 67259 Foam Handle Grip 2 26 61250 Spacer 1
8 20231-L Left Steering Lever 1 27 B-165 3/8"-16 x 2" Bolt 1
9 20232-L Right Steering Lever 1 28 B-124 3/8 Bolt 1
10 W -170 Teflon W asher 2 29 W -104 3/8 Standard Flat W asher 1
11 W -110 Machine W asher 4 30 100011 Idler Arm 1
12 20252 Spring 2 31 N-103W Nut 4
13 N-110 Hex Nut 2 32 200008 Hydraulic Tank (3-1-02) 1
14 N-111 Jam Nut 2 33 W -125 W asher 1
15 F-101 Grease Fitting 90 degree 2 34 W -126 W asher 3
16 B-131 Bolt 4 35 N-107 Nut 1
17 B-143G Bolt 2 36 10222 Spring 1
XW2300,XW2400,XF2500,XW2500,XWK2501,XWK2503
TRANSMISSION FRAME ASSEMBLY (CONT’D)
15
14 13 12

4
9 10
8
12
18
7
9 11 4
5

4
6
18
5
4 1
17 16
3
2
1
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 B-105 Bolt 2 9 20221 Plastic Bushing 2
2 W -113 W asher 2 10 P-101 Pin 2
3 N-103 Nut 2 11 200002 Left Pump Control Rod 1
4 20224 Hairpin Clip 4 20214 Yoke 1
5 20222 Plastic Bushing 2 N-105 Nut 1
6 200001 Right Pump Control Rod 1 12 W -110 W asher 4
20214 Yoke 1 13 20252 Spring 2
N-105 Nut 1 14 N-175 Coupling Nut 2
7 65207-R Right Pump Control Arm 1 15 B-138 Bolt 2
P-118 Roll Pin 1 16 68142 Plastic Plug 1"x1" 2
B-131 Bolt 1 17 67256 Plastic Plug 1"x2" 2
8 65207-L Left Pump Control Arm 1 18 20223 Backing Clip 2
P-118 Roll Pin 1
B-131 Bolt 1
 XF2600,XW2600
TRANSMISSION FRAME ASSEMBLY (CONT’D)
15 12
14 13 12

4
9 10
8
7 10A
9
20 18 11 4
19 5
4
6
10A 5
4
16
21
1
22 17 16
3
25 2
24 23 1

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 B-105 Bolt 2 11 200002 Left Pump Control Rod 1
2 W-113 Washer 2 20214 Yoke 1
3 N-103 Nut 2 N-105 Nut 1
4 20224 Hairpin Clip 4 12 W-110 Washer 4
5 20222 Plastic Bushing 2 13 20252 Spring 2
6 200001 Right Pump Control Rod 1 14 N-175 Coupling Nut 2
20214 Yoke 1 15 B-138 Bolt 2
N-105 Nut 1 16 68142 Plastic Plug 1"x1" 3
7 65207-R Right Pump Control Arm 1 17 67256 Plastic Plug 1"x2" 2
P-118 Roll Pin 1 18 B-165 Bolt 1
B-131 Bolt 1 19 W-113 Washer 1
8 65207-L Left Pump Control Arm 1 20 N-108 Nut 1
P-118 Roll Pin 1 21 97021 Wide Fender Brace 1
B-131 Bolt 1 22 B-206 U Bolt 1
9 20221 Plastic Bushing 2 23 600031 EFI Module Mount 1
10 P-101 Pin 2 24 W-104 Washer 2
10A 20223 Backing Clip 2 25 N-107 Nut 2
 TRANSMISSION & DRIVE

23
19 20 21 22
2

18 3
4 5 6
7
17 8
24
9
16
10
15 14

REF # PART # DESCRIPTION QTY.

1 65070 Sundstrand 10A Pump - Right 1
12
2 N-168 Nut - 3/8"-24 4
3 W-169 Washer - 5/16" Grade 8 Flat 4
4 000365201 T Gear Box 1 13
5 788101 T Box Gasket 1
6 772150 T Box Cover Plate 1 REF # PART # DESCRIPTION QTY.
7 792025 T Box Cover Plate Bolt 4 16 67015 Case Bleed Fitting 2
8 65206 3/8" Threaded Rod 2 17 65072 Charge Pump Inlet Fitting 2
9 K-102 Woodruff Key 3/16"x 3/4" 1 18 25-130-30 Dump Valve - no cross port 2
10 W-167 3/4"X1/8" Hardened Flat Washer 1 19 65001 Small Bell Housing 2
11 9907500X750S Transmission Pulley 1 20 788030B Bearing Plate Gasket 2
12 W-132 3/4" Belleville Washer 1 21 792026 Bell Housing Bolt 8
13 N-114 Nut - 3/4"-16 1 22 65024 Pump O-Ring 2
14 65004 High Pressure Port Fitting 4 23 68031 T Box Fitting (Brass) 2
15 65071 Sundstrand 10A Pump - Left 1 24 N-184 Nut 3/8"-24 ( Harden ) 4
 WHEEL MOTOR

WHEEL MOTOR IDENTIFICATION #18

14 Cu. In. W80379
18 Cu. In. W80380

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

PB333700 Seal Kit (Contains item 1-5) 12 PB332014 Rotor Assembly (14 cu.in.) 1
1 PB018069 Dust/Shaft Seal 1 PB332018 Rotor Assembly (18 cu.in.) 1
2 IN KIT Body Seal 4 13 PB015008 Manifold 1
3 IN KIT Commutator Seal 1 14 PB012013 Commutator Assembly 1
4 IN KIT O-ring Seal 1 15 PB018056 Endcover Piston 1
5 IN KIT Teflon Back-up Seal 1 16 PB018059 Piston Spring 1
6 PB018073 Snap Ring 1 17 PB160007G Endcover 1
7 PB018054 Thrust Washer 3 18 N/A ID Tag 1
8 PB018052 Thrust Bearing 1 19 PB334014 Assembly Bolts (14 cu.in.) 4
9 PB018053 Housing Bearing 2 PB334018 Assembly Bolts (18 cu.in.) 4
10 PB130015 Housing 1 20 PW72545 Shaft 1
11 PB014027 Drive Link (14 cu.in.) 1 21 PW72546 Shaft Key 1
PB014027 Drive Link (18 cu.in.) 1 22 PB339303P Shaft Nut 1
 HYDRAULIC HOSE DIAGRAM

1 2 16 6
14 16 3
16 20
6
5
16
6
4
15 17 13 6
8

3 16
16
16 16
20 7
9
5 16 6
6 4 6 17 16 11
16 19 12
16 6 7 10 6
6
8

12
11
10 19 18
9

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 200008 Hydraulic Tank (3-1-02) 1 10 67017 90 - degree fitting 2
2 40117-T T- Handle Cap w/ Dipstick 1 67014 Brass fitting 2
3 60125 90 - 3/8" NPT x3/8" Barb 2 11 87104 Steel Fitting 2
4 65072 Charge Pump Inlet Fitting 2 12 87104 Steel Fitting 2
5 68140 Filter - Hydro Zinga 40 Micron 2 13 67008 3/8" Tee 1
6 65108 5/8" Clear Hose /ft 14 67014 3/8" Barbed X 1/4 MPT Fitting 1
7 65073 High Pressure Black Hydro Hose 4 15 65009 3/8" Pipe Plug 1
8 67016 1/4" Oring x 3/8" Barb 90 2 16 67013 Clamps for 65108 (Green ) 20
9 67114 Wheel Motor - 14 Cu. In. 17 65004 High Pressure Port Fitting 4
(XF2400,XWK2501,XF2500, XF2600) 2 18 60103-L Oil Cooler 1
67118-W Wheel Motor - 18 Cubic In. (XW2300, 19 68231 #4 Micro Hose Clamp 2
XW2400,XW2500, XWK2503,XW2600) 2 20 67015 90 degree fitting 2
XW2300,XW2400,XF2500,XW2500,XWK2501,XWK2503
FUEL SYSTEM
1 2 10
2

9
7

5
3
8
4
3
9 6 9 4
5 5

9
5

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 40204-1 3 Gal. Fuel Tank (XWK2501 Both) 1 6 97369 Gas Line "Y" - 5/16" 1
2 40117-1 Fuel Cap - Manual Vent w/Guage 2 7 60124 Hose Clamp 1
3 40220 Fuel Tank Bushing 2 8 97392 Filter - Gas & Water Parker 1
4 400016 Valve - Fuel Tank Shut-Off 2 9 72012 Spring Clamp (Black) 7
5 97374 Gas Line - 5/16" /ft. 10 400015 7 Gal. Fuel Tank 1

XF2600,XW2600 EFI FUEL SYSTEM

2

2
1 9

3 10 3 7
5
5 4
6A
7 5
7
21 7
7 17 16

16 5 7 7 3
6 5
8 4
19
11
13 19
7 14 18 2 0
22 15 12 23
19
24

REF # PART # D E S C R I P T IO N Q TY . REF # PA RT # D E S C R I P T IO N Q TY.

1 4 0 2 0 4 -1 3 G a l. F u e l Ta n k 1 13 C -1 1 0 C la m p 1
2 4 0 1 1 7 -1 F uel C ap - M anual V ent w /G uage 2 14 N/A K o h le r P a rt - ( R e g u la t o r ) 1
3 40220 F u e l Ta n k B u s h in g 4 15 N/A K o h le r P a rt - ( F ilt e r ) 1
4 400016 V a lve - F u e l Ta n k S h u t -O ff 2 16 N -1 0 2 Nut 5
5 97374 G a s L in e - 5 / 1 6 " / ft . 17 B -2 0 6 U B o lt 1
6 97369 G a s L in e " Y " - 5 / 1 6 " 1 18 W -1 0 4 W as her 2
6a 65008 TE E - 5 / 1 6 x 5 / 1 6 x 5 / 1 6 1 19 B -1 0 2 B o lt 5
7 72012 S p rin g C la m p (B la c k ) 14 20 N -1 0 7 Nut 2
8 97392 F ilt e r - G a s & W a t e r P a rk e r 1 21 97374 G a s L in e - 5 / 1 6 / ft .
9 400015 7 G a l. F u e l Ta n k 1 22 600029 C la m p 5
10 400041 F it it in g 1 / 8 M P x 5 / 1 6 9 0 ' 2 23 500005 G ro u n d W ire - ( F / F u e l P . ) 1
11 N /A K o h le r P a rt - ( P u m p ) 1 24 N -1 8 2 N u t (F o r F u e l P u m p ) 2
12 C -1 0 8 C la m p 2
 22

5 6 21
13 17 18
5 6 7
12 18 19 20
10 11 14 16 15 15 16 5 6 7
28
29 5 6 41 2 4
30 8
40 9
BODY

31 23
24
32 25 10 11
33 26
34
27
8 9 1
37 5 6 7 3
38
39 8 9
36

35
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 400001 Fender - 3Gal. Low Ride Left 1 22 40100-W Seat (Complete) (XF2600)
2 400035 Left Fender Mounting Tab 1 (XW2300,2400,2500,2600) 1
3 400029 Left Front 3 Gal. Fuel Tank Support Bracket 1 176801 Armrest Kit (L &R) 1
4 400031 Left Rear 3 Gal. Fuel Tank Support Bracket 1 176803 Left Arm 1
5 B-103 1/4"-20 Stainless Bolt 17 176802 Right Arm 1
6 W-153 1/4" Stainless Flat Washer 17 176201 Arm Pad (L or R) 1
7 N-101 1/4"-20 Stainless Whiz Flange Nut 9 306025 Back Cover 1
8 B-102 1/4"-20 Bolt 6 305839 Cushion Cover 1
9 W-102 1/4" Flat Washer 6 177827PS Spring Kit 1
10 B-209 1/4"-20X3/4" Stainless Bolt 2 64100-S Seat (Complete) (XWK2501,2503) 1
11 W-153 1/4" Stainless Flat Washer 2 176200 Armrest Kit (Optional) 1 pair
12 400004 Fender - 7 Gal. Low Ride Right 1 23 20275 Grey Carpet 1
400002 Fender - 3Gal. Low Ride Right (XWK2501) 1 24 N-106 Wing Nut 2
13 400034 Right Rear 7Gal. Fuel Tank Support Bracket 1 25 W-106 Washer 2
400032 Right Rear 3Gal. Fuel Tank Support Bracket (XWK2401) 1 26 67268 Floor Pan 1
400030 Right Front 3Gal. Fuel Tank Support Bracket (XWK2501) 1 27 B-104 Carriage Bolt 2
BODY

14 400036 Right Fender Mounting Tab 1 28 B-131 5/16"-18x1" Bolt 2

15 B-105 5/16"-18x1.75" Bolt 2 29 B-171 5/16"-18x1.5" Bolt 2
16 W-113 5/16" Flat Washer 4 30 400007 Connecting Arm 2
17 B-131 5/16"-18x1 Bolt 2 31 W-125 3/8" Plastic Washer 4
18 W-118 5/16"x1.5" Fender Washer 4 32 400006 Floor Pan Mounting Bracket (Right) 1
19 S-115 5/16"-18x1.75" Stud 2 33 N-176 1/4"-20 Nylon Lock Nut 4
20 N-103W 5/16"-18 Hex Nut 4 34 N-131 5/16"-18 Nylon Lock Nut 4
21 400026 Seat Pan 1 35 400005 Floor Pan Mounting Bracket (Left) 1
36 B-157 1/4"-20x1/2" Carriage Bolt 4
37 400011 Front Panel 1
38 20248 Choke 1
600002 Choke (Kawasaki/Honda) 1
39 20245 Ignition Switch 1
40 C-111 Cap - Floor Pan Christmas Tree 2
41 68247 Hourmeter Bracket 1
 THROTTLE ASSEMBLY

2
16
18 15
3
17
14 4

7
5
13

12 6
7
8

REF # PART # DESCRIPTION QTY.

9
1 67258 Handle Grip (Black) 1
2 97012 Handle Weldment 1 11 6 10
3 N-134 5/16" Flange Lock Nut 1
4 20224 Hairpin Cotter 1
5 N-107 3/8" -16 Nyloc Nut 1
6 W-104 3/8" Standard Flat Washer 2 REF # PART # DESCRIPTION QTY.
7 W-125 3/8" Nylon Washer 3 11 B-108 3/8"-16 x1" Bolt 1
8 C-105 C Clip 2 12 B-107 5/16"-18 x 3/4" Bolt 1
9 68249 Throttle Cable 1 13 W-113 5/16" Flat Washer 1
364000668211 Throttle Cable (Honda/Kawasaki) 1 14 65270 Upper Stainless Throttle Bracket 1
Washer 2 15 W-152 #10 Stainless Washer 2
Hex Nut 2 16 B-203 10-32x3/4" Stainless Bolt 2
Cable and Liner 1 17 W-153 1/4" Stainless Flat Washer 1
10 97011 Lower Throttle Mounting Bracket 1 18 B-209 1/4"-20x3/4" Bolt 1
 BRAKE ASSEMBLY
5 4 3
2

7
8

9
10

11

12
15
13
16 14

18

17

20

1
28 19
27
24 26
25

21

23 22

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 N/A Complete Brake 1 16 W-102 Flat Washer 2
2 97094 Brake Handle Assembly (Inc. #2 - #18) 1 17 65247 Right Brake Cable (Long) 1
3 N/A Bolt 1 18 65246 Left Brake Cable (Short) 1
4 N-134 Nut 2 19 65277 Bushing (Welded on Frame) 2
5 W-106 Washer 4 20 65244 Brake Band 2
6 65061 R Clip 2 21 P-108 Hairpin Cotter 2
7 65063 Spacer 1 22 P-107 Pin 2
8 65060 Pivot Plate 2 23 P-118 Roll Pin 2
9 N/A Nut 1 24 67266 Brake Drum 2
10 65062 Spacer 2 25 991100025 Brake Cable Retainer 2
11 B-156 Bolt 2 26 65278 Spacer Use # 65278 and 30112 or
12 N/A Hairpin Cotter 2 65284 #65284 to
13 P-129 Pin 1 30112 place brake band fully onto brake drum.
14 P-112 Pin 2 27 65243 Brake Pin 2
15 N/A Hairpin Cotter 1 28 P-118 Roll Pin 2
 XF2600,XW2600 BRAKE ASSEMBLY 4
5

2
3 4 35 36
6 3
7
8

9 37
10 33
32
11
12 31
15
30
16 13 29
1 14

18

17

20

28 19
27
24 26
25

21

23 22

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 N/A Complete Brake 1 21 P-108 Hairpin Cotter 2
2 97094 Brake Handle Assembly (Inc. #2 - #18) 1 22 P-107 Pin 2
3 N/A Bolt 1 23 P-118 Roll Pin 2
4 N-134 Nut 2 24 67266 Brake Drum 2
5 W-106 Washer 4 25 991100025 Brake Cable Retainer 2
6 65061 R Clip 2 26 65278 Spacer Use # 65278 and #30112 or
7 65063 Spacer 1 65284 # 65284 to
8 65060 Pivot Plate 2 30112 place brak e band fully onto brak e drum.
9 N/A Nut 1 27 65243 Brake Pin 2
10 65062 Spacer 2 28 P-118 Roll Pin 2
11 B-156 Bolt 2 29 B-257 1/4"-20x1.75" Bolt 2
12 N/A Hairpin Cotter 2 30 N\A Kohler Part - EFI Module 1
13 P-129 Pin 1 31 N-179 Nut 3
14 P-112 Pin 2 32 600009 EFI Module Mount 1
15 N/A Hairpin Cotter 1 33 N-102 1/4"-2- Whiz Nut 2
16 W-102 Flat Washer 2 34 N/A Fuse Holder 2
17 65247 Right Brake Cable (Long) 1 35 W-175 Washer 3
18 65246 Left Brake Cable (Short) 1 36 B-258 Bolt 3
19 65277 Bushing (Welded on Frame) 2 37 N\A Relay 1
20 65244 Brake Band 2
 ENGINE - Kohler 23 Hp
15
18 19 20 21
14
16
17

22

12
13 11 1 23
10
2 24
9
25
8
5 26
3
7
4 28
6 27

Note: Donaldson air filter wing nut

Part #P101870
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 70100-22 Oil Cooler Bracket 1 13 72120 Air Plenum Cover 1
2 B-165 3/8"-16x2" Bolt 3 14 72126 2" Rubber Hose 90 Degree 1
3 W-104 3/8" Standard Flat Washer 3 15 90125 2" Worm Clamp 4
4 N-107 3/8"-16 Nyloc Nut 3 16 60103-L Oil Cooler 2
5 90121 Donaldson Air Cleaner Complete 1 17 72126-T 2" Rubber Hose Straight 1
P103007 End Cap 1 18 90115 Turbo Pre-Cleaner 1
P002904 Clamp 1 19 B-107 5/16"-18x3/4" Bolt 4
P102523 Rubber Baffle 1 20 W-102 1/4" Standard Flat Washer 4
P101870 Internal Wing Nut 1 21 N-103-W 5/16"-18 Whiz Flange Nut 4
90122 Filter Element 1 22 90123 Donaldson Mounting Bracket 2
6 60119 Amsoil Filter 1 23 K-100 1/4" Key 1
7 B-172 1/4"-20x1" Bolt 3 24 W-145 1-1/8" x 1-3/4" x 1/8" Washer 1
8 W-102 1/4" Standard Flat Washer 3 25 9907500X600D Split Pulley 5" x 6" 1
9 60113 1/8"x3/8" 90 degree fitting 2 26 W-144 7/16" Belleville Washer 1
10 N-102 1/4"-20 Whiz Flange Nut 11 27 W-108 7/16" Lock Washer 1
11 W-102 1/4" Standard Flat Washer 16 28 B-114 7/16"-20 x 3/4" Bolt 1
12 B-102 1/4"-20x3/4" Bolt 8 29 600011 Muffler - Hp Plus One 1
 ENGINE - HONDA 24 Hp
17
18
Long
19 Short
16
21 22

18 1
13 14 15 20

Clamp for clear hose

(1 each side) 12
Part #C-113
11

2 Worm clamp for Mercury Switch

3 (fasten to starter bolt)
8 Part #68231
4
10 9 5
OPTION 6
Note: Drain Valve (Honda) 7
Part #600007

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 600008 Assembly - Hp Plus One Muffler 1 11 400010 Bracket - Honda Oil Cooler 1
600004 Muffler - Hp Plus One 1 12 N/A Ignition Module 1
600003 Manifold - Hp Plus One Exhaust 1 13 B-148 1/4" - 20 x 1 1/4" 2
600013 Gasket - Exhaust Manifold 2 14 W-102 1/4" Flat Washer 2
600012 Clamp - Hp Plus One Muffler 1 15 N-102 1/4"-20 Whiz Flange Nut 2
2 K-100 1/4" Key 1 16 B-101 1/4" - 20 x 1/2" Bolt 4
3 W-145 1-1/8" x 1-3/4" x 1/8" Washer 1 17 60103-L Oil Cooler 1
4 9907500X600D Split Pulley 5" x 6" 1 18 W-102 1/4" Flat Washer 8
5 W-144 7/16" Belleville Washer 1 19 N-177 M6-1.0 Acorn Nut 2
6 W-108 7/16" Lock Washer 1 20 N-102 1/4"-20 Whiz Flange Nut 4
7 B-114 7/16"-20 x .750" Bolt 1 21 600015 Bolt - 1/2" x 10" Hex Honda Oil
8 N-108 3/8"-16 Whiz Flange Nut 4 Cooler 1
9 W-104 3/8" Flat Washer 4 22 600014 Bolt - 1/2" x 9.5" Hex Honda Oil
10 B-124 3/8"-16 x 1.75" Bolt 4 Cooler 1
 ENGINE - KOHLER 25 Hp
14
13
12
11
10
23 24 9
8

22 Horn clamp
Part #C-113
21 Mercury Switch clamp
15 Part #C-112

20
19
2 1
17 18
3
16 4
5
7 6

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 600011 Muffler - Hp Plus One 1 13 W-102 1/4" Flat Washer 4
2 K-100 1/4" Key 1 14 B-101 1/4" - 20 x 1/2" Bolt 4
3 W-145 1-1/8" x 1-3/4" x 1/8" Washer 1 15 N-102 1/4"-20 Whiz Flange Nut 3
4 9907500X600D Split Pulley 5" x 6" 1 16 N-107 3/8"-16 Nyloc Nut 1
5 W-144 7/16" Belleville Washer 17 B-165 3/8"-16 x 2" Bolt 1
6 W-108 7/16" Lock Washer 1 18 W-104 3/8" Standard Flat Washer 1
7 B-114 7/16"-20 x .750" Bolt 1 19 400025 Amsoil Filter Mount 1
8 600016 Bolt - 1/2" x 4" Hex Kohler Oil 20 60119 Amsoil Filter 1
Cooler 2 21 60122 Amsoil Filter Head 1
9 N-102 1/4"-20 Whiz Flange Nut 4 22 W-102 1/4" Washer 3
10 400017 Bracket - Kohler Oil Cooler 1 23 B-172 1/4"-20 x 1" Bolt 3
11 N-177 M6-1.0 Acorn Nut 2 24 60113 1/8"x3/8" 90 degree fitting 2
12 60103-L Oil Cooler 1
 ENGINE - KAWASAKI 25 Hp
1
2
3
4
5
6

18 19 2 0 7

16 17 M e r c u r y S w it c h c la m p
P a rt # C - 11 2

8
15 9

10

11
REF # PART # DESCRIPTION QTY.
1 W-102 1/4" Flat Washer 4 12
2 B-101 1/4" - 20 x 1/2" Bolt 4 13
3 60103-L Oil Cooler 1 14
4 N-177 M6-1.0 Acorn Nut 4
5 400024 Bracket - Kawasaki Oil Cooler 1
6 N-102 1/4"-20 Whiz Flange Nut 4
7 600017 Bolt - 1/2" x 4.25" Hex Kawasaki REF # PART # DESCRIPTION QTY.
Oil Cooler 4
8 K-100 1/4" Key 1 15 600010 Assembly - Hp Plus One Muffler 1
9 W-145 1-1/8" x 1-3/4" x 1/8" Washer 2 N/A Gasket - Exhaust Manifold 2
10 9907500X600D Split Pulley 5" x 6" 1 16 600021 Bracket - Left Muffler Mount 1
11 364000168203 Spacer - Kawasaki Crank 1 17 600020 Bracket - Right Muffler Mount 1
12 W-144 7/16" Belleville Washer 2 18 B-107 5/16"-18x3/4" Bolt 2
13 W-108 7/16" Lock Washer 1 19 W-102 1/4 Flat Washer 2
14 B-164 7/16"-20 x 1.75" Bolt 1 20 N-103W 5/16" Whiz Flange Nut 2
 ENGINE - KOHLER 26 Hp
14
13
12
11
10
23 24 9
8

22 Horn clamp
Part #C-113
21 Mercury Switch clamp
15 Part #C-112

20
19
2 1
17 18
3
16 4

5
7
6
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 600018 Muffler - Hp Plus One EFI 1 13 W-102 1/4" Flat Washer 4
2 K-100 1/4" Key 1 14 B-101 1/4" - 20 x 1/2" Bolt 4
3 W-145 1-1/8" x 1-3/4" x 1/8" Washer 1 15 N-102 1/4"-20 Whiz Flange Nut 3
4 9907500X600D Split Pulley 5" x 6" 1 16 N-107 3/8"-16 Nyloc Nut 1
5 W-144 7/16" Belleville Washer 1 17 B-165 3/8"-16 x 2" Bolt 1
6 W-108 7/16" Lock Washer 1 18 W-104 3/8" Standard Flat Washer 1
7 B-114 7/16"-20 x .750" Bolt 1 19 400025 Amsoil Filter Mount 1
8 600016 Bolt - 1/2" x 4" Hex Kohler Oil 20 60119 Amsoil Filter 1
Cooler 2 21 60122 Amsoil Filter Head 1
9 N-102 1/4"-20 Whiz Flange Nut 4 22 W-102 1/4" Washer 3
10 400017 Bracket - Kohler Oil Cooler 1 23 B-172 1/4"-20 x 1" Bolt 3
11 N-177 M6-1.0 Acorn Nut 2 24 60113 1/8"x3/8" 90 degree fitting 2
12 60103-L Oil Cooler 1
 HONDA ELECTRICAL DIAGRAM

W BK BK GRY GRY Mercury

M Seat Switch
B S BRN R
BK

G L W
Relay W
BK Seat
86 87A 85 BK
BK
BLU
Connector
30
HORN Engine
R
R
R
DIODE
Fuse GRN BLK
FUEL
SOLENOID
BLK/YLW
BK
R
Solenoid
W
Regulator
R Starter

Battery

Low Oil Horn Mount

Kawasaki No Horn
Kohler Mounts to Engine via C-113
Honda Mounts to Oil Cooler Bracket
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 500001 Honda Wiring Harness 1 10 20226-B Battery Cable Ground (12") 1
2 20245 Ignition Switch 1 11 40229 Mercury Switch 1
3 20246-T Hour Meter/Tach 1 12 68231 Clamp for Mercury Switch 1
4 68247 Tach Bracket 1 C-112 Honda Merc. Switch Clmp. 1
5 N/A Battery 1 13 65510 Seat Relay 1
6 20228 Battery Strap 1 14 97191 Seat Relay Pigtail 1
7 14078 Battery Box 1 15 65509 Fuse 1
8 20225-B Red Rubber Boot 1 16 20254 Fuse Holder 1
9 20227-72 Battery Cable Positive (72") 1 17 60117 Low Oil Horn 1
 KOHLER ELECTRICAL DIAGRAM
1 1.
2.
White (kill wire)
Red (charge wire)
Kohler Wiring 3 2 3.
4.
Blue (start wire)
Fused wire (to hot post o n starter)
Harness 5. Green (from oil sending unit)

5 4
Connect to Kohler Dixie Chopper Wiring Harness Co nnect to Ignition
Wiring Harn ess Switch

1 W W
1 BLU
OR
R
4 3 BLU
BLK
2 3
2 5 4
BLK GR R
BLK

R R

GR

BLK
HORN OR
R
R
Starter
So leno id
1
BLK
2 3 4 R

Starter B LK
+ -
Battery
SEAT
SWITCH
Conne ct to Seat Relay
R BLK
Ground to
All connectors are viewed Transmission
Fram e BLK
from wire e nd.
REF # PART # DESCRIPTIO N Q TY. REF # PART # DESCRIPTION Q TY.
1 65522 K ohler W iring Harness 1 10 20226-B Battery Cable Ground (12") 1
2 20245 Ignition Switch 1 11 40229 M ercury Switch 1
3 20246-T Hour M eter/Tach 1 12 C-112 Clam p for M ercury Switch 1
4 68247 Tach B racket 1 13 65510 Seat Relay 1
5 N/A B attery 1 14 97191 Seat Relay Pigtail 1
6 20228 B attery S trap 1 15 65509 Fuse 1
7 14078 B attery B ox 1 16 20254 Fuse Holder 1
8 20225-B Red Rubber B oot 1 17 60117 Low Oil Horn 1
9 20227-72 B attery Cable Positive (72") 1
 KAWASAKI ELECTRICAL DIAGRAM

BK Mercury
BK
M BK
Seat BK
Switch
B S
R or BR BK
G L
Seat Engine
BL Relay Ignition BK W (Charging Coil)
R Coil
Br W W
W W

R
Fuse So Fuel
Gn

BK
l Solenoid
e R
n Regulator
o Starter
i
d
Abbr. Color
Red Battery Cable W White
Battery Red Battery Cable R Red
BK Black
Description Part Number BL Blue
Keyswitch 20245
Seat 64100-S
Br Brown
25 HP Engine 600000 Gn Green
Regulator N/A
Battery N/A
Seat Relay Connector
Starter N/A
Solenoid 20253 White
Brown
Seat Relay 65510
Fuse 65509
Fuse Holder 20254
16" Battery Cable 20226-R
72" Battery Cable 20227-72 86 87A 85
Wiring Harness 364000168205
Ground Cable
Fuel Solenoid
20226-B
N/A 30 Black
Mercury Switch 40229 Big Red
Red Rubber Boot 20225-B
 KOHLER 26Hp EFI
ELECTRICAL DIAGRAM
K e y S w it c h
S e a t R e la y C o n n e c to r
R ed
L G 30
B la c k B ro w n
S B
85 87A 86 Seat B la c k

W h ite
M
G re e n

K e y S w itc h C o n n e c to r B la c k

L G
B la c k Red
S B B la c k B lu e H o rn
M W h ite

W h ite C o n n e c to r " A " Red

M a te to C o n n e c to r " B "
B lu e
Red

C o n n e c to r " C "
M a te to E C U M o d u le Green B la c k
Y e llo w C o n n e c to r "B "
M a te to C o n n e c to r "A " Fuse
Red Red B lu e

O ra n g e
W h i te So
G re e n
l
B la c k B la c k e
n
M e rc u ry o
i
S w it c h d Red

Red B A
D io d e
Fuel B la c k Red
Pum p E C U L ig h t
G r o u n d W ir e
C o n n e c t to B r o w n w ir e o n
K o h le r E C U H a r n e s s
B a tt e r y
500005

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 65522 Kohler W iring Harness 1 11 20226-B Battery Cable Ground (12") 1
2 500002 Kohler 26Hp EFI W iring Harnes 1 12 40229 Mercury Switch 1
3 20245 Ignition Switch 1 13 C-112 Clam p for Mercury Switch 1
4 20246-T Hour Meter/Tach 1 14 65510 Seat Relay 1
5 68247 Tach Bracket 1 15 97191 Seat Relay Pigtail 1
6 N/A Battery 1 16 65509 Fuse 1
7 20228 Battery Strap 1 17 20254 Fuse Holder 1
8 14078 Battery Box 1 18 60117 Low Oil Horn 1
9 20225-B Red Rubber Boot 1 19 500003 ECO Light 1
10 20227-72 Battery Cable Positive (72") 1 20 500005 Ground W ire 1
 6302 E. County Road 100 North
Coatesville, IN. 46121
Phone 1-765-CHOPPER
www.dixiechopper.com

Dixie Chopper, Magic Circle, and the Magic Circle Atom Logo are all trademarks of Magic Circle Corporation and
may not be reproduced without permission.
Printed In USA
Specifications and instructions subject to change without notice.
Print Date 3/01
 Serial Numbers
2037165
and Higher

Model # ____________________ Engine Model # ____________________

Serial # ____________________ Engine Serial # ____________________

Date Purchased ____________________ Engine Spec. # ____________________

X X W-72 PARTS MANUAL

700006 April, 2002
Congratulations on your purchase of a DIXIE CHOPPER lawn
mower. We believe you have exercised excellent judgement, and are most
appreciative of your patronage.

Your DIXIE CHOPPER Dealer is your #1 SOURCE for

DIXIE CHOPPER parts and service !

Please call or visit your nearest authorized Dixie Chopper Dealer for
additional service information.

AUTHORIZED DEALER

Let us know how you are getting along with your new CHOPPER!
www.dixiechopper.com

Dixie Chopper reserves the right to make changes or add improvements to its products at any time without
incurring any obligation to make such changes to products previously manufactured. Neither Dixie Chopper, nor
its dealers, accept responsiblility for variations which may be evident in the actual specifications of its products and
the statements and descriptions contained in this publication.
 CONTENTS

Quick Reference Parts 1

Decals 2
Decal Placement 5
Frame 6
Wheels & Tires 9
Foot Pedal 10
Deck Lift System 11
OCDC 12
Deck 13
Hubs and Belts 15
Transmission Frame 17
Transmission & Drive 20
Wheel Motor 22
Hydraulic Hose Diagram 23
Fuel System 25
Throttle 27
Body 29
Brake 33
Center Hub 35
Engine POD 36
Engine 20Hp Kohler 39
Engine 26Hp EFI Kohler 40
Electrical Diagram 20Hp Kohler 41
Electrical Diagram 26Hp EFI Kohler 42
Notes 43
 XXW MODEL
QUICK REFERENCE PARTS
MODEL XXW2600 XXW4000
Engine Kohler 26 Hp Kohler 20Hp (2X)
Deck 72" 72"
Rear Tires 97200 97200
Rear Rims 97130 97130
Front Tire & Rim 97166 97166
Front Rims 10239 10239

Belts
Engine-Transmission 9907B41 97345
Engine-Deck 68081 68082
Deck 68162 68162
CenterHub - Engine 2 2 / 20256

Filters
Fuel Filter 97392 97392
Nelson Air Filter
Amsoil Oil Filter 60119 2 / 60119
Zinga-Hydro Filter 68140 68140

Blades
Standard 30227-72H 30227-72H
Heavy-Duty 30227-72N 30227-72N

VARIOUS PARTS ALL MODELS

Fiber Washer W-101
Spindle Bearing 30218
Deck Roller (Ctr) 30240-O
Choke Control 20248
Throttle Cable 68249
Brake Cable 65246 (Left) 65247 (Right)
Parking Brake Band 65244
Fuel Cap 40117-1
 DECALS

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 800013 XXW2600 Front Panel 1 9 97013 VTC Only 1
2 65435 XXW4000 Front Panel 1 10 30591 Warranty Notice 1
3 65436 S'Burb'N Turb"N 1 11 97160 RPM Notice 1
4 97018 City Slicker 1 12 30588 Hillside Danger 1
5 65413 Patent Pending 1 13 264000200210 VTC 1
6 800014 Ignition (Twin unit takes two.) 1 14 30586 Tractor Buster 1
7 800015 Choke (Twin unit takes two.) 1 15 30590 USA Decal 1
8 65406 Caution Brake 1
 DECALS (CONT’D)

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

16 40118 Fuel Caution 1 21 30585 Fender Caution 1
17 990765438 Belt Information 1 22 65422 Belt Route Decal 1
18 97072 OCDC Safety Decal 1 23 63401 Throttle 1
19 97514 Horn Warning 1 24 63402 Brake & Steering 1
20 30229 Deck Danger Decal 2
 DECALS (CONT’D)

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

25 30573 Floor Pan Decal 2 26 30571 Fender Decal 2
 DECAL PLACEMENT

5 T-Box
9 Oil Tank 14 Rear Left Side Left
Rear Right Fender Fender
12 24 26
15 Fender 16
23 19
32

4
1 2
11
18
10

21
16 26
13
3,4 6 7 25
25

20

17

22
 FRAME

5
4
16

6
7

17 8
14
13 11A 9
12 11 10 3

15
18
1

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 65100-XWW Weldment - XXW Frame 1 10 W-168 7/16" Standard Flat Washer 8
2 B-200 3/8"-16 U-Bolt 4 11 B-216 7/16"-20 x 3" Bolt (XXW4000) 4
3 N-160 3/8"-16 Coupling Nut 8 11A B-199 7/16"-20 x 2" Bolt (XXW2600) 4
4 97096 Rear Guard 1 12 67045-72 Bumper - XXW 1
5 400026 Weldment - Low Ride Seat Pan 13 W-160 10mm Flat Washer 3
w/ Hinge 1 14 B-179 3/8-16x2 1/2" Bolt 3
6 100007 Weldment - Low Ride 15 N-108 3/8"-16 Whiz Flange Nut 3
Transmission Frame 1 16 N-152 1/4"-20 Insert Nut 6
7 B-229 3/8"-16 x 5" Bolt 2 17 68205 1" Spacer (XXW4000) 4
8 N-107 3/8"-16 Nylon Locknut 2 18 400008 Mount - Floor Pan Hinge Frame 2
9 N-135 7/16"-20 Nyloc Nut 4
 XXW2600 CROSSMEMBER & ENGINE ADJUSTMENT

13
14 8 3
2
4
15 5
10 6
16
7
9
12 11

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 N-103-W 5/16"-18 Whiz Flange Nut 4 9 72220 Belt Guide Assembly (#10-#12) 1
2 97024 Crossmember 1 10 72217 Belt Guide Weldment 2
3 72216 Pull Stop Weldment 1 11 72222 All Thread 1/2"-13x12" 1
4 N-110 1/2"-13 Nut 7 12 N-110 1/2"-13 Nut 6
5 72221 16"x1/2" Bolt 1 13 N-157 1/2"-13 Whiz Flange Nut 6
6 W-113 5/16" Standard Flat Washer 4 14 W-109 1/2" Flat Washer 6
7 B-156 5/16"-18x2" Gr.5 Bolt 4 15 B-123 1/2"-13x1 1/2" Bolt 6
8 W-107 3/8"x1 5/8" Beveled Washer 1 16 97008 Stop Void Warrenty Decal 1
 XXW4000 CROSS MEMBER& CENTER HUB
PLACEMENT
Narrow bolt pattern to
rear of machine.
1
2

13
3
12
4
15 5
14 9 6
16
7
8
11 10

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 N-103-W 5/16"-18 Whiz Flange Nut 4 9 72217 Belt Guide Weldment 2
2 68242 Center Drive Hub Assembly 1 10 72222 All Thread 1/2"-13x12" 1
3 72216 Pull Stop Weldment 1 11 N-110 1/2"-13 Nut 6
4 N-110 1/2"-13 Nut 7 12 97024 Crossmember 1
5 72221 16"x1/2" Bolt 1 13 N-157 1/2"-13 Whiz Flange Nut 6
6 W-113 5/16" Standard Flat Washer 4 14 W-109 1/2" Flat Washer 6
7 B-131 5/16"-18x1" Gr.5 Bolt 4 15 B-123 1/2"-13x1 1/2" Bolt 6
8 72220 Belt Guide Assembly (#9-#11) 1 16 97008 Stop Void Warrenty Decal 1
 WHEELS & TIRES
1 1A
2
3
4
4
5
8 6
7
25 11
9
12
10 15
14
27 26 16
27 17
28
23 24
REF # PART # DESCRIPTION QTY. 23 19
22
1 10220 Dust Cap 2 21
1A P-108 Cotter Pin 2
2 N-142 1"-14 Slotted Hex Nut 2 18 20
3 10207 Top Bearing 2
4 10206 Outer Bearing Race 4 Tire Sealant - Part#68211 1 Liter Bottle
5 97171 Bottom Bearing 2 Front Tire @ 1 Liter
Rear Tire @ 2 Liter (Optional)
6 10208 Oil Seal 2
7 97170 Front Fork Weldment 2 REF # PART # DESCRIPTION QTY.
8 B-122 Bolt - 5/8"-11x7" Hex Head 2 97200-RB Right Tire Assembly (XXW2600)
9 N-115 Nut - 5/8"-11 Nyloc 2 (XXW4000) 1
10 67205 Inner Front Wheel Bearing 2 97200 Turf Boss III Tire (Only) 1
11 10203 Outer Front Wheel Spacer 2 97130 Rim 1
12 10205 Outer Front Wheel Bearing 2 10127-S Valve Stem 1
13 97166 Front Tire Assembly 2 19 N-113 1/2"-20 Wheel Lug Nut 8
N/A Front Tire 2 20 PB339303P Wheel Motor Axle Nut 2
10239 Rim 2 21 67266 Brake Drum 2
10127-S Valve Stem 2 22 67002 Wheel Flange w/studs 2
14 67205 Inner Front Wheel Bearing 2 23 B-183 1 1/4"x3/8" Allen Head Wheel Bolt 12
15 67204 Inner Front Wheel Spacer 2 24 W-138 Wheel Motor Square Washer 8
16 10205 Outer Front Wheel Bearing 2 25 PW72546 1/4" Key 2
17 10203 Outer Front Wheel Spacer 2 26 67118-W Wheel Motor 18Cu. In. 2
18 97201-LB Left Tire Assembly (XXW2600) (XXW2600)
(XXW4000) 1 97363 Wheel Motor 24Cu. In.
97200 Turf Boss III Tire (Only) 1 (XXW4000) 2
97130 Rim 1 27 N-127 3/8"-24 Locknut Wheel Motor Nut 12
10127-S Valve Stem 1 28 990700138 Wheel Motor Block (Twin Machine Only) 4
 FOOT PEDAL ASSEMBLY
19
15 1
18

17
7

16
4 5 6

8
9

14 3
13 2

10
11
12

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 10107-1/2 Kit - Foot Pedal 1 11 10228-1 Pin 1
2 10225-2 Weldment - #50 Foot Lift Arm 1 12 F-100 3/16" Drive-In Grease Fitting 1
3 10224-1 Pawl 1 13 B-131 5/16"-18x1" Bolt 1
4 990735020 Foot Pedal Lock (Incl. #5 - #6) 1 14 W-113 5/16" Standard Flat Washer 1
5 W-164 5/16" Wafer Spring Washer 1 15 68219 #50 Chain 1
6 N-144 5/16"-18 Nylon Jam Nut 1 16 10233 #50 Half Link 1
7 300008 Deck Height Pointer 1 17 10232 #50 Master Link 1
8 N-130 5/16"-18x1 3/4" Coupling Nut 1 18 20217-25 Spring 1
9 300007 Deck Height Indicator 1 19 30213 Hair Pin Clip 1
10 10226-1 Lift Sprocket 1
 DECK LIFT SYSTEM
7
6

2 5 1 2
1
3
4
4
4

19 13
14
10
8
11 15
12
9 8

20 16

18
8
17

R EF # PA R T # D ESC R IPTIO N Q TY .
1 68108 2 7/8" Long B us hing 2
2 61250 3/4" Long B us hing 2
3 S -114 1/2" -13 S tud 4
4 N -157 1/2" -13 W hiz F lange Nut 8 R EF # PA R T # D ESC R IPTIO N Q TY .
5 68105 1/4" Long B us hing 1 13 B -241 3/8"-16 E y e B olt 1
6 68104 #50 S m all S proc k et 1 14 N-108 3/8"-16 W hiz F lange N ut 1
7 68106 1 3/16" B us hing 1 15 W -154 3/4" F lat W as her 4
8 68103 Dec k Lift S proc k et #50 7 16 B -240 3/4"-10x 11" B olt 1
9 990710005 #50 Rear Dec k Lift Chain 2 17 B -239 3/4"-10x 10" B olt 1
10 68217 #50 F ront Dec k Lift C hain 2 18 N-158 3/4"-10 Ny loc N ut 2
11 990710002 #50 Return S pring Chain 1 19 68110 3/4" x 34 3/4" Rod 1
12 97456 225 lb. Return S pring 1 20 10232 #50 M as ter Link 10
 72” OCDC

4 5
3 2 1
6
7
2
2
17
8

11
16 17 10

7
15

13
12
14 10

13
12

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

72122 Assembly - 72" OCDC 9 68130 Control Rod (Inc. #9,11,15) 1
1 B-179 3/8"-16 x2.5" Bolt 1 10 N-157 1/2"-13 Whiz Flange Nut 2
2 W-104 3/8" Standard Flat Washer 3 11 68121 3/8"-24 Yoke 1
3 20252 Spring 1 12 B-138 1/2"-13x1" Bolt 2
4 900014 Handle 1 13 W-109 1/2" Standard Flat Washer 2
5 68142 1"x1" Plastic Plug 1 14 72123 Lower Screen 1
6 N-107 3/8"-16 Nylon Locknut 1 15 N-150 3/8"-24 Nut 1
7 20224 Hair Pin Clip 2 16 P-102 3/8"x1.25" Clevis Pin 1
8 67258 Handle Grip 1 17 W-104 3/8" Standard Flat Washer 2
 72” Deck
7 48 49 50
37 51
53
52A 51A
45
46
3 37 61
19 55
47 56
44 54
36
43 37 52
42
57
37 7
38 58
41 8
35
55
7 35A 19
39
34 3 37
40 7 7
33 60
1 8
60
7 32 29 8
30 31
8 31
30 7
27 6 7 8
28 29 8
26 1
25 2
7 3
23 24
4
12 9
11 5
22 10
21 13A 12
10
19 11
18 10 62
13 59
3 13A
20A 10
14 3
3 11 15
12 13 13
3 16
20 3
3 10 19 18
17
 72” DECK (CONT’D)
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
300020 72" Deck Assembly 34 10203 1" Shim (if needed)
1
2
67317-72
10222
Pulley Guard
Spring
2
2
35 65278
35A 30112
1/2" Shim (if needed)
1/8" Shim (if needed) **
3
4
5
N-108
65308
300016
3/8" Whiz Flange Nut
Idler Spring Tab
72" Top Plate Weldment
51
2
1
36 N-107
37
38
W-104
P-113
3/8 -16 Nylon Lock Nut
3/8" Flat Washer
3/16"x1" Roll Pin
*
1
6
1
6 334000130111 Left 3-Hole Tab 1 39 30211 Enguaging Shaft 1
7 20224 Hairpin Clip 10 40 30210 Cam Weldment 1
8 P-102 3/8"x1.25" Clevis Pin 6 30209-1 Enguaging Rod Assembly
9 30232 Left Scissor Arm 1 (Inc. #36,37,41,42,43)
10 N-156 5/8"-11 Nyloc Jam Nut 5 41 97343 Enguaging Rod 1
11 30240-0 Long Roller 3 42 30209-B Connecting Arm Bracket 1
12 B-255 5/8"-11x9" Carriage Bolt 3 43 30207-S Enguaging Spring 1
13 B-110 3/8"-16x3/4" Carriage Bolt 29 44 20217-25 Return Spring 1
13A B-135 3/8"-16x1" Carriage Bolt 4 45 N-173 #10 Nyloc Nut 1
14 B-136 3/8"-16x1.25" Carriage Bolt 10 46 30212 Enguaging Handle 1
15 300014 72" Deck Weldment 1 47 B-245 #10-24x1 1/4" Carriage Bolt 1
16 300017 Weldment - Roller Bracket 1 48 30206 5/8"x1/2" Bushing 1
17 B-253 5/8"-11x6" Carriage Bolt 1 300012 Triangle Plate Assembly
18 67240 Short Roller 2 Inc. #48,49,50,51,51A,F-102 1
19 W-135 5/8" Flat Washer 6 49 300011 Weldment- Triangle Plate 1
20 300019 Left Blowout Baffle 1 50 B-185 5/8"-11 x 2" Bolt 2
20A 300018 Right Blowout Baffle 1 51 N-180 5/8"-11 Jam Lock Nut 2
21 10203 Spacer 1 51A N-181 5/8"-11 Center Lock Nut 2
22 B-254 5/8"-11x7" Carriage Bolt 1 52 68224 Flat Idler Pulley 1
23 B-172 1/4"-20x1" Bolt 4 52A 30224 Flat Idler Pulley 1
24 F-100 3/16" Drive in Grease Fitting 2 53 30234 V Idler Pulley 1
25 67131 Scissor Link Tower Weldment 1 54 B-117 1/2"-13x1.25" Bolt 1
26 Enguaging Tower Weldment 1 55 W-140 5/8" ID. Nylon Washer 4
27 30231 Right Scissor Arm 1 56 97139 T-Idler Slide Bushing 1
28 334000130110 Right 3-Hole Tab 1 57 W-112 1/2" Lock Washer 1
29 C-104 Ring Clip 2 58 68225 T-Idler Slide 1
30 334000130109 2-Hole Tab 2 59 B-223 3/8"-16x2 1/4" Carriage Bolt 2
31 P-103 3/8" x 2" Clevis Pin 2 60 30214-72 Stabilizer Bar 2
32 97006 Pivot Stand 1 61 W-149 Waffer Washer 10
33 N-102 1/4"-20 Whiz Flange Nut 4 62 B-190 3/8"-16x1 1/2" 2

*
Use individually or a combination of 10203, 65278 and 30112 to achieve proper belt
alignment between the triangle plate and the top center deck spindle pulley.
 XXW2600 HUBS AND BELTS
1
22
3
21

16

20 19

2
1
2
3 4
4
5 5
6 6
Complete Spindle Assembly
7 9
Outside - 10161 8 8
Center - 10161-L 9 7
6
2 6
10 2
11
17
12 14
13 11
15
18
OPTIONAL
Hard-Faced 72” Blades #98125
12
Offset 72” Blades #98007
Magic Mulcher Optio nal on City Slicker 13

14

15

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 N-167 1"-14 Jam Nut 3 14 W-100 5/8" Belleville Washer 3
2 W-146 1/4" Washer 11 15 B-121 2.5" Blade Bolt (use w/o blade spacer) 3
3 W-137 1" Belleville Washer 6 B-121-L 3" Blade Bolt (use with blade spacer) 3
4 9907675X100S 6.75" Split Pulley 3 B-121-LL 3.25" Blade Bolt (use with Whiz-Mow) 3
5 W-131 1/8" Washer 3 16 9907600X100S 6.00" Pulley 1
6 30218 Sealed Bearing 6 17 30217-L Long Blade Shaft 1
7 30241 Deck Hub 3 18 30302 Whiz-Mow (Optional) 3
8 F-102 Grease Fitting 3 19 68081 Engine - Deck Belt (B-81) 1
9 30219 Inner Deck Hub Spacer 3 20 68162 Deck Belt (B-162) 1
10 30217 Short Blade Shaft 2 21 72266 Fan 1
11 30242 1/2" Blade Spacer 3 22 9907B41 Engine - Trans. Belt (not shown) (B-41) 1
12 W-101 2 1/4" OD. Fiber Washer 3
13 30227-72H 72" Standard High Lift Blades 3
30227-72N 72" Heavy Duty Lift Blade 3
 XXW4000 TWIN HUBS AND BELTS
1

3
23 21

16

23
22
2
1
2
3 4
20 19 4
5 5
6 6
7 9
8 8
9 7
6
2 6
10 2
Complete Spindle Assembly 11
17
Outside - 10161 12 14
13 11
Center - 10161-L 15
18

12
Magic Mulcher on all Twin Spindle 13
OPTIONAL Hubs.
Hard-Faced 72” Blades #98125 14
Offset 72” Blades #98007 15

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 N-167 1"-14 Jam Nut 3 14 W-100 5/8" Belleville Washer 3
2 W-146 1/4" Washer 11 15 B-121 2.5" Blade Bolt (use w/o blade spacer) 3
3 W-137 1" Belleville Washer 6 B-121-L 3" Blade Bolt (use with blade spacer) 3
4 9907675X100S 6.75" Split Pulley 3 B-121-LL 3.25" Blade Bolt (use with Whiz-Mow) 3
5 W-131 1/8" Washer 3 16 9907600X100S 6.00" Pulley 1
6 30218 Sealed Bearing 6 17 30217-L Long Blade Shaft 1
7 30241 Deck Hub 3 18 30302 Whiz-Mow 3
8 F-102 Grease Fitting 3 19 68082 Engine - Deck Belt (B-82) 1
9 30219 Inner Deck Hub Spacer 3 20 68162 Deck Belt (B-162) 1
10 30217 Short Blade Shaft 2 21 72266 Fan 1
11 30242 1/2" Blade Spacer 3 22 97345 Engine - Trans. (B-40) 1
12 W-101 2 1/4" OD. Fiber Washer 3 23 20256 Clutch - Center Drive Belt (B-38) 2
13 30227-72H 72" Standard High Lift Blades 3
30227-72N 72" Heavy Duty Lift Blade 3
 XXW2600,XXW4000
TRANSMISSION FRAME ASSEMBLY
29
28 30 1 3
27 31 32 34 2
35 7A 7
33 4 5
26 36

4
23 8
22 6
41
21 9

40 10
18 11
19
39 20 14 11
38 37 17 12
15 16 13

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 100007 Low Ride Transmission Frame 1 21 N-117 3/8"-16 Large Flange Lock Nut 1
2 B-150 5/16"x 2 1/2" Eye Bolt 1 22 30234 Pulley 1
3 N-103W 5/16"-18 Whiz Flange Nut 2 23 W-124 3/8" Machine Washer .120" 1
4 W-171 1/2" IDx1 1/4" OD Teflon Washer 2 24 W-123 3/8" Machine Washer .060" 1
5 65205 Steering Block Weldment 2 25 W-176 3/8" Machine Washer .031" 1
6 20257 Rubber Handle 2 26 61250 Spacer 1
7 400037 Foam Lever Sleeve 2 27 B-165 3/8"-16x2 Bolt 1
7A 67259 Foam Grip 2 28 B-124 3/8"x16x1 3/4" 1
8 20231-L Left Steering Lever 1 29 W-104 3/8 Standard Flat Washer 1
9 20232-L Right Steering Lever 1 30 100011 Idler Arm 1
10 W-170 1/2" IDx7/8" OD Teflon Washer 2 31 N-103W 5/16"-18 Whiz Flange Nut 4
11 W-110 1/2" Machine Washer 4 32 200008 Hydraulic Tank 1
12 20252 Spring 2 33 W-125 3/8"x7/8" Washer Plastic 1
13 N-110 1/2"-13 Nut 2 34 W-126 3/8" Washer 3
14 N-111 1/2"-13 Hex Nut 2 35 N-107 3/8"-16 Nylon Locknut 1
15 F-101 Grease Fitting 90 degree 2 36 10222 Spring 1
16 B-131 5/16-18x1" Bolt 4 37 97021 Fender Bracket 2
17 B-143G 1/2"x4 1/2" Bolt 2 38 68142 Plug 2
18 40218 Seat Strap 2 39 B-165 3/8"-16x2" Bolt 2
19 N-103-W 5/16"-18 Whiz Flange Nut 2 40 N-108 3/8"-16 Whiz Flange Nut 2
20 W-113 5/16" Standard Washer 2 41 W-104 3/8" Flat Washer 2
 XXW2600 EFI
TRANSMISSION FRAME ASSEMBLY (CONT’D)
12 26 27
15 12
17 14
4
8 10
20 19 9
12
23 13
12
18
7 25
9
19 18 11 4
23 5
4
6
25 5
4
17
20
1
21 17 16
3
24 2
23 22 1
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 B-105 5/16"-18x1 3/4" Bolt 2 12 W -110 1/2" Machined Bushing 4
2 W -113 5/16" Standard W asher 2 13 20252 Spring 2
3 N-103 5/16"-18 Hex Nut 2 14 N-175 1/2"-13 Coupling Nut 2
4 20224 Hairpin Clip 2 15 B-138 1/2"-13x1" Bolt 2
5 20222 Plastic Bushing 2 16 68142 Plastic Plug 1"x1" 4
6 200001 Right Pump Control Rod 1 17 67256 Plastic Plug 1"x2" 2
20214 Yoke 1 18 B-165 3/8"-16x2" Bolt 2
N-105 5/16"-24 Hex Nut 1 19 N-108 3/8"-16 whiz Flange Nut 2
7 65207-R Right Pump Control Arm 1 20 97021 W ide Fender Brace 2
P-118 Roll Pin 1 21 B-206 3/8"-16x1 3/8wx2"L U-Bolt 1
B-131 5/16"-18x1 Bolt 1 22 600031 EFI Module Mount 1
8 65207-L Left Pump Control Arm 1 23 W -104 3/8" Flat W asher 4
P-118 Roll Pin 1 24 N-107 3/8"-16 Nylon Locknut 2
B-131 5/16"-18x1 Bolt 1 25 20223 Spring Backing Clip 2
9 20221 Plastic Bushing 2 26 67259 Foam Grip 2
10 P-101 Pin 2 27 400037 Foam Lever Sleeve 2
11 200002 Left Pump Control Rod 1
20214 Yoke 1
N-105 5/16-24 Hex Nut 1
 XXW4000 TRANSMISSION FRAME ASSEMBLY
(CONT’D)
14
12
15 13 12
4
10
9
8

18
7
11 5
4

6
4
5
18
16
3
2 17

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 B-105 5/16"-16x1 3/4" Bolt 2 9 20221 Plastic Bushing 2
2 W-113 5/16" Standard Washer 2 10 P-101 Pin 2
3 N-103 5/16"-18 Hex Nut 2 11 200002 Left Pump Control Rod 1
4 20224 Hairpin Clip 2 20214 Yoke 1
5 20222 Plastic Bushing 2 N-105 5/16"-24 Hex Nut 1
6 200001 Right Pump Control Rod 1 12 W-110 1/2" Machinery Bushing 4
20214 Yoke 1 13 20252 Spring 2
N-105 5/16"-24 Hex Nut 1 14 N-175 1/2"-13 Coupling Nut 2
7 72207 Right Pump Control Arm 1 15 B-138 1/2"-13x1" Bolt 2
P-118 Roll Pin 1 16 68142 Plastic Plug 1"x1" 2
B-131 5/16"-18x1" Bolt 1 17 67256 Plastic Plug 1"x2" 2
8 72207 Left Pump Control Arm 1 18 20223 Spring Backing Clip 2
P-118 3/16"x1 1/2" Roll Pin 1
B-131 5/16"-18x1" Bolt 1
 TRANSMISSION & DRIVE FOR XXW2600
24
16

1
17

23
19 20 21 22
2
24

18 3
4 5 6
7 2A
17 2A 8
2
9
16
10
15
11
14

12

13
REF # PART # DESCRIPTION QTY.
1 65070 Sundstrand 10A Pump - Right 1 REF # PART # DESCRIPTION QTY.
2 N-168 3/8"-24 Whiz Flange Nut 4 13 N-114 Nut - 3/4"-16 1
2A N-184 3/8"-24 Hex Nut 4 14 65004 High Pressure Port Fitting 4
3 W-169 Washer - 5/16" Grade 8 Flat 4 15 65071 Sundstrand 10A Pump - Left 1
4 000365201 T Gear Box 1 16 67015 Case Bleed Fitting 2
5 788101 T Box Gasket 1 17 65072 Charge Pump Inlet Fitting 2
6 772150 T Box Cover Plate 1 18 25-130-30 Dump Valve - no cross port 2
7 792025 T Box Cover Plate Bolt 4 19 65001 Small Bell Housing 2
8 65206 3/8" Threaded Rod 2 20 788030B Bearing Plate Gasket 2
9 K-102 Woodruff Key 3/16"x 3/4" 1 21 792026 Bell Housing Bolt 8
10 W-167 3/4"X1/8" Hardened Flat Washer 1 22 65024 Pump O-Ring 2
11 9907500X750S Transmission Pulley 1 23 68031 T Box Fitting (Brass) 2
12 W-132 3/4" Belleville Washer 1 24 67013 Green Clamps 2
 TRANSMISSION & DRIVE FOR XXW4000
1
17

22

18 19 20 21

16
24

14
23
3 2 25
24
4 5 6
3
7
2 8

10 9

15
11
25 23 17

12
13

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 991168006 Pump - Twin Big Right 1 14 65004 High Pressure Port Fitting 4
2 N-157 1/2"-13 Whiz Flange Nut 4 15 991168005 Pump - Twin Big Left 1
3 N-185 1/2"-13 Grade 8 STD. Nut 4 16 25-130-30 Dump Valve 2
4 000365201-L T Gear Box 1 17 72016 Fitting 2
5 788101 T Box Gasket 1 18 72024 Bell Housing O-Ring 2
6 772150 T Box Cover Plate 1 19 72001 Big Bell Housing 2
7 792025 T Box Cover Plate Bolt 4 20 788030B Bearing Plate Gasket 2
8 72206 1/2" Threaded Rod 2 21 792026 Bell Housing Bolt 8
9 K-102 Woodruff Key 3/16"x 3/4" 1 22 68031 T-Box Fitting (Brass) 2
10 W-167 3/4"X1/8" Hardened Flat Washer 1 23 72021 1/2"x3/8" 90 Fitting 2
11 9907500X750S Transmission Pulley 1 24 68010 U-Tube Steel Line 2
12 W-132 3/4" Belleville Washer 1 25 60124 3/8" Hose Clamp 2
13 N-114 Nut - 3/4"-16 1
 WHEEL MOTOR

WHEEL MOTOR IDENTIFICATION #18

18 Cu. In. W80380/City Slicker
24 Cu. In. W80394/Twin S’Burb’N Turb’N

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

PB333700 Seal Kit (Contains item 1-5) 12 PB332018 Rotor Assembly (18 cu.in.) 1
1 PB018069 Dust/Shaft Seal 1 PB332024 Rotor Assembly (24 cu.in.) 1
2 IN KIT Body Seal 4 13 PB015008 Manifold 1
3 IN KIT Commutator Seal 1 14 PB012013 Commutator Assembly 18 Cu. In. 1
4 IN KIT O-ring Seal 1 PB012015 Commutator Assembly24 Cu. In.
5 IN KIT Teflon Back-up Seal 1 15 PB018056 Endcover Piston 1
6 PB018073 Snap Ring 1 16 PB018059 Piston Spring 1
7 PB018054 Thrust Washer 3 17 PB160007G Endcover 1
8 PB018052 Thrust Bearing 1 18 N/A ID Tag 1
9 PB018053 Housing Bearing 2 19 PB334018 Assembly Bolts (18 cu.in.) 4
10 PB130015 Housing 1 PB334024 Assembly Bolts (24 cu.in.) 4
11 PB014027 Drive Link (18 cu.in.) 1 20 PW72545 Shaft 1
PB014031 Drive Link (24 cu.in.) 1 21 PW72546 Shaft Key 1
22 PB339303P Shaft Nut 1
 XXW2600 HYDRAULIC HOSE DIAGRAM
25
24 3 18 18
2 1 16
18
23
5 20
5
18 7
17 22 18
21 15
3
18 4 14
23

19 13
4 18 12
5 14
18 20
5 21 18
11
10
6 6
9
18
19

18 5
8
7
Black Solid Hose
Clear Hose
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 200008 Hydraulic Tank (3-1-02) 1 14 65075 High Pressure Black Hydro Hose 2
2 40117-T T- Handle Cap w/ Dipstick 1 15 67008 3/8" Tee 1
3 60125 Fitting - 90 Deg. 3/8" Pipe Thraed x 3/8" Barb 2 16 67014 3/8" Barbed X 1/4" MPT Fitting 1
4 68140 Filter - Hydro Zinga 40 Micron 2 17 65009 3/8" Pipe Plug 1
5 65108 5/8" Clear Hose /ft. 18 67013 Clamps for 65108 (Green ) 22
6 65074 High Pressure Black Hydro Hose 2 19 68231 #4 Worm Clamp 2
7 67118-W Wheel Motor - 18 Cubic In. XXW2600 2 20 67015 Case Bleed Fitting 2
8 60103-L Oil Cooler 1 21 65004 High Pressure port Fitting 4
9 67014 3/8" barb x 1/4" MPT Fitting 2 22 68031 T Box Fitting (Brass) 2
10 67017 90 - degree fitting 2 23 65072 Charge Pump Inlet Fitting 2
11 87104 Steel Fitting 2 24 97374 5/16" Black Hose /ft.
12 87104 Steel Fitting 2 25 72012 Black Clamp 1
13 67016 1/4" Oring x 3/8" Barb 90 2
 XXW4000 HYDRAULIC HOSE DIAGRAM
19
26
3
25 16

2 1
18
5

4
16 19 22
23
3 13
15
17
19 24
4 14
12
28
15 11
10
5 18 8
21 9
23 15
6 15
7 14
25 22 19
20
9
21
9
10
11 18 8 9
Solid Hose
Ribbed Hose
Clear Hose
3/8" Solid Hose
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 200008 Hydraulic Tank (3-1-02) 1 15 65108 5/8" Clear Hose /ft.
2 40117-T T-Handle Cap w/ Dipstick 1 16 67014 3/8" Barbed X 1/4" MPT Fitting 2
3 72015 Fitting - 90 Deg. 3/8" x 1/2" 2 17 72010 High Pressure Black Hydro Hose 2
4 68140 Filter - Hydro Zinga 40 Micron 2 18 67013 Clamps for 65108 (Green) 10
5 72108 1/2" Ribbed Hose /ft. 19 68233 #8 Worm Clamp 4
6 72011 High Pressure Black Hydro Hose 2 20 87103 45 DEG. Fitting 2
7 97363 Wheel Motor - 24 Cu. In. (XXW4000) 2 21 60109 3/8" Black Hose /ft.
8 60103-L Oil Cooler 2 22 72021 Straight 1/2"x1/2" Fitting 2
9 68231 Worm Clamp 4 23 65004 High Pressure Port Fitting 4
10 67014 3/8" barb x 1/4" MPT Fitting 2 24 68031 T-Box Fitting (Brass) 2
11 67017 90 degree fitting 2 25 72021 1/2"x3/8" 90 Deg. Fitting 2
12 87104 Steel Fitting 1 26 97374 5/16" Black Hose /ft.
13 200009 Steel Fitting 1 27 72012 5/16" Black Clamp 1
14 67016 1/4" O-ring x 3/8" Barb 2 28 68010 U-Tube Steel Line 2
 XXW2600 EFI FUEL SYSTEM
1 2

3 2
1

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

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 400015 7 Gal. Fuel Tank 2 13 C-110 Clamp 1
2 40117-1 Fuel Cap - Manual Vent w/Guage 2 14 N/A Kohler Part - (Regulator) 1
3 40220 Fuel Tank Bushing 4 15 N/A Kohler Part - (Filter) 1
4 400016 Valve - Fuel Tank Shut-Off 2 16 N-102 1/4"-20 Whiz Flange Nut 5
5 97374 Gas Line - 5/16" /ft. 17 B-206 3/8"-16x1 3/8" w 2"L SQ U-Bolt 1
6 97369 Gas Line "Y" - 5/16" 1 18 W-104 3/8" Flat Washer 2
7 72012 Hose Clamp 13 19 B-102 1/4"-20x3/4" Bolt 5
8 97392 Filter - Gas & Water Parker 1 20 N-107 3/8"-16 Nylon Locknut 2
9 65008 Gas Line "T" - 5/16" 1 21 600029 Clamp 5
10 400041 Fitting 1/8MP x 5/16" 90 Deg. 2 22 500005 Ground Wire - (F/Fuel P.) 1
11 N/A Kohler Part - (Pump) 1 23 N-182 Nut (For Fuel Pump) 2
12 C-108 Clamp 2
 XXW4000-72
FUEL SYSTEM

2
1 2
1

4
8 5

5 3
6 8 4
8 6
8 8
7
8 7

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 400015 7 Gal. Fuel Tank 2 5 97374 Gas Line - 5/16" /ft.
2 40117-1 Fuel Cap - Manual Vent w/Guage 2 6 60124 Hose Clamp 2
3 40220 Fuel Tank Bushing 2 7 97392 Filter - Gas & W ater Parker 2
4 400016 Valve - Fuel Tank Shut-Off 2 8 72012 Spring Clamp (Black) 6
 XXW2600 THROTTLE ASSEMBLY

2
16
18 15
3
17
14 4

7
5
13

12 6
7
8

REF # PART # DESCRIPTION QTY. 9

1 67258 Handle Grip (Black) 1
2 97012 Handle Weldment 1
3 N-134 5/16" Flange Lock Nut 1 11 6 10
4 20224 Hairpin Cotter 1
5 N-107 3/8" -16 Nyloc Nut 1
6 W-104 3/8" Standard Flat Washer 2
7 W-125 3/8" Nylon Washer 3 REF # PART # DESCRIPTION QTY.
8 C-105 C Clip 2 12 B-107 5/16"-18 x 3/4" Bolt 1
9 68249 Throttle Cable 1 13 W-113 5/16" Flat Washer 1
Washer 2 14 65270 Upper Stainless Throttle Bracket 1
Hex Nut 2 15 W-152 #10 Stainless Washer 2
Cable and Liner 1 16 B-203 10-32x3/4" Stainless Bolt 2
10 97011 Lower Throttle Mounting Bracket 1 17 W-153 1/4" Stainless Flat Washer 1
11 B-108 3/8"-16 x1" Bolt 1 18 B-209 1/4"-20x3/4" Bolt 1
 XXW4000 THROTTLE ASSEMBLY

1 2

16
18 15 16 3
17 7
15
2
5
12 13
6
7 4
9
14
8
3
7

9
6
7 10
11
9

REF # PART # DESCRIPTION QTY.

1 67258 Handle Grip (Black) 2
2 97012 Handle Weldment 2
3 N-134 5/16" Flange Lock Nut 2 REF # PART # DESCRIPTION QTY.
4 20224 Hairpin Cotter 1 10 97010 Lower Throttle Mounting Bracket 1
5 N-107 3/8" -16 Nyloc Nut 1 11 B-165 3/8"-16x2" Hex Head Bolt 1
6 W-104 3/8" Standard Flat Washer 2 12 B-107 5/16"-18x3/4" Bolt 2
7 W-125 3/8" Nylon Washer 4 13 W-113 5/16" Flat Washer 2
8 C-105 C Clip 2 14 68271 Upper Stainless Throttle Bracket 1
9 68249 Throttle Cable 2 15 W-152 #10 Stainless Washer 2
Washer 4 16 B-203 10-32x3/4" Stainless Bolt 2
Hex Nut 4 17 W-153 1/4" Stainless Flat Washer 1
Cable and Liner 2 18 B-209 1/4"-20x3/4" Bolt 1
 21

20
17 16
19
6 5 4 18
12 5 17
11 4
27 15
39 14
28 13 15
29 14
5 9 10
4 6
30 2 5
31 4 5
40 4
32 8 7

33 23 22
XXW2600 BODY

24
3
25
9 10
26
36 7 8 1
37
38 4 5

35

34
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 400003 Fender - 7 Gal. Low Ride Left 1 22 20275 Grey Carpet 1
2 400035 Left Fender Mounting Tab 1 23 N-106 Wing Nut 2
3 400033 Left Rear 7 Gal. Fuel Tank Support Bracket 1 24 W-106 Washer 2
4 B-103 1/4"-20 Stainless Bolt 24 25 68272 Floor Pan 1
5 W-153 1/4" Stainless Flat Washer 24 26 B-104 Carriage Bolt 2
6 N-101 1/4"-20 Stainless Whiz Flange Nut 8 27 B-131 5/16"-18x1" Bolt 2
7 B-102 1/4"-20 Bolt 6 28 B-171 5/16"-18x1.5" Bolt 2
8 W-102 1/4" Flat Washer 6 29 400007 Connecting Arm 2
9 B-209 1/4"-20X3/4" Stainless Bolt 2 30 W-125 3/8" Plastic Washer 4
10 W-153 1/4" Stainless Flat Washer 2 31 400006 Floor Pan Mounting Bracket (Right) 1
11 400046 Fender - 7 Gal. Low Ride Right 1 32 N-176 1/4"-20 Nylon Lock Nut 4
12 400034 Right Rear 7Gal. Fuel Tank Support Bracket 1 33 N-131 5/16"-18 Nylon Lock Nut 4
13 400036 Right Fender Mounting Tab 1 34 400005 Floor Pan Mounting Bracket (Left) 1
14 B-105 5/16"-18x1.75" Bolt 2 35 B-157 1/4"-20x1/2" Carriage Bolt 4
15 W-113 5/16" Flat Washer 4 36 400011 Front Panel 1
16 B-131 5/16"-18x1 Bolt 2 37 20248 Choke 1
17 W-118 5/16"x1.5" Fender Washer 4 38 20245 Ignition Switch 1
18 S-115 5/16"-18x1.75" Stud 2 39 68247 Tachometer/Hourmeter Bracket 1
XXW2600 BODY

19 N-103W 5/16"-18 Hex Nut 4 40 C-111 Plastic Cap For Floor Pan 2
20 400026 Seat Pan 1
21 40100-W Seat (Complete) 1
176801 Armrest Kit (L &R) 1
176803 Left Arm 1
176802 Right Arm 1
176201 Arm Pad (L or R) 1
306025 Back Cover 1
305839 Cushion Cover 1
177827PS Springs Kit 1
 21
42
39 10 9 5
12 17
27 4
10 16
20
28 9
13 17 18 19
11 14 15
29
41
30 6
15
5 4 2 5
31 14
5 4 4
32 24 40 5
8 7 4
33 23 22
XXW4000 BODY

25 3

26 9 10
7 8 1
36
37 4 5
38
35
34
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 400003 Fender - 7 Gal. Low Ride Left 1 22 20275 Grey Carpet 1
2 400035 Left Fender Mounting Bracket 1 23 N-106 Wing Nut 2
3 400033 Left Rear 7 Gal. Fuel Tank Support Bracket 1 24 W-106 Washer 2
4 B-103 1/4"-20 Stainless Bolt 23 25 400045 Floor Pan 1
5 W-153 1/4" Stainless Flat Washer 22 26 B-104 Carriage Bolt 2
6 N-101 1/4"-20 Stainless Whiz Flange Nut 8 27 B-131 5/16"-18x1" Bolt 2
7 B-102 1/4"-20 Bolt 6 28 B-171 5/16"-18x1.5" Bolt 2
8 W-102 1/4" Flat Washer 6 29 400007 Connecting Arm 2
9 B-209 1/4"-20X3/4" Stainless Bolt 3 30 W-125 3/8" Plastic Washer 4
10 W-153 1/4" Stainless Flat Washer 4 31 400006 Floor Pan Mounting Bracket (Right) 1
11 400046 Fender - 7 Gal. Low Ride Right 1 32 N-176 1/4"-20 Nylon Lock Nut 4
12 400034 Right Rear 7Gal. Fuel Tank Support Bracket 1 33 N-131 5/16"-18 Nylon Lock Nut 4
13 400036 Right Fender Mounting Tab 1 34 400005 Floor Pan Mounting Bracket (Left) 1
14 B-105 5/16"-18x1.75" Bolt 2 35 B-157 1/4"-20x1/2" Carriage Bolt 4
15 W-113 5/16" Flat Washer 4 36 400044 Front Panel 1
16 B-131 5/16"-18x1 Bolt 2 37 20248 Choke 2
17 W-118 5/16"x1.5" Fender Washer 4 38 20245 Ignition Switch 2
18 S-115 5/16"-18x1.75" Stud 2 39 68247 Tachometer/Hourmeter Bracket 2
19 N-103W 5/16"-18 Hex Nut 4 40 C-111 Plastic Cap 2
20 400026 Seat Pan 1 41 68248 Guage Panel 1
XXW4000 BODY

21 40100-W Seat (Complete) 1 42 400043 Heat Seat Guard 1

176801 Armrest Kit (L &R) 1
176803 Left Arm 1
176802 Right Arm 1
176201 Arm Pad (L or R) 1
306025 Back Cover 1
305839 Cushion Cover 1
177827PS Spring Kit 1
 XXW2600 BRAKE ASSEMBLY
5 4

2
34 35 36
6 3
7
8

9 37
10 33
32
11
12 31
15
1 30
16 13 29
14

18

17

20

28 19
27

24 26
25

21

23 22

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 N/A Complete Brake 1 21 P-108 3/32"x1 1/2" Cotter Pin 2
2 97094 Brake Handle Assembly (Inc. #2 - #18) 1 22 P-107 5/16x1 1/4" Clevis Pin 2
3 N/A Bolt 1 23 P-118 3/16"x1 1/2" Roll Pin 2
4 N-134 5/16"-18 Large Flange Nut 2 24 67266 Brake Drum 2
5 W-106 3/8" Washer 4 25 991100025 Brake Cable Retainer 2
6 65061 R Clip 2 26 65284 Spacer - Use #65284 and #30112 or
7 65063 Spacer 1 65278 #65278 to
8 65060 Pivot Plate 2 30112 place brake band fully onto brake drum.
9 N/A Nut 1 27 65243 Brake Pin 2
10 65062 Spacer 2 28 P-118 3/16"x1 1/2" Roll Pin 2
11 B-156 5/16"-18x2" Bolt 2 29 B-257 1/4"-20x1.75" Bolt 2
12 N/A Hairpin Cotter 2 30 N\A EFI Module 1
13 P-129 5/16"x1 1/2" Clevis Pin 1 31 N-179 M5 -.8 Hex Locknut 3
14 P-112 5/16"x3/4" Clevis Pin 2 32 600009 EFI Module Mount 1
15 N/A Hairpin Cotter 1 33 N-102 1/4"-20 Whiz Nut 2
16 W-102 1/4" Flat Washer 2 34 N/A Fuse Holder 2
17 65247 Right Brake Cable (Long) 1 35 W-175 M5 Flat Washer 3
18 65246 Left Brake Cable (Short) 1 36 B-258 M5 - .8x16mm Bolt 3
19 65277 Bushing (Welded on Frame) 2 37 N\A Relay 1
20 65244 Brake Band 2
 XXW4000 BRAKE ASSEMBLY
5 4 3
2

7
8

9
10

11

12
15
1 13
16 14

18

17

20

28 19
27
24 26
25

21

23 22

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 N/A Complete Brake 1 16 W-102 1/4" Flat Washer 2
2 97094 Brake Handle Assembly (Inc. #2 - #18) 1 17 65247 Right Brake Cable (Long) 1
3 N/A Bolt 1 18 65246 Left Brake Cable (Short) 1
4 N-134 5/16"-18 Large Flange 2 19 65277 Bushing (Welded on Frame) 2
5 W-106 3/8" Washer 4 20 65244 Brake Band 2
6 65061 R Clip 2 21 P-108 3/32"x1 1/2" Cotter Pin 2
7 65063 Spacer 1 22 P-107 5/16"x1 1/4" Clevis Pin 2
8 65060 Pivot Plate 2 23 P-118 3/16"x1 1/2" Roll Pin 2
9 N/A Nut 1 24 67266 Brake Drum 2
10 65062 Spacer 2 25 991100025 Brake Cable Retainer 2
11 B-156 5/16"-18x2" Bolt 2 26 65284 Spacer Use #65284,# 65278 and
12 N/A Hairpin Cotter 2 65278 #30112 to
13 P-129 5/16"x1 1/2" Clevis Pin 1 30112 place brake band fully onto brake drum.
14 P-112 5/16" X3/4" Clevis Pin 2 27 65243 Brake Pin 2
15 N/A Hairpin Cotter 1 28 P-118 3/16"x1 1/2" Roll Pin 2
 XXW4000 CENTER HUB ASSEMBLY
1
2
2
3

4
There should be a .03125 gap between the
4 pulleys. You may have to add more 62263
3 shim, W-131, or W-146 to achieve this
5 measurement.
6
7
8
9

10

11
COMPLETE ASSY. #68242 11
12
11
13 11
14
14
Welded hub pulley faces up
15

2
2

16

REF # PART # DESCRIPTION QTY.

68242 Center Drive Hub Assembly (#1-#16) REF # PART # DESCRIPTION QTY.
1 N-167 1"-14 Jam Nut 1 9 68111 Twin Hub Mounting Plate 1
2 W-137 1"X2" Belleville Washer 4 10 B-135 3/8"-16x1" Carriage Bolt 4
3 68222 6" Cast Pulley 2 11 30218 Bearing & Spacer 4
4 W-131 1" ID x 1 1/2" OD x 1/8" Thick 2 12 300022 Spacer 1/2" Machined 1
5 W-146 1" ID x 1 3/4" OD x 1/4" Thick 1 13 788080 Retainer Ring 1
6 N-108 3/8"-16 Whiz Flange Nut 4 14 62263 Shim - Bearing 2
7 F-102 1/4"-28 Grease Fitting 1 15 9907600X600-D Center Drive Pulley 1
8 68241 Trans Center Hub 1 16 97388 Jackshaft 1
 XXW4000 ENGINE POD ASSEMBLY

2
23 24
25
1 5
3 8
22
6 7
8
8

6 8
5 20
5
9

12 10
11
21
11
13
10A
14
19
18
17 11
4
15 16 12
5
10
11
2
13
15 14

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 68076 Twin Engine Pod 1 13 W -106 3/8" Fender Washer 4
2 B-202 1/2"-13x7" Bolt 2 14 W -104 3/8" Standard Flat washer 4
3 B-124 3/8"-16x1 3/4" Bolt 1 15 N-107 3/8"-16 Nylon Lock Nut 4
4 B-188 5/8"-11x1 1/4" Bolt 1 16 B-181 5/8"-11x2 1/2" Bolt 1
5 N-111 1/2"-13 Jam Hex Nut 5 17 W -111 5/8" Lock Washer 1
6 68280 Spring Engine Idler 2 18 30234 V-Idler Pulley 2
7 B-124 3/8"-16x1 3/4" Bolt 4 19 68109 1" OD x 1" Spacer 1
8 W-110 1/2" Machined Bushing 4 20 N-108 3/8"-16 W hiz Flange Nut 1
9 68226-L Idler Engine Bracket Left 1 21 68226-R Idler bracket Right 1
10 61250 5/8"OD x .381ID x 3/4" Bushing 4 22 B-156 5/16"-18x2" Bolt 8
10A W-119 1"OD.x 5/8"ID. Machine Bushing 2 23 W -113 5/16" Flat Washer 8
11 W-140 5/8"ID.x 1 5/8"OD. Plastic W asher 8 24 W -107 3/8"ID.x 1 5/8" Beveled W asher 2
12 W-149 5/8" Wafer Spring Washer 20 25 N-103-W 5/16"-18 Whiz Flange Nut 8
 XXW4000 ENGINE OIL COOLER AND AIR
FILTER
18 17
18 18A
15
15 17 16
2 14
18A
3
4
5 13 12
6
7 11
9
8 35 34 12
10
21
36
33 19
34 22
21
31
31 20
32 22
12
31
28 23
1 24

25
37
29
30 27 26
38
26
39

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

90121 Donaldson Assembly 2,4-7,11 1 20 68014 Intake Air Hose T-Fitting 1
1 68076 Twin Engine Pod 1 21 72126 Intake Air Hose 90 Deg. 2" 2
2 P103007 Air Filter Housing Cup 1 22 Kohler No. Air Filter cap Cover 2
3 N/A Refer To Ref. #4 1 23 72120 Aluminum Plenum Cover 2
4 P002904 Clamp 1 24 Kohler No. Air Filter 2
5 P102523 Donaldson Air Filter Baffle 1 25 Kohler No. Air Filter Mount 2
6 P101870 Donaldson Air Filter Wing Nut 1 26 N/A Base Frame Plate 2
7 90122 Donaldson Air Filter 1 27 B-124 3/8"-16x1 3/4" Bolt 1
8 90123 5.3" air Filter Clamp 2 28 N-108 3/8"-16 Whiz Flange Nut 1
9 N/A 1/4"-20x1 1/4" Bolt 2 29 97033-R Back Oil Cooler Frame Bracket 1
10 N/A 1/4"-20 Nut 2 30 B-108 3/8"-16x1" Bolt 2
11 N/A Air Cleaner Canister 1 31 N-108 3/8"-16 Whiz Flange Locknut 10
12 90125 2.5 Hose Clamp 8 32 97033-F Front Oil Cooler Frame Bracket 1
13 72126-T Intake Air Hose 1 33 70100-72 Oil Cooler Bracket 1
14 90115 Tubinator 1 34 B-206 3/8"-16x1 3/8W x 2"L SQ U-Bolt 4
15 60103-L Oill Cooler 2 35 B-101 1/4"-20x1/2" Bolt 4
16 68231 Worm Clamp 4 36 N-102 1/4"-20 Whiz Flange Nut 4
17 W-102 1/4" Flat Washer 8 37 N-107 3/8"-16 Nyloc Lock Nut 8
18 B-102 1/4"-20x3/4" Bolt 8 38 600043 Spacer - Mounting Pod 4
18A N-102 1/4"-20 Whiz Flange Nut 8 39 B-244 1 3/8"W x 3 1/4"L U-Bolt 8
19 90126-T Intake Air Hose 1
 XXW4000 ENGINE PLACEMENT

15

10
20

17
11A
15
12 19
12 15
17
16 19
9
20 11 18
8
16 10 1
7

2
14 16 6
21 5
13 21
3

4
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 B-172 1/4"-20x1" Bolt 6 11A 72230 3/8"x3" Pipe Nipple 1
2 W-102 1/4" Flat Washer 6 12 Kohler No. 45 Deg.elb-1/4"mpx-.3/8" barb 2
3 N-102 1/4"-20 Whiz Flange Nut 6 13 60113 1/8"x3/8" 90 Deg. Fitting 2
4 60119 Amzoil Filter 2 14 60114 1/8"x3/8" Straight Fitting 2
5 60122 Amzoil Filter Mounting Base 2 15 68231 #4 Clamp 5
6 68119 Mounting Bracket 1 16 67013 Spring Clamp (Green) 10
7 B-135 3/8"-16x1" Carriage Bolt 2 17 67019 Hose Barb Brass 4
8 10231 Oil Drain Pipe cap 2 18 60109 3/8" Black Hose Ft./
9 68230 Oil Drain Hose 2 19 67022 1/4" Street Tee 2
10 60102 3/8" T-Union Fitting 2 20 87113 3/8" Male Pipe 3/8" Barb Straight 2
11 10230 3/8"x4" Pipe Nipple 1 21 60116 3/8" Swivel x 3/8" Barb 4
 20Hp KOHLER ENGINE

4
3

REF # PART # DESCRIPTION QTY.

1 B-199 7/16"-20x3/4" Hex Head Bolt 2
2 W-108 7/16" Lock Washer 2
3 W-144 7/16" Stainless Belleville Washer 2
4 K-100 1/4"x2 1/2" Key Stock 2
5 68300 Clutch Pulley 2
6 68306 Spacer 2
 KOHLER 26Hp EFI ENGINE
14 25
13
12
11
25
10
9
8

19
34
15
24

22 33
21

23
1 20

25 33 16
32 31
31
3
30
17 18
4

2
28 27 26
29 6 5

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 600018 Muffler - Kohler 26Hp EFI 1 18 W-104 3/8" Standard Flat Washer 1
2 K-100 1/4"x2 1/2" Key Stock 1 19 400025 Amsoil Filter Mount 1
3 W-145 1-1/8" x 1-3/4" Washer 1 20 60119 Amsoil Filter 1
4 9907500X475D Split Pulley 5" x 4 3/4"x1 1/8" Bore 1 21 60122 Amsoil Filter Head 1
5 W-144 7/16" Belleville Washer 1 22 W-102 1/4" Washer 3
6 W-108 7/16" Lock Washer 1 23 B-172 1/4"-20x1" Bolt 3
7 B-114 7/16"-20x3/4" Bolt 1 24 60113 1/8"x3/8" 90Deg. Fitting 2
8 600016 Bolt - 1/2" x 3 1/2" Hex Kohler Oil 25 68231 #4 Hose Clamp 3
Cooler 2 26 87113 3/8" Male Pipe 3/8" Barb Straight 1
9 N-102 1/4"-20 Whiz Flange Nut 4 27 60102 3/8" Black Pipe Tee 1
10 400017 Bracket - kohler Oil Cooler 1 28 68230 Oil Drain Hose Assembly 1
11 N-177 M6-1.0 Acorn Nut 2 29 10231 3/8" Steel Pipe Cap 1
12 60103-L Oil Cooler 1 30 10230 4" Pipe Nipple 1
13 W-102 1/4" Flat Washer 4 31 67019 Hose Barb Brass 2
14 B-101 1/4"-20x1/2" Bolt 4 32 67022 1/4" Street Tee 1
15 N-102 1/4"-20" Whiz Flange Nut 3 33 67013 Spring Clamp Green 6
16 N-107 3/8"-16 Nyloc Nut 1 34 60116 3/8" Swivel to 3/8" Barb 2
17 B-165 3/8"-16x2" Bolt 1
 KOHLER 20 Hp ELECTRICAL DIAGRAM

1 1. White (kill wire)

2. Red (charge wire)
Kohler Wiring 3 2 3. Blue (start wire)
4. Fused wire (to hot post on starter)
Harness 5. Green (from oil sending unit)

5 4
Connect to Kohler Dixie Chopper Wiring Harness Connect to Ignition
Wiring Harness Switch

1 W W
1 BLU
OR
R
4 3 BLU
BLK
2 3
2 5 4
BLK GR R
BLK

Vac Guage
R R
R
GR

BLK
HORN OR
R
R
Starter
Solenoid
1 Volt Guage

BLK
2 3 4 R

Starter BLK
+ -
Battery
SEAT Vac Guage
SWITCH
Connect to Seat Relay
Ground to R BLK
All connectors are viewed Transmission
Frame BLK
from wire end.

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 12 20227-36 36" Red Battrey Cable 1
2 65526 Twin Harness 2 13 60117 Horn 2
3 20245 Ignition Switch 2 14 40229 Mercury Switch 2
4 20246-T Hour Meter/Tach 2 15 C-112 Clamp for Mercury Switch 2
5 68247 Tach Bracket 2 16 65510 Seat Relay 2
6 N/A Battery 1 17 97191 Seat Relay Pigtail 2
7 20228 Battery Strap 1 18 65509 Fuse 2
8 14078 Battery Box 1 19 20254 Fuse Holder 2
9 20225-B Red Rubber Boot 1 20 68238 Vac Guage 2
10 20227-72 Battery Cable Positive (72") 1 21 68239 Volt Guage 1
11 20226-B Battery Cable Ground (12") 1
 KOHLER 26Hp EFI
ELECTRICAL DIAGRAM
K ey Sw itch
Se at R elay C o n ne cto r
R ed
L G 30

S B
B lac k 8 5 87 A 8 6 Bro wn
Seat Black

White
M
G re en

K ey Sw itch Co n ne cto r B la ck

L G
Black Red
S B B lac k B lu e H o rn
M W hite

W hite C o nne cto r "A" Re d

M ate to Co nn ec to r "B "
B lue
Red

C o nn ecto r "C "

M a te to E CU M o d ule G reen Black
Y ello w
Fu se
Red Red B lu e

O rang e

Gre en
Wh ite So
l
B la ck Bla ck e
n
M ercury o
i
S w itch d R ed

Red B A
Diode
Fu el Bla ck Red
Pu m p ECU Light
Gro un d Wire
C o n nec t to B ro w n w ire o n
K o hle r EC U Ha rne ss
Ba ttery
50 00 0 5

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 500002 Kohler 26Hp EFI W iring Harness 1
2 20245 Ignition Switch 1 11 40229 Mercury Switch 1
3 20246-T Hour Meter/Tach 1 12 C-112 Clamp for Mercury Switch 1
4 68247 Tach Bracket 1 13 65510 Seat Relay 1
5 N/A Battery 1 14 97191 Seat Relay Pigtail 1
6 20228 Battery Strap 1 15 65509 Fuse 1
7 14078 Battery Box 1 16 20254 Fuse Holder 1
8 20225-B Red Rubber Boot 1 17 60117 Low Oil Horn 1
9 20227-72 Battery Cable Positive (72") 1 18 500005 Ground W ire 1
10 20226-B Battery Cable Ground (12") 1 19 500003 ECO Light 1
 6302 E. County Road 100 North
Coatesville, IN. 46121
Phone 1-765-CHOPPER
www.dixiechopper.com

Dixie Chopper, Magic Circle, and the Magic Circle Atom Logo are all trademarks of Magic Circle Corporation and
may not be reproduced without permission.
Printed In USA
Specifications and instructions subject to change without notice.
Print Date 3/01
23(5$7,213$5760$18$/
;;:'',(6(/02'(/
 CONTENTS
XXW-72 DIESEL
Cover Page………………………………………………………………………………………… 1
Contents……………………………………………………………………………………………… 2-3
Section 1 - Introduction……………………………………………………………………………4
General Safety Suggestions………………………………………………5
Section 2 - Vehicle Identification Number Locations……………………………………………6
Section 3 - Warranty / Startup/ Maintenance / Service…………………………………………7-9
Section 4 - Mowing Machine Controls……………………………………………………………10
Section 5 - Operating Your Mowing Machine……………………………………………………10-12
Safety Interlock System……………………………………………………… 10
Correct Engine Operation……………………………………………………10-11
Starting The Engine………………………………………………………… 11
Stopping The Engine………………………………………………………11
Throttle Control……………………………………………………………… 11
Fuel Specifications…………………………………………………………11
Oil Specifications…………………………………………………………… 11
Correct Transmission Operation……………………………………………11
To Go Forward or Reverse…………………………………………………11
To Change Speed or Direction……………………………………………12
To Stop………………………………………………………………………12
Correct Machine Usage………………………………………………………12
Operation of the Machine with Mower………………………………………12
Mowing Speed………………………………………………………………12
Mowing Height………………………………………………………………12
Section 6 – Maintaining Your Machine…………………………………………………………… 13-16
Maintenance Checklist………………………………………………………13
Diesel Engine Maintenance Procedures………………….…….………. 14
General…………………………………………….………………………14
Cooling System…………………………………………………………… 14
Warning Horn……………………………………………………………… 14
Fuel System………………………………………………………………14
Priming Procedure……………………………………………………… 15
Bleeding The Injector…………………………………………………… 16
General Operating Instructions…………………………………………16
Deck Engagement……………………………………………………… 16
Section 7 – Mower Specifications and Adjustments……………………………………………17-18
Mower Adjustments………………………………………………………17
Level Mower………………………………………………………………… 17
Blade Maintenance……………………………………………………… 17
Underside Cleaning……………………………………………………… 17
Mower Drive Belt Replacement………………………………………………18
Mower Spindle Belt Replacement……………………………………………18
Mower Removal and Installation……………………………………………… 18
Cleaning and Storage…………………………………………………………18


 CONTENTS
(CONTINUED)

XXW-72 DIESEL
Section 9 – Parts List and Illustrations…………………………………………………………….. 29-61
Decals………………………………………………………………………….. 29-30
Wheel Motor / Parts List……………………………………………………………31
Deck and Rollers / Parts List………………………………………………………32
Top Plate (Assembled)…………………………………………………………… 33
Top Plate………………………………………………………………………… 34
Top Plate / Parts List………………………………………………………… 35
Deck Hubs and Belts…………………………………………………………… 36
Deck Hubs and Belts Parts List……………………………………………. 37
Deck Engaging Clutch…………………………………………………………… 38
Deck Engaging Clutch Parts List……………………………………………. 39
Operator Controlled Discharged Chute………………………………………. 40
Operator Controlled Discharged Chute Parts List………………………………41
Oil Cooler and Filters…………………………………………………………. 42
Oil Cooler and Filters Parts List……………………………………………. 43
Hydraulic Hose Routing Chart………………………………………………… 44
Hydraulic Hose Parts List…………………………………………………… 45
Engine…………………………………………………………………………….. 46
Engine Parts List……………………………………………………………………47
Transmission Frame Assembly………………………………………………… 48
Transmission Frame Assembly / Parts List………………………………………49
Parking Brake………………………………………………………………………50
Parking Brake / Parts List…………………………………………………………51
Throttle Assembly………………………………………………………………… 52
Throttle Assembly / Parts List…………………………………………………… 53
Fuel and Exhaust………………………………………………………………. 54
Fuel and Exhaust / Parts List…………………………………………………. 55
Electrical / Parts List……………………………………………………………… 56
Fenders and Covers……………………………………………………………… 57
Fenders and Covers / Parts List……………………………………………….. 58
Wheels and Tires……………………………………………………………………59
Wheels and Tires / Parts List………………………………………………… 60
Seat / Parts List…………………………………………………………………… 61
Section 10 – Notes…………………………………………………………………………………. 62-63


 INTRODUCTION
Prior to operating the Dixie Chopper M owing M achine,
you should be trained in its proper use and warned of its
dangers before operating, adjusting, or servicing it. You
should also read and understand this entire manual.
DANGER This symbol, if used, warns of
immediate hazards which will result in
severe personal injury or death.
WARNING This symbol refers to a hazard
or unsafe practice which can result in severe
personal injury or death.
CAUTION This symbol refers to a hazard
or unsafe practice which can result in
personal injury or product or property damage.
The customer is responsible for filling out the
warranty registration card. Within ten (10)
days, the customer MUST mail card to
Magic Circle Corporation
6302 E. County Road 100 North
Coatesville, Indiana 46121
Any extended warranties expressed or implied are
null and void unless proper documentation has been
sent to Magic Circle Corporation by the original
purchaser of the machine.
* Familiarize yourself with the controls and
know how to stop the mower quickly.
* Inspect your work area carefully. Remove
debris from the turf area to be cut.
* Avoid contact with moving parts. Keep
away from whirling blades. Keep feet and
hands from underneath mower deck.
* Never direct the discharge of material
toward bystanders, nor allow anyone near
the machine while in operation.
* This machine is not meant for highway or
street use. It is not a recreational vehicle
and you should never carry passengers.
* Never tamper with safety devices or
guards. If a guard or safety device is
damaged, or removed, replace before
operating the mower
* Handle gasoline carefully. Never add fuel
to tank while the engine is running or hot.

 GENERAL SAFETY SUGGESTIONS
Recommended by Outdoor Power Equipment Institute
SAFE OPERATION PRACTICE - RIDING VEHICLES
1. Know the controls and how to stop quickly - READ
THIS OWNERS MANUAL and instructions furnished
w ith attachments.
2. Do not allow children to operate machine. Do not
allow adults to operate machine w ithout proper
instruction.
3. Do not carry passengers. Do not m ow w hen
children and others are present.
4. Clear w ork area of objects (w ire, rocks, etc.)
w hich might be picked up and throw n.
5. Disengage all attachment clutches and shift into
neutral before attempting to start engine (motor).
6. Disengage pow er to attatchments and stop engine
(motor) before leaving operator position.
7. Disengage pow er to attachments and stop engine
(motor) before making any repairs or adjustments.
8. Disengage pow er to attachments w hen transporting
or not in use.
9. Take all possible precautions w hen leaving vehicle
unattended; such as disengaging pow er-take-off,
low ering attachments, shifting into neutral, stopping
engine and removing key.
10. Do not stop or start suddenly w hen going uphill or
dow nhill. Mow up and dow n the face of steep
slopes; never across the face. If a steep hill must
be asdended, back up the hill; drive forw ard w hen
descending.
11. Reduce speed and exercise extreme caution on
slopes and in sharp turns to prevent tipping or loss
of control. Be especially cautious w hen changing
directions on slopes.
12. Stay alert for holes, rocks and roots in the terrain
w hich may cause the vehicle to upset. Keep aw ay
from dropoffs.
13. Use care w hen pulling loads or using heavy
equipment.
a. Use only approved draw bar hitch points.
b. Limit loads to those you can safely control.
c. Do not turn sharply. Use care w hen backing.
d. Use counterw eights w hen suggested in ow ner’s
manual.
14. Watch out for traffic w hen crossing or near roadw ays.
15. When using any attachments never direct discharge
of material tow ard bystanders nor allow anyone near
vehicle w hile in operation.
16. Handle gasoline w ith care - it is highly flammable.
A. Use approved gasoline container. Place container
out of reach of children.
B. Use gasoline only as fuel - never as a cleaner.
Never remove cap or add gasoline to a running or
hot engine or an engine that has not been allow ed
to cool for several minutes after running. Never fill
fuel tank indoors. Wipe up spilled gasoline. And
positively NO SMOKING.

C. Open doors if engine is run in garage - exhaust
fumes are dangerous. Do not run engine (motor)
indoors.
17. Keep vehicle and attachments in good operating
condition and keep safety devices in place and
w orking.
18. Keep all nuts, bolts and screw s tight to be sure
equipment is in safe w orking condition.
19. Never store equipment w ith gasoline in the tank
inside a building w here fumes may reach an open
flame or spark
20. Allow engine to cool before storing in any enclosure
21. To reduce fire hazard keep engine free of grass,
leaves or excessive grease.
22. Vehicle and attachments should be stopped and
inspected for damage after striking a foreign object
and the damage should be repaired before restarting
and operating the equipment.
23. Do not change engine governor settings or over-
speed engine.
24. When using vehicle w ith mow er:
1. Mow only in daylight or in good artificial light.
2. Never make a cutting height adjustment w hile
engine (motor) is running if operator must
dismount to do so.
3. Shut engine (motor) off w hen unclogging chute.
4. Check blade mounting bolts for proper tightness at
frequent intervals.
25. Under normal usuage, grass catcher bag material is
subject to deterioration and w ear. It should be
checked frequently for bag replacement. Replacement
bags should be checked to ensure compliance w ith
original manufacturers recommendations or
specifications.
26. Disengage pow er to mow er before backing up. Do
not mow in reverse unless absolutely necessary
and then only after careful observation of the entire
area behind the mow er.
27. Use personal protective equipment w hen operating
or performing maintenance such as (but not limited
to) protection for eyes, ears, feet & head.
 VEHICLE INDENTIFICATION NUMBER
(VIN) LOCATIONS
Vehicle identification numbers are used to
identify your new mowing machine and
attachments. These numbers should always be
referred to when consulting your dealer or the
factory concerning service, parts, or other
information you may require, if these plates are
removed during repair operations, they should
always be replaced.
The mowing machine vehicle indentification
number plate is located on frame under seat. This
number identifies both the chassis and mower.
Engine identification number is located on engine
shrouding, and indicates model, type number and
serial number of your mowing machines engine.
For your convenience and ready reference, enter
mowing machine and engine numbers below.

Mowing Machine Identification Number

Dixie Chopper VIN Plate

Model_________________________________ Model Spec.____________________________

VIN___________________________________ Serial No._______________________________

OWNER REGISTRATION
Service and warranty assurance are as important
to Dixie Chopper as they are to you, the owner.
Magic Circle Corp. requires factory registration to
facilitate warranty service at an authorized Dixie
Chopper Dealer. A registration card is supplied
with each new machine and attachment. You must
fill in the required information and mail the card
to Magic Circle Corp.
The Dixie Chopper Limited Warranty Statement is
described on page _. This statement describes
what items are covered by the Dixie Chopper
Limited Warranty, your rights and obligations and
the procedure to follow to obtain warranty service.
Please familiarize yourself with the warranty
statement. All of us at Dixie Chopper want you to
be satisfied with your Dixie Chopper mowing
machine. Please don’t hesitate to contact us for
assistance.

* Warranty void unless registration card is returned
within 10 days from purchase. Warranty to be used only
to cover correction of manufacturing defects, it will not
be used to cover lack of maintenance, operator mis-use,
normal wear, accidents, customer dissastisfaction,
transportation charges to and from the servicing dealer
or loss of revenue.
This commercial mower has safety features that exceeded
the national specifcations; however, the user is ultimately
responsible for the safe operations of the mower.
THESE ARE NLY A FEW RECOMMENDATIONS,
BE SURE TO COMPLETELY READ ENGINE
MANUFACTURER’S OPERATOR’S MANUAL BEFORE
OPERATION OF THIS MACHINE.
FAILURE TO PERFORM ROUTINE DAILY
MAINTENANCE AS DESCRIBED WILL RESULT IN
PREMATURE ENGINE FAILURE, AND WILL VOID
ENGINE MANUFACTURER’S WARRANTY.


 WARRANTY
INTRODUCTION

Congratulations on your purchase of a Dixie

Chopper lawn mower. We believe you have
exercised excellent judgement. We are most
appreciative of your patronage. We reserve
the right to make changes or add
improvements to our products at any time
without incurring any obligation to make such
changes to our products manufactured
previously. As with all lawn mowers, if
handled carelessly, it is a dangerous piece
of equipment. If incorrectly used, this
machine can cause severe injury. YOU THE
OPERATOR ARE RESPONSIBLE WHEN
OPERATING IT. Therefore safety is of the
utmost importance.

WARRANTY

This mower is warranted for one year from
date of purchase against all defects in
materials and workmanship. Under normal
use and service our obligation, under this
warranty shall be limited to the replacement
or repair, to the original retail purchaser, of
any part or parts, which, within the warranty
period, shall be shown to be defective due to
faulty workmanship at the factory. All parts
claimed defective must be returned to the
factory for inspection, repair or replacement
with transportation charges prepaid. This
warranty does not apply to damage in transit,
or damage caused by misuse, negligence, or
accident, to alterations or repairs done outside
the factory or authorized service center, nor
does it obligate us to assume any
transportation charges in connection with the
replacement of the parts claimed to be
defective.
OUR WARRANTY DOES NOT APPLY
APPLY TO THE CHAINS, BLADES,
OR BELTS ON OUR MOWERS DUE
TO THE VERY NATURE OF THE
FUNCTION THEY PERFORM AND
THE ELEMENTS THEY ARE
EXPOSED TO, NOR LOST REVENUE.
The warranty specifically excludes engines, tires
and batteries which are separated warranted by
their respective manufacturers. All claims for
defective engines and engine parts must be made
in accordance with the engine manufacturers
warranty. This warranty is null and void if any
parts other than the original manufacturers parts
are used. There are no other warranties expressed
or implied.


 MAINTENANCE & SERVICE
DECK PITCH ADJUSTMENT
The mower deck is set to mow level at 3 1/2"
from the factory, using these settings: MOWER
DECK FRONT-second hole from the top.
MOWER DECK REAR-top hole. AXLE MOUNT
second hole from the top. When mowing at a
lower height, with the factory setting it is possible
to leave a streaking appearance. This is easily
remedied by pitch adjustment of the deck.
Dropping the rear of the deck one hole will result
in a 1" change in pitch. However, dropping the
front AND the rear will result in only a 1/2"
change pitch. Which should provide satisfactory
results when mowing at a lower height.
TRANSMISSION DRIVE BELT ADJUSTMENT
(vertical shaft engines only)
1. Loosen engine mounting nuts and bolts.
2. Loosen drive belt tensioning jam nut, and
tighten drive belt tensinoing bolt until 1/2" to
3/4" deflection exists midway between the
double engine and transmission pulleys.
3. Re-tighten engine mounting bolts and
locknuts.
4. Re-tighten jam nut.
RECOMMENDED HYDRO FILTER CHANGE
Change filter at 500 hours or annually.
1. Clean area around filters so it’s free of any
dirts and debris.
2. Fill replacement filter with 15W40 Schaeffers oil
Part #6010 6. Filter will absorb oil, so fill until it
takes no more. Pinch line to stop oil from
leaking.
3. Remove old filter on unit and replace with new.
4. You may want to loosen the charge line at the
pump and pressurize the reservoir to purge air
from the line, purge the line until no air is
present (tighten fitting).
5. With handles in neutral crank engine over with
the starter and observe oil movement in clear
line from filter base to the charge pump
(flashlight may be necessary).
6. Oil should be flowing from the filter to the
pump when you are cranking the engine. DO
NOT START THE ENGINE UNLESS OIL IS
FLOWING FROM FILTER TO PUMP.
7. If step 6 is not accomplished, check for air leaks
between charge pump port and reservoir. Note:
You must have pump primed before starting the
engine, if it is not primed it will self-destruct in
16 seconds or less.
8. With above steps accomplished, leave handles
in neutral and throttle at idle speed. You may
now start the unit. Let idle in neutral and
observe oil flow in clear line from filter mount
to pump. It chould be flowing toward the
pump. You may see a few air pockets shoot
through the line. This is OK as long as you
have movement toward the pump. If oil stops
flowing toward the pupm shut down
immediately ( check for air leaks between
charge pump and inlet to reservoir).
9. Let unit idle in neutral for at least 2 minutes and
and until no more air is observed. Bring engine
up to 2000 R.P.M.
10. Then gently stroke levers for an additional 2
minutes. At this point unit can be put back in
service.
Notes:
1. Failure to observe this procedure will destroy
pumps in 16 seconds or less.
2. Pump failure due to charge pump loosing its
prime is not a warranty item.
3. Read instructions carefully.
4. You may benefit by reading instructions twice.
LUBRICATION
See service intervals
NEUTRAL ADJUSTMENT
THE FOLLOWING PROCEDURE SHOULD BE
DONE WITH THE REAR WHEELS OFF THE
GROUND AND THE ENGINE ON.
1. Remove clevis pin from neutral adjustment
yoke at right side pump control and at steering
pivot on left side drive linkage.

 MAINTENANCE & SERVICE
2. Loosen neutral spring mounting bolt, located
on oil filter mounting bracket, adjust neutral
spring assembly to the front or rear until the
pump is in neutral and there is no motion at
drive wheels. Once this is achieved, tighten
neutral spring mounting bolt.
3. Loosen jam nut on adjustment yoke and turn
yoke so that clevis can be inserted without
force. When control lever is in neutral lock
position, the wheel should continue to sit still.
4. Start engine, operate tires in forward and
reverse and return lever to the neutral lock
position, tires should not move, if tires move
repeat above procedure.
FORWARD LEVER STOP ADJUSTMENT
THIS PROCEDURE DONE WITH ENGINE OFF!
1. Move control lever to the full forward position,
applying gentle pressure.
2. With control lever in full forward position, turn
forward lever, stop bolt down, until it contacts
steering lever pivot block arm. Onc contact is
made, give additional 1/4 to 1/2 turn.
Re-tighten jam nut.
3. Test drive machine and observe operation at
full forward on level surface. If machine does
not go straight, correct by slowing fast wheel,
(lengthen lever stop bolt). Adjust lever stop
until machine travels in a straight path with
both control levers at full forward.
4. Align control levers by swinging into neutral
position and bending levers until hangles are
parallel. Both controls should be spaced
evenly at rest and should travel together and
reach full forward uniformly.
*Lubricate beetween the transmission frame
mounting point and steering lever pivot block.
*NOTE - Late model machines are equipped with
a greaseable mounting bolt. These mounting
bolts utilize a compression spring for positive
steering resistance. Although this assembly does
not require adjustment, it should be lubricated
every 100 hours.
(Continued)
SUNDSTRAND PUMP START UP
PROCEDURE
1. With new pump installed and charge pump
return disconnected, pitch hose together to
seal off hose 1" behind swivel fitting. Note:
Vice grips will work to pinch hose, it must be
sealed off completely.
2. Remove reservoir overflow tube from plastic
overflow nipple.
3. The system is now ready to pressurize. Note:
This is done to purge air from the lines on the
inlet side of the pupm and to assure the pump
has an immediate oil supply to the inlet side of
the pump. Maximum 5 lbs.
4. Using an air regulator, pressurize the system
until clear line is full of oil down to pump inlet
90 fitting (page 60 Fig. 10) and oil comes out of
charge pump return 90 fiting. Note: maintain
pressure on the reservoir through step 5.
5. With handles in neutral position (Note: Brake
must be in off position) crank engine over and
observe oil in clear tube. The oil should be
traveling towards the pupm and coming out of
the charge pump return 90 fitting. Do not start
engine unless you have determined you have
oil flowing to the pump while cranking engine
with the starter. Note: If this condition does
not exist, check for air leaks from 90 inlet fitting
to reservoir.
6. Remove pressure from reservoir and install
overflow tube back onto overflow nipple, and
remove vise grips from charge pump return line
and connect line back onto charge pump return
90 fitting. With throttle in idle position, and
handle in neutral, start engine, let idle for no
less than 60 seconds, then lightly stroke the
levers. After 2 minutes of lightly stroking the
levers and achieving steady movement of the
wheel hub, you may stroke the levers fully.
7. Reinstall rear wheel and lug nuts.
8. Check fluid level in hydraulic reservoir and fill
if necessary.
NOTES
1. You must follow this procedure.
2. Failure to observe above procedure will destroy
this pump in 16 seconds or less.
 MAINTENANCE & SERVICE (Continued)

3. Pump failure due to a dry start up is not a

warranty item.
4. You may profit from reading your instuction
twice.

ENGINE TO DECK BELT ADJUSTMENT

This belt only requires 40 lbs of tension to
achieve satisfactory results. New mchaines
equipped with the 30209-1 connecting arm may be
adjusted using this procedure: With engine off,
engage mower deck, tighten bolt to compress
spring. Proper tension has been chaieved when
spring height reaches 2" in the engaged position,
which should allow 1/2" to 3"4 distance between
the double jam nut and the tensioner assembly. A
visual check can be made by simply engaging the
mower deck. During this action the last 1/4 turn
should be spring compression.


 MOWING MACHINE CONTROLS
1. THROTTLE CONTROL
Throttle is located on top of right fuel tank
just ahead of fuel cap. Move throttle
forward all the way to operate machine.
Move throttle all the way to rear before
shutting engine off.
2. IGNITION SWITCH
Ignition switch is located on right side of
front panel below seat. Ignition switch has
three positions: (1) Off, (2) Run, and (3)
Start. To start engine, turn key all the way
to the left. Release key when engine starts
and it will automatically return to Run
position. Turn switch to Off position to stop
engine.
3. CHOKE CONTROL
Choke control is located on right side of
front panel next to ignition switch. Pull
choke knob out when starting engine.
Slowly push knob in after engine starts. If
engine is warm and has been running,
choking may not be necessary to restart
engine.
5. RIGHT AND LEFT MOTION CONTROL
LEVERS
To enter seat, move levers all the way left and
right into neutral lock position. Enter seat and
move levers in toward center of machine. Left
lever controls left rear wheel and right lever
controls right rear wheel. To go forward, push
both levers forward evenly; the further levers
are pushed forward, the faster the machine will
travel. To turn, slow machine down and slow
speed of wheel in direction you want to turn.
6. FUEL TANK VALVES
Fuel tank valves are located at bottom of each
tank. Fuel valves are normally left open except
when service on fuel system becomes
necessary.
5
6

4. MOWER LIFT PEDAL

Mower foot lift pedal is located on left side
of foot platform. To raise mower, push OPERATING YOUR
down on front of pedal. To lower, push MOWING MACHINE
down on and rotate foot to move bottom of
pedal down, remove foot from pedal when SAFETY INTERLOCK SYSTEM
desired height is obtained.
Each machine has interlock switches. Switches
1 are actuated by the seat. Seat switch will stop
engine when seat is vacated with engine
2 running. Seat must be occupied.
3 If machine will not starts, check that seat is
occupied.
4 To test operation, the following functions must
be performed by an Authorized Dixie Chopper
Dealer for your protection.
1. Engine should NOT start if seat is not occupied.
2. With engine running, test operate seat switch by
rising off seat. Engine should shut off.


 OPERATING YOUR MOWING MACHINE
WARNING
Care should be taken to avoid inhaling exhaust
gases as they contain carbon monoxide gas, which
is colorless and odorless. Carbon monoxide is a
dangerous gas that can cause unconsciousness and
is potentially lethal. Do not run engine in confined
areas such as a closed garage.
STARTING ENGINE
To start engine, occupy seat. Move throttle
control lever halfway to operate position. Pull
choke control all the way out to cold position.
Turn ignition key to relase key. Switch is
spring-loaded and will return to run position
automatically.
If the engine fails to start after 10 seconds of
continuous cranking, turn the key to the OFF
position and allow the starter motor to cool.
Check for the cause of hard starting; consult the
Troubleshooting Checklist.
Once engine has started, slowly return choke
control to its normal position. If engine stalls at
low speeds, or hesitates during acceleration,
choke should be applied as necessary until engine
reaches normal operating temperature.
STOPPING ENGINE
To stop engine, move throttle lever to idle
position and turn ignition key to OFF position. If
engine has been working hard or engine is hot,
allow engine to idle a short time before turning
key off. This practice will help cool engine before
stopping.
Note: In case of emergency, engine may be
stopped by turning ignition key to OFF position.
CAUTION
Always remove key when leaving machine
unattended, even if for just a few minutes. Prevent
accidents; don’t give children or unauthorized
persons an opportunity to operate this machine.
THROTTLE CONTROL
Throttle control regulates speed of engine as
measured in RPM (Revolution Per Minute). This
control should not be used to regulate the ground
speed.
Engine has been designed with a special
governor that limits engine RPM. Unlike an
automobile, this governor allows engine to
operate most efficiently at a set speed and
protects it from damage caused by excessive
RPM. Always operate machine with throttle
control set a 3/4 to full speed.
CHOKE CONTROL
Choke control activates a "butterfly" valve in
carburetor. When choke is partially or completely
closed, less air is admitted to engine. This results
in a higher fuel-to-air (richer) mixture that is
required when engine is started cold. Warm
engines may not need choking.
CAUTION
Handle fuel with care-it is highly flammable.
Use only approved fuel container. Never add fuel
while engine is running. Fill fuel tanks outdoors
with extreme care. Never fill fuel tanks indoors.
Replace gasoline cap securely and wipe up all
spilled fuel.
CORRECT TRANSMISSION OPERATION TO
GO FORWARD OR REVERSE
Machine is equipped with a separate
transmission for each rear wheel. Transmissions
are controlled with "Motion Control Levers," one
for each wheel.
CAUTION
Sudden starts can be damaging to equipment and
could cause loss of operator control.
For safe operation, never move the motion
control lever too rapidly, especially on grades.
To go forward, push both levers forward evenly.
To go in reverse, pull both levers evenly.

 OPERATING YOUR MOWING MACHINE
TO CHANGE SPEED OR DIRECTION
To change direction of machine, slowly move
levers to neutral and move levers in direction you
want to go.
The further levers are moved away from neutral
position, the faster machine will travel. To turn
machine left or right, slow speed of wheel in
direction you want to turn.
TO STOP
To stop machine, return both levers evenly to
neutral position.
CORRECT MACHINE USAGE
CAUTION
Read manuals provided with attachments before
operating. These manuals give a more detailed
description of operation and point out other areas
of caution. Familiarize yourself thoroughly with
equipment before attempting to use it.
OPERATION OF THE MACHINE WITH
MOWER
IMPORTANT
Keep all shields and mower discharge chute in
place. Never attempt to clear discharge areas or
mower blades without disengaging mower and
removing ignition key.
For best operation on average lawn, operate
engine at full throttle; control ground speed with
transmission. Average lawns ate usually cut at a
height between 2 and 3 in. (5-7.6 cm). Tall grass
and weeds should be cut with the mower in its
highest position, making a second pass cutting to
height desired. Always keep mower blades sharp.

MOWING SPEED
Mower is designed to operate most efficiently at
maximum blade seds. Speed of machine should
allow mower blades to maintain this maximum
speed while mowing across turf. Slow machine for
cutting tall grass, grass that is heavy with
moisture, or when moving uphill. If ground speed
is too fast, or blade speed is too slow, mowing
will be uneven because moer blades will not be
able to lift grass into cutting position as mower
passes over ground.
MOWING HEIGHT
Best cutting height for your lawn has probably
been established from previous experience. First
time you mow, set mower to cut a little higher than
you have in past. This will help you determine the
best approach to uneven areas, to be sure wider
cut does not result in scalping high spots, in
general, recommended cutting height is 2 to 3 in.
(5-7.6 cm).
Very tall grass can be cut without difficulty by
using a little care. Set mower in its highest cutting
position and enter area slowly. If necessary, take
a cut one half width of mower, overlapping
previously cut area on each pass. Then, with
mower set to desired height, make a finish cut
over the entire area.
LUBRICATION POINTS

Every 50 Idler Arm Pivot

Left Side Drive Hub
Hours

Every 50 Front Wheel Bearing

1 Each Front Wheel
Hours

Every 250 Deck Spindle

Hours Discharge Side


 LUBRICATION POINTS

Belt Tensioning Swing

Every 250 Arm, Center Spindle,
Scissor Linkage Pivot,
Hours Engaging Rod Cam

Every 250 Steering Lever Pivots

(Under Seat)
Hours

Every 500
Front Caster Bearings
Hours


 Routine Maintenance

Che ck Engine Oil Level C he ck Hydraulic Oil Level Che ck T ire Pre
Daily Checks Use oil in accordance 15W40 Synthetic or full synthetic Rear 5-7 psi - 6 prefer
manufact urers reco mmend at io ns Front 10-14 psi

Lube Deck Spindles, Idler Arm

Every 50 Hours Pivots, Front Wheel Bearings,
(3-5 pumps)

Check engine to T ran

Every 100 Hours Change Engine Oil Check Battery Fluid Level Belt T ension
(If ap p licab le) 1-1/2 " fro m id ler t o frame

Lube Steering Cle an Donaldson Air Filter End Cap

Every 250 Hours Levers (DO NOT BLOW OUT WIT H COMPRESSED AIR)

Every 500 Hours

Change Hydraulic Filters C hange Amsoil Filter Re move Be lts and C he c
or Annually Bearings, Idlers, and Pu
Lube Front C lean or Replace C he ck Steering for Cre
Caster Bearings Spark Plugs in the Neutral Position
Che ck Front and Rear Re place Engine
T ires for T read Wear Fuel Filter(s)

C hange Hydraulic Drive Oil

Every 2000 Hours DO NOT USE HYDRAULIC OIL, HYTRAN, OR AUTOMATIC TRANSMISSION FLUID.
USE ONLY A HIGH GRADE 10W50,15W40,20W50 MOT OR OIL T HAT MEET S T HE
MINIMUM VISCOSIT Y REQUIREMENT S OF: 89 SUS or BETTER @ 212 DEGREES
FAHRENHEIT.

Note: The recommended Hydraulic Drive oil for your Dixie Chopper machine is
D/C Part#60106. We strongly urge that you use this oil in the event that you
should need to refill or add to your hydraulic reservoir. However, if this oil is
unavailable to you, any premium grade 10W40, 15W50, 20W50 synthetic or
synthetic blend may be used PROVIDING IT MEETS THE ABOVE
REQUIREMENTS.


 Diesel Engine Maintenance Procedures
General
The Dixie Chopper Diesel Engine machines are
equipped with several features that have special
operating and maintenance procedures. Please
read and fully understand these before operating
your machine.
All diesel models are liquid cooled and are
equipped with a radiator. The radiator screen
and cooling fins should be cleaned and
checked on a daily basis.
Cooling System
The radiator air intake screen (A) should be
visually inspected and cleaned on a daily basis.
The screen may be cleaned by simply running
your hand over it to remove the accumulated
chaff.
The radiator cooling fins should be cleaned
weekly by blowing compressed air through the
fins. This is accomplished by releasing the
rubber straps (B) and allowing the air intake
screen to open outward as pictured in figure 2.
The air intake screen seal (C) should be
inspected for a proper seal. Oil from spilled
diesel fuel needs to be removed with soap
and water.

Warning Horn
The diesel powered Dixie Chopper machines are
equipped with a warning horn that will should in the
event of low oil pressure or excessive coolant temp-
erature. This horn will sound for a short period of
time when the engine is first started. If the horn
should sound after start-up, you should maneuver the
machine to a safe stopping area immediately and
shut off the engine as quickly as possible to avoid
severe engine damage.
Fuel System
The fuel system is equpped with many safety
features to prevent engine damage. If you should
run out of fuel, YOU MUST FOLLOW THE PROPER
PRIMING, BLEEDING, AND STARTING PROCE-
DURES OR SEVERE ENGINE DAMAGE WILL
RESULT!!!!! Please read and understand the following
procedures to avoid potential problems.
 Diesel Engine Maintenance Procedures
Priming Procedure - XXWD5000 Bleeding The Injector

The XXWD5000 series diesel machine is Locate the rear injector as shown by letter "A" in figure
equipped with a self bleeding fuel delivery 2 below.
system and should only need to be primed
manually if it should run out of fuel. Locate the
fuel shut-off petcock on the water seperator and
fuel filter as shown in letter "C" in photo Figure 5
below. Be certain that it is in the run or down
position as shown. Loosen the two phillips head A
bleed screws on the water seperator. These are
identified as A and B in Figure 1.

FIGURE 2
Loosen the injector fuel supply line as shown in Figure
3 by turning counterclockwise. Crank engine until fuel
A B spray is visible from the injector fuel supply line.
Remember not to exceed 30 seconds of cranking
without releasing the ignition switch.
Once you have fuel spray at the injector nozzle, stop
C cranking and tighten the fuel supply line. If your engine
does not start and operate normal, repeat the injector

FIGURE 1 D bleeding procedure as needed until all air is removed

from the supply line.
Radiator removed for clarity of photo.

Locate the manual fuel pump lever located on

the fuel delivery pump as identified by letter "D" A
in Figure 1. Pump the handle in an up and down
motion until you see fuel coming out of bleed
screw "A" at the water seperator. Once you
have fuel at screw "A", tighten screw. Continue
pumping while the water seperator fills. Once it
is full of fuel you will see fuel coming from bleed
screw "B". You may then tighten screw "B".
Continue pumping until the fuel filter is full of
fuel. At this point you are ready to start the
engine.
Be extremely cautious while cranking the
FIGURE 3
engine. DO NOT USE ETHER IN AN
ATTEMPT TO START THIS ENGINE.
DO NOT CRANK THE ENGINE FOR MORE NO
THAN 10 SECONDS AT ONE TIME WITHOUT
ETHER
RELEASING THE KEY. ALLOW AT LEAST 1
NO
MINUTE OR MORE BETWEEN ATTEMPTS OR
ETHER
PERMANENT DAMAGE TO THE FUEL
SOLENOID AND/OR STARTER, WILL RESULT!


 Diesel Engine Maintenance Procedures
General Operating Instructions

Please refer to the general operating and safety

information included in the forward section of this
book. The following is informational procedure
that is unique to the XW2600 and the XXW5000
machines only. Do not attempt to operate these
machines until you have read and thoroughly
understand these instructions and the ones
included in the general operation and safety
sections in the front of this book.

Deck Engagement

The mower deck engaging lever and parking brake

lever are located to the left of the seat as shown in
Figure 4 below. Position engine speed at idle and
depress the button on the mower engaging handle
and push forward to engage mower deck.
To set parking brake simply pull up toward you.

Parking
Brake

Engagement

FIGURE 4
Routine Maintenance

For lubrication and filter information please see

the routine maintenance section on pages
5,6, and 7.


 MOWER
GENERAL
Refer to Usage Section of this manual for basic
mowing information.
MOWER ADJUSTMENTS
Drive and Spindle Belts
* Check that all belts seats in pulleys.
* Check that connecting arm spring height is 2
inches in the "engaged" position. Adjust
turnbuckle if necessary.
LEVEL MOWER
Side-to-side leveling of mower deck is
accomplished by lowering mower and adjusting
threaded eyebolts, at front of deck. Park mower
on level surface and place a level across front of
mower deck or position mower blade tips side-to-
side. Adjust eyebolts, so that mower is level or
distance between right and left blade tip ends and
surface is the same.
Mower leel front-to-rear is adjusted by changing
stabilizer bar positions. Always adjust each side
evenly. Adjust at rear or middle of stabilizer bar
by removing hairpin cotters and clevis pins and
raising or lowering stabilizer bar position,
changing mower deck pitch.
To mow in 2 1/2" to 4" cutting height range,
leave as shipped. For cutting below 2 1/2", it may
be necessary to lower rear deck.
NOTE: NEVER allow rear of deck to be lower
than front unless cutting height is in fully raised
position (6"). And you are mowing tall weeds.
This is the ONLY exception and will happen
automatically with deck at fully raised position.
BLADE MAINTENANCE
CAUTION
Sharp edges of mower blades can cut you
during blade maintenance or adjustment. Use
suitable covering over cutting edges of blade
to prevent bodily harm.
To obtain optimum mower results, mower blades
should be kept sharp and well balanced. To
sharpen blades, simply lift front of machine and
support it with jack stands or floor jack. Remove
blade attaching bolts and washers from end of
spindles and remove blades. A short piece of
2" x 4" lumber may be placed between side of
mower deck and blade to "lock" it in position
when loosening attaching hardware.
File or grind blades evenly. Take care to retain
angle of original cutting edge. Blade balance can
be checked on an inexpensive blade balancer,
available at most hardware stores.
Reinstall blades with lift area (turned up section)
facing mower deck. Tighten blade attaching bolts
to a torque of 80-100 ft. lbs. (112-140 nm)
UNDERSIDE CLEANING
It is vital importance to clean the underside of
deck frequently. Accumulation of matter clippings
seriously impairs mower’s ability to "lift" grass
blades into cutting position and discharge
clippings evenly. Matted grass clogging under-
side of mower is often cause of uneven cutting.

 MOWER
MOWER DRIVE BELT REPLACEMENT
Be sure to purchase genuine Dixie Chopper belts
for replacement purposes as these belts are
designed specifically for each application.
MOWER SPINDLE BELT REPLACEMENT
Be sure to purchase genuine Dixie Chopper belts
for replacement purposes as these belts are
designed specifically for each application.
TO REMOVE MOWER SPINDLE BELT:
* Remove engine to deck belt from top groove
of center spindle.
* Make note of wrapping procedure of belt to
insure placement of new belt.
* Graspbelts on both sides of either outboard
deck spindle and pull belt away from pulley
until it is possible to remove belt. Once this is
done remove from remaining pulleys and
discard.
(FOR MOWER BELT INSTALLATION,
REVERSE SEQUENCE OF REMOVAL
PROCEDURES.)
CLEANING AND STORAGE
After 30 days, painted surfaces may be waxed to
protect the luster of the original finish. Machine
should be washed regularly with a mild
automotive type detergent and water.* Exposed
bare metal surfaces should be coated with oil, or a
light coating of grease, to prevent rust until
permanent repairs can be made. Aerosol cans of
touch up paint are available through your
Authorized Dealer.

(CONTINUED)
When the machine will not be used for an
extended period of time, the following steps will
help insure minimum difficulty when unit is
returned to service:
* Perform required maintenance steps called for in
the "Maintenance Checklist."
* Check tires for proper inflation.
* Wash machine and repaint all bare metal
surfaces.
* Start machine and engage mower for
approximately 1 minute to remove excess water
water from belts and pulleys. Let engine run out
of gas. As gasoline grows old, it becomes less
volatile and forms harmful gum and varnish
deposits in carburetor and fuel system. DO
NOT STORE GASOLINE FOR MORE THAN 2
MONTHS.
* If applicable, charge battery. In temperatures
lower than 40 F (4 C) a battery will maintain a
charge for about 60 days. In temperatures
above 40 F (4 C) water level should be checked
and batter "trickle charge" every 30 days (more
often in higher temperatures). Battery must be
fully charged to prevent freezing and internal
damage in weather below 32 F (0 C).
* Remove key from machine.
* Cover seat swich and solenoid from direct water
spray.
 DECALS

1
2 3

7
4 13

5 9 14

15
10

11 16

18

17
12 19


 DECALS

21

20

22

23

24


 DECALS PARTS LIST
ITEM PART
NO. DESCRIPTION NO.

1 Belt Route……………… 65422

2 Brake and Steering…… 40202-87
3 Throttle……………………40203-87
4 Patent Pending…………65413
5 Warranty Notice…………30591
6 USA………………………30590
7 Choke……………………65412-C
8 Ignition……………………65412-I
9 Check Oil…………………65431
10 Idler Position…………… 97014
11 Tractor Buster……………30586
12 Deck Decal………………65437
13 Air Filter………………… 30589
14 Hillside Caution…………30588
15 Parking Brake……………65406
16 Motor Oil Caution……… 97013
17 Deck Danger……………30229
18 Fender Caution…………30585
19 Fuel Caution…………… 40118
20 OCDC Safety……………97072
21 RPM Decal…………….. 97160
22 Fender………………….. 30571
23 Floor Pan…………………30573
24 Suburban Turbine………65436
25 Diesel Fuel Only……………………
26 XXWD5000…………………..


Item Description Part Number Item Description Part Number
1 Dust/Shaft Seal………………… PB018069 12 Rotor Assembly…………PB332018
2 Body Seal (4)………………… Items 13 Manifold……………………PB015008
3 Commutator Seal………………1-5 See kit 14 Commutator Assembly…PB012013
4 O-ring Seal……………………… below 15 Endcover Piston…………PB018056
5 Teflon Back-up Seal…………… 16 Piston Spring…………… PB018059
Kit Seal…………………………PB333700 17 Endcover………………… PB160007G
6 Snap Ring………………………PB018073 19 Assembly Bolts………… PB334018
7 Thrust Washers……………… PB018054 20 Shaft………………………PW72545
8 Thrust Bearing…………………PB018052 21 Shaft Key…………………PB339101
9 Housing Bearing………………PB018053 22 Shaft Nut…………………PB339303P
10 Housing…………………………PB130015 25 Bearing Spacer…………… PB018096
11 Drive Link………………………PB014027


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Item Description Part Number

1 3/8"-16 x 1" Carriage Bolt…………… B-135
2 72" Blowout Baffle……………………50315-72
3 3/8"-16 Whiz Flange Nut……………N-108
4 5/8" Flat Washer…………………… W-135
5 "Danger" Deck Decal………………… 30229
6 72" Cut Decal…………………………65437
7 5/8"-11 Nylon Insert Lock Nut………N-115
8 Bolt 5/8 - 11 x 9………………………B-146
9 72" Deck Shell w/Weldments………72302
10 5/8"-11 x 7" Bolt……………………… B-122
11 7 1/2" Long Roller……………………30240-O
12 3 3/4" Short Roller……………………67240
13 Long Roller with Bearing……………50240-OB
14 Short Roller with Bearing……………67240-B
15 Bearing………………………………… 10205

 :UV6RGZK'YYKSHR_
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 :UV6RGZK3U]KX*KIQ
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Item Description Part Number
1 Top Plate w/ Weldments…………………72303
2 Pulley Guard……………………………… 67317-72
3 Decal Belt Info…………………………… 65438
4 Spring Tab…………………………………65308
5 Spring………………………………………10222
6 3/8" x 1" Carriage Bolt……………………B-135
7 3/8" Whiz Flange Nut…………………… N-108
8 3/8" Flat Washer…………………………… W-104
9 5/8" Flat Washer…………………………… W-135
10 5/8" id x 1 5/8" od Nylon Washer……… W-140
11 "T" Idler Arm………………………………68225
12 Bushing for "T" Idler Arm ………………97139
13 5/8" Wafer Spring Washer………………W-149 (5)
14 1/2" Whiz Flange Nut…………………… N-157
15 5" Flat Idler Pulley…………………………68224
16 1/2"-13 x 1" Hex Bolt………………………B-138
17 Danger Deck Decal………………………… 30229
18 1/4"-20 x 3/4" HHCS Bolt…………….. B-102


 .[HY

























 .[HYGTJ(KRZY

Item Description Part Number

1 B-162 Belt…………………………………68162
2 B-82 Belt………………………………… 68082
3 Long Blade Shaft…………………………30217-L
4 24" x 2.5" H (standard) Blade…………… 30227-72H
24" x 3" (wide) Blade…………………… 30227-72N opt
5 Inner Deck Hub Spacer………………… 30219
6 Deck Hub…………………………………30241
7 5/8" Belleville Washer……………………W-100
8 Grease Fitting…………………………… F-102
9 Blade Spacer (1/2" thick)……………… 30242
10 5/8"-18 x 3 1/4" Blade Bolt………………B-121 L
11 5/8" id x 2 1/4" od Fiber Washer……… W-101
12 Fan…………………………………………72266
13 6" V Pulley………………………………… 68222
14 1"-14 Slotted Hex Nut……………………N-142
15 1" x 2" Belleville Washer…………………W-137
16 1" id x 1 1/2"od x 1/8" Washer…………W-131
17 1" id x 1 3/4" od x 1/4" Washer…………W-146
18 1" Sealed Bearing………………………… 30218
19 1" id x 7" od x 1/8" Washer…………… W-148
20 7" V Pulley………………………………… 68223
21 Short Blade Shaft…………………………30217


 *KIQ+TMGMOTM
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Item Description Part Number

1 5/16" x 1 14" Clevis Pin………………P-107
2 Clutch Handle Assembly………………97303
3 5/16"-18 Hex Nut………………………N-103
4 5/16"-18 x 1 1/2" Bolt HHGR5……… B-171
5 Long Spacer……………………………65062
6 5/16"-18 x 2" Bolt HHGR5……………B-156
7 Clutch Cable……………………………990597303-C
Cable Only


 

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Item Description Part Number

1 1/4" Eye Bolt……………………… B-100
2 Clip Hair Pin # 13…………………20224
3 1/4"-20 Whiz Flange…………… N-102
4 3/8"-24 Yoke………………………68121
5 Spring………………………………10222
6 3/8"-24 Nut………………………… N-148
7 1/2"-13 x 1" HH Bolt……………… B-138
8 1/2"-13 Whiz Flange Nut………… N-157
9 Handle Grip……………………… 67258
10 5/8" Flat Washer…………………W-109
11 3/8" Jam Friction Nut……………N-112
12 3/8"-16 x 2" Carriage Bolt………B-205
13 3/8" Plastic Washer……………… W-125
14 Control Rod……………………… 68130
15 Lower Screen…………………… 72123
16 Control Lever………………………97044
17 3/8" Flat Washer…………………W-104
18 3/8" Nylon Lock Nut……………… N-107
19 1"x1" Plug…………………………68142
20 3/8" x 1 1/4" Bolt…………………B-109
21 Plastic Knob………………………68139
22 3/8" x 1 1/4" Clevis Pin………… P-102


 +TMOTK'OX,ORZKX
Item Description Part Number
1 Turbo Pre-cleaner…………………………90115
2 2" Hose Clamp…………………………… 90125
3 Intake Air Hose (Short)……………………90126-T
4 Air Cleaner Cannister……………………… 90121
5 Primary Donaldson Air Filter……………… 90122
6 5 1/3" Air Cleaner Cannister Clamp………90123
7 Donaldson Air Filter Wing Nut……………P101870
8 Donaldson Air Filter Rubber Baffle………P102523
9 Air Cleaner Cannister and Cup Clamp… P002904
10 Air Filter Cup Housing…………………… P103007
11 Donaldson Air Cleaner Bracket………… 97331
12 3/8"-16 Hex Bolt……………………………B-108
13 3/8"-16 Whiz Flange Nut…………………N-108

 

 







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Item Description Part Number
1 Oil Tank Reservoir…………………… 68018
1A 1/2"MP x 3/8" Barb Fitting…………72014
2 Oil Filter Mount………………………60104
3 Hydraulic Oil Filter………………… 68140
4 Left Hydro Pump……………………97308
4a Right Hydro Pump………………… 97307
5 Wheel Motor…………………………67118-W
6 Short Oil Cooler……………………… 60103-L
7 Hose Fitting…………………………65004
8 3/8" Clear Oil Line…………………… 65108
9 3/8" Black Hose - 67"………………60109
10 1/2" Braided Clear Hose……………72108
11a 1" Steel Braided Hose - Left………97309
11b 1" Steel Braided Hose - Left………97310
11c 1" Steel Braided Hose - Right……… 97311
11d 1" Steel Braided Hose - Right……… 97312
12 1/2" Barb Fitting…………………… 72015
13 3/8" Hose Clamp……………………60124
14 Hose Fitting…………………………65005
15 1/2"Pipe to 1/2"Hose Fitting………72017
16 1/2" MP x 3/8" Barb 90° Fitting……72021
17 3/8" Barb Fitting…………………… 67016
18 3/8" Pipe Fitting…………………… 87104
19 45° Fitting……………………………87104
20 3/8" Hose Fitting……………………67014
21 #4 Micro Hose Clamp………………68231
22 Spring Clamp (Green)………………67013
23 3/8"FPx1/4" O-ring 90° Fitting…… 67017
24 45 deg Fitting 65005


 =NKKRYGTJ:OXKY





 
 

  

 
 







  
 
 





 PARTS LIST
ITEM PART
NO. DESCRIPTION NO.

1 Front Tire Assembly………………………………………97166

(Contains 2,3,31,32)
2 Front Rim (Rim Only)……………………………………10239
Hairpin Cotter…………………………………………N/A
3 Front Tire (Tire Only)……………………………………97165
4 Front Fork…………………………………………………97170
5 Outer Front Wheel Spacer……………………………… 10203
6 Outer Front Wheel Bearing………………………………10205
7 Inner Front Wheel Bearing………………………………67205
8 Inner Front Wheel Spacer………………………………… 67204
9 5/8"-11 X 7" Hex Head Bolt……………………………… B-122
10 5/8"-11 Hex Nut………………………………………… N-115
11 Grease Fitting…………………………………………… F-100
12 Dust Cap………………………………………………… 10220
13 1" Slotted Hex Nut……………………………………… N-142
14 Top Bearing………………………………………………10207
15 Outer Bearing Race………………………………………10206
16 Bottom Bearing…………………………………………… 97171
17 Seal……………………………………………………… 10208
18a Back Right Tire Assembly……………………………… 97200-RB
(Contains 19,20,31,32)
18b Back Left Tire Assembly…………………………………97201-LB
(Contains 19,20,31,32)
19 Rear Rim (Rim Only)……………………………………97130
20a Rear Tire Turf Boss III (Tire Only)………………………97200
20b Rear Tire CTR (Tire Only)………………………………10156-C72
21 Wheel Motor (18 Cu In)…………………………………67118-W
22 Thrust Washers……………………………………………PB018054
23 Thrust Bearings…………………………………………… PB018052
24 Dust/Shaft Seal……………………………………………PB018069
25 Snap Ring…………………………………………………PB018073
26 Wheel Stud……………………………………………… B-226
27 Wheel Flange…………………………………………… N/A
Wheel Flange Assembly (Contains 26,27)……………67002
28 Lug Nuts………………………………………………… N-113
29 Shaft Nut…………………………………………………PB339303P
30 Shaft Key…………………………………………………PW72546

NOT SHOWN
31 Valve Stem……………………………………………… 10127-S
32 Tire Sealant (32 Fluid Oune Bottle)………………………68211


 

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 PARTS LIST
ITEM PART
NO. DESCRIPTION NO.

1 Lever Arm and Sprocket Assembly……………………10225-1

2 Height Control Sprocket………………………………… 10226-1
3 Lift Arm Pawl…………………………………………… 10224-2 (#50)
4 Foot Pedal……………………………………………… 10218-1
5 Pivot Link…………………………………………………10223-1
6 Pin…………………………………………………………10228-1
7 Long Foot Spring………………………………………… 10222
8 Short Foot Spring……………………………………… 20217-25
9 Foot Pedal Chain………………………………………… 68219 (#50)
10 5/16"-18 x 1 1/2" Full Thread Hex Head Bolt…………B-105
11 5/16"-18 x 1" Full Thread Hex Head Bolt…………… B-131
12 5/16" Standard Flat Washer……………………………W-113
13 5/16"-18 Nyloc Nut………………………………………N-103
14 5/16"-18 x 3/4" Coupling Hex Nut……………………… N-130
15 Clevis Pin…………………………………………………P-101
16 Nylon Spacer……………………………………………N/A
17 Clip………………………………………………………… 30213
18 Grease Fitting……………………………………………F-100
19 Hairpin Cotter……………………………………………N/A

Complete Foot Pedal Assembly…………………… 10107-2 (#50)

Contains 1,2,3,5,7,8,9,10,13,17,19


,XUTZ+TMOTK'YYKSHR_ 




 



 





 


  

 





 


















 
 


 ,XUTZ+TMOTK'YYKSHR_

Item Description Part Number Item Description Part Number

1 1/2" x 1 1/2" Hex Bolt…………………B-123 16 1/4" Whiz Flange Nut…………………Yanmar
2 1/2" Machine Washer…………………W-110 17 1/2" x 1 1/2" Carriage Bolt……………B-211
3 1/2" Plastic Washer……………………W-139 18 Alternator……………………………… Yanmar
4 5/16" x 1 1/2" Hex Bolt……………… B-171 19 1/2" Whiz Flange Nut…………………N-157
5 5/8" x 1" Hex Bolt………………………B-120 20 Spacer…………………………………… Yanmar
6 Plastic Fan……………………………… 62207 21 Square Washer (Bent)…………………Yanmar
7 5/16" Whiz Flange Nut………………… N-103-W 22 1/4" x 4 1/2" Hex Bolt…………………Yanmar
8 Spring……………………………………10222 23 5/16" x 1" Hex Bolt……………………Yanmar
9 Pulley……………………………………97137 24 Left Idler Arm……………………………97403
10 Belt (Engine to Left Pump)……………B-40 25 Right Idler Arm…………………………97402
11 Belt (Engine to Right Pump)…………B-40 26 4 1/2" Pulley……………………………30234
12 Belt (Engine to Alternator)……………A-38 27 Right Hydro Pump……………………… 68006-R
13 Double Groove 3-hole Pulley…………97320 28 Left Hydro Pump………………………68005-L
14 3/16" x 3/4" Hex Bolt………………… Yanmar 29 Right Pump Mount Bracket…………. 97060
15 Alternator Bracket………………………Yanmar 30 Left Pump Mount Bracket…………… 97059
ENGINE REAR
ASSEMBLY


 
UPPER DECK DRIVE  

ASSEMBLY 


 





 


  

 


 




 
  




DECK DRIVE BELT 

TENSION TRUNION



 






 

 
  


 



 
 





  
  


 












BELT TENSION ARM ASSEBLY 


  


 REAR ENGINE ASSEMBLY





 
 


 







 REAR ENGINE ASSEMBLY


















 






 REAR ENGINE PARTS LIST

ITEM PART
NO. DESCRIPTION NO.

1 1"-14 HEX NUT…………………………………………N-167

2 1" x 2" BELLIVILLE WASHER……………………… W-137
3 7" OD x 1" ID "C" SECTION PULLEY………………… 97318
4 1" ID x 1 3/4" OD x 1/4" WASHER……………………W-146
5 FAN………………………………………………………72266
6 1" ID x 1 1/2" OD x 1/8" WASHER……………………W-131
7 5/16"-18 x 3/4" HEX HEAD BOLT……………………B-107
8 CRANK DRIVE SUPPORT PLATE……………………97064
9 PLATE…………………………………………………… N/A
10 BEARING………………………………………………N/A
KIT CONTAINS: 8 & 9"……………………………… 63301
11 5/16"-18 WHIZ FLANGE NUT…………………………N-103-W
12 LOCKING COLLAR……………………………………63216
13 6" OD x 1" ID CAST PULLEY…………………………68222
14 1" SEALED BEARING…………………………………30218
15 3/8"-16 x 1 1/4" CARRIAGE BOLT……………………B-136
16 DIESEL JACKSHAFT MOUNT……………………… 97061
17 CENTER HUB………………………………………… 30242
18 JACKSHAFT……………………………………………97388
19 BELT GUIDE BRACKET (LEFT)……………………… 97349
20 3/8"-16 x 1 1/4" HEX HEAD BOLT……………………B-109
21 3/8" FLAT WASHER……………………………………W-104
22 DECLUTCH BELT GUIDE……………………………97149
23 3/8"-16 WHIZ FLANGE NUT………………………… N-108
24 IDLER SPROCKET ADJUSTABLE ARM……………20216-1
25 5/8"-11 FIN HEX NUT…………………………………N-120
26 IDLER TRUNION………………………………………97350
27 1/2"-13 NYLON INSET LOCK…………………………N-143
28 ENGAGING SPRING TUBE WELD…………………… 97357
29 TRUNION ALL-THREAD……………………………… 97397
30 1/2 MACHINRY BUSHINGS………………………… W-110
31 SPRING…………………………………………………30207-S
32 1/2"-13 NYLON JAM NUT…………………………… N-126
33 1/2"-20 ADJUSTABLE YOKE N-163
34 3/8"-16 x 6-1/2 HHCS GR5…………………………… B-140
35 5/16" STANDARD FLAT WASHER…………………… W-113
36 3/8" ID x 5/8" OD x 5/8" BUSHING……………………97415
37 4 1/4" IDLER V PULLEY………………………………30234
38 DIESEL DECLUTCH PIVOT ARM……………………97063
39 3/8"-16 NYLON LOCK NUT…………………………… N-107
40 DRIVE BELT GUIDE ( TOP RIGHT)…………………97396
 REAR ENGINE PARTS LIST (cont’d)

ITEM PART
NO. DESCRIPTION NO.

41 REAR DRIVE BELT GUIDE (BOTTOM RIGHT)……97393

42 SPRING…………………………………………………20252
43 1/2" FLAT WASHER……………………………………W-109
44 5/16"-18 x 1 1/4" HEX HEAD BOLT………………… B-174
45 CABLE MOUNT BRACKET…………………………… 65061
46 ALUMINUM CABLE BRACKET……………………… 99071016
47 CABLE BRACKET SHIM………………………………99071017
48 DECLUTCH ASSEMBLY MOUNT BRACKET………97062
49 1/2-13 x R" BOLT HHCS………………………………B-207
50 GREASE FITTING………………………………………F-100
51 ENGAGING SPRING…………………………………… 97390
52 5/16"-18 x 2 1/2" HEX HEAD BOLT………………… B-173
53 3/8" ID x 9/16" ID x .395 SPACER…………………… 97417
54 5/16"-18 NYLON JAM NUT……………………………N-144
55 ENGAGING CABLE……………………………………990597303-C
56 3/8" ID x 5/8" OD x .26 SPACER………………………97416
57 #10 METRIC FLAT WASHER…………………………W-160
58 #8 METRIC LOC WASHER……………………………W-163
59 #10-1.50 x 25 MM HEX HEAD BOLT…………………B-219
60 #8-1.25 x 20 MM SOCKET HEAD CAP SCREW…… B-221
61 #10 METRIC LOC WASHER………………………… W-162
62 REAR CRANKPLATE…………………………………97342
63 TAPER SHAFT FOR CRANKPLATE…………………97341
64 #8 METRIC FLAT WASHER………………………… W-161
65 #8-1.25 x 20MM HEX HEAD BOLT…………………… B-220
66 B-40 DAYCO BELT……………………………………97345
67 3/8"-16 x 1" CARRIAGE BOLT……………………… B-135
 ,[KR

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Item Description Part Number
1 3-Gallon Fuel Tank…………………………………………
40204-1
2 Fitting 90 deg Elbow 1/4" Barb x 1/4" THD (Shutoff)… 40230
3 Fuel Tank Valve………………………………………… 40219
4 Fuel Gauge Cap……………………………………………40117-1
5 40211
1/4" ID Fuel Line……………………………………………
6 Gas Tank Grommet…………………………………… 40220
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Item Description Part Number Item Description Part Number

1 Radiator Screen Box………… 97150 9 Turbo Pre-cleaner………… 90115
2 Rubber Tubing………………… 97385 10 Rear Pulley Guard…………97347
3 Radiator Deep Core……………97188 11 Coolant Overflow Tank……97337
4 Rubber Latch Assembly………97368 12 Coolant Overflow Cap…… N/A
5 Radiator Mount……………… 97187 13 Low Oil Siren………………97362
6 Electric Fan……………………97189 14 1/4" Hose…………………… 40211
7 2" Hose Clamp………………… 90125 15 Top 1" Hose………………… 97336
8 2" Rubber Hose……………… 72126 16 Bottom 1" Hose……………97335
 
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Item Description Part Number Item Description Part Number

1 Short Oil Cooler………………………… 60103-L 13 Steering Control Block…………………65205
2 5/16"-18 Hex Nut………………………N-103 14 Left 1/2" Linkage Rod…………………97348
3 Transmission Frame…………………… 65250 15 Right 1/2" Linkage Rod……………… 97348
4 Reserve Oil Tank………………………68018 16 .08" x 1.2" Hair Pin……………………20224
5 5/16"-18 x 1" Hex Bolt…………………B-131 17 3/16" Bolt……………………………… B-102
6 1/2" x 4 1/2" Grease Fitting Bolt…… B-143-G 18 3/16" Washer…………………………… W-102
7 Left Steering Rod………………………97304 19 3/16" Nut………………………………… N-102
8 Steering Lever Spring…………………20252 20 5/16" Flat Washer……………………… W-113
9 Right Steering Rod…………………… 97305 21 5/16"-18 x .84 Nutsert…………………N-153
10 1/2"-13 Hex Nut………………………… N-110 22 5/16"-18 x 1 3/4" Hex Bolt……………B-105
11 1/2"-13 Hex Jam Nut………………… N-111 23 Outer Hand Grip……………………… 67259
12 1/2" Machinery Bushing………………W-110 24 Inner Hand Grip…………………………20257
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Item Description Part Number
1 Long Brake Cable……………………………………65247
2 Short Brake Cable……………………………………65246
3 Plate ………………………………………… 65060
4 5/16" x 3/4" Clevis Pin………………………………P-112
5 3/16" x 1 1/2" Roll Pin………………………………P-118
6 3/16" x 1" Roll Pin……………………………………P-100
7 Brake Band……………………………………………65244
8 5/8" ID x 7/8" OD x 1" Spacer………………………65278
9 Bar Stock 5/8" x 4.25" With Groove & Holes……65243
10 Short Spacer…………………………………………65063
11 5/16" x 1 1/4" Clevis Pin…………………………… P-107
12 5/16" Flat Washer……………………………………W-113
13 5/16" Black Flat Washer……………………………W-113
14 Brake Handle…………………………………………65245
15 5/16"-18 Nylon Jam Nut……………………………… N-144
16 5/16"-18 x 1 1/2" Bolt HH GR5……………………… B-171
17 Cable Retainer Clamps (New Style)……………… 65061
18 5/16" Fender Washer………………………………. W-134
19 Long Spacer………………………………………… 65062
20 5/16"-18 x 2" Bolt HH GR5…………………………B-156
21 3/32" x 1 1/2" Cotter Pin……………………………P-108
22 5/16" X 1 1/4" Pin……………………………………P107
23 Brake Drum……………………………………………67266
24 Knob for Brake Handle………………………………65281
25 Screw For Brake Handle……………………………65282
26 5/16"-18 Whiz Flange Nut…………………………… N-103
 :NXUZZRK'YYKSHR_





  

 

 

 



 


 




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Item Description Part Number
1 Handle Grip - Black………………………67258
2 Throttle Handle………………………….. 97147
3 Mounting Bracket…………………………65270
4 Throttle Handle Bracket………………… 97011
5 3/8" Yoke………………………………….68121
6 Throttle Rod……………………………… 97144
/ 7
8
1/4"-20 Nut…………………………………N-100
5/16" x 1" Clevis Pin………………………P-101
9 Hair Pin………………………………….…20224
10 5/16"-16 Nylon Lock Nut…………………N-107
11 3/8" Plastic Washer………………………W-125
12 1/4" Flat Washer………………………… W-102
13 5/16"-18 Whiz Flange……………………N-103-W
14 #10-32 x 3/4" Bolt…………………………B-203
15 #10 S.S. Flat Washer…………………… W-152
16 3/8" Fender Washer………………………W-106
17 5/16" Standard Flat Washer…………… W-113
18 5/16" x 3/4" Bolt……………………………B-131
19 3/16" C-Clip……………………………… C-105
20 5/16" x 1 1/4" Bolt…………………………B-174

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Item Description Part Number Item Description Part Number

1 Main Frame…………………………97300 13 R.H. Swing Out Fender…………………97365
2 Transmission Frame………………65250 14 Bumper……………………………………67045-72
3 3/8" x 3" U-Bolt……………………B-200 15 Tiny Tach - Tachometer / Hour Meter…20246-T
4 L.H. Front Fender Bracket……… 68275 16 Water Temp Gauge……………………… 97355
5 R.H. Front Fender Bracket……… 68276 17 Oil Pressure Gauge…………………… 97354
6 L.H. Rear Fender Bracket…………68273 18 Volt Meter………………………………… 68239
7 R.H. Rear Fender Bracket………… 68274 19 Instrument Panel…………………………68248
8 Floor Pan (Stainless)………67268 20 3/8"-16 x 1" Hex Bolt……………………B-108
(Powder Coating)………67271 21 3/8" Standard Washer………………… W-104
9 Louvered Front Panel………………68268 22 3/8" Whiz Flange Nut……………………N-108
10 L.H. Swing Out Fender……………97364 23 3/8"-16 Nylon Lock Nut…………………N-107
11 Carpet………………………………97359 24 3/8" Machine Washer…………………… W-124
12 Crash Guard……………………… 68026
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Item Description Part Number

1 Arm Rest Cover 40097
2 RH Armrest Kit 40095
3 LH Armrest Kit 40096
4 High Back Seat Top Cover 40098
5 High Back Seat Bottom Cover 64100
6 Right Lumbar Adjustment Knob 64098
7 Left Back Adjustment Knob 64099
8 Vertical Adjustment Detent Guide 64096
9 4-Way Lumbar Vertical Adjustment Knob 64097
10 Self Tapping Screw 64095

High Back Seat Complete 64100-W

Seat Pan (not shown) 68401

Rubber Bushing (not shown) 97177
Steel Cable (not shown) 40218
X Information Bulletin
Technical Bulletin
Service Bulletin

Date: 06/17/02

Bulletin Number: 061702

Models Affected: XXWD2600, XXWD5000
Reason For Change: From Idac to Yanmar Key switch.
Description Of Change: All new deisel machines coming out of factory have
the new yanmar key switch. The ‘new’ switch has no diagram to go by.
Also the hole in the front panel needs to be enlarged to 1.100 to accept
the new key switch.
(THIS IS A STOPGAP MEASURE UNTIL A NEW DIAGRAM CAN BE MADE)

Yanmar Key switch

P.N. 933110-00100

YELLOW PURPLE

19 50
30
17

AC

RED
GREEN
BROWN

ORANGE
 

  


 
 



 
  

 

 






 
 










  
 






 




 XWD2600-60 & XXWD2600-72
UPDRIVE PARTS LIST
ITEM PART
NO. DESCRIPTION NO.

1 1"-14 Hex Nut…………………………………………… N-167

2 1" ID x 2" OD Belliville Washer………………………… W-137
3 Engine to Deck Pulley (Pre-2000 Models)……………… 97318
Engine to Deck Pulley (2000 & Newer Models)…………9907700X100C
4 1" ID x 1 3/4" OD x 1/4" Washer……………………… W-146
5 Fan……………………………………………………… 72266
6 1" ID x 1 1/2" OD x 1/8"………………………………… W-131
7 5/16"-18 x 3/4" Bolt……………….…………………… B-107
8 Crank Drive Support Plate……………………………… 97064
9 Plate……………………………………………………… N/A
10 Bearing…………………………………………………… N/A
Kit Containing: 9 & 10………………………………… 63301
11 5/16"-18 Whiz Flange Nut……………………………… N-103-W
12 Locking Collar…………………………………………… 63216
13 Jackshaft Drive Pulley (Pre-2000 Models)……………… 68222
Jackshaft Drive Pulley (2000 & Newer Models)…………9907600X100S
14 1" ID Sealed Bearing…………………………………… 30218
15 3/8"-16 x 1 1/4" Carriage Bolt…………………………… B-136
16 Diesel Jackshaft Mount………………………………… 97061
17 5/16"-18 x 2 1/2" Bolt…………………………………… B-173
18 5/16" Flat Washer……………………………………… W-113
19 Declutch Belt Guide……………………………………… 97149
20 Belt Guide Bracket (Left)……………………………… 97349
21 5/16"-18 Lock Nut……………………………………… N-131
22 Center Drive Hub………………………………………… 30242
23 3/8"-16 Whiz Flange Nut………………………………… N-108
24 Jackshaft………………………………………………… 97388
25 Rubber Mount Pad……………………………………… N/A
26 3/4" Belliville Washer…………………………………… W-132
27 Donaldson Filter Mounting Bracket…………………… 97411
28 Rubber Mount Pad……………………………………… N/A
Rubber Mount Pads (Contains 25 & 28)………………… 97412
29 5/16" Fender Washer…………………………………… W-118
30 Donaldson Filter End Cap……………………………… P103007
31 Donaldson Filter Rubber Baffle………………………… P102523
32 Donaldson Filter Clamp………………………………… P002904
33 5/16"-18 x 1 3/4" Bolt…………………………………… B-105
34 Donaldson Filter Mounting Clamps……………………… 90123
35 Wing Nut………………………………………………… P101870
36 Donaldson Filter………………………………………… 90122
37 Donaldson Filter Cannister……………………………… N/A

Donaldson Filter Kit (Contains 30-32 & 35-37)……… 90121

 Document # 700001

60” Diesel Engine Mount Diagram




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Mount *S LNSJ 5FIX < J QIJ IYT +WFR J 
NOTE: Discard both (Ref.#10) W-172 Washers that are in the kit.
Diesel Engine Mount Kit (Contains 1-10) Part # 600025
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 Document # 700001

72” Diesel Engine Mount Diagram

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Mount 

*SLNSJ5FIX <JQIJIYT+WFRJ

Diesel Engine Mount Kit (Contains 1-10) Part # 600025

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FRONT WEIGHT
',;,(&+233(5
/4,

* BUMPER REMOVED FOR CLARITY*

INSTRUCTIONS

1. Remove contents and verify proper parts and quantities are included.
2. Place Front Weight Weldment (1) on front frame rail.
3. Insert one U-Bolt (2) on each side through the holes in bracket.
As shown in Figure 1.
4. Thread Nyloc Nuts (3) onto each U-Bolt (2) and tighten into place.
Also shown in Figure 1.
',;,(&+233(5
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ITEM PART
NO. DESCRIPTION NO. QUANTITY
1 FRONT WEIGHT WELDMENT…………… 10100-DW 1
2 3/8'-16 x 2 1/2" x 2" U-BOLT………………. B-218 2
3 3/8"-16 NYLOC NUT………………………. N-107 4

FRONT WEIGHT ASSEMBLY………….. 10100-ADW 1

ROLL CAGE

INF#000801
 1

3
5
6
6

7
Ref # Description Part # Quanitity
1 Roll Cage for All 72" Models (Shown)……… 97888 1
Roll Cage for 60" Gas Models………………… 97887 1
Roll Cage for 60" Diesel Models……………… 97333 1
2 3/8-16x2 1/2 Bolt……………………………… B-179 3
3 3/8 Flat Washer………………………………… W-104 3
4 3/8"-16x1 3/4 Coupling Nut…………………… N-160 8
5 XXWD 5000 Frame (Shown)………………… 97300 1
XXWD 2600 Frame…………………………… 97398 1
XXW Frame…………………………………… 65100-XWW 1
XWD 26000 Frame…………………………… 98399 1
XW & XF-60 Frame…………………………… 65100-W 1
6 3/8x3 U-Bolt..……………………………….… B-222 4
7 3/8-16 Whiz Flange Nut……………………… N-108 3
',;,(&+233(5
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ITEM PART PRICE

NO. DESCRIPTION QTY NO. EACH
1. Shoe 3 68301 $
2. Spring 3 68302 $
3. Bearing 2 97155
4. Outer Snap Ring 1 68303
5. Inner Snap Ring 1 68304
GENERA
GENERAC C REPO WER
REPOWER
Par ts & Inf
arts or
Infor ma
ormation
mation
26.5Hp and 30Hp
Repo wer Kits
pow
July 2002
 S.N. Engine______________________________________
S.N. Machine_____________________________________
Engine to Deck Belt Part Number ___________________
Engine to Transmission Part Number_________________
Date Engine Was Installed__________________________

Engine
Engine warranty is provided by the engine manufacturer. Please refer to the engine manufacturer warranty
statement included within the ownership materials provided with the unit. Dixie Chopper is not authorized
to handle warranty adjustments on engines. Engine warranty claims must be filed with the appropriate
engine manufacturer ( Generac, Kohler, Kawasaki, Honda etc.) for necessary warranty repairs. In general, engines
used on Dixie Chopper units are warranted by the respective engine manufacturer for a period of two years
from the retail purchase date on behalf of the original owner.
Transportation for Warranty Repairs
A Dixie Chopper complete unit (including any defective part’s) requiring warranty repair, must be returned
to an authorized Dixie Chopper Service Dealer within the warranty period. The expense of transporting the
unit to and from the dealer for warranty work will be the responsibility of the unit owner.
All warranty work must be performed by an authorized Dixie Chopper Servicing Dealer.
This warranty covers only Dixie Chopper complete units which are properly serviced, maintained, and operated under
conditions considered normal for commercial turf equipment.
Disclaimer
Any and all statements or representations made by seller of this equipment, including those set forth in any sales
literature or made orally by any sales representative, are superceded by the terms of this warranty. There are no
representations or warranties, which have been authorized and provided to the buyer of Dixie Chopper equipment,
other than as set forth in this warranty. Any affirmation of fact or promise made by Dixie Chopper or any of its
representatives to the buyer which relates to the goods that are the subject of this warranty shall not be regarded as
part of the basis of the bargain and shall not be deemed to create any express warranty that such goods shall
conform to the affirmation or promise.

Dixie Chopper reserves the right to make changes or add improvements to its products at any time without
incurring any obligation to make such changes to products previously manufactured. Neither Dixie Chopper, nor
its dealers, accept responsiblility for variations which may be evident in the actual specifications of its products
and the statements and descriptions contained in this publication.

To obtain the latest information on your Dixie Chopper lawn mower, and receive the highest quality
service, please call or visit your nearest authorized Dixie Chopper Dealer.

Dealer Name-_______________________________________________
Phone Number-______________________________________________
Please Note All Parts in this brochure are for the
2000 and newer mowers, for older mowers Please
refer to page 8 for additional parts.

Also a new throttle and choke assembly is highly

recommended.

P.N. 900062-Kit- Repower Generac 26.5hp.

P.N. 900063-Kit- Repower Generac 30hp.
 26.5Hp GENERAC
Repo
powwer P ar
artt List
Par
33

11
33A
12

13 10
14
16 35
36 8 34
8 34
17
8 27 24 28
23 9 25 32
8 9
26 29
22 1
24 7
24 21 6
24 35 8 2
19 15 3 30 31
2 0 15 7
8 8
4
24
7 18 5
18
REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.
1 W-145 1 1/8" x1 3/4" Flat Washer (26.5Hp. Generac) 1 18 B-247 3/8"-16x2 1/2"W x 2"L Sq. U-Bolt 4
2 9907500X600D Pulley - 5x6 Engine (26.5Hp. Generac) 1 19 60117 Oil Shut Down Horn 1
3 W-144 7/16" Stainless Belleville Washer 1 20 400062 Bracket - Main Mounting Bracket 1
4 W-108 7/16" Lock Washer 1 21 400061 Bracket - Amsoil Generac 1
5 B-114 7/16"-20x3/4" Hex Head Bolt 1 22 400059 Bracket - Oil Cooler Generac 1
6 B-204 3/8"-16x1 3/8"W x 3"L Sq U-Bolt 2 23 60103-L New Short Oil Cooler 1
7 N-107 3/8"-16 Nylon Locknut 12 24 N-102 1/4"-20 Whiz Flange Nut 17
8 W-113 5/16" Flat Washer 19 25 500011 Generac Electric Fuel Pump 1
9 B-107 5/16"-18x3/4" Bolt 6 26 68015 90 Deg. Fitting 1/8"MP x 1/4" Push-Loc 1
10 600032 Muffler - Generac 1 27 400041 90 Deg. Fitting 1/8"MP x 5/16" Push-Loc 1
B-265 M8 x 25 Socket Head Cap Screw 4 28 72230 3/8" Black Pipe Nipple 3" Long 1
W-163 M8 mm Lock Washer 4 29 60102 3/8" Black Pipe Tee 1
11 600036 Canister - Air for Generac Engine 1 30 68230 Oil Drain Hose Assembly 1
600046 Filter - Enginaire Primary Air 1 31 10231 3/8" Steel Pipe Cap 1
600047 Filter - Enginaire Secondary Air 1 32 87113 3/8" Male Pipe 3/8" Barb - Straight 1
12 600039 Hose - Air Cleaner Hose For Generac 30Hp 1 33 90115 Turbo Pre-cleaner 1
13 60116 3/8" Swivel to 3/8" Barb 2 33A 90125 2" Worm Clamp 3
14 60113 1/8"x3/8" 90Deg. Fitting 2 34 N-103-W 5/16" Whiz Nut 6
15 B-102 1/4"-20x3/4" Stainless Steel Bolt 6 35 B-172 1/4"x20x1" Bolt 5
16 60122 Bracket - Filter Mount Amsoil 1 36 B-101 1/4"x20x1/2" Bolt 4
17 60119 Filter - 1 Micron Amsoil 1
 30Hp GENERAC
Repower Part List
33

11
33A
12
10
13
14
16 35 34
36
8 34 8 28
17 32
8 24
27 8 9
23 9 25 29
26 1
22 7
24 6
24 2
21
24 35 8 30 31
3
19 15 15
20 7 4
8 8
24 5
7 18
18

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 W-178 1 1/4"ID x1 7/8"OD x1/8" Thick Washer (30Hp. Generac) 1 18 B-247 3/8"-16x2 1/2"W x 2"L Sq. U-Bolt 4
2 600033 Pulley - 5x6x1 1/4 Engine (30Hp. Generac) 1 19 60117 Oil Shut Down Horn 1
3 W-144 7/16" Stainless Belleville Washer 1 20 400062 Bracket - Main Mounting Bracket 1
4 W-108 7/16" Lock Washer 1 21 400061 Bracket - Amsoil Generac 1
5 B-114 7/16"-20x3/4" Hex Head Bolt 1 22 400059 Bracket - Oil Cooler Generac 1
6 B-204 3/8"-16x1 3/8"W x 3"L Sq U-Bolt 2 23 60103-L New Short Oil Cooler 1
7 N-107 3/8"-16 Nylon Locknut 12 24 N-102 1/4"-20 Whiz Flange Nut 17
8 W-113 5/16" Flat Washer 19 25 500011 Generac Electric Fuel Pump 1
9 B-107 5/16"-18x3/4" Bolt 6 26 68015 90 Deg. Fitting 1/8"MP x 1/4" Push-Loc 1
10 600032 Muffler - Generac 1 27 400041 90 Deg. Fitting 1/8"MP x 5/16" Push-Loc 1
B-265 M8 x 25 Socket Head Cap Screw 4 28 72230 3/8" Black Pipe Nipple 3" Long 1
W-163 M8 mm Lock Washer 4 29 60102 3/8" Black Pipe Tee 1
11 600036 Canister - Air for Generac Engine 1 30 68230 Oil Drain Hose Assembly 1
600046 Filter - Enginaire Primary Air 1 31 10231 3/8" Steel Pipe Cap 1
600047 Filter - Enginaire Secondary Air 1 32 87113 3/8" Male Pipe 3/8" Barb - Straight 1
12 600039 Hose - Air Cleaner Hose For Generac 30Hp 1 33 90115 Turbo Pre-cleaner 1
13 60116 3/8" Swivel to 3/8" Barb 2 33A 90125 2" Worm Clamp 3
14 60113 1/8"x3/8" 90Deg. Fitting 2 34 N-103-W 5/16" Whiz Nut 6
15 B-102 1/4"-20x3/4" Stainless Steel Bolt 6 35 B-172 1/4"x20x1" Bolt 5
16 60122 Bracket - Filter Mount Amsoil 1 36 B-101 1/4"x20x1/2" Bolt 4
17 60119 Filter - 1 Micron Amsoil 1
 K e y S w itc h
K o h le r a n d W h it e
G e n e r a c P lu g
T o g e th e r
1

Orange
M

4 3 B lu e
B S

G L
2 5

Black
B la c k
Red
Green

Red
B la c k HORN Red 1 R e la y
K o h le r Seat

Red
F e m a le E n d 2 3 4
C o n n e c to r
65522
M e rc u ry
S w it c h

Red

Black
Red
G ra y G ra y Red

Fuel FUEL
C o ils
Pum p S O L E N O ID
Seat
B la c k
G re e n
G e n e ra c
M a le E n d S ta r te r
DIODE

500004 S o le n o id
W h ite
Red

S ta rte r
2 G A . R e d C a b le
Black

1
O il S w itc h 2 G A . B la c k C a b le
o n E n g in e 4 3 Fuse
Green

2 5 B la c k
B a tte ry
R e c t if ie r O n
B lu e M o to r B lu e

REF # PART # DESCRIPTION QTY. REF # PART # DESCRIPTION QTY.

1 65522 Kohler Wiring Harness 1 11 500010 Battery Boot (XT3000) 1
2 500004 Generac Wiring Harness 1 97327 Battery Boot (XFG2700) 1
3 20245 Ignition Switch 1 12 40229 Mercury Switch 1
4 20246-T Hour Meter/Tach 1 13 C-112 Clamp For Mercury Switch 1
5 68247 Tach Bracket 1 14 65510 Seat Relay 1
6 N/A Battery 1 15 600038 30Hp Generac Engine 1
7 400072 Battery Box (XT3000) 1 600041 26.5HP generac Engine 1
97145 Diesel Battery Box (XFG2700) 1 16 97191 Seat Relay Pigtail 1
8 400073 Battery Strap (XT3000) 1 17 65509 Fuse 1
20228 Battery Strap (XFG2700) 1 18 20254 Fuse Holder 1
9 500008 Battery 2Ga. Cable Positive 38" (XT3000) 1 19 20253 Starter Solenoid 1
97323 Battery 2Ga. Cable Positive 80" (XFG2700 1 20 60117 Low Oil Horn 1
10 500009 Battery Cable Ground 46" (XT3000) 1
97322 Battery Cable Ground 12" (XFG2700) 1
 BATTERY BOX

3
2
1

6 4
5
7

REF # PART # D E S C R IP T IO N QTY.

1 400072 B attery B ox & S trap 1
2 400073 S trap 1
3 B -101 1/4"-20x1/2" B olt 1
4 N -102 1/4-20 W hiz F lange N ut 1
5 N -108 3/8"-16 W hiz N ut 2
6 B -158 3/8"x1 1/2 B olt 2
7 100007 Low R ide T ransm ission Fram e 1
8 100018 W eldm ent - X w F ram e 1
500008 P ostive B attery C able 1
500009 N egtive B attery C able 1
When converting the 72in deck machines to a 30hp engine you will
need change some additional parts.
1 P.N. 9907750X100S Center Spindle Pulley
1 P.N. 9907B85 Engine to Deck Belt
For 72in machines 99XXXXX and older you will need the
following parts.
1 P.N. 9907500X750 Transmission Pulley (for 99XXXXX and
older)
1 P.N. 9907B41 Engine to Transmission Belt (for 99XXXXX and
older)
No additional parts are needed on the 00XXXXX and newer
60in machines, when converting to the 26.5 or 30 hp. engines.
When converting a 60in deck machine that is 99XXXXX and older
you will need for the following parts.
1 P.N. 9907675X100S Center Spindle Pulley
1 P.N. 9907500X750 Transmission Pulley
1 P.N. 9907B85 Engine to Deck Belt
1 P.N. 9907B41 Engine to Transmission Belt
1 P.N. 72220 Belt Guard

Belt Guard Assembly 72220

T-Box Pulley 9907500X750S

Center Deck Pulley 9907525X100S

 Hydro-Gear
Serial Number Start
On BDP-10A Pump
2034040 and Higher

Shock Valve Start

On
2037271 and Higher

BDP-21L Pump Start

On Twin in 1997 or
S.N. starting with 79
 We set the wheels in motion.

BDP-10A/16A/21L
Hydrostatic Pumps
Service and Repair Manual
BLN-51337
Revision March 2002
 Table of Contents

Section Page
Foreword .............................................................................................................................. i
Description and Operation ................................................................................................ 1
Introduction .................................................................................................................................................. 1
General Description ..................................................................................................................................... 1
External Features BDP-10A ......................................................................................................................... 2
External Features BDP-16A ......................................................................................................................... 3
External Features BDP-21L ......................................................................................................................... 4
Hydraulic Schematic BDP-10A/16A ............................................................................................................. 5
Hydraulic Schematic BDP-21L ..................................................................................................................... 6
Graphical Schematic BDP-10A/16A/21L ...................................................................................................... 7
Technical Specifications BDP-10A/16A/21L ................................................................................................. 8
Product Identification ................................................................................................................................... 8

Safety .................................................................................................................................. 9
Personal Safety ........................................................................................................................................... 9
Tool Safety ................................................................................................................................................... 9
Work Area Safety ........................................................................................................................................ 9
Servicing Safety ........................................................................................................................................... 9

Troubleshooting ............................................................................................................... 10
BDP Flow Test Kit Instructions ............................................................................................................. 11,12

Service and Maintenance ................................................................................................ 13

External Maintenance ................................................................................................................................ 13
Service and Maintenance Procedures ........................................................................................................ 13
Fluids ........................................................................................................................................................ 13
Fluid Volume and Level .............................................................................................................................. 14
Fluid Change ............................................................................................................................................. 14
Filters ........................................................................................................................................................ 14
Purging Procedures ................................................................................................................................... 14

Repair ................................................................................................................................ 15
Tools and Torques ................................................................................................................................. 15,16
Input Shaft Seal BDP-10A/16A/21L ............................................................................................................ 17
Trunnion Arm Seal BDP-10A/16A/21L ........................................................................................................ 18
Check Valves BDP-10A/16A/21L ............................................................................................................... 19
System Check Reliefs or Shock Valves BDP10A/16A/21L ......................................................................... 20
Bypass BDP-10A/16A/21L ........................................................................................................................ 21
Charge Pump BDP-10A/16A/21L .......................................................................................................... 22,23
End Cap and Valve Plate BDP-10A/16A/21L ......................................................................................... 24-26
Cylinder Block BDP-10A/16A/21L ......................................................................................................... 27,28
Block Spring, Thrust Washer and Thrust Bearing BDP-10A/16A/21L .......................................................... 29
Swashplate and Cradle Bearings BDP-10A/16A/21L ................................................................................. 30
Input Shaft BDP-10A/16A/21L ............................................................................................................... 31,32
Trunnion Arm BDP-10A/16A/21L ................................................................................................................ 33

Notes ................................................................................................................................. 34
Parts List ...................................................................................................................... 35-40
Glossary of Terms ....................................................................................................... 41-42
 FOREWORD
Headquartered in Sullivan, Illinois, Hydro-Gear is
a world leader in the design, manufacture, and
service of quality hydrostatic transaxles for the
lawn and garden industry. The mission of our
company is to be recognized by our customers
and the industry as a world-class supplier and the
quality leader in everything we do.
the mechanics to be supplied with the latest
information available. All repair procedures illus-
trated in this guide are suggested, but
preferred methods of repair.
Some repair procedures require that the BDP be
removed from the vehicle.

This Service and Repair Manual is designed to This is not a certification, test or study guide for a
provide information useful in servicing the certification test. If a technician is interested in
Hydro-Gear 10cc Bantam Duty Pump (BDP- certification they should contact an agent
10A), 16cc Bantam Duty Pump (BDP-16A) and representing the ESA (Engine Service
21cc Bantam Duty Pump (BDP-21L). Association) (610) 363-3844 or their Hydro-Gear
Distributor. Many distributors will be hosting
Also included is a glossary of terms that are certification testing. These study guides will cover
frequently used throughout the industry and most of the products and manufacturers in our
in Hydro-Gear service publications. Under- industry.
standing terminology is very important!
For more information about Hydro-Gear or our
It is necessary, and good shop practice, that your products, please contact your Central Service
service area be equipped with proper tools and Distributor, or call our Customer Service Depart-
ment at (217) 728-2581.

i
BDP-10A/16A/21L
 SECTION 1. DESCRIPTION AND OPERATION
INTRODUCTION
The purpose of this manual is to provide infor-
mation useful in servicing the Hydro-Gear Ban-
tam Duty Pumps (BDP’s). This manual includes
the BDP’s general descriptions, hydraulic sche-
matics, technical specifications, servicing and
troubleshooting procedures for BDP models
10A, 16A and 21L.
The BDP’s normally will not require servicing dur-
ing the life of the vehicle in which it is installed.
Should other servicing be required, the exterior
of the BDP’s will need to be thoroughly cleaned
before beginning most procedures.
The models BDP -10A, 16A and 21L differ from
the BDP model 10L. The physical distinction in
appearance of the BDP-10A, 16A and 21L is
signified by the design of an aluminum end cap.
This end cap improves versatility in the applica-
tion of these products.
GENERAL DESCRIPTION
The BDP’s can be combined with wheel motors
and other remotely located units. These pumps
provide an infinitely variable speed range be-
tween zero and full displacement in both forward
and reverse modes of operation.
The BDP-10A, 16A and 21L are of the axial pis-
ton design, utilizing spherical nosed pistons. A
compression spring, located inside each piston,
holds the nose of the piston against a thrust bear-
ing race.
The variable displacement pump features a
cradle swashplate with a direct-proportional dis-
placement control. Reversing the direction of
the angle of the swashplate reverses the flow of
oil from the pump and thus reverses the direc-
tion of motor output rotation.
Movement of the directional control shaft pro-
duces a proportional swashplate movement and
a change in pump flow and/or direction.
A fixed displacement gerotor charge pump is pro-
vided in the BDP units. Oil from the external res-
ervoir and filter is pumped into the closed loop by
a charge pump. Fluid not required to replenish
the closed loop flows either into the pump hous-
ing through a cooling orifice, or back to the charge
pump inlet through the charge pressure relief
valve.
Check valves are included in the pump end cap
to control the makeup oil flow for the system. The
size and type of check valve can play an impor-
tant role on the system pressure, response, and
amount of heat generated, due to the recircula-
tion of makeup oil flow. Additionally, some BDP’s
may be equipped with System Check Reliefs
(SCR’s). SCR’s are factory preset pressure regu-
lating check valves.
In some applications of the BDP’s, it is desirable
to move the machine for short distances at low
speeds without operating the engine. An increase
in resistance will occur with movement at higher
speeds. A screw type bypass valve is utilized in
the pumps to permit movement of the machine.
The bypass valve is fully opened when unscrewed
two (2) turns maximum. The bypass valve allows
oil to be routed from one side of the pump/motor
circuit to the other, thus allowing the motor to turn
with minimal resistance. The bypass valve must
be fully closed during normal operation.
WARNING
Actuating the bypass will result in the loss
of hydrostatic braking capacity. The ma-
chine must be stationary on a level sur-
face and in neutral when actuating the
bypass.
Additionally, some BDP’s may be equipped with
an Auxiliary Pump. The Auxiliary incorporates
the principles of the charge gerotor assembly and
provides the capability of an external auxiliary flow
for an alternate hydraulic circuit to operate ac-
cessories without loss of drive.
BDP-10A/16A/21L
EXTERNAL FEATURES BDP-10A

SAE "A" PAD

FLANGE STYLE

TRUNNION ARM

INLET INPUT SHAFT

CHARGE
PRESSURE
DIAGNOSTIC
PORT

"A" and "B"

PORTS

STANDARD CHECK
STANDARD VALVE
CHECK CHARGE STANDARD CHECK VALVE
STANDARD CHECK
ORVALVE
SHOCK VALVE
OR SCR COVER OR SHOCK
VALVEVALVE
OR SCR TRUNNION ARM

CASE DRAIN CASE DRAIN

OPTION BYPASS VALVE OPTION

Figure 1. BDP-10A With Standard Charge Pump

EXTERNAL FEATURES BDP-16A

SAE “A” PAD

FLANGE STYLE
BYPASS
VALVE

TRUNNION ARM

INPUT SHAFT INLET

CHARGE PRESSURE
DIAGNOSTIC PORT

“A” and “B” PORTS

SYSTEM CHECK VALVE

SYSTEM CHECK VALVE
OR SHOCK VALVE OR SHOCK VALVE

CHARGE
CASE DRAIN COVER CASE DRAIN
BYPASS VALVE

Figure 2. BDP-16A With Standard Charge Pump

EXTERNAL FEATURES BDP-21L

SAE "B" PAD

FLANGE STYLE

TRUNNION ARM
CHARGE
PRESSURE
"A" and "B" DIAGNOSTIC
INPUT SHAFT PORTS PORT

INLET

BYPASS VALVE CASE DRAIN

STANDARD CHECK VALVE

STANDARD CHECK CHARGE STANDARD
STANDARDCHECK VALVE
CHECK
OR SHOCK VALVE
VALVE OR SCR COVER OR SHOCK
VALVE OR VALVE
SCR

Figure 3. BDP-21L With Standard Charge Pump

HYDRAULIC SCHEMATIC
SYSTEM CHECK & RELIEF VALVE OPTIONS:
1) NO SCR, NO BLEED
2) NO SCR, .024” BLEED
3) NO SCR, .031” BLEED
4) NO SCR, .044” BLEED
5) 3000 PSI SCR, NO BLEED (BDP-10A/16A)
3000 PSI SHOCK, NO BLEED (BDP-10A/16A)
6) 3000 PSI SHOCK, .024” BLEED (BDP-10A/16A)
7) 3000 PSI SCR, .031” BLEED (BDP-10A/16A)
3000 PSI SHOCK, .031” BLEED (BDP-10A/16A)
8) 3000 PSI SHOCK, .044” BLEED (BDP-10A/16A)

PORT A

PORT B

CHARGE DIAGNOSTIC
CHARGE PUMP INLET
BYPASS VALVE BLEED OPTIONS:
1) NO BLEED ORIFICE
2) .031” BLEED ORIFICE
3) .043” BLEED ORIFICE (BDP-10A/16A)

Figure 4. BDP-10A/16A With Standard Charge Pump Hydraulic Schematic

SYSTEM CHECK & RELIEF VALVE OPTIONS:

1) NO SCR, NO BLEED
2) NO SCR, .024” BLEED
3) NO SCR, .031” BLEED
4) NO SCR, .044” BLEED
5) 3000 PSI SCR, NO BLEED (BDP-10A/16A)
3000 PSI SHOCK, NO BLEED (BDP-10A/16A)
6) 3000 PSI SHOCK, .024” BLEED (BDP-10A/16A)
7) 3000 PSI SCR, .031” BLEED (BDP-10A/16A)
AUXILIARY RETURN
3000 PSI SHOCK, .031” BLEED (BDP-10A/16A)
8) 3000 PSI SHOCK, .044” BLEED (BDP-10A/16A)
AUXILIARY DISCHARGE

PORT A

PORT B

CHARGE DIAGNOSTIC
CHARGE PUMP INLET
BYPASS VALVE BLEED OPTIONS:
1) NO BLEED ORIFICE
2) .031” BLEED ORIFICE
3) .043” BLEED ORIFICE (BDP-10A/16A)

Figure 5. BDP-10A/16A With Auxiliary Charge Pump Hydraulic Schematic

BDP-10A/16A/21L
HYDRAULIC SCHEMATIC

9) SHOCK, .031” BLEED ORIFICE

10) SHOCK, .044” BLEED ORIFICE

SCR, NO BLEED ORIFICE

6) SCR, .031” BLEED ORIFICE
7) SHOCK, NO BLEED ORIFICE
8) SHOCK, .024” BLEED ORIFICE

3) .043” BLEED ORIFICE

Figure 6. BDP-21L With Standard Charge Pump Hydraulic Schematic

SCR, NO BLEED ORIFICE

6) SCR, .031” BLEED ORIFICE
7) SHOCK, NO BLEED ORIFICE
8) SHOCK, .024” BLEED ORIFICE
9) SHOCK, .031” BLEED ORIFICE
10) SHOCK, .044” BLEED ORIFICE

3) .043” BLEED ORIFICE

Figure 7. BDP-21L With Auxiliary Charge Pump Hydraulic Schematic

BDP-10A/16A/21L
GRAPHICAL SCHEMATIC
Figure 8. BDP-10A,16A and 21L Standard Charge Pump Graphical Schematic
Figures 4-7 represent hydraulic schematics of
the standard charge and auxiliary charge pump.
Figure 8 provides a graphical illustration of the
hydraulic oil circuit.
The input shaft and pump cylinder block are turned
in one direction only by the engine/ drive belt/
pulley combination or direct drive gear box.
The oil is drawn through an external filter that pre-
vents contaminants within the reservoir from en-
tering into the charge pump gerotor.
The charge pump supplies fluid to keep the
closed loop pressurized, preventing cavitation
and providing cooling oil flow for the system.
The charge relief valve is used to maintain charge
at a predetermined pressure.
Output of the system oil flow is controlled by the
direction and amount that the swashplate is
angled. As the pump pistons compress, they
force oil into one of two passageways (“A” or “B”)
in the system hydraulic circuit. Oil is supplied ex-
ternally under pressure to an external load, (e.g.,
a vehicle wheel motor). As the angle of the pump
swashplate is increased, the amount of oil being
pumped will increase and cause a higher speed
output of the wheel motor. Reversing the angle
of the swashplate will reverse the direction of the
oil flow. During the operation of the pump, fluid
is “lost” from the hydraulic loop through leak paths
designed into the product for lubrication purposes
(around pistons, under the rotating cylinder
block, etc.). This “lost” fluid returns to the reser-
voir through the case drain. This fluid must be
made up in the loop. The charge pump makes
up this fluid loss.
The makeup flow is controlled (or directed) by
the system check valves. The check valves are
used to direct makeup fluid into the low pressure
side of the closed loop. Each check valve will
either be held open or closed, depending upon
the direction of the vehicle operation: Closed in
a pressurized system passage, open in a low
pressure, “charged” system passage.
BDP-10A/16A/21L
TECHNICAL SPECIFICATIONS
B D P -10A B D P -16A B D P -21L

0.623 in3 /rev (10.2 cc /rev) 0.97 in3 /rev (16 cc /rev) 1.33 in3 /rev.(21.8 cc /rev)
D isplacem ent
7.6 gpm @ 3000 rpm (1000 psi) 12 gpm @ 3000 rpm (1000 psi) 16.4 gpm @ 3000 rpm (1000 psi)

InputS peeds
M axim um : 3600 rpm 3600 rpm 3600 rpm
M inim um : 1800 rpm 1800 rpm 1800 rpm

S ystem O perating P ressure

Interm ittent: 2100 psi(145 bar) 2500 psi(172 bar) 2500 psi(172 bar)
C ontinuous: 1000 psi(70 bar) 1250 psi(86 bar) 1250 psi(86 bar)

O ilTem perature
M axim um Interm ittent: 230o F (110o C ) 230o F (110o C ) 230o F (110o C )
N orm alO perating R ange: -10o to 200o F (23o C to 93o C ) -10o to 200o F (23o C to 93o C ) -10o to 200o F (23o C to 93o C )

Fluid V iscosity Lim its

@ 230o F (110o C )O ptim um : 70 S U S (13 cS T) 70 S U S (13 cS T) 70 S U S (13 cS T)
@ 230o F (110o C )M inim um : 55 S U S (9.0 cS T) 55 S U S (9.0 cS T) 55 S U S (9.0 cS T)

W eight 8 lbs (3.6 kg) 12 lbs (5.4 kg) 14 lbs (6.3 kg)

Table 1. BDP-10A/16A/21L Technical Specifications

PRODUCT IDENTIFICATION
The label in Figure 9. can be located on the pump housing. It identifies the model and configura-
tion of the BDP.

H Y D R O - G E A R
SULLIVAN, IL. U.S.A.
OEM Model/
Hydro-Gear
I IIII III IIII II II
Number
BDP- 10A - 300 or (BDP - 21L - 102)
I II IIII IIII III III I II IIII
0 131 P1 476 Made in U.S.A.

Serial Number
Year Built
(unique number for that model - for that day)

Date
(Julian - day of year)

Type of Product and Build Information

Figure 9. BDP Configuration Label

BDP-10A/16A/21L
 SECTION 2. SAFETY
This symbol points out important safety
instructions which, if not followed, could endan-
ger the personal safety and/or property of your-
self and others. Read and follow all instructions
in this manual before attempting maintenance
on your BDP’s. When you see this symbol -
HEED ITS WARNING.
WARNING
POTENTIAL FOR SERIOUS INJURY
Inattention to proper safety, operation, or
maintenance procedures could result in
personal injury, or damage to the equip-
ment. Before servicing or repairing the
BDP-10A, 16A or 21L, fully read and un-
derstand the safety precautions de-
scribed in this section.
PERSONAL SAFETY
Certain safety precautions must be observed
while servicing or repairing the BDP-10A, 16A
or 21L. This section addresses some of these
precautions but must not be considered an all-
inclusive source on safety information. This sec-
tion is to be used in conjunction with all other
safety material which may apply, such as:
Other manuals pertaining to this machine
Local and shop safety rules and codes
Governmental safety laws and regulations
Be sure that you know and understand the equip-
ment and the hazards associated with it. Do not
place speed above safety.
Notify your supervisor whenever you feel there is
any hazard involving the equipment or the per-
formance of your job.
Never allow untrained or unauthorized person-
nel to service or repair the equipment.
Wear appropriate clothing. Loose or hanging
clothing or jewelry can be hazardous. Use the
appropriate safety equipment, such as eye and
hearing protection, and safety-toe and slip-proof
shoes.
Never use compressed air to clean debris from
yourself or your clothing.
TOOL SAFETY
Use the proper tools and equipment for the task.
Inspect each tool before use and replace any tool
that may be damaged or defective.
WORK AREA SAFETY
Keep the work area neat and orderly. Be sure it
is well lit, that extra tools are put away, trash and
refuse are in the proper containers, and dirt or
debris have been removed from the working ar-
eas of the machine.
The floor should be clean and dry, and all exten-
sion cords or similar trip hazards should be re-
moved.
SERVICING SAFETY
Certain procedures may require the vehicle to
be disabled in order to prevent possible injury
to the servicing technician and/or bystanders.
The loss of hydrostatic drive line power may re-
sult in the loss of hydrostatic braking capability.
Some cleaning solvents are flammable. Use only
approved cleaning materials: Do not use explo-
sive or flammable liquids to clean the equipment.
To avoid possible fire, do not use cleaning sol-
vents in an area where a source of ignition may
be present.
Discard used cleaning material in the appropri-
ate containers.
BDP-10A/16A/21L
 SECTION 3. TROUBLESHOOTING

In many cases problems with the BDP-10A, 16A

WARNING
Do not attempt any servicing or adjust-
ments with the engine running.
Use extreme caution while inspecting the
drive belt assembly and all vehicle link-
age!
Follow all safety procedures outlined in
the vehicle owner’s manual!
Table 2. BDP 10A, 16A and 21L Troubleshooting Checklist
Possible Cause
and 21L are not related to a defective pump but
are caused by slipping drive belts, partially en-
gaged bypass valves, and loose or damaged
control linkages. Be sure to perform all opera-
tional checks and adjustments outlined in Sec-
tion 3. before assuming the pump is malfunction-
ing. Table 2. below provides a troubleshooting
check list to help determine the cause of opera-
tional problems.
Corrective Action

VEHICLE DOES NOT DRIVE/TRACK STRAIGHT

Vehicle tires improperly inflated Refer to vehicle manufacturer suggested pressure
Control linkage bent, loose or out of adjustment Repair, adjust or replace vehicle linkage
Bypass loose Tighten bypass per page 11
Inlet leak Check all externals to BDP inlet
UNIT IS NOISY
Excessive input speed Adjust input speed above 1800 rpm and below 3600 rpm
Oil level low or contaminated oil Fill to proper level or change oil
Excessive loading Reduce vehicle load
Air trapped in hydraulic system Purge hydraulic system per page 12
Bypass loose Tighten bypass per page 11
Inlet leak, line or filter partially blocked or damaged Check all externals to BDP inlet
UNIT HAS NO/ LOW POWER
Engine speed low Adjust to correct setting
Control linkage bent, loose or out of adjustment Repair or replace vehicle linkage
Drive belt slipping or pulley damaged Repair or replace drive belt or pulley
Oil level low or contaminated oil Fill to proper level or change oil per page 11
Excessive loading Reduce vehicle load
Bypass loose Tighten bypass per page 11
Air trapped in hydraulic system Purge hydraulic system per page 12
Inlet leak Check all externals to BDP inlet
Inlet filter clogged Replace filter per page 12
Suspected internal damage Check per page 9

UNIT OPERATING HOT

Debris buildup Remove debris
Cooling fan or heat exchanger damaged Repair or replace cooling fan or heat exchanger
Oil level low or contaminated oil Fill to proper level or change oil per page 11
Excessive loading Reduce vehicle load
Air trapped in hydraulic system Purge hydraulic system per page 12
Inlet leak Check all externals to BDP inlet
BDP LEAKS OIL
Damaged seals or gaskets Remove debris, replace seals
Air trapped in hydraulic system Purge hydraulic system per page 12

BDP-10A/16A/21L
BDP FLOW TEST KIT INSTRUCTIONS BLN-51334 MARCH 2002
(This Instruction Sheet supersedes all previous flow testing instructions)

Description: BDP Flow Test Kit (Part Number 70661)

(Part Number 70661 Supersedes Part Numbers 70511 and BB-76810)
Purpose: The design purpose of the BDP Flow Test Kit is to allow the dealer to isolate the BDP from the wheel
motor and determine if the BDP is faulty. The following information can be used to install and test the BDP by
simulating a wheel motor load.

WARNING
Certain procedures require the vehicle engine
to be operated and the vehicle to be raised off of
the ground. To prevent possible injury to the
servicing technician and/or bystanders, insure
the vehicle is properly secured.
WARNING
Do not attempt any adjustments with the engine
running. Use extreme caution while working in
or around all vehicle linkage! High temperatures
can be generated. Follow all safety procedures
outlined in the vehicle owner’s manual!

INSTALLATION AND TESTING PROCEDURES:

1. Disconnect the system hoses at the wheel motor, or system hoses from the BDP and connect the BDP Flow
Test Kit. (Special care should be taken to prevent contamination debris from entering pump or wheel motor
system ports).
Note: Using the Bi-Directional Flow Test Kit, determination of directional flow is not necessary. The flow meter
may be connected in either direction into the forward and reverse high pressure system lines.

CAUTION: Ensure all fittings and hoses are attached securely. This test is being completed on the
vehicle’s high pressure system lines. Failure to perform this properly could result in bodily injury.

TESTING PROCEDURES:
1. Raise the drive tires off the ground. Block the remaining tires on the ground to prevent accidental vehicle
movement.

2. Open the restriction valve all the way.

3. Make certain all external BDP directional control stops are removed or backed off on the vehicle linkage to
obtain full pump directional control arm travel.

4. Start the engine and engage the drive pulley if necessary.

5. Bring the engine to maximum operating speed.

(This should not exceed 3600 rpm input speed on the BDP-10A/10L or BDP-16A)
(This should not exceed 2800 rpm input speed when testing the BDP-21L)
Engine speed adjustment may be necessary to obtain 2800 rpm.

CAUTION: Damage to the flow meter and/or re-calibration may result from testing the BDP-21L at
input speeds that exceed 2800 rpm.

6. With the directional control lever (on the vehicle) for the pump being tested, move the control arm in full
forward motion. (It may be necessary to lock the control arm into full forward position to prevent false
readings).

7. Operate without any load for approximately 30 seconds to 1 minute, this allows the system oil temperature to
rise.

BDP-10A/16A/21L
Note: Raising the system oil temperature will make a difference in the readings you receive. It has been
determined that to complete this test accurately, the oil temperature must be near system operating temperatures.
Suggested temperature range 160°- 210°F (71.1° - 98.9°C)

8. (On the BDP-10A/10L and BDP-16A), tighten the restriction valve until you read 300 psi (21 bar).
(On the BDP-21L), tighten the restriction valve until you read 500 psi (34 bar).
Record the flow reading from the Bi-Directional Flow Meter.

9. Increase the pressure to 1100 PSI (76 bar) for all models (BDP-10A/10L, BDP-16A and BDP -21L).
Record the flow reading from the Bi-Directional Flow Meter.

10. The acceptable gpm “flow droop” or (difference) is:

BDP-10A/10L 1.5 gpm (5.6 l/min)
BDP-16A 1.7 gpm (6.4 l/min)
BDP-21L 2.0 gpm (7.6 l/min)
If the difference exceeds these values the pump would not be acceptable.

TEST EXAMPLE: BDP-10A/10L

RESTRICTION
VALVE
BI-DIRECTIONAL
FLOWMETER
300 psi (21 bar) reading 5 gpm (19 l/min) (1st reading)

CONNECTIONS TO
THE FWD./RVS. LINES
DISCONNECTED
FROM WHEEL MOTOR

RESTRICTION
VALVE
BI-DIRECTIONAL
FLOWMETER
1100 psi (76 bar) reading 3 gpm (11 l/min) (2nd reading)

(BDP-10A/10L)
300 psi (21 bar) reading 5 gpm (19 l/min) (1st reading)
1100 psi (76 bar) reading 3 gpm (11 l/min) (2nd reading)
2 gpm (8 l/min) (the difference)
CONNECTIONS TO
THE FWD./RVS. LINES
DISCONNECTED Subtract the 1st reading from the 2nd.
FROM WHEEL MOTOR
(In this example, 2 gpm difference would
indicate a defective pump).

BDP-10A/16A/21L
 SECTION 4. SERVICE AND MAINTENANCE
NOTE: Any servicing dealer attempting
a warranty repair must have prior ap-
proval before conducting maintenance
of a Hydro-Gear product unless the ser-
vicing dealer is a current Authorized Hy-
dro-Gear Service Center.
EXTERNAL MAINTENANCE
Regular external maintenance of the BDP should
include the following:
1. Check the vehicle operator’s manual for
the recommended load ratings. Insure
the current application does not exceed
load rating.
2. Check fluid level in reservoir in accordance
with vehicle manufacturer’s recommenda-
tions.
NOTE: After oil has been drained and
maintenance has been performed, clean
oil should be poured directly into the
pump inlet and high pressure ports prior
to plumbing reconnection and start-up.
3. Inspect the vehicle drive belt, idler pulley(s),
and idler spring(s). Insure that belt slippage
is not causing low input rpm to the pump.
4. Inspect all external plumbing for possible
leaks or loose fittings. An air leak may be
difficult to detect on the “suction side” or inlet
line to the pump. See purging procedures
page 12.
5. Insure correct inlet filter(s) has been installed
in accordance with the vehicle manufacturer.
6. Insure the reservoir is free of contaminants
and is properly vented.
7. Inspect the BDP cooling fan (if applicable)
for broken or distorted blades and remove
any obstructions (grass clippings, leaves or
dirt). Inspect oil cooler (if applicable) for dam-
aged fins and debris.
8. Inspect the vehicle control linkage to the di-
rectional control arm on the BDP. Also, in-
sure the control arm is securely fastened to
the trunnion arm.
9. Inspect the bypass on the BDP to insure it is
properly engaged for operation. If the bypass
is not fully engaged (rotated fully clockwise)
it will not function properly. For vehicle move-
ment, the bypass may be backed out (2) turns
maximum. This is only recommended for
movement of short distances at low speeds.
WARNING
Loosening the bypass will result in loss
of hydraulic braking capability.
SERVICE AND MAINTENANCE
PROCEDURES
NOTE: Damage to BDP’s may result from
external or internal contamination: Heat
from excess debris or lack of lubrication
and over-pressurization of the product.
Follow guidelines established in this
manual and the vehicle manufacturer’s
recommendations.
All the service procedures presented on the fol-
lowing pages can be performed while the BDP
is mounted on the vehicle. Any servicing beyond
those given must be performed after the unit has
been removed from the vehicle.
FLUIDS
The fluids used in Hydro-Gear products have
been carefully selected, and only equivalent, or
better products should be substituted.
Typically, an engine oil with a minimum rating of
55 SUS (9.0 cSt) at 230° F (110° C) maximum
operating temperature and an API classification
of SJ/ CD is allowed. Refer to the vehicle manu-
facturer for recommended oil.
BDP-10A/16A/21L
FLUID VOLUME AND LEVEL
Certain situations may require additional fluid to
be added or even replaced. Refer to the vehicle
manufacturer’s recommendations for the proper
fill location and level. After maintenance or oil
change, follow purging procedures below and re-
check the fluid level once the unit has been oper-
ated for approximately 1 minute.
FLUID CHANGE
In the event of oil contamination or degradation,
oil addition or change may alleviate certain per-
formance problems. Refer to the vehicle
manufacturer’s recommended oil change fre-
quency. Refer to purging procedures below.
FILTERS
An inlet filter is required to insure that only clean
fluid enters the system. Refer to the vehicle manu-
facture for approved filter replacement.
PURGING PROCEDURES
Due to the effects air has on efficiency in hydro-
static drive applications, it is critical that air is
purged from the system.
These purge procedures should be imple-
mented anytime a hydrostatic system has been
opened to facilitate maintenance or any addi-
tional oil has been added to the system.
Air creates inefficiency because it has compres-
sion and expansion rates that are higher than
that of oil.
Entrained air in the oil may cause the following
symptoms:
1. Noisy operation
2. Lack of power or drive after short-term op-
eration
3. High operation temperature and excessive
expansion of oil.
Before starting, make sure the reservoir is at the
proper oil level. If it is not, fill to the vehicle
manufacturer’s specifications.
BDP-10A/16A/21L
The following procedures should be performed
with the vehicle drive wheels off the ground, then
repeated under normal operating conditions.
WARNING
POTENTIAL FOR SERIOUS INJURY
Certain procedures require the vehicle
engine to be operated and the vehicle to
be raised off of the ground. To prevent
possible injury to the servicing techni-
cian and/or bystanders, insure the ve-
hicle is properly secured.
1. With the bypass valve open and the engine
running, slowly move the directional control
in both forward and reverse directions (5 to 6
times), as air is purged from the unit, the oil
level will drop.
2. With the bypass valve closed and the engine
running, slowly move the directional control
in both forward and reverse directions (5 to 6
times). Check the oil level, and add oil as re-
quired after stopping engine.
3. It may be necessary to repeat Steps 1 and 2
until all the air is completely purged from the
system. When the BDP’s move forward and
reverse at normal speed purging is complete.
Cleanliness is a key factor in the successful re-
pair of BDP’s. Thoroughly clean all exposed
surfaces prior to any type of maintenance. Clean-
ing of all parts by using a solvent wash and air
drying is usually adequate. As with any preci-
sion equipment, all parts must be kept free of
foreign material and chemicals. Protect all ex-
posed sealing areas and open cavities from dam-
age and foreign material.
Upon removal, all seals, O-rings, and gaskets
should be replaced. During installation, lightly
lubricate all seals, O-rings, gaskets with clean
petroleum jelly prior to assembly. Also protect
the inner diameter of seals by covering the shaft
machined features with plastic wrap or equiva-
lent.
 SECTION 5. REPAIR
HOW TO USE THIS MANUAL
Each assembly is provided with an exploded
view showing the parts involved. The item
reference numbers in each illustration are
for assembly instructions only. See pages
35-40 for part names and descriptions. A
complete exploded view and item list of the pump
is provided at the end of this section.
GENERAL INSTRUCTIONS
Cleanliness is a primary means of assuring
satisfactory life on repaired pumps. Thoroughly
clean all exposed surfaces prior to any type of
maintenance. Cleaning of all parts by using a
solvent wash and air drying is usually adequate.
As with any precision equipment, all parts must
be kept free of foreign material and chemicals.
Protect all exposed sealing surfaces and open
cavities from damage and foreign material. The
external surfaces should be cleaned before
beginning any repairs.
TOOLS AND TORQUES
Table 3. Required Tools
Miscellaneous
BDP-10A/16A/21L Service & Repair Manual
Torque Wrench
Scribe, Paint Pen, or Marker
Seal Hook with a Magnet
Flat Blade Screw Driver
Pliers
Internal Snap Ring
Allen Wrenches
5 mm
3/16”
1/4”
Lip type seals (shaft seals) are used on the input
shaft and directional control shaft of the
BDP-10A, 16A and 21L. These seals can be
replaced without major disassembly of the unit.
However, replacement of these seals generally
requires removal of the pump from the machine.
Upon removal, it is recommended that all seals,
O-rings and gaskets be replaced. During
installation lightly lubricate all seals, O-rings and
gaskets with a clean petroleum jelly prior to
assembly. Also protect the inner diameter of the
seals by covering the shaft with a cellophane
(plastic wrap, etc.) material.
Parts requiring replacement must be replaced
from the appropriate kits identified in the Items
Listing, found at the end of this manual. Use only
original Hydro-Gear replacement parts found
listed in BLN-50937 (microfiche) or BLN-51427
(CD).
Sockets
3/8” Drive Ratchet
9/16”
1/2”
5/8”
10 mm
Combination Wrenches
9/16”
1/2”
5/8”
7/8”
10 mm
BDP-10A/16A/21L
 Table 4. BDP-10A Plug Fitting Torque Values

Item # or Description Torque

Case Drain (fitting torque) 200-250 lb-in (22.6-28.2 N-m)
System Port (fitting torque) 370-470 lb-in (41.8-53.1 N-m)
Inlet (fitting torque) 200-250 lb-in (22.6-28.2 N-m)
42A, 42B, Check Valves/Shock Valves 180-240 lb-in (20.3-27.1 N-m)
42A, 42B, Check Reliefs (cap) 200-275 lb-in (22.6-31.0 N-m)
15, Bypass Valve 84-120 lb-in (9.5-13.6 N-m)
56, Diagnostic Plug 84-120 lb-in (9.5-13.6 N-m)
10, Cap Screw (non-auxiliary) 87-118 lb-in (9.8-13.3 N-m)
4, End Cap Bolts 167-217 lb-in (18.8-24.5 N-m)

Table 5. BDP-16A Plug Fitting Torque Values

Item # or Description Torque

Case Drain (fitting torque) 200-250 lb-in (22.6-28.2 N-m)
System Port (fitting torque) 370-470 lb-in (41.8-53.1 N-m)
Inlet (fitting torque) 370-470 lb-in (41.8-53.1 N-m)
42A, 42B Check Valves/Shock Valves 180-240 lb-in (20.3-27.1 N-m)
42A, 42B Check Reliefs (cap) 200-275 lb-in (22.6-31.0 N-m)
50, Bypass Valve 95-120 lb-in (10.7-13.6 N-m)
52, Diagnostic Plug 85-120 lb-in (9.6-13.6 N-m)
56, Charge Cover Cap Screw (non-auxiliary) 180-220 lb-in (20.3-24.9 N-m)
58, End Cap Bolts 255-300 lb-in (28.8-33.9 N-m)

Table 6. BDP-21L Plug Fitting Torque Values

Item # or Description Torque

Case Drain fitting (fitting torque) 370-470 lb-in (41.8-53.1 N-m)
System Port (fitting torque) 370-470 lb-in (41.8-53.1 N-m)
Inlet (fitting torque) 370-470 lb-in (41.8-53.1 N-m)
42A, 42B, Check Valves/Shock Valves 180-240 lb-in (20.3-27.1 N-m)
42A, 42B, Check Reliefs (cap) 200-275 lb-in (22.6-31.0 N-m)
50, Bypass Valve 84-120 lb-in (9.5-13.6 N-m)
52, Diagnostic Plug 84-120 lb-in (9.5-13.6 N-m)
56, Charge Cover Cap Screw (non-auxiliary) 200-275 lb-in (22.6-31.0 N-m)
58, End Cap Bolts 255-345 lb-in (28.8-38.9 N-m)

BDP-10A/16A/21L
REMOVAL, INSPECTION AND/OR RE-
PLACEMENT OF INPUT SHAFT
SEAL BDP-10A
Refer to Figure 10.
Disassembly BDP-10A
1. Remove retaining ring (22) from housing.
2. Remove lip seal (20). Care must be taken to
prevent damage to the housing bore, shaft seal-
ing surface, or bearing. Once removed, the seal
is not reusable.
Inspection BDP-10A
1. With seal removed inspect the spacer (21),
input shaft bearing (19) and housing (1) bore for
damage, corrosion or wear.
Assembly BDP-10A
1. Lubricate the new lip seal (20) with petroleum
jelly.
2. Wrap the input shaft (18) with plastic wrap to
prevent damage to the inner surface of the lip
seal (20).
3. Slide seal (20) over shaft (18) so that letter-
ing on the seal faces out.
4. Press the lip seal (20) into the housing bore.
Insure the lip seal (20), shaft (18) or housing (1)
bore does not become damaged.
5. Install the retaining ring (22) into the housing
(1) bore groove.
REMOVAL, INSPECTION AND/OR RE-
PLACEMENT OF INPUT SHAFT
SEAL BDP-16A/21L
Refer to Figure 11.
Disassembly BDP-16A/21L
1. Remove retaining ring (3) from housing (15).
2. Remove lip seal (6). Care must be taken to
prevent damage to the housing bore, shaft, seal-
ing surface, or bearing. Once removed the seal
is not reusable.
Inspection BDP-16A/21L
1. With the lip seal (6) removed, inspect the
spacer (4) the shaft bearing (5) and housing (15)
bore.
Assembly BDP-16A/21L
1. Lubricate the new lip seal (6) with petroleum
jelly.
2. Wrap the input shaft (1) with plastic wrap to
prevent damage to the inner surface of the lip
seal (6).
3. Slide the seal (6) over shaft (1) so that letter-
ing on the seal (6) faces out.
4. Press the lip seal (6) into the housing (15)
bore. Insure seal (6), shaft (1) or housing (15)
bore does not become damaged.
5. Install the retaining ring (3) into the housing
(15) bore groove.

22 3
20 6
21
5

19 4

18
15

Figure 10. BDP-10A Figure 11. BDP-16A/21L

BDP-10A/16A/21L
REMOVAL, INSPECTION AND/OR RE-
PLACEMENT OF TRUNNION ARM
(CONTROL ARM) SEAL BDP-10A/16A
Refer to figure 12.
Disassembly BDP-10A/16A
1. Remove the retainer and lip seal (49/12) from
the housing (1/15). Care must be taken to pre-
vent damage to the housing trunnion bore, trun-
nion arm (37/13) and sealing surface. Once re-
moved the retainer and lip seal is not reusable.
Inspection BDP-10A/16A
1. With the lip seal (49/12) removed, inspect the
area for corrosion and wear. Inspect the trun-
nion bore area sealing surface for damage or
wear.
Assembly BDP-10A/16A
1. Lubricate the new lip seal (49/12) with petro-
leum jelly.
2. Wrap the trunnion arm (37/13) with plastic
wrap to prevent damage to the inner surface of
the lip seal (49/12).
3. Slide the lip seal (49/12) over the trunnion arm
(37/13) so that the lettering on the seal (49/12) faces
out.
4. Press the lip seal (49/12) into the housing
bore (1/15). Insure the seal (49/12), trunnion arm
(37/13), and housing bore does not become
damaged.
5. Install the retainer from (49/12) over the trun-
nion arm (37/13) on top of the lip seal from (49/
12). Press into the trunnion seal bore in the hous-
ing until it mates against the trunnion seal.
1/15
37/13
49/12
Figure 12. BDP-10A/16A
BDP-10A/16A/21L
REMOVAL, INSPECTION AND/OR RE-
PLACEMENT OF TRUNNION ARM
(CONTROL ARM) SEAL BDP-21L
Refer to figure 13.
Disassembly BDP-21L
1. Remove the retainer (10) and lip seal (2).
Care must be taken to prevent damage to the
housing trunnion bore, trunnion arm (13) and
sealing surface. Once removed lip seal (12) is
not reusable.
Inspection BDP-21L
1. With the lip seal (12) removed, inspect the
area for corrosion and wear. Inspect the trun-
nion bore area sealing surface for damage or
wear.
Assembly BDP-21L
1. Lubricate the new lip seal (12) with petroleum
jelly.
2. Wrap the trunnion arm (13) with plastic wrap
to prevent damage to the inner surface of the lip
seal (12).
3. Slide the lip seal (12) over the trunnion arm
(13) so that lettering on the seal (13) faces out.
4. Press the lip seal (12) into the housing bore
(15). Insure the seal (12), trunnion arm (13), and
housing bore does not become damaged.
5. Install the retainer (10) over the trunnion arm
(13) on top of the lip seal (12). Press into the
trunnion seal bore in the housing (15) bore ring
groove.
15
10
12
13
Figure 13. BDP-21L
REMOVAL, INSPECTION AND/OR RE-
PLACEMENT OF CHECK VALVES
BDP-10A/16A
Refer to Figure 14.
Disassembly BDP-10A/16A
Perform disassembly, inspection and assembly
on check valves one side at a time. Some units
vary in “A” side to “B” side check configuration.
1. Remove the check valve (42) with 1/4” allen
wrench.
2. Remove the valve spring and poppet from
the BDP end cap (2/25).
Inspection BDP-10A/16A
1. Inspect the poppets and mating seats in the
end cap (2/25) for damage or foreign material.
Assembly BDP-10A/16A
1. Lay the BDP on its side, so the check plug
port is horizontal.
2. Insert the check plug, spring and poppet (42)
as one assembly into the check plug port.
Tighten, reference Tables 4 & 5, page 16, for
torque values.
Repeat disassembly, inspection and assembly
for the opposite port side.
REMOVAL, INSPECTION AND/OR RE-
PLACEMENT OF CHECK VALVES
BDP-21L
Refer to Figure 15.
Disassembly BDP-21L
Perform disassembly, inspection and assembly
on check valves one side at a time. Some units
vary in “A” side to “B” side check configuration.
1. Remove the check valve (42) with 1/4” allen
wrench.
2. Remove the valve spring and poppet from
the BDP end cap (25).
Inspection BDP-21L
1. Inspect the poppet and mating seats in the
end cap (25) for damage or foreign material.
Assembly BDP-21L
1. Lay the BDP on its side, so the check plug
port is horizontal.
2. Insert the check plug, spring and poppet (42)
as one assembly into the check plug port.
Tighten, reference Table 6, page 16, for torque
values.
Repeat disassembly, inspection and assembly
for the opposite port side.

42B

42A
(PORT "A"
SIDE)

42A
2/25
42B
(PORT "B" 25
SIDE)

Figure 15. BDP-21L

Figure 14. BDP-10A/16A

BDP-10A/16A/21L
REMOVAL, INSPECTION AND/OR RE-
PLACEMENT OF SYSTEM CHECK
RELIEFS (SCR’s) OR SHOCK
VALVES BDP-10A/16A
Refer to Figure 16.
Disassembly BDP-10A/16A
Perform disassembly, inspection and assembly
on SCR/shock valve one side at a time. Some
units vary in “A” side to “B” side configuration.
1. Remove the SCR (42) with a 7/8” wrench or
the shock valve (42) with an 11/16” wrench.
2. Remove the check relief/shock valve spring
and the check relief/shock valve from the BDP
end cap (2/25).
Inspection BDP-10A/16A
1. Inspect the check relief or shock valve (42)
and mating seat in the end cap (2/25) for dam-
age or foreign material.
Assembly BDP-10A/16A
1. Lay the BDP on its side, so the check plug
port is horizontal.
2. Insert the system check relief spring and
check relief or shock valve spring and shock
valve as one assembly into the check plug port.
Tighten to the correct torque value. See page 16.
Repeat disassembly, inspection and assembly
for the opposite port side.
42A
42B
2/25
Figure 16. BDP-10A/16A
BDP-10A/16A/21L
REMOVAL, INSPECTION AND/OR RE-
PLACEMENT OF SYSTEM CHECK
RELIEFS (SCR’s) OR SHOCK
VALVES BDP-21L
Refer to Figure 17.
Disassembly BDP-21L
Perform disassembly, inspection and assembly
on SCR/shock valve one side at a time. Some
units vary in “A” side to “B” side configuration.
1. Remove the SCR (42) with a 7/8” wrench or
the shock valve (42) with an 11/16” wrench.
2. Remove the check relief/shock valve spring
and the check relief/shock valve from the BDP
end cap (25).
Inspection BDP-21L
1. Inspect the check relief or shock valve(42)
and mating seat in the end cap (25) for damage
or foreign material.
Assembly BDP-21L
1. Lay the BDP on its side, so the check plug
port is horizontal.
2. Insert the system check relief spring and
check relief or shock valve spring and shock
valve as one assembly into the check plug port.
Tighten, reference Table 6, page 16, for torque
values.
Repeat disassembly, inspection and assembly
for the opposite port side.
42B
42A
25
Figure 17. BDP-21L
REMOVAL, INSPECTION AND/OR RE- REMOVAL, INSPECTION AND/OR RE-
PLACEMENT OF THE BYPASS BDP- PLACEMENT OF THE BYPASS BDP-
10A/16A 21L
Refer to Figure 18. Refer to Figure 19.

Disassembly BDP-10A/16A Disassembly BDP-21L

1. Loosen the bypass valve (15/50) using a 5/8”
wrench.
2. Remove the bypass (15/50) from the BDP
end cap (2/25).
Inspection BDP-10A/16A
1. Inspect the bypass O-rings and mating seats
in the end cap (2/25) for damage or foreign mate-
rial.
2. If damaged or worn replace bypass (15/50).
1. Loosen the bypass valve (50) using a 5/8”
wrench.
2. Remove the bypass (50) from the BDP end
cap (25).
Inspection BDP-21L
1. Inspect the bypass O-rings and mating seats
in the end cap (25) for damage or foreign mate-
rial.
2. If damaged or worn replace bypass (50).

Assembly BDP-10A/16A Assembly BDP-21L

1. Lay the BDP on its side, so the bypass port 1. Lay the BDP on its side, so the bypass port
is horizontal. is horizontal.

2. Insert the bypass (15/50) into the bypass 2. Insert the bypass (50) into the bypass port
port on the end cap (2/25). Tighten to the proper on the end cap (25). Tighten, reference Table 6,
torque value. See page 16. page 16, torque values.

50

2/25

15/50

25

Figure 18. BDP-10A/16A Figure 19. BDP-21L

BDP-10A/16A/21L
REMOVAL, INSPECTION AND Assembly BDP-10A
ASSEMBLY OF THE STANDARD 1. Lay the BDP (input shaft down), so the end
CHARGE PUMP BDP-10A cap (2) is horizontal. Place the charge ball (44)
in the end cap (2) charge pocket so it mates to
Refer to Figure 20.
the end cap (2) charge ball seat. Place the
charge spring, also identified as item (44), on
Disassembly BDP-10A
top of the charge ball.
1. Prior to removal of the charge cover, place a
2. Insert the inner gerotor over input shaft (18).
mark on the charge cover and end cap for re-
alignment. 3. Align the outer gerotor to fit over the inner
gerotor.
2. Using a 5 mm allen wrench, loosen the charge
cover bolts (10) from the BDP end cap (2). While 4. Insert the O-ring into the charge cover.
holding the charge cover in place, remove the
charge cover bolts (10). 5. Position the charge cover and O-ring with the
aligning mark on the end cap. Place the charge
3. Remove the charge cover, O-ring, gerotor cover and O-ring as one piece over the charge
items (6), charge spring and charge ball (44). spring and gerotor assembly. Insure the spring
fits into the charge cover spring retaining groove.
Inspection BDP-10A
6. Align and insert the allen screws (6) into the
1. Inspect the charge cover O-ring and running
end cap (2). Tighten, reference Table 4, page
surfaces for damage. Inspect the spring , check
16, torque values.
ball (44), and mating seat in the end cap (2) for
damage or foreign material.
Note: If end cap (2) is to be removed, de-
lay charge components reassembly.

44

Partial View 18

10

Figure 20. BDP-10A

BDP-10A/16A/21L
REMOVAL, INSPECTION AND AS-
SEMBLY OF THE STANDARD
CHARGE PUMP BDP-16A/21L
Refer to Figure 21.
Disassembly BDP-16A/21L
1. Prior to removal of the charge cover, place a
mark on the charge cover and end cap for re-
alignment.
2. Using a 1/2” wrench loosen the charge cover
bolts from the BDP end cap (25). While holding
the charge cover in place, remove the charge
cover bolts (56).
3. Remove the charge cover, O-ring, gerotor
items (40), charge spring and charge ball (44).
Inspection BDP-16A/21L
1. Inspect the charge cover O-ring and running
surfaces for damage. Inspect the spring , check
ball (44), and mating seat in the end cap (25) for
damage or foreign material.
2. If damaged or worn, replace O-ring and
gerotor assembly (40), charge spring and charge
ball (44) and end cap (25).
Note: If end cap (25) is to be removed,
delay charge components reassembly.
Assembly BDP-16A/21L
1. Lay the BDP (input shaft down), so the end
cap is horizontal. Place the charge ball in the
end cap (25) charge pocket so it mates to the
end cap (25) charge ball seat. Place the charge
spring on top of the charge ball.
2. Insert the inner gerotor over input shaft (1).
3. Align the outer gerotor to fit over the inner
gerotor.
4. Insert the O-ring into the charge cover.
5. Position the charge cover and O-ring with the
aligning mark on the end cap (25). Place the
charge cover and O-ring as one piece over the
charge spring and gerotor assembly. Insure the
spring fits into the charge cover spring retaining
groove.
6. Align and insert the cap screws (56) into the
charge cover. While holding the charge cover in
place tighten the cap screws (56) per Tables 5
and 6, page 16.

44

Partial View 1

1 40
4x 58

40
25

56
25

44
56 x2

56 58 x4
BDP-16A BDP-21L

Figure 21. BDP-16A/21L

BDP-10A/16A/21L
REMOVAL, INSPECTION AND AS-
SEMBLY OF THE END CAP AND
VALVE PLATE BDP-10A
Refer to Figure 22.
Disassembly BDP-10A
1. Using a 10 mm wrench, loosen the end cap
bolts (4) evenly.
2. Keeping the end cap (2) held in place, re-
move the four end cap bolts (4).
3. Slowly remove the end cap (2).
4. Remove the valve plate (31).
5. Remove housing alignment pins (3).
6. Remove housing gasket (5).
Inspection BDP-10A
1. Inspect the end cap (2) body for damage,
nicks or unusual wear patterns. Replace if nec-
essary.
2. Inspect the running surface (side that con-
tacts the cylinder block) of the valve plate (31).
The running surface may show evidence of
minor abrasive rings.
44
6
10
Figure 22. BDP-10A
BDP-10A/16A/21L
This is normal. Grooving in the plate, or material
transfer that is evident when the surface is
checked by dragging a fingernail across it, would
be cause for replacement of the valve plate.
3. Inspect and replace alignment pins (3) if bent
or distorted.
4. Replace the housing gasket (5) with a new
gasket before reassembly.
Assembly BDP-10A
1. Install housing gasket (5) into housing gasket
seat in housing (1).
2. Install alignment pins (3) into housing (1).
3. Lubricate the valve plate prior to installation.
Install valve plate (31) so the stamped letters “CL”
on the valve plate are facing up toward the
endcap.
4. Install end cap (2). Before installing the four
end cap bolts (4), push down on end cap (2)
verifying alignment and insuring that the cylinder
block pistons spring back and forth. Install end
cap bolts (4). Tighten, reference Table 4, page
16, torque values.
3
31
2
REMOVAL, INSPECTION AND AS-
SEMBLY OF THE END CAP AND
VALVE PLATE BDP-16A
Refer to figure 23.
Disassembly BDP-16A
1. Using any combination of two, 9/16” wrenches
or 9/16” socket and rachet drive, loosen the end
cap bolts (58) evenly.
2. Keeping the end cap (25) held in place re-
move the four end cap bolts (58).
3. Slowly remove the end cap (25).
4. Remove the valve plate (29).
5. Remove housing alignment pins (26).
6. Remove housing gasket (28).
Inspection BDP-16A
1. Inspect the end cap (25) body for damage,
nicks or unusual wear patterns. Replace if nec-
essary.
2. Inspect the running surface (side that contacts
the cylinder block) of the valve plate (29). The
running surface may show evidence of minor
abrasive rings.
44
58 x4
40
56
56
Figure 23. BDP-16A
This is normal. Grooving in the plate, or material
transfer that is evident when the surface is
checked by dragging a fingernail across it, would
be cause for replacement of the valve plate.
3. Inspect and replace alignment pins (26) if bent
or distorted.
4. Replace the housing O-ring (28) with a new
O-ring before reassembly.
Assembly BDP-16A
1. Install housing O-ring (28) into housing O-ring
seat in housing (15).
2. Install alignment pins (26) into housing (15).
3. Lubricate the valve plate prior to installation.
Install valve plate (29) so the stamped letters “UP”
on the valve plate are facing up toward the
endcap.
4. Install end cap (25). Before installing the four
end cap bolts (58), push down on end cap (25)
verifying alignment and insuring that the cylinder
block pistons spring back and fourth. Install end
cap bolts. Tighten, per Table 5, page 16, torque
values.
26
26 15
28
29
25
BDP-10A/16A/21L
REMOVAL, INSPECTION AND AS- This is normal. Grooving in the plate, or material
SEMBLY OF THE END CAP AND transfer that is evident when the surface is
checked by dragging a fingernail across it, would
VALVE PLATE BDP-21L
be cause for replacement of the valve plate.
Refer to figure 24.
3. Inspect and replace alignment pins (26) if bent
or distorted.
Disassembly BDP-21L
4. Replace the housing O-ring (28) with a new
1. Using any combination of two, 9/16” wrenches O-ring before reassembly.
or 9/16” socket and rachet drive, loosen the end
cap bolts (58) evenly. Assembly BDP-21L

2. Keeping the end cap (25) held in place re- 1. Install housing O-ring (28) into housing O-ring
move the four end cap bolts (58). seat in housing (15).

3. Slowly remove the end cap (25). 2. Install alignment pins (26) into housing (15).

4. Remove the valve plate (29). 3. Lubricate the valve plate prior to installation.
Install valve plate (29) with the bronze side down,
5. Remove housing alignment pins (26). contacting the cylinder block.
6. Remove housing gasket (28). 4. Install end cap (25). Before installing the four
end cap bolts (58), push down on end cap (25)
Inspection BDP-21L
verifying alignment and insuring that the cylinder
1. Inspect the end cap (25) body for damage, block pistons spring back and fourth. Install end
nicks or unusual wear patterns. Replace if nec- cap bolts. Tighten, per Table 6, page 16, torque
essary. values.

2. Inspect the bronze side of the valve plate

(29). The running surface may show evidence
of minor abrasive rings.

15

26

29 26

28

40 39
41

25

44
56 x2
58 x4

Figure 24. BDP-21L

BDP-10A/16A/21L
REMOVAL, INSPECTION AND AS-
SEMBLY OF THE CYLINDER BLOCK
BDP-10A
Refer to Figure 25.
Disassembly BDP-10A
1. Tilt the BDP on its side, drain remaining oil.
Lift out the cylinder block assembly (25).
2. Remove the pistons, springs and piston seats.
Inspection BDP-10A
1. Inspect the running surface of the cylinder
block and piston ends for damage, nicks or un-
usual wear patterns. The running surface may
show evidence of minor abrasion . This will be a
normal wear. If grooved or smeared, replace with
a new cylinder block assembly.
2. Inspect the piston springs for distortion or
breakage. If necessary, replace with new cylin-
der block kit.
3. Inspect the piston seats. Residual oil may
cause these to remain stuck to the inside of the
pistons.
Assembly BDP-10A
1. Install piston seats into the end of the pistons.
2. Install springs into the pistons.
3. Install one at a time, pistons, springs and seats
as one assembly into the cylinder block.
4. With the BDP housing tilted on its side, install
the cylinder block assembly (25) with pistons con-
tacting the thrust bearing.
NOTE: To check that piston placement
is correct, push downward on the cylin-
der block assembly (38). If this results in
a spring action the block assembly has
been installed correctly. If this cannot be
accomplished, remove and reassemble
the block assembly. Place a rubber band
around the cylinder block pistons to hold
them in position during installation. Then
after installation cut the rubber band and
remove it. Check for cylinder block as-
sembly for spring action.

Piston

Piston
Seat
Spring
Cylinder
Block

25

Figure 25. BDP-10A

BDP-10A/16A/21L
REMOVAL, INSPECTION AND AS-
SEMBLY OF THE CYLINDER BLOCK
BDP-16A/21L
Refer to Figure 26.
Disassembly BDP-16A/21L
1. Tilt the BDP on its side, drain remaining oil.
Lift out the cylinder block assembly (38).
2. Remove the pistons, springs and piston seats.
Inspection BDP-16A/21L
1. Inspect the running surface of the cylinder
block and piston ends for damage, nicks or un-
usual wear patterns.
The running surface may show evidence of mi-
nor abrasion . This will be normal wear. If
grooved or smeared, replace with a new cylin-
der block assembly.
2. Inspect the piston springs for distortion or
breakage. If necessary, replace with new cylin-
der block kit.
3. Inspect the piston seats. Residual oil may
cause these to remain stuck to the inside of the
pistons.
Assembly BDP-16A/21L
1. Install piston seats into the end of the pistons.
2. Install springs into the pistons.
3. Install one at a time, pistons, springs and seats
as one assembly into the cylinder block.
4. With the BDP housing tilted on its side, install
the cylinder block assembly (38) so that the
pistons contact the thrust bearing.
NOTE: To check that piston placement
is correct, push downward on the cylin-
der block assembly (38). If this results in
a spring action the block assembly has
been installed correctly. If this cannot be
accomplished, remove and reassemble
the block assembly. Place a rubber band
around the cylinder block pistons to hold
them in position during installation. Then
after installation cut the rubber band and
remove it. Check for cylinder block as-
sembly for spring action.

Piston (7x)

Piston
Seat (7x)

38

Cylinder Spring (7x)

Block

Figure 26. BDP-16A/21L

BDP-10A/16A/21L
REMOVAL, INSPECTION AND ASSEM-
BLY OF BLOCKSPRING, THRUST
WASHER, AND THRUST BEARING,
BDP-10A/16A
Refer to Figure 27.
Disassembly BDP-10A/16A
1. Remove the block spring (29/20).
2. Remove the thrust washer (30/19).
3. Remove the thrust bearing and race (34/17).
Inspection BDP-10A/16A
1. Inspect and replace the block spring (29/20)
and thrust washer (30/19) if they are distorted
or broken.
2. Inspect the running surface of the bearing
race for damage, nicks or unusual wear patterns.
The running surface may show evidence of mi-
nor abrasion . This will be normal wear. Inspect
the bearings for free movement. Inspect the
bearing cage for distortion or damage. Replace
if necessary.
REMOVAL, INSPECTION AND AS-
SEMBLY OF THRUST BEARING,
BDP-21L
Refer to Figure 28.
Disassembly BDP-21L
1. Remove the thrust bearing and race (17).
Inspection BDP-21L
1. Inspect the running surface of the bearing
race for damage (17), nicks or unusual wear pat-
terns. The running surface may show evidence
of minor abrasion . This will be normal wear.
Inspect the bearings for free movement. Inspect
the bearing cage for distortion or damage. Re-
place if necessary.
Assembly BDP-21L
1. Install bearing and race assembly (17).
NOTE: The difference in race thickness:
The thin race seats into the swashplate.
The thicker race will be installed toward
the piston noses.

Assembly BDP-10A/16A
1. Install thrust bearing and race assembly
(34/17).

NOTE: The difference in race thickness:

The thin race seats into the swashplate
(32/31). The thicker race will be installed
17
toward the piston noses.

Figure 28. BDP-21L

2. Install thrust washer (30/19).
3. Install block spring (29/20).

34/17

30/19

29/20

Figure 27. BDP-10A/16A

BDP-10A/16A/21L
REMOVAL, INSPECTION OF
SWASHPLATE, INSPECTION OF
CRADLE BEARINGS BDP-10A/16A
Refer to Figure 29.
Disassembly BDP-10A/16A
1. Remove the swashplate(32/31).
Inspection BDP-10A/16A
1. Inspect the running surface of the bearing
pocket for damage (32/31), nicks or unusual
wear patterns. The running surface may show
evidence of minor abrasion . This will be nor-
mal wear. Inspect the cradle bearing side of the
swashplate (32/31) for damage. Replace if nec-
essary.
2. Inspect the cradle bearings attached to the
inside of housing (1/15) for normal wear patterns,
placement, and insure they are staked in place.
If damaged, replace housing (1/15).
NOTE: The cradle bearings will have dis-
coloration due to normal wear. This, un-
der normal circumstances, will not war-
rant replacement.
Assembly BDP-10A/16A
1. Install swashplate (32/31) by holding trunnion
arm’s (37/13) slot guide (38/14) with the aide of
a flat tip screwdriver. Use the screwdriver to hold
the slot guide (38/14) in place while positioning
the swash plate (32/31) onto the cradle bearing
in the housing (1/15).
2. Rotate trunnion arm (37/13) to assure
swashplate pivoting action.
32/31
38/14
34
30
29
(Cradle Bearings cannot be
removed from housing as depicted)
Figure 29 . BDP-10A/16A
BDP-10A/16A/21L
REMOVAL, INSPECTION AND AS-
SEMBLY OF SWASHPLATE, AND
CRADLE BEARINGS, BDP-21L
Refer to Figure 30.
Disassembly BDP-21L
1. Remove the swashplate (31).
Inspection BDP-21L
1. Inspect the running surface of the bearing
pocket for damage (31), nicks or unusual wear
patterns. The running surface may show evi-
dence of minor abrasion . This will be normal
wear. Inspect the cradle bearing side of the
swashplate (31) damage. Replace if neces-
sary.
2. Inspect the cradle bearings attached to the
inside of housing (15) for normal wear patterns,
placement, and insure they are staked in place.
If damaged, replace housing (15).
NOTE: The cradle bearings will have dis-
coloration due to normal wear. This un-
der normal circumstances will not war-
rant replacement.
Assembly BDP-21L
1. Install swashplate (31) by holding trunnion
arm’s (13) slot guide (14) with the aide of a flat
tip screwdriver. Use the screwdriver to hold the
slot guide (14) in place while positioning the
swash plate (31) onto the cradle bearing in the
housing (15).
2. Rotate trunnion arm (13) to assure swashplate
pivoting action.
13
14
37/13
31
17 15
1/15
(Cradle Bearings cannot be
removed from housing as depicted)
Figure 30 . BDP-21L
REMOVAL, INSPECTION AND AS- Note: If trunnion arm is to be removed,
SEMBLY OF INPUT SHAFT BDP- delay reassembly of input shaft assem-
10A bly.
Refer to Figure 31.

Disassembly BDP-10A Assembly BDP-10A

1. Remove the retaining ring (22).
2. Remove the lip seal (20).
3. Remove the spacer (21).
4. Remove the shaft assembly (18) from the BDP.
Inspection BDP-10A
1. Inspect the input shaft (18) for worn splines,
surface damage, or keyway damage. Replace
shaft assembly if necessary.
2. Inspect the bearing (19) for evidence of scor-
ing, corrosion, or damage. Replace shaft as-
sembly if necessary.
3. Inspect and replace the spacer (21) if it is
bent or broken.
4. Inspect and replace the retaining ring (22) if
it is bent or broken.
Note: Upon removal, it is recommended
that all seals, O-rings and gaskets be re-
placed. During installation, lightly lubri-
cate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also, protect the inner diameter of seals
by covering the shaft with plastic wrap.
1. Install input shaft assembly (18) into the hous-
ing (1) bore. Light tapping with a rubber mallet
may be necessary on the input shaft (18) once
the bearing is aligned with the housing (1) bore.
Rotate the input shaft (18) to insure free move-
ment.
2. Install spacer (21).
3. Install new lip seal (20).
4. Install retaining ring (22).

Note: Replace the input shaft seal (20)

after removal.

22
20

21

23
19

18

Figure 31. BDP-10A

BDP-10A/16A/21L
REMOVAL, INSPECTION AND 4. Inspect and replace the retaining ring (3) if it
ASSEMBLY OF INPUT SHAFT, is bent or broken.
BDP-16A/21L Note: If trunnion arm is to be removed,
delay reassembly of input shaft assem-
Refer to Figure 32.
bly.
Disassembly BDP-16A/21L 5. Inspect and replace the thrust spring (20) and
thrust washer (19) if they are distorted or broken.
1. Remove the retaining ring (3).
Assembly BDP-16A/21L
2. Remove the lip seal (6).
Note: Upon removal, it is recommended
3. Remove the spacer (4). that all seals, O-rings and gaskets be re-
4. Remove the shaft assembly (1) from the BDP. placed. During installation, lightly lubri-
cate all seals, O-rings and gaskets with
Inspection BDP-16A/21L clean petroleum jelly prior to assembly.
Also, protect the inner diameter of seals
1. Inspect the input shaft (1) for worn splines, by covering the shaft with plastic wrap.
damage, or keyway damage. Replace shaft
assembly if necessary. 1. Install the shaft (1) assembly, into the housing
(15) bore. Light tapping with a rubber mallet may
2. Inspect the bearing (5) for evidence of scor-
be necessary on the input shaft (1) once the bear-
ing, corrosion, or damage. Replace shaft as-
ing is aligned with the housing bore (15). Rotate
sembly if necessary.
the input shaft (1) to insure free movement.
3. Inspect and replace the spacer (4) if it is bent
2. Install the spacer (4).
or broken.
3. Install a new lip seal (6).
Note: Replace the input shaft seal (6) af-
ter removal. 4. Install the retaining ring (3).

3
6

5
4

2
2
15 19
20

Figure 32. BDP-16A/21L

BDP-10A/16A/21L
REMOVAL, INSPECTION TRUNNION
ARM BDP-10A/16A
Refer to Figure 33.
Disassembly BDP-10A/16A
1. Remove and discard the trunnion seal retainer
and seal (49/12).
2. Remove the slot guide (38/14).
3. Remove the trunnion arm (37/13).
Inspection BDP-10A/16A
1. Inspect the trunnion arm (37/13) for wear or
damage. Replace the trunnion arm if necessary.
Assembly BDP-10A/16A
1. Install the trunnion arm (37/13) into the hous-
ing (1/15) bore. Rotate the trunnion arm to in-
sure free movement.
2. Install a new seal and seal retainer.
3. To completely reassemble the pump, refer to
the assembly steps on pages 19-33. Begin with
the trunnion arm assembly steps listed on page
33 and complete the assembly steps in reverse
order working towards the front of the manual.
Note: Upon removal, it is recommended
that all seals, O-rings, and gaskets be re-
placed. During installation, lightly lubri-
cate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also protect the inner diameter of seals
by covering the shaft with plastic wrap.
Remove the plastic wrap after the seal is
installed.
1/15
38/14
37/13
49/12
Figure 33. BDP-10A/16A
REMOVAL, INSPECTION TRUNNION
ARM BDP-21L
Refer to Figure 34.
Disassembly BDP-21L
1. Remove trunnion seal retainer (10) and seal
(12).
2. Remove slot guide (14).
3. Remove trunnion arm (13).
Inspection BDP-21L
1. Inspect the trunnion arm (13) for wear or dam-
age. Replace trunnion if necessary.
Assembly BDP-21L
1. Install the trunnion arm (13) into the housing
(15) bore. Rotate the trunnion arm to insure free
movement.
2. Install a new seal and seal retainer.
3. To completely reassemble the pump, refer to
the assembly steps on pages 19-33. Begin with
the trunnion arm assembly steps listed on page
33 and complete the assembly steps in reverse
order working towards the front of the manual.
Note: Upon removal, it is recommended
that all seals, O-rings, and gaskets be re-
placed. During installation, lightly lubri-
cate all seals, O-rings and gaskets with
clean petroleum jelly prior to assembly.
Also protect the inner diameter of seals
by covering the shaft with plastic wrap.
Remove the plastic wrap after the seal is
installed.
16
13
14 10
12
Figure 34. BDP-21L
BDP-10A/16A/21L
 BDP-21L

Figure 35. BDP-21L

85 - Overhaul Seal Kit BRACKETS INDICATE ITEMS INCLUDED IN KITS.
ITEMS IN KITS CANNOT BE ORDERED SEPARATELY.

BDP-10A/16A/21L
ITEMS LIST BDP-21L
Part numbers are not provided in this manual. See microfiche or CD for part numbers.
No. Description No. Description
1 Kit Pump Shaft (19T spline) 41 Gerotor Assembly (0.19 in3/rev)
Kit Pump Shaft (closed key) Aux Gerotor & HSG Assembly (0.19 in3/rev)
Kit Pump Shaft (thru shaft spline) Gerotor Assembly (0.13 in3/rev)
Kit Pump Shaft (tapered thru shaft) 42 Check Valve Kit (0.031")
Kit Pump Shaft (shaft - thru pump) Check Valve Kit (0.044")
Retaining Ring Check Valve Kit (blank)
4 Spacer System Check/Relief Kit
5 Shaft Ball Bearing 44 Charge Relief Kit (w/ 1/2” SAE valve plug, 40-70 psi)
6 Lip Seal 17 x 47 x 8 PTCN1 Charge Relief Kit (w/ 1/2” SAE valve plug,135-165 psi)
10 Trunion Seal Retaining Ring Charge Relief Kit (w/ 9/16” SAE valve plug)
12 Lip Seal 15 x 27 x 7 Charge Relief Kit (w/ 9/16” SAE valve plug, 75-105 psi)
13 Trunnion Arm Charge Relief Kit (7/32" plastic ball & spring)
14 Slot Guide Charge Relief Kit (1/4” plastic ball & spring)
15 Housing Kit 45 Aux Relief Valve Kit
17 Thrust Ball Bearing Assembly 49 Aux Bypass/Check Kit
19 Block Thrust Washer 50 Bypass Valve Kit (blank)
20 Block Spring Bypass Valve Kit (0.031")
25 Endcap Kit (w/poppets) 54 Auxiliary Filter Kit
End Cap Kit (w/ poppets, .078” cooling orifice) 56 Hex Screw, 5/16-18 x 1.0
End Cap Kit (w/SCR'S) Hex Hd Cap Screw, 5/16-18 x 1.38
End Cap Kit (Aux w/ poppets) Flange Hd Screw, 5/16-18 x 2.5
End Cap Kit (Aux w/ SCR's) 58 Hex Screw, Flanged Head
End Cap Kit (Aux w/LH:SCR and RH:poppet) 59 Hex Flange Nut
End Cap Kit (w/LH: poppet and RH:SCR) 69 Pin
26 Pin 85 Overhaul Seal Kit
28 O-Ring
29 Valve Plate
31 Variable Swashplate
38 Cylinder Block Kit
39 O-Ring
R-Ring (-144)
40 Charge Pump Kit (0.19 std splined)
Charge Pump Kit (0.13 std splined)
Charge Pump Kit (0.13 std thru shaft)
Charge Pump Kit (0.13 std spline,clear zinc cover)
Charge Pump Kit (CW - splined Aux, 40-70 psi)
Charge Pump Kit (CW - splined Aux,135-165 psi)
Charge Pump Kit (CCW - splined Aux, 40-70 psi)
Charge Pump Kit (AL Aux, 7/16 SAE port, 40-70 psi)
Charge Pump Kit (AL Aux, 7/16 SAE port, 75-105 psi)

Table 7. BDP-21L
BDP-10A/16A/21L
 99 - OVERHAUL SEAL KIT
BDP-16A

Figure 36. BDP-16A

BDP-10A/16A/21L
ITEMS LIST BDP-16A
Part numbers are not provided in this manual. See microfiche or CD for part numbers.
No. Description No. Description
1 Pump Shaft Kit (19T spline) 41 Gerotor Assembly (.13 cu. in./rev)
Pump Shaft Kit (17mm keyed) Gerotor Assembly (.19 cu. in./rev.)
Pump Shaft Kit (17mm keyed thru taper) Aux Gerotor & Hsg Assembly (0.19 cu.in./rev.)
Pump Shaft Kit ( double tapered thru shaft) 42 Check Valve Kit (blank orifice)
3 Retaining Ring Check Valve Kit (.024” orifice)
4 Spacer Check Valve Kit (.031” orifice)
5 Shaft Ball Bearing Check Valve Kit (.044” orifice)
6 Lip Seal 17 x 47 x 8 PTCN1 Shock Valve Kit (blank orifice)
12 Trunnion Seal Kit Shock Valve Kit (.024” orifice)
13 Trunnion Arm Shock Valve Kit (.031” orifice)
14 Slot Guide Shock Valve Kit (.044” orifice)
15 Housing Kit 44 Charge Relief Kit (1/4” plastic ball & spring)
17 Thrust Ball Bearing Assembly Charge Relief Kit (1/4” plastic ball & spring)
19 Block Thrust Washer Charge Relief Kit ( w/ 9/16” SAE valve plug,
20 Block Spring 40-70 psi)
25 End Cap Kit (w/poppets & std chg) Charge Relief Kit (w/ 9/16” SAE valve plug,
End Cap Kit (w/poppets & aux chg) 75-105 psi)
26 Pin Charge Relief Kit (w/ 1/2” SAE valve plug,
28 O-Ring 40-70 psi)
29 Valve Plate Charge Relief Kit (w/ 1/2” SAE valve plug,
31 Variable Swashplate 135-165 psi)
38 Cylinder Block Kit (16cc) 45 Aux Relief Valve Kit
39 O-Ring 49 Aux Bypass/Check Kit
R-Ring (-144) 50 Bypass Valve Kit (blank orifice)
40 Charge Pump Kit (.19 std splined) Bypass Valve Kit (.031” orifice)
Charge Pump Kit (.13 std thru shaft) Bypass Valve Kit (.043” orifice)
Charge Pump Kit (CW-Iron Aux, 40-70 psi, .001” shim) 54 Auxiliary Filter Kit
Charge Pump Kit (CW-Iron Aux, 135-165 psi, .001” shim) 56 Socket Hd Cap Screw (M8 x 1.25-25mm)
Charge Pump Kit (CCW-Iron Aux, 40-70 psi, .001” shim) Flange Hd Screw (5/16-18 x 2.5)
Charge Pump Kit (Al Aux, 7/16 SAE port, 40-70 psi, .001” shim) 58 Hex Screw, Flanged Hd (M10 x1.50-65mm)
Charge Pump Kit (Al Aux 7/16 SAE port, 75-105 psi,.001” shim) 69 Dowel Pin
99 Overhaul Seal Kit

Table 8. BDP-16A

BDP-10A/16A/21L
 BDP-10A

Figure 37. BDP-10A

100 - Overhaul Seal Kit

BOXES INDICATE ITEMS INCLUDED IN KITS.

ITEMS IN KITS CANNOT BE ORDERED SEPARATELY.

BDP-10A/16A/21L
ITEMS LIST BDP-10A
Part numbers are not provided in this manual. See microfiche or parts manual for part numbers.
No. Description No. Description
1 Housing Kit 30 Block Thrust Washer
2 End Cap Kit (W/ Poppets, Standard Charge) 31 Valve Plate (Steel N-Tec:Black)
End Cap Kit (W/ SCR'S, Standard Charge) 32 Swashplate
End Cap Kit (W/ Poppets, Auxiliary Charge) 34 Ball Thrust Bearing
End Cap Kit (W/ SCR'S & Auxiliary Charge) 35 Stud, Torque
End Cap Kit (STD CHG) LH:SCR / RH:Poppet 37 Trunnion Arm
End Cap Kit (STD CHG) LH:Poppet / RH:SCR 38 Slot Guide
End Cap Kit (AUX CHG) LH:SCR / RH:Poppet 42 Check Valve Kit (Blank Orifice)
End Cap Kit (AUX CHG) LH:Poppet / RH:SCR Check Valve Kit (0.024"Orfice)
End Cap Kit (STD CHG) LH:SCR / RH:Poppet,Thru Check Valve Kit (0.031"Orfice)
End Cap Kit (STD CHG) W/Poppets, Thru Check Valve Kit (0.044"Orfice)
End Cap Kit (STD CHG) W/SCR’s, Thru System Check / Relief Kit
End Cap Kit (STD CHG) LH:Poppet/ RH:SCR,Thru System Check Relief Kit
3 Straight Headless Pin (.031” Orifice)
4 Hex Flange Bolt M8-1.25 X 60mm LG 44 Charge Relief Valve Kit (1/4"
5 Housing O-Ring Plastic Ball & 50654 Spring)
6 Charge Pump Kit (STD) Charge Relief Valve Kit (9/16”
Charge Pump Kit (STD CHG), Thru SAE Plug & 3101536 Spring)
Aux Pump Kit (AL., 15T Splined, 2-7/16 SAE Ports) 45 Aux Relief Valve Kit (1/4" Steel
7 STD Gerotor Assy (.11 cu. In/rev D-Drive) Ball)
Auxiliary Gerotor & Housing Assembly Aux Relief Valve Kit (Aux
8 O-Ring Poppet)
10 Socket Head Screw M6 x 1.0-20mm Lg (STD Chg) 49 Trunnion Seal/ Retainer Kit
Hex Flange Bolt 8M-1.25 x 60mm (Aux Chg) 54 Auxiliary Filter Kit
Cap Screw, Hex 5/16-18 x 1.00 (Thru Chg) Supplied 56 Straight Thread Plug
with item #2 only 59 O-Ring
15 Bypass Valve Kit (Blank) 66 5/16" SAE Plug
Bypass Valve Kit (0.031") 67 Filter Cover
Bypass Valve Kit (0.043") 69 Straight Headless Pin
18 Pump Shaft Kit (Blind 15mm Keyway W/ Std Chg) 75 Shim - Charge Pump (.002-
Pump Shaft Kit (Blind 15mm Keyway W/Aux Chg) Red)
Pump Shaft Kit (9 Tooth W/Std Chg) 85 R-Ring -144
Pump Shaft Kit (9 Tooth W/Aux Chg) 90 Hub / 6” Fan Kit
Pump Shaft Kit (15mm Keyed, Std Chg, Thru) Hub / 7” Fan Kit
Pump Shaft Kit (9 tooth Thru Chg) 100 Overhaul Seal Kit
Pump Shaft Kit (Tapered)
19 Ball Bearing 17 x 40 x 12
20 Lip Seal 17 x 40 x 7 PTC
21 Spacer
22 Retaining Ring
25 Cylinder Block Kit
29 Block Spring

Table 9. BDP-10A
BDP-10A/16A/21L
 GLOSSARY OF TERMS
Axial Piston: Type of design for hydraulic motors and pumps in which the pistons are arranged
parallel with the spindle (input or output shaft).

Bantam Duty: A descriptive term relating to the product capacity (meaning: light duty).

Bypass Valve: A valve whose primary function is to open a path for the fluid to bypass the motor or
pump. Also referred to occasionally as the freewheel valve or dump valve.

Case Drain Line (Return Line): A line returning fluid from the component housing to the reservoir.

Cavitation: A phenomenon of boiling in a flowing liquid at normal temperatures, as a result of low

pressure condition. The gas liberated from the fluid implodes rapidly and damages pump compo-
nents.
Center Section: A device which acts as the valve body and manifold of the transmission.

Charge Pump: A device which supplies replenishing fluid to the fluid power system (closed loop).

Charge Pressure: The pressure at which replenishing fluid is forced into a fluid power system.

Charge Relief Valve: A pressure control valve whose primary function is to limit pressure in the
charge circuit.

Check Valve: A valve whose primary function is to restrict flow in one direction.

Closed Loop: A sealed and uninterrupted circulating path for fluid flow from the pump to the motor
and back.

Decay Rate: The ratio of pressure decay over time.

End Cap: See “Center Section”

Entrained Air: A mechanically generated mixture of air bubbles having a tendency to separate from
the liquid phase.

Gerotor: A fixed displacement pump frequently used as a charge pump.

Hydraulic Motor: A device which converts hydraulic fluid pressure and flow into mechanical force
and motion.

Hydraulic Pump: A device which converts mechanical force and motion into hydraulic fluid pres-
sure and flow.

Hydrostatic Motor: See “Hydraulic Motor”

Hydrostatic Pump: See “Hydraulic Pump”

BDP-10A/16A/21L
Hydrostatic Transaxle: A multicomponent assembly including a gear case and a hydrostatic trans-
mission.
Hydrostatic Transmission: The combination of a hydraulic pump and motor in one housing to form
a device for the control and transfer of power.
Inlet Line: A supply line to the pump.
Integrated Hydrostatic Transaxle (IHT): The combination of a hydrostatic transmission and gear
case in one housing to form a complete transaxle.
Manifold: A conductor which provides multiple connection ports.
Neutral: Typically described as a condition in which fluid flow and system pressure is below that
which is required to turn the output shaft of the motor.
Pressure Decay: A falling pressure.
Priming: The filling of the charge circuit and closed loop of the fluid power system during start up,
frequently achieved by pressurizing the fluid in the inlet line.
Purging: The act of replacing air with fluid in a fluid power system.
Rated Flow: The maximum flow that the power supply system.
Scoring: Scratches in the direction of motion of mechanical parts caused by abrasive contami-
nants.
Swash Plate: A mechanical device used to control the displacement of the pump pistons in a fluid
power system.
System Charge Check Valve: A valve controlling the replenishing flow of fluid from a charge circuit
to the closed loop in a fluid power system.
System Pressure: The pressure which overcomes the total resistance in a system, including all
efficiency losses.
Valve: A device which controls fluid flow direction, pressure, or flow rate.
Variable Displacement Pump: A pump in which the displacement per revolution can be varied.
Volumetric Displacement: The fluid volume for one revolution.

BDP-10A/16A/21L
BDP-10L
ITEM HYDRO-GEAR DESCRIPTION ITEM HYDRO-GEAR DESCRIPTION
# PART # # PART #
1 2513017 HOUSING KIT 22 2003052 RETAINING RING
2 2513016 END CAP KIT (STD) 23 2003016 WIRE RETAINING RING
2513045 END CAP KIT (AUX) 25 70331 CYLINDER BLOCK KIT
3 9004800-2506 STRAIGHT HEADLESS PIN 29 2003014 BLOCK SPRING
4 9007314-0810 SOCKET HEAD SCREW 30 2003017 BLOCK THRUST WASHER
5 2003067 HOUSING GASKET 32 2003087 SWASHPLATE
6 2513027 CHARGE PUMP KIT (STD) 34 50551 BALL THRUST BEARING
70582 AUX PUMP KIT (AL, SPLINED, 9/16 TUBING FITTINGS) 37 2003005 TRUNNION ARM
70386 AUX PUMP KIT (AL., SPLINED, 7/16 SAE PORTS) 38 2000015 SLOT GUIDE
70505 AUX PUMP KIT (AL., SPLINED, 7/16 SAE PORTS, AUX POPPET) 41 50761 AUX GEROTOR & HSG ASSEMBLY
50260 CHARGE COVER 42 2510008 CHECK VALVE KIT (3/8" BALL)
51074 AUX PUMP MANIFOLD (AL, SAE PORTS) 2510062 (.024" ORIFICE)
7 50273 GEROTOR ASSEMBLY 2510027 (.031" ORIFICE)
8 9004101-1340 O-RING 2510034 (.044" ORIFICE)
10 50095 SOCKET HEAD SCREW 44 2510064 CHARGE RELIEF VALVE KIT (1/4" STEEL BALL)
50969 HEX FLANGE BOLT 8M-1.25 x 60mm 2510081 (w/9/16" SAE PLUG)
15 2513030 BYPASS VALVE KIT (BLANK) 45 2510082 AUX RELIEF VALVE KIT (1/4"BALL)
2513031 (.031") 70504 AUX RELIEF VALVE KIT (AUX POPPET)
2510084 (.043") 49 2513043 TRUNNION SEAL / RETAINER KIT
50918 (SPECIAL: PROPRIETARY) 54 2510090 AUXILIARY FILTER KIT
18 2003020 PUMP SHAFT (BLIND KEYWAY) 56 9005110-4400 STRAIGHT THREAD PLUG
2003073 (9 TOOTH SPLINE) 59 9004100-1430 O-RING
50185 (KEYED TAPER) 66 9005110-3100 5/16" SAE PLUG
51059 (AUX-BLIND KEYWAY) 67 50994 FILTER COVER
19 2003043 BALL BEARING 69 50408 STRAIGHT HEADLESS PIN
20 9008000-0128 LIP SEAL 15 x 35 x 7 75 51148 CHARGE PUMP SHIM (RED)
21 2003018 SPACER 85 2513018 OVERHAUL SEAL KIT

p.3 of 3 70385-s4
BDP-10A
ITEM HYDRO-GEAR DESCRIPTION ITEM HYDRO-GEAR DESCRIPTION
# PART # # PART #
1 70516 HOUSING KIT 21 50951 SPACER
2 70517 END CAP KIT W/ POPPETS & STD CHG 25 70331 CYLINDER BLOCK KIT
70518 END CAP KIT W/ SCR'S & STD CHG 29 2003014 BLOCK SPRING
70519 END CAP KIT W/ POPPETS & AUX CHG 30 2003017 BLOCK THRUST WASHER
70520 END CAP KIT W/ SCR'S & AUX CHG 31 51444 VALVE PLATE (STEEL N-TEC: BLACK)
70573 END CAP KIT (STD CHG) LH:SCR / RH:POPPET 32 2003087 SWASHPLATE
70574 END CAP KIT (STD CHG) LH:POPPET / RH:SCR 34 50551 BALL THRUST BEARING
70575 END CAP KIT (AUX CHG) LH:SCR / RH:POPPET 35 51530 STUD, TORQUE
70576 END CAP KIT (AUX CHG) LH:POPPET / RH:SCR 37 2003005 TRUNNION ARM
70621 END CAP KIT (STD CHG) LH:SCR/RH:POPPET, THRU 38 2000015 SLOT GUIDE
70623 END CAP KIT (STD CHG) W/POPPETS, THRU 42 2510050 CHECK VALVE KIT (BLANK ORIFICE)
70624 END CAP KIT (STD CHG) W/SCR'S, THRU 2510062 CHECK VALVE KIT (.024" ORIFICE)
70625 END CAP KIT (STD CHG) LH:POPPET/RH:SCR, THRU 2510027 CHECK VALVE KIT (.031" ORIFICE)
3 50641 STRAIGHT HEADLESS PIN 2510034 CHECK VALVE KIT (.044" ORIFICE)
4 50969 HEX FLANGE BOLT M8-1.25 x 60mm LG 2510067 SYSTEM CHECK / RELIEF KIT
5 51232 HOUSING O-RING 70589 SYSTEM CHECK RELIEF KIT (.031" ORIFICE)
6 2513027 CHARGE PUMP KIT (STD) 44 70403 CHARGE RELIEF VALVE KIT (1/4" PLASTIC BALL & 50654 SPRING)
70622 CHARGE PUMP KIT (STD CHG), THRU 2510081 CHARGE RELIEF VALVE KIT (9/16" SAE PLUG & 3101536 SPRING)
70577 AUX PUMP KIT (AL., 15T SPLINED, 2-7/16 SAE PORTS) 45 2510082 AUX RELIEF VALVE KIT (1/4" STEEL BALL)
7 50273 STD GEROTOR ASSEMBLY (.11 cu. In/rev D-DRIVE) 70504 AUX RELIEF VALVE KIT (AUX POPPET)
51049 AUXILIARY GEROTOR & HOUSING ASSEMBLY 49 2513043 TRUNNION SEAL / RETAINER KIT
8 9004101-1340 O-RING 54 2510090 AUXILIARY FILTER KIT
10 50095 SOCKET HEAD SCREW M6 X 1.0-20mm LG (STD CHARGE) 56 9005110-4400 STRAIGHT THREAD PLUG
50969 HEX FLANGE BOLT M8-1.25 x 60mm (AUX CHARGE) 59 9004100-1430 O-RING
9007200-3116 CAP SCREW, HEX 5/16-18 X 1.00 (THRU CHARGE) 66 9005110-3100 5/16" SAE PLUG
SUPPLIED WITH ITEM #2 ONLY 67 50994 FILTER COVER
15 2513030 BYPASS VALVE KIT (BLANK) 69 50408 STRAIGHT HEADLESS PIN
2513031 BYPASS VALVE KIT (.031") 75 51148 SHIM - CHARGE PUMP (.002 - RED)
2510084 BYPASS VALVE KIT (.043") 85 51016 R-RING -144
18 70521 PUMP SHAFT KIT (BLIND 15MM KEYWAY W/ STD CHG) 90 70617 HUB / 6" FAN KIT
70522 PUMP SHAFT KIT (BLIND 15MM KEYWAY W/ AUX CHG) 70628 HUB / 7" FAN KIT
70523 PUMP SHAFT KIT (9 TOOTH W/ STD CHG) 100 70525 OVERHAUL SEAL KIT
70524 PUMP SHAFT KIT (9 TOOTH W/ AUX CHG)
70620 PUMP SHAFT KIT (15MM KEYED, STD CHG, THRU)
70726 PUMP SHAFT KIT (9 TOOTH THRU CHG)
70727 PUMP SHAFT KIT (TAPERED)
19 50315 BALL BEARING 17 X 40 X 12
20 51161 LIP SEAL 17 X 40 X 7 PTC
22 50329 RETAINING RING
p. 3 of 3 70514-P4
70514-P6
This will help to identify the Part Number of the wheelmotor by measuring the length of the motor from
the mounting plate to the flange.

W HEEL M OTOR COM PARISON

12 cubic inch
PN#67112

6.062 Or 6 1/16 in

14 cubic inch
PN#67114

Or 6 3/8 in
6.375

18 cubic inch
PN#67118-W

6.625 Or 6 5/8 in

24 cubic inch
PN#97363

Or 7 1/4 in
Z1:\DRAWING FILES\PARTS\HYDRAULIC 7.250
Kohler Engine PartNumbers
Production 2002 Model Yr.
Dixie Chopper Application Specific Kohler 20Hp.
Dixie Chopper Application Specific Kohler 20Hp.
Dixie Chopper Application Specific Kohler 20Hp.
Dixie Chopper Application Specific Kohler 20Hp.
Dixie Chopper Application Specific Kohler 23Hp.
Dixie Chopper Application Specific Kohler 23Hp.
Dixie Chopper Application Specific Kohler 23Hp.
Dixie Chopper Application Specific Kohler 23Hp.
 Dixie Chopper
Dixie Chopper Application Specific Kohler Engine Part
Application
Reference 27 Hp. Carburetor
Chopper specific Parts List for
Engine
the Dixie Chopper
Application specific Kohler
Dixie Chopper Application Specific Kohler Engine Part
Reference 27 Hp. Carburetor Engine
Dixie Chopper Application Specific Kohler Engine Part
Reference 27 Hp. Carburetor Engine
Dixie Chopper Application Specific Kohler Engine Part
Reference 27 Hp. Carburetor Engine
Dixie Chopper Application Specific Kohler 28Hp. EFI
Dixie Chopper Application Specific Kohler 28Hp. EFI
Dixie Chopper Application Specific Kohler 28Hp. EFI
Dixie Chopper Application Specific Kohler 28Hp. EFI
 Kohler Engine Part
Numbers for Past
Production 2001 Model Yr.
And Older
Dixie Chopper Application Specific Kohler 17Hp.
Dixie Chopper Application Specific Kohler 17Hp.
Dixie Chopper Application Specific Kohler 17Hp.
Dixie Chopper Application Specific Kohler 17Hp.
Dixie Chopper Application Specific Kohler 20Hp.
Dixie Chopper Application Specific Kohler 20Hp.
Dixie Chopper Application Specific Kohler 20Hp.
Dixie Chopper Application Specific Kohler 20Hp.
Dixie Chopper Application Specific Kohler 22Hp.
Dixie Chopper Application Specific Kohler 22Hp.
Dixie Chopper Application Specific Kohler 22Hp.
Dixie Chopper Application Specific Kohler 22Hp.
Dixie Chopper Application Specific Kohler 23Hp. Liquid Cooled
Dixie Chopper Application Specific Kohler 23Hp. Liquid Cooled
Dixie Chopper Application Specific Kohler 23Hp. Liquid Cooled
Dixie Chopper Application Specific Kohler 23Hp. Liquid Cooled
Dixie Chopper Application Specific Kohler 23Hp.
Dixie Chopper Application Specific Kohler 23Hp.
Dixie Chopper Application Specific Kohler 23Hp.
Dixie Chopper Application Specific Kohler 23Hp.
Dixie Chopper Application Specific Kohler 25Hp. Smart Spark Engine
Dixie Chopper Application Specific Kohler 25Hp. Smart Spark Engine
Dixie Chopper Application Specific Kohler 25Hp. Smart Spark Engine
Dixie Chopper Application Specific Kohler 25Hp. Smart Spark Engine
Dixie Chopper Application Specific Kohler 25Hp. Stud and
Smart Spark Engine
Dixie Chopper Application Specific Kohler 25Hp. Stud and
Smart Spark Engine
Dixie Chopper Application Specific Kohler 25Hp. Stud and
Smart Spark Engine
Dixie Chopper Application Specific Kohler 25Hp. Stud and
Smart Spark Engine
Dixie Chopper Application Specific Kohler 25Hp. Non
Smart Spark Stud Engine
Dixie Chopper Application Specific Kohler 25Hp. Non
Smart Spark Stud Engine
Dixie Chopper Application Specific Kohler 25Hp. Non
Smart Spark Stud Engine
Dixie Chopper Application Specific Kohler 25Hp. Non
Smart Spark Stud Engine
Dixie Chopper Application Specific Kohler Engine Part Reference
26Hp. EFI
Dixie Chopper Application Specific Kohler Engine Part Reference
26Hp. EFI
Dixie Chopper Application Specific Kohler Engine Part Reference 26Hp.
EFI
Dixie Chopper Application Specific Kohler Engine Part Reference
26Hp. EFI
Dixie Chopper Application Specific Kohler Engine Part
Reference 26Hp. EFI
 Dixie Chopper Application Specific Kohler Engine Part Reference
26Hp. EFI

Reference
Dixie Chopper Application Specific Kohler Engine Part
Dixie Chopper Application Specific Kohler Engine Part Reference
26Hp. EFI
Dixie Chopper Application Specific Kohler Engine Part Reference
26Hp. EFI
 CHO
DIXIE CH O PP E R

50-60 Snow Blade

Information Explosion
 CHO
DIXIE CH O PP E R
Frame Explosion

1 2

4 5
3
2 4
5
 CHO
DIXIE CH O PP E R

Ref # Description Part # Quantity

1 STD Snow Blade With Electric Lift 90100-97E 1
STD Snow Blade Without Lift 90100-97 1
2 1/2"-13x3 1/2" Bolt B-194 2
3 3/8"-16x3 1/2" HHCS B-191 4
4 1/2"-13 Nylon Inset Lock N-143 2
5 3/8"-16 Nylon Lock Nut N-107 4
 CHO
DIXIE CH O PP E R

Blade 2

Explosion 4

5
6

7
1

5
3
 CHO
DIXIE CH O PP E R

Ref # Description Part # Quantity

1 50-60" Snow Blade 90102 1
2 End Bracket 97048 2
3 Left Ground Skid Weldment 97092 1
4 3/8"-16x3/4" Bolt B-137 6
5 3/8"-16x1" Carriage Bolt B-135 4
6 3/8"-16 Whiz Flange Nut N-108 10
7 Right Ground Skid Weldment 97091 1
 CHO
DIXIE CH O PP E R
18

19
3
15
2
17 8
2
3
14 4
16
2 1
8 5 3
10
9
10 4 6
5 3
3
11
8
12
8 11 7
10
3 4 13
 CHO
DIXIE CH O PP E R

Ref # Description Part # Quantity

1 Frame Mount 97051 1
2 1/2"-13 Nylon Inset Lock N-143 4
3 1/2"-13 Whiz Flange Nut N-157 9
4 1/2"-13x3" Eye Bolt B-234 4
5 Spring 90106 4
6 1/2"-13x3 1/2" Bolt B-194 1
7 Bottom Pivot 97049 1
8 1/2"-13x1 3/4" HH Bolt B-139 4
9 60" Rod 98036 1
10 3/4" STD Flat Washer W-154 3
11 Clips 30213 2
12 3/4"-9x2" Bolt B-250 1
13 3/4"-10 Nylon Nut N-158 1
14 1/2"-13x2 1/2" Bolt B-195 1
15 3" Actuator 90153 1
Elec. Foot Pedal 97116 1
Wiring Harness 97119 1
16 1/2" Pin 1 1/2" Long w/Ring & Ball P-120 2
17 3/16" Drive-In Grease Fiiting F-100 2
18 1/2"-13x3/4" HH Bolt B-149 1
19 Swivel Plate Weldment 97050 1
 CHO
DIXIE CH O PP E R
Blade Explosion

2 1

4
3

4
5

2
 CHO
DIXIE CH O PP E R

Ref # Description Part # Quantity

1 50-60" Snow Blade 90102 1
2 3/4" STD Flat Washer W-154 2
3 50-60" Rod 97084 1
4 1/2"-13x1 3/4" HH Bolt B-139 2
5 Clip 30213 2
72" SNOWBLADE

11/127
 27

5 7
4 6
8
3

2
8
1 11 9

11 10 16 17 19
14
11

11
12
12
15
13 18
13
13

20
19
9

13 13 13 12

22 17
13
2/127 16
11 12 18
21 11
25
22
20 23 26
24
20
14
ITEM PART
NO. DESCRIPTION NO. QUANTITY

1 Frame Mount Weldment…………………… 97088 1

2 Snowblade Footpedal……………………… 97093 1
3 1" x 1" Plastic Plug………………………… 68142 1
4 Swivel Plate Weldment……………………… 97087 1
5 Grease Fitting……………………………… F-100 2
6 3/4"-9 x 2" Bolt……………………………… B-250 1
7 1/2"-13 x 3/4" Bolt………………………… B-149 1
8 1/2"-13 x 2 1/4" Bolt………………………… B-180 2
9 1/2"-13 Nyloc Nut…………………………… N-143 4
10 1/2"-13 x 2 1/4" Bolt………………………… B-180 1
11 1/2"-13 Whiz Flange Nut…………………… N-157 9
12 1/2"-13 x 2 1/2" Eyebolt.…………………… B-234 4
13 Spring……………………………………… 90106 4
14 3/8"-16 x 1" Carriage Bolt………………… B-135 4
15 Left Ground Skid Weldment………………… 97092 1
16 3/8"-16 x 3/4" Bolt………………………… B-137 6
17 End Bracket………………………………… 97048 2
18 3/8"-16 Whiz Flange Nut…………………… N-108 10
19 72" Snowblade Weldment………………… 97035 1
20 3/4" Flat Washer…………………………… W-154 3
21 Bottom Pivot………………………………… 97054 1
22 1/2"-13 x 1 3/4" Bolt………………………… B-139 2
23 3/4"-9 Nyloc Nut…………………………… N-158 1
24 Right Ground Skid Weldment……………… 97091 1
25 Pin…………………………………………… 30213 2
26 Pivot Angle Rod…………………………… 97085 1
27 1/2" x 1 1/2" Pin w/ Ring & Ball…………… P-120 2

72" Standard Snowblade Assembly……… 97089 1 13/127

 3

2
1

14/127
ITEM PART
NO. DESCRIPTION NO. QUANTITY

1 1/2"-13 x 3 1/2" Bolt………………………… B-194 1

2 1/2"-13 x 2 1/2" Bolt………………………… B-195 1
3 3" Actuator………………………………… 90153 1
4 1/2"-13 Nyloc Nut…………………………… N-143 2
5 Electric Footpedal (Not Shown)…………… 97116 1
6 Wiring Harness (Not Shown)……………… 97119 1

72" Electric Snowblade Assembly………… 90213 1

15/127
 1
1 2
2

4 5
4 5

16/127
ITEM PART
NO. DESCRIPTION NO. QUANTITY

1 3/8"-16 x 3 1/2" Bolt………………… B-191 4

2 1/2"-16 x 3 1/2" Bolt………………… B-194 2
3 Standard Snowblade Assembly……… 97089 1
Electric Snowblade Assembly……… 90213 1
4 3/8"-16 Nyloc Nut…………………… N-107 4
5 1/2"-13 Nyloc Nut…………………… N-143 2

17/127
 ZEBRA KIT
DRAG CHAIN BRACKET
xxw
41.000
Sent as an XXW. NO MODIFICATION IS NEEDED

xw
34.000
Sent as an XW. NO MODIFICATION IS NEEDED.

3.750 3.750

XF
26.500
Cut off as shown above.

6.750
3.750
x
23.500
Cut off as shown above.
 41.500

Sent as XXW. No modification needed. .500

XXW

34.500

Sent as XW. No modification needed. .250

XW
31.000
.250
Cut off as shown. 3.500
XF

24.000
.250
10.500
Cut off as shown.
X
ITEM PART
NO. DESCRIPTION NO.
1. XXW Zebra Kit……………98023
2. XW,XF,X Zebra Kit………98024
3. XXW Zebra Bracket…… 98027
4. XW,XF,X Zebra Bracket. 98028
5. XXW Zebra Rod…………98029
6. XW,XF,X Zebra Rod…… 98030
7. 12 Link Chain (30)………98031
8. 11 Link Chain (2)……… 98032
9. 10 Link Chain (2)……… 98033
10. Clip………………………. C-104
11. Washer………………….. W-123
Notes
 6302 E. County Road 100 North
Coatesville, IN. 46121
Phone 1-765-CHOPPER
www.dixiechopper.com

Dixie Chopper, Magic Circle, and the Magic Circle Atom Logo are all trademarks of Magic Circle Corporation.
Kohler, Command, and Born to Run, are all trademarks of Kohler Co. Hydro-Gear is the trademark and Company
name. The logos, trademarks and company names may not be reproduced without permission.
Printed In USA
Specifications and instructions subject to change without notice.
Print Date 9/18/02