Dixon Grizzly SE 6029FX BF User Manual

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GRIZZLY SE

Operator Manual

6029FX / 966516601 6029FX BF / 966516602 7234FX / 966516701 7234FX BF / 966516702

Please read the operator’s manual carefully and make sure you understand the instructions before using the machine.

To implement improvements, specifications and designs can be altered without prior notification. Note that no legal demands can be placed based on the information contained in these instructions. Use only original parts for repairs. The use of other parts voids the warranty.

Do not modify or install non-standardequipment to the unit without consent from the manufacturer. Modifications to the unit may cause unsafe operations or damage the unit.

When this product is worn out and no longer used, it should be returned to the reseller or other party for recycling.

©2009 HTC. All rights reserved. Beatrice, NE. Printed in U.S.A.

Contents

INTRODUCTION.......................................................

5

Driving and Transport on Public Roads..............

5

Towing.................................................................

5

Operating............................................................

5

Good Service......................................................

6

Manufacturing Number..................................

6

SYMBOLS AND DECALS.........................................

7

SAFETY.....................................................................

9

Safety Instructions..............................................

9

Personal Safety Equipment...............................

11

Slope Operation................................................

11

Safe Handling of Gasoline................................

13

General Maintenance.......................................

14

Transport...........................................................

16

Rollover Protection System (ROPS)..................

17

Spark Arrestors.................................................

17

CONTROLS............................................................

18

Control Locations..............................................

18

Motion Control Levers.......................................

19

Hour Meter........................................................

20

Tracking............................................................

20

Parking Brake...................................................

21

Blade Switch.....................................................

21

Ignition Switch...................................................

21

Fuses................................................................

23

Choke Control...................................................

23

Cutting Height Pedals.......................................

23

Seat Adjustment Lever......................................

24

Fuel Shut Off Valve............................................

24

Refueling...........................................................

25

OPERATION............................................................

26

Training.............................................................

26

Steering.............................................................

26

Roll Bar and Safety Belt....................................

27

Before Starting..................................................

27

Starting the Engine...........................................

28

Jumper Cables............................................

32

Running.............................................................

33

Operating on Hills.............................................

34

Stopping the Engine.........................................

35

Mowing Tips......................................................

36

Manual Transport..............................................

37

Pump Release Valves..................................

37

MAINTENANCE......................................................

38

Battery...............................................................

40

Safety System...................................................

41

Fuel Filter .........................................................

41

Tire Pressures...................................................

41

Parking Brake...................................................

42

Parking Brake Adjustments.........................

42

Neutral Adjustments.........................................

43

Deck Belt..........................................................

44

Pump Belt.........................................................

45

V-belts...............................................................

45

Cutting Blades..................................................

46

Adjusting the Mower Deck................................

47

Leveling Deck..............................................

47

Anti-scalpRollers.........................................

48

Caster Wheels...................................................

49

Hardware..........................................................

49

Cleaning............................................................

49

LUBRICATION........................................................

50

Lubrication Schedule........................................

50

Wheel and Deck Zerks.....................................

51

Front Wheel Mount.......................................

51

Front Wheel Bearings..................................

51

Deck Spindle...............................................

51

Cables...............................................................

51

Hydraulic Drive.................................................

52

Fluid Change...............................................

52

Purging Procedures.....................................

53

TROUBLESHOOTING GUIDE................................

54

STORAGE...............................................................

56

Winter Storage..................................................

56

Service..............................................................

56

WIRING DIAGRAMS...............................................

57

TECHNICAL DATA..................................................

58

Torque Specifications........................................

60

CONFORMITY CERTIFICATES...............................

61

SERVICE JOURNAL...............................................

62

WARNING!

Failure to follow cautious operating practices can result in serious injury to the operator or other persons. The owner must understand these instructions, and must allow only trained persons who understand these instructions to operate the mower.

Each person operating the mower must be of sound mind and body and must not be under the influence of any mind altering substance.

WARNING!

Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

WARNING!

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

INTRODUCTION

Congratulations

Thank you for purchasing a Dixon ride-onmower. This machine is built for superior efficiency to rapidly mow primarily large areas. A control panel easily accessible to the operator and a hydrostatic transmission regulated by steering controls both contribute to the machine’s performance.

This manual is a valuable document. Read the contents carefully before using or servicing the machine. The following of instructions (use, service, maintenance) by all who operate this machine is important for the safety of the operator and others. It can also considerably increase the life span of the machine and increase its resale value.

If you sell your machine, be sure to give the operator’s manual to the new owner.

The final chapter of this operator’s manual provides a Service Journal. Ensure that service and repair work are documented. A well-keptservice journal reduces service costs for the maintenance and affects the machine’s resale value. Please contact your dealer for more information. Take the operator’s manual along when the machine is taken to your dealer for service.

General

In this operator’s manual, left and right, backward and forward are used in relation to the machine’s normal driving direction.

Continuous dedication to improve our products require that specifications and design are subject to change without notice.

Driving and Transport on Public Roads

Check applicable road traffic regulations before transporting on public roads. If the machine is transported, you must always use approved fastening equipment and ensure that the machine is well anchored. DO NOT operate this machine on public roadways.

Towing

If machine is equipped with a tow hitch, use extreme caution when towing. Never allow children or others in or on the towed equipment. Make wide turns to avoid jack-knifing.Travel slowly and allow extra distance to stop.

Do not tow on sloped ground. The weight of the towed equipment may cause loss of traction and loss of control.

Follow the manufacturer's recommendation for weight limits for towed equipment. Do not tow near ditches, canals, and other hazards.

Operating

This machine is constructed only for mowing grass on lawns and even ground without obstacles such as stones, tree stumps, etc. The machine can also be used for other tasks when equipped with special accessories provided by the manufacturer. Operating instructions for the accessories are provided with delivery. All other types of uses are incorrect. The manufacturer’s directions concerning operation, maintenance, and repairs must be carefully followed.

Lawn mowers and all power equipment can be potentially dangerous if used improperly. Safety requires good judgment, careful use in accordance with these instructions and common sense.

The machine must only be operated, maintained, and repaired by persons familiar with the machine’s special characteristics and who are also

knowledgeable about the safety instructions. Use only approved repair parts to maintain this machine.

Accident prevention regulations, other general safety regulations, occupational safety rules, and traffic regulations must be followed without fail.

Unauthorized modifications to the design of the machine may absolve the manufacturer from liability for any resulting personal injury or property damage.

5

INTRODUCTION

Good Service

Dixon’s products are sold only in specialized retail stores with complete service. This ensures that you as a customer receive only the best support and service. Before the product is delivered, the machine has, for example, been inspected and adjusted by your retailer. See the certificate in the Service Journal in this operator’s manual.

When you need spare parts or support in service questions, warranty issues, etc., please consult the following professional:

 

 

 

This Operator’s Manual belongs to the machine with

Engine

Transmission

the manufacturing number:

 

 

 

 

 

Manufacturing Number

The machine’s manufacturing number can be found on the printed plate affixed to the right side in the engine compartment. Stated on the plate, from the top are:

The machine’s type designation (I.D.). The manufacturer’s type number (Model). The machine’s serial number (Serial no.)

Please have the type designation and serial number available when ordering spare parts.

The engine’s manufacturing number is stamped either on one of the valve covers or an affixed serial plate. The plate states:

The engine’s model. The engine’s type. Code

Please have these available when ordering spare parts.

The wheel motors and hydrostatic pumps have a barcode decal affixed at the rear.

6

symbols and decals

These symbols are found on the machine and in the operator’s manual.

Study them carefully so that you know what they mean.

WARNING!

Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx.

Used in this publication to notify the reader of a risk of personal injury or death, particularly if the reader should neglect to follow instructions given in the manual.

IMPORTANT INFORMATION

Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx.

Used in this publication to notify the reader of a risk of material damage, particularly if the reader should neglect to follow instructions given in the manual.

Used also when there is a potential for misuse or misassembly.

R N

Reverse

Neutral

 

Fast

Slow

 

Choke

Fuel

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Warning!

Parking Brake

CE conformity

Warning! Rotating blades,

Do not touch parts

 

 

marking. Only for

keep away from the

 

 

 

 

 

European market

discharge deck

 

 

 

 

 

 

 

 

 

 

Battery acid is corrosive, explosive and flammable

Do not stand here

 

Noise emissions to the

 

surroundings in accordance

 

with the European Union’s

 

directive. The machine’s

 

emission is stated in the

 

chapter TECHNICAL DATA

 

and on the decals.

 

Only machines for European

 

market

Use protective glasses

Use protective gloves

7

symbols and decals

Read

Shut off engine and

Keep a safe

Use on slopes

No passengers

Operator’s

remove key before

distance from

no greater

 

Manual

performing any

the machine

than 10°

 

 

maintenance or repair work

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Whole body

Severing of fingers

Do not open or

Careful backing up,

 

Careful going

exposure to

and toes

remove safety

watch for other

forward, watch for

thrown objects

 

shields while

 

 

 

people

 

other people

 

 

engine is running

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Moving sharp blades under cover

8

SAFETY

Safety Instructions

These instructions are for your safety. Read them carefully.

WARNING!

This symbol means that important safety instructions need to be emphasized. It concerns your safety.

IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

General Operation

Read, understand, and follow all instructions on the machine and in the manual before starting.

Do not put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times.

Only allow responsible adults, who are familiar with the instructions, to operate the machine.

Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blades.

Be sure the area is clear of bystanders before operating. Stop machine if anyone enters the area.

Never carry passengers. The machine is only intended for use by one person.

Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing.

Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blades when crossing gravel surfaces.

Do not operate machine without the entire grass catcher, discharge guard, or other safety devices in place and working

Slow down before turning.

Never leave a running machine unattended. Always turn off blades, set parking brake, stop engine, and remove keys before dismounting.

Disengage blades when not mowing. Shut off engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher, or unclogging the discharge guard.

Operate machine only in daylight or good artificial light.

Do not operate the machine while under the influence of alcohol or drugs.

8011-512

Read the operator’s manual before starting the machine

8011-513

Clear the area of objects before mowing

9

SAFETY

Watch for traffic when operating near or crossing roadways.

Use extra care when loading or unloading the machine into a trailer or truck.

Always wear eye protection when operating machine.

Data indicates that operators age 60 years and above are involved in a large percentage of riding mower-relatedinjuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

Follow the manufacturer’s recommendation for wheel weights or counterweights.

Anyone who operates this machine must first read and understand this Operation Manual. Local laws may regulate the age of the user.

Keep machine free of grass, leaves or other debris buildup which can touch the hot exhaust or engine parts and burn. Do not allow the mower deck to plow leaves or other debris, causing buildup to occur.

Clean any oil or fuel spillage before operating or storing the machine.

Allow machine to cool before storage.

8011-520

Never take passengers

WARNING!

Engine exhaust and certain vehicle components contain or emit chemicals considered to cause cancer, birth defects, or other reproductive system damage. The engine exhaust contains carbon monoxide, which is an odorless, colorless, poisonous gas. Do not use the machine in enclosed spaces.

10

SAFETY

Personal Safety Equipment

WARNING!

When using the machine, approved personal protective equipment (shown in illustrations) shall be used. Personal protective equipment cannot eliminate the risk of injury but it

will reduce the degree of injury if an accident does happen. Ask your retailer for help in choosing the right equipment.

Make sure that you have first aid equipment close at hand when using the machine.

Never use the machine when barefoot.

Always wear protective shoes or boots, preferably with steel toe caps.

Always wear approved protective glasses or a full visor when assembling or driving.

Always wear gloves when handling the blades.

Never wear loose clothing that can get caught in moving parts.

Use ear protectors to avoid damage to hearing.

Slope Operation

Slopes are a major factor related to loss of control and tip-overaccidents, which can result in severe injury or death. Operation on all slopes requires extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.

Mow up and down slopes (10 degrees maximum), not across.

Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.

Choose a low ground speed so that you will not have to stop while on the slope.

Do not mow on wet grass. Tires may lose traction.

Avoid starting, stopping, or turning on a slope. If the tires lose traction, disengage the blades and proceed slowly straight down the slope.

Keep movement on the slopes slow and gradual. Do not make sudden changes in speed or direction, which could cause machine to roll over.

Use extra care while operating machine with grass catchers or other attachments; they can affect the stability of the machine.

Do not use on steep slopes.

Do not try to stabilize the machine by putting a foot on the ground.

Do not mow near drop-offs,ditches, or embankments. The machine could suddenly roll over if a wheel is over the edge or if the edge caves in.

8011-670a

Personal protective equipment

6003-004

Mow up and down, not side to side

WARNING!

Do not drive up or down hills with slopes greater than 10 degrees. Do not drive across any slopes.

11

SAFETY

Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain out of the path of danger.

Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator.

Be alert and turn machine off if a child enters the area.

Before and while backing, look behind and down for small children.

Never carry children, even with the blades shut off. They may fall off and be seriously injured or interfere with safe machine operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine.

Never allow children to operate the machine.

Use extra care when approaching blind corners, shrubs, trees, or other objects that may block the view of a child.

8011-518

Keep children away from work area

8011-517

Never allow children to operate the machine

12

SAFETY

WARNING!

The engine must not be started when the driver’s floor plate or any protective plate for the mower deck’s drive belt is removed.

Safe Handling of Gasoline

To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

Use only approved gasoline container.

Never remove gas cap or add fuel with the engine running. Allow engine to cool at least two (2) minutes before refueling.

Never fuel the machine indoors.

Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or other appliance.

Before beginning to refuel, minimize the risk of static electricity by touching a metal surface.

Never fill containers inside a vehicle or on a truck or trailer bed with plastic liner. Always place containers on the ground away from the vehicle when filling.

Remove gas-poweredequipment from the truck or trailer and refuel it on the ground. If this is not possible, refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle.

Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-opendevice.

If fuel is spilled on clothing, change clothing immediately.

Never overfill fuel tank. Replace gas cap and tighten securely.

Do not start the engine near spilled fuel.

Never use gasoline as a cleaning agent.

If leaks arise in fuel system, engine must not be started until problem has been resolved.

Check the fuel level before each use and leave space for the fuel to expand, as the heat from the engine and the sun may otherwise cause the fuel to expand and overflow.

8011-516

Never fill the fuel tank indoors

WARNING!

The engine and the exhaust system become very hot during operation.

There is risk for burns if touched.

Allow engine and exhaust system to cool at least two (2) minutes before refueling.

13

SAFETY

General Maintenance

Never operate machine in a closed area.

Keep all nuts and bolts tight to be sure the equipment is in safe working condition.

Never tamper with safety devices. Check their proper operation regularly.

Keep machine free of grass, leaves, or other debris buildup. Clean oil or fuel spillage and remove any fuel-soakeddebris. Allow machine to cool before storing.

If the machine strikes a foreign object, stop and inspect the machine. Repair, if necessary, before restarting.

Never make any adjustments or repairs with the engine running.

Check grass catcher components and the discharge guard frequently and replace with manufacturer’s recommended parts, when necessary.

Mower blades are sharp. Wrap the blade or wear gloves, and use extra caution when servicing them.

Check brake operation frequently. Adjust and service as required.

Maintain or replace safety and instruction labels, as necessary.

Do not modify safety equipment. Check regularly to be sure it works properly. The machine must not be driven with defective or unmounted protective plates, protective cowlings, safety switches, or other protective devices.

Do not change the settings of governors and avoid running the engine with overly high engine speeds. If the engine runs too fast, there is risk for damaging the machine components.

Be very careful when handling battery acid. Acid on skin can cause serious corrosive burns. If battery acid is spilled on skin, rinse immediately with water.

Acid in the eyes can cause blindness, contact a doctor immediately.

Be careful when servicing the battery. Explosive gases form in the battery. Never perform maintenance on the battery when smoking or near open flames or sparks.

The battery can explode and cause serious injury or damage.

Ensure that the equipment is in good condition and that all nuts and bolts, especially those fastening the blade attachments, are properly tightened and torqued

8011-515

Never drive the machine in an enclosed space

WARNING!

Use protective glasses for maintenance work.

WARNING!

The battery contains lead and lead compounds, chemicals that are considered to cause cancer, birth defects, and other reproductive system damage. Wash your hands after handling the battery.

14

SAFETY

Sparking can occur when working with the battery and the heavy cables of the starter circuit. This can cause battery explosion, fire or eye injury. Sparking in this circuit can not occur after the chassis cable (normally negative, black) is removed from the battery.

WARNING!

Avoid electrical sparking and its consequences by the following routines:

Use protective goggles.

Ensure that the fuel filler cap is mounted tightly and no flammable substances are stored in an open vessel.

Never work with the starter circuit if there is spilled fuel.

Disconnect the negative cable from the battery first and reconnect it last.

Do not make a bridge short circuit across the starter relay to run the starter.

Never use the machine indoors or in spaces lacking proper ventilation. The exhaust fumes contain carbon monoxide, an odorless, poisonous, and lethal gas.

Stop to inspect the equipment if the machine runs over or into anything. If necessary, make repairs before starting.

Never make adjustments with the engine running.

The machine is tested and approved only with the equipment originally provided or recommended by the manufacturer. Only use approved repair parts for the machine.

The blades are sharp and can cause cuts and gashes. Wrap the blades or use protective gloves when handling them.

Check the parking brake’s functionality regularly. Adjust and service as necessary.

The mulch blades should only be used in familiar areas when higher quality mowing is desired.

Reduce the risk of fire by removing grass, leaves, and other debris that may have accumulated on the machine.

Allow the machine to cool before putting it in storage.

Regularly clean deck and underside of deck, avoid spraying engine and electrical components with water.

6003-009

Do not smoke when performing maintenance on the battery. The battery can explode and cause serious injury/damage.

8009-728

Risk of sparking

8011-514

Regularly clean deck

15

SAFETY

Transport

The machine is heavy and can cause serious crushing injuries. Be extra cautious when it is loaded on or unloaded from a vehicle or trailer.

Use an approved trailer to transport the machine. Activate the parking brake, turn off the fuel supply, and fasten the machine with approved fastening devices, such as bands, chains, or straps, when transporting.

Do not operate this machine on public roadways.

Check and abide by local traffic regulations before transporting the machine on any road.

Do not tow this machine: it may cause damage to the drive system.

Load the unit onto truck or trailer by driving up ramps of suitable strength using a slow speed. Do not lift! The machine is not intended to be lifted by hand.

WARNING!

Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin, causing serious injury. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop

if proper medical treatment is not administered immediately.

IMPORTANT INFORMATION

The parking brake is not sufficient to lock the machine in place during transport. Ensure that the machine is well fastened to the transport vehicle. Always reverse the machine onto the transport vehicle to avoid tipping it over.

16

SAFETY

Rollover Protection System (ROPS)

The ROPS increases the basic weight of the unit by 73 lbs/33 kg.

Do not use ROPS as a lifting, attaching or anchoring point.

Do not use ROPS for wrecking or towing.

Do not exceed Max GVW: 2822 lbs/1283 kg.

Read machine’s operator manual before each use.

Securely fasten the seat belt if the unit has a ROPS.

Where possible, avoid operating the unit near ditches, embankments and holes.

Reduce speed when turning, crossing slopes and on rough, slick or muddy surfaces.

Stay off slopes too steep for safe operation.

Watch where you are going, especially at row ends, on roads and around trees.

Do not permit others to ride.

Operate the mower smoothly - no jerky turns, starts or stops.

When mower is stopped, set brakes securely and use park brake.

If any part of ROPS is damaged, the entire ROPS must be replaced.

Check all bolts including seat belt for correct torque before each use.

Check ROPS structure for damage before each use.

ROPS bar is NOT intended for use in sub zero temperatures.

WARNING!

The rollover protection system's capabilities may be impaired by damage if the mower is overturned or if alteration to the ROPS occurs. If these conditions take place, the total structure MUST be replaced.

WARNING!

This mower is equipped with an internal combustion engine and should not be used on or near any unimproved forested, bush covered or grassy lands unless the engine's system is equipped with a spark arrester meeting applicable local or state laws (if any).

WARNING!

The engine and the exhaust system become very hot during operation.

There is risk for burns if touched.

Allow engine and exhaust system to cool at least two (2) minutes before refueling.

Spark Arrestors

A spark arrester is standard equipment on the unit and is attached to the engine muffler. Clean the interior screen regularly, depending on usage and conditions.

To clean, remove the clamp securing the tail pipe. Remove the tail pipe and slide the spark arrestor screen out of the muffler. Clean carbon from the screen with a soft brush or cloth.

Replace screen and reattach the tail pipe, orienting the tail pipe either horizontally or upwards, away from grassy surfaces.

8011-514

Regularly clean spark arrestor screen

17

CONTROLS

This operator’s manual describes the Dixon Zero Turn Rider. The rider is fitted with a Kawasaki fourstroke overhead valve engine developing 29-34horse power*.

Transmission from the engine is made via belt-drivenhydraulic pumps. Using the left and right steering controls, the flow is regulated and thereby the direction and speed.

Control Locations

4

3

2

1

15

14 5

6

 

13

 

 

7

 

12

 

 

8

 

 

9

10

11

 

8066-002

1.

Motion control levers

6.

Right fuel tank

11.

Blade switch

7.

Choke control

2.

Left tracking bolt

12.

Seat adjustment lever

8.

Hour meter

3.

Parking brake

13.

Right tracking bolt

9.

Ignition switch

4.

Left fuel tank

14.

Deck lift

10.

Throttle control

5.

Fuses

15.

Deck release

 

 

*The power rating of the engines indicated is the average net power output (at specified rpm) of a typical production engine for the engine model measured to SAE standard J1349/ISO1585. Mass production engines may differ from this value. Actual power output for the engine installed in the final machine will depend on the operating speed, environmental conditions and other variables.

18

CONTROLS

Motion Control Levers

The machine’s speed and direction are continuously variable using the two steering controls. The steering controls can be moved forward or backward about a neutral position. Furthermore, there is a neutral position, which is locked if the steering controls are moved outward.

When both controls are in the neutral position (N), the machine stands still.

By moving both controls an equal amount forward or backward, the machine moves in a straight line forward or backward respectively.

For example,to turn right while moving forward, move the right control towards the neutral position. The rotation of the right wheel is reduced and the machine turns to the right.

Zero turn can be achieved by moving one control backward (behind the neutral position) and carefully moving the other steering control forward from its neutral position. The rotation direction when zero turning is determined by which steering control is moved backward behind the neutral position. If the left steering control is pulled backward, the machine turns to the left. Use extra care when using this maneuver.

8065-003

Steering controls

WARNING!

The machine can turn very rapidly if one steering control is moved much further forward than the other.

8065-053

1.Forward

2.Neutral

3.Neutral slot, Neutral lock

4.Reverse

Motion control lever pattern (right side)

19

CONTROLS

Hour Meter

The hour meter displays the total operating time.

It will flash CHG OIL (Change Oil) at 50 hour intervals. The flash duration is one hour before and one hour after the interval. The CHG OIL icon will come on and shut off automatically. The hour meter cannot be manually reset.

Tracking

If the mower is not tracking straight, check the air pressure in both rear tires. Recommended air pressure for the rear tires is 15 psi (1 bar).

1.Tracking adjustments are made using the tracking bolts. The tracking bolts act as limiting devices for the motion control levers when in the full-forwardposition.

2.For preliminary tracking adjustment, move unit to an open, unobstructed area such as an empty parking lot or open field.

3.Back the tracking bolts out until flush with nut.

4.Test operate unit by driving it at full throttle and the full forward position on both motion control levers. Gradually turn in the tracking bolt on the right hand side until the unit noticeably starts drifting right.

5.Drive forward at full throttle with both motion control levers in the full forward position. Gradually turn in the left tracking bolt until unit tracks straight.

8062-002

Hour meter

8066-003

Tracking adjustment

20

CONTROLS

Parking Brake

The parking brake is found on the left of the machine. Pull the lever backward to activate the brake and forward to release it.

IMPORTANT INFORMATION

The machine must stand absolutely still when applying the parking brake. Always set the parking brake before dismounting. Release the parking brake before moving the mower.

Blade Switch

To engage the mower deck, pull the blade switch knob out. The mower blades are disengaged when the knob is pressed down fully.

Ignition Switch

The ignition key is placed on the control panel and is used to start and stop the engine.

Turn the key clockwise to start the engine.

8065-006

Parking brake

8066-002

Blade switch

8066-004

Ignition switch

21

CONTROLS

Release the key to the RUN position when the engine has started.

For using “accessory”, turn the key counter clockwise.

8066-010

Ignition switch - RUN position

8066-005

Ignition switch - accessory

22

CONTROLS

Fuses

Fuses are located on the right hand side of the machine. They are accessed by tilting the seat forward. Fuses are flat pin fuses type as used in automobiles.

There are three fuses with ratings and functions:

1.20 A, Primary fuse.

2.7.5 A, Mower deck coupling.

3.10 A, Accessories

Choke Control

The choke control is used for cold starts to provide the engine with a richer fuel mixture.

For cold starts the control should be pulled out to its extent.

As the engine reaches operating temperature, gradually push the choke in (normal operating choke position).

Cutting Height Pedals

The cutting height pedals release the deck lift to allow setting the desired deck height. Apply pressure to the lift pedal and rotate foot to also apply pressure to the release pedal, unlocking the deck lift.

For transport, push the lift pedal fully forward until the deck lift latches in the transport (highest) position.

8011-420

Fuses

8066-002

Choke control

2

1

8065-017

1.Lift pedal

2.Release pedal

Cut height selection pedals

23

CONTROLS

Seat Adjustment Lever

The seat can be adjusted lengthways. The lever is located at the right side of the seat (as seen by the driver in the seat). When making adjustments the lever is moved to the left or upward depending on model.

Fuel Shut Off Valve

The fuel shut off valve is located at the left rear of the seat. The valve is off when the handle tab is turned perpendicular to the fuel line.

8066-006

Lengthways adjustment

8065-010

Fuel shut off valve in the CLOSED position.

24

CONTROLS

Refueling

IMPORTANT INFORMATION

It is recommended that fuel be added to both tanks on initial start up.

Read the safety instructions before refueling. The machine has two fuel tanks, one on each side just behind the seat. The capacity for each tank is 6 gallons (11.4 liters).

Regularly check the gas cap gasket for damage and keep the cap properly tightened.

The engine will run on a minimum of 87-octaneunleaded gasoline (no oil mix). Environmentally adapted alkylate gasoline can be used. See Technical Data concerning ethanol fuel. Methanol fuel is not allowed. Do not use E85 alcohol based fuel. Damage to the engine and components may occur.

When operating in temperatures below 32° F. (0° C.), use fresh, clean winter grade gasoline to help insure good cold weather starting.

WARNING!

Gasoline is highly flammable. Observe caution and fill the tank outdoors (see the safety instruction).

WARNING!

The engine and the exhaust system become very hot during operation.

Risk for burns if touched.

Allow engine and exhaust system to cool at least two (2) minutes before refueling

WARNING!

Fill to bottom of filler neck. Do not overfill. Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open flame.

8065-007

Gasoline fuel tanks

IMPORTANT INFORMATION

Experience indicates that alcohol blended fuels (called gasohol, ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel the next season. See Storage Instructions for additional information. Never use engine or carburetor cleaners in the fuel tank or permanent damage may occur.

25

OPERATION

Read the Safety Instructions section and the following pages if you are unfamiliar with the machine.

Training

Zero turn mowers are far more maneuverable than typical riding mowers due to their unique steering capabilities.

We suggest that this section be reviewed in its entirety prior to attempting to move the mower under its own power. Additionally, we suggest when first operating the mower, use a reduced throttle speed and reduced ground speed by NOT moving control levers to the furthest forward or reverse positions during initial operation, or until operator becomes comfortable with controls. We also suggest first time users, or new users to Zero Turn mowers to become familiar with the mower’s movement on a hard surface, such as concrete or blacktop PRIOR to attempting to operate on turf. Until operator becomes comfortable with mower controls and zero turning capability, they may damage turf due to overly aggressive maneuvers.

Steering

To move forward and backward

The direction and speed of the mower’s movements is effected by the movement of the control lever(s) on each side of mower. The left control lever controls the left wheel. The right control lever controls the right wheel.

IMPORTANT INFORMATION

When control levers are in the reverse position they return to neutral when released. This may cause the mower to suddenly stop.

First time users should push mower (see Manual Transport in theOperation section) to an open, flat area, without other people or vehicles or obstacles nearby. To move unit under its own power, the operator must be in the seat, start engine (seeBefore Starting in theOperation section), adjust engine speed to idle, disengage parking brake, do not engage blades at this time, rotate control levers inward. As long as the control levers have not been

moved forward or backwards, the mower will not move. Slowly move both control levers forward slightly. This will allow mower to start moving forward in a straight line. Pull back on control levers to the neutral position and mower should stop moving. Pull back slightly on control levers, this will allow mower to start moving backwards. Push forward on control levers to the neutral position and mower should stop moving.

To turn to the right

While moving in a forward direction, pull the right lever back towards the neutral position while maintaining the position of the left lever, this will slow the rotation of the right wheel and cause the machine to turn in that direction.

To turn to the left

While moving in a forward direction pull the left lever back towards the neutral position while maintaining the position of the right lever, this will slow the rotation of the left wheel and cause the machine to turn in that direction.

To zero turn

While moving in a forward direction, first pull both control levers back until the mower stops or slows dramatically.

Then by alternating one lever slightly to the forward position and the other in the reverse position, the mower turns to the direction of the reverse position lever.

26

OPERATION

Roll Bar and Safety Belt

Operate the unit with the roll bar in the raised and locked position and use the seat belt. There is no rollover protection when the roll bar is down. If it is necessary to lower roll bar, do not wear the seat belt. Raise the roll bar as soon as clearance permits.

WARNING!

The seat belt must be used when the roll bar is in upright position.

Before Starting

Read the sections Safety Instructions and Controls before starting the machine.

Perform the daily maintenance before starting (see maintenance schedule in the Maintenance section).

Check that there is sufficient fuel in the fuel tank.

Adjust the seat to the desired position.

The following conditions must be fulfilled before the engine can be started:

1.The blade switch for engaging the mower blades must be depressed.

2.The parking brake must be on.

3.Both steering controls must be in the locked (outer) neutral position.

8011-464

Roll bar in upright position

8065-006

Activate parking brake before starting

8065-018

Place controls in neutral position

27

OPERATION

Starting the Engine

1.Sit on the seat.

2.Raise the mower deck to the transport position by setting the lift pedals fully forward.

3.Activate the parking brake.

4.Disengage the mower blades by depressing the blade switch.

5.Move the steering controls outward to the locked (outer) neutral position.

8065-017

Set mower deck to the transport position

8066-002

Press the control for disengaging the mower deck

8065-018

Place controls in neutral position

28

OPERATION

6. Move the throttle to the middle position.

7.If the engine is cold, the choke control should be pulled outward to the choke position.

8. Open the fuel tank valve.

8066-007

Set the throttle

8066-002

Set the choke control

8065-013

Fuel valve in the OPEN position

29

OPERATION

9.Press in and turn the ignition key to the start position.

10.When the engine starts, immediately release the ignition key back to the run position.

IMPORTANT INFORMATION

Do not run the starter for more than 5 seconds each time. If the engine does not start, wait about 10 seconds before retrying.

8066-007

Turn to START position

8066-008

Release ignition to the RUN position

30

OPERATION

11.Push the choke control in gradually when the engine has started.

8066-007

Push choke in after starting

12. Set the desired engine speed with the throttle.

 

Allow the engine to run at a moderate speed,

 

“half throttle”, for 3-5minutes before loading

 

it too heavily. USE FULL THROTTLE WHEN

 

MOWING (no choke).

 

WARNING!

 

Engine exhaust and certain vehicle

 

components contain or emit

 

chemicals considered to cause

 

cancer, birth defects or other

 

reproductive system damage. The

 

engine exhaust contains carbon

 

monoxide, which is an odorless,

8066-002

colorless, poisonous gas. Do not use

Set the engine speed

 

the machine in enclosed spaces.

 

31

OPERATION

Weak Battery

WARNING!

Lead-acidbatteries generate

explosive gases. Keep sparks, flame and smoking materials away frombatteries. Always wear eye protection when around batteries.

IMPORTANT INFORMATION

 

The mower is equipped with a 12-voltnegative

 

grounded system. The other vehicle must also

 

be a 12-voltnegative grounded system. Do not

 

use the mower to start other vehicles.

 

If “jumper cables” are used for emergency starting,

 

follow this procedure:

 

Jumper Cables

 

• Connect each end of the RED cable to the

 

POSITIVE (+) terminal on each battery, taking

 

care not to short against chassis.

 

• Connect one end of the BLACK cable to the

8011-642

NEGATIVE (-)terminal of the fully charged battery.

Jumper cable connection

 

• Connect the other end of the BLACK cable to a

 

good CHASSIS GROUND on the mower with the

 

discharged battery, away from the fuel tank and

 

battery.

 

To remove cables, reverse order

Remove BLACK cable first from chassis and then from the fully charged battery.

Remove RED cable last from both batteries.

32

OPERATION

Running

1.Release the parking brake by moving the lever downward.

NOTE: The mower is equipped with an operator presence system. When the engine is running, any attempt by the operator to leave the seat without first setting the parking brake will shut off the engine.

2.Move the steering controls to the neutral position (N).

3.The cutting height can be set from 1"- 5" (2.5 cm-12.7cm) by setting the cutting height

pin into the desired hole. Release deck height control by applying equal pressure to both pedals.

Push foot pedal fully forward for transport position. Set pin at desired cutting height. (Pin is removed by rotating 180O.) Push pedals again to lower deck to selected setting.

8065-006

Release the parking brake

8065-017

Cut height selection pedals

8065-016

Set deck to selected cutting height

33

OPERATION

4.Make sure the work area is free from objects that could be thrown by the rotating blades.

WARNING!

Ensure that no one is near mower when engaging blade switch.

5.Engage the mower deck by pulling out the blade switch.

6.Move throttle control to full throttle. The machine’s speed and direction are

continuously variable using the two steering controls. When both controls are in the neutral position, the machine stands still.

By moving both controls an equal amount forward or backward, the machine moves in a straight line forward or backward respectively.

8066-002

Engage the mower deck and move throttle to full.

Operating on Hills

Read the Safety Instructions Driving on Slopes in the

Safety Instructions.

WARNING!

Do not drive up or down hills with slopes greater than 10 degrees. Do not drive across slopes.

The slowest speed possible should be used before starting up or down hills.

Avoid stopping or changing speed on hills.

IMPORTANT INFORMATION

Control levers return to neutral when released. This may cause the mower to suddenly stop.

If stopping is absolutely necessary, pull drive levers into the neutral position and push to the outside of the unit and engage the parking brake.

To restart movement, release the parking brake.

Pull the control levers back to the center of the mower and press forward to regain forward motion.

Make all turns slowly.

8065-018

Place controls in neutral position

8065-006

Release the parking brake

34

OPERATION

Stopping the Engine

Move the throttle to the minimum position (tortoise symbol). If the engine has been worked hard, allow it to idle at least 60 seconds to attain a normal operating temperature before stopping. To prevent fouling

the spark plugs, avoid idling the engine for longer periods.

Disengage the mower deck by depressing the blade switch.

Raise the mower deck by pressing the foot pedal forward to the transport position.

When the machine is standing still, activate the parking brake by pulling the lever upward.

Turn the ignition key to the stop position.

Move the steering controls outward.

Remove key. To prevent unauthorized use, always remove key when leaving the mower.

8066-009

Disengage the mower deck and move throttle to minimum

8065-016

Raise deck to transport position

8065-018

Place controls in neutral position to stop

35

OPERATION

Mowing Tips

Observe and flag rocks and other fixed objects to avoid collisions.

Begin with a high cutting height and reduce it until the desired mowing result is attained. The average lawn should be cut to 2½" (64 mm) during the cool season and over 3" (76 mm) during the hot months. For healthier and better looking lawns, mow often after moderate growth.

For best cutting performance, grass over 6" (15 cm) in height should be mowed twice. Make the first cut relatively high; the second to the desired height.

The mowing result will be best with a high engine speed (the blades rotate rapidly) and low speed (the rider moves slowly). If the grass is not

too long and dense, the driving speed can be increased without negatively affecting the mowing result.

The finest lawns are obtained by mowing often. The lawn becomes more even and the grass clippings more evenly distributed over the mown area. The total time taken is not increased as a higher operating speed can be used without poor mowing results.

Avoid mowing wet lawns. The mowing result is poorer because the wheels sink into the soft lawn, clumps build, and the grass clippings fasten under the cowling.

Hose the mower deck underside with water after each use. When cleaning, the mower deck shall be raised into the transport position. Make sure the mower is cooled and the engine is off.

Use compressed air to clean top surface of the deck. Avoid flooding water on top surface, engine and electrical components.

When the mulching kit is used, it is important that the mowing interval is frequent and that the deck is cleaned more often.

WARNING!

Clear the lawn of stones and other objects that can be thrown out by the blades.

8011-603b

Mowing pattern

WARNING!

Never drive the rider on terrain that slopes more than 10 degrees. Mow slopes up and down, never side to side. Avoid sudden directional changes.

36

OPERATION

Manual Transport

IMPORTANT INFORMATION Tighten the valve moderately.

Do not overtighten the valve when closing. That can damage the valve seat.

Pump Release Valves

Pump release valves are located at the rear of each pump. They are used to release the system so the machine may be moved by hand when not running. Tilt the seat forward and remove the fan cover to gain access to the pump.

Use a 5/8" wrench or socket and ratchet. Turn the pump release valve ½ turn. Reverse the procedure to reset the pump.

8065-061

Remove fan cover to access release valves

WARNING!

No adjustments or maintenance should be carried out unless:

the engine stopped

the ignition key removed

the parking brake activated

37

maintenance

 

Daily

At least

Maintenance interval

 

 

 

once

 

in hours

 

 

 

 

each

 

 

 

 

 

 

 

 

 

MAINTENANCE

Before

After

year

50

250

500

 

 

 

 

 

 

 

Check the parking brake

 

 

 

 

 

Check the engine’s oil level (every refueling)

 

 

 

 

 

Check the safety system

 

 

 

 

 

Check for fuel and oil leakages

 

 

 

 

 

Check/clean the engine’s cooling air intake

 

 

 

 

 

Check the mower deck

 

 

 

 

 

Check for loose hardware (screws, nuts)

 

 

 

 

 

Clean under the mower deck

 

 

Start the engine and blades, listen for unusual sounds

 

 

 

 

 

Check for damage

 

 

Thoroughly clean around the engine

 

 

Clean around belts, belt pulleys

 

 

Check the tire pressures

 

 

Check battery connections

 

 

Sharpen3)/ Replace mower blades

 

 

Clean the engine’s cooling air intake 2)

 

 

Clean the air cleaner’s pre-filter2) (foam)

 

 

 

 

Clean the air cleaner’s filter cartridge 2) (paper filter)

 

 

 

 

Check/adjust the parking brake

 

 

Inspect muffler/spark arrester

 

 

1) First change after8-10hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.2) In dusty conditions, cleaning and replacement are required more often.3) Performed by authorized service workshop.

= Described in this manual

= Not described in this manual

= Refer to the engine manufacturer's manual

38

maintenance

 

Daily

At least

Maintenance interval

 

 

 

once

 

in hours

 

 

 

 

each

 

 

 

 

 

 

 

 

 

MAINTENANCE

Before

After

year

50

250

500

 

 

 

 

 

 

 

Check/adjust throttle cable

 

 

 

 

 

Check the condition of belts, belt pulleys

 

 

 

 

Change the engine oil 1)

 

 

 

 

Replace the engine oil filter

 

 

 

 

Clean/replace the spark plugs

 

 

 

 

Replace the fuel filter

 

 

 

 

Replace air filter 2) (paper filter)

 

 

 

 

Check the caster wheels (every 200 hours)

 

 

 

 

Replace the air cleaner’s pre-filter2) (foam)

 

 

 

 

 

Check the hydraulic oil in the oil tank

 

 

 

 

 

Change the hydraulic oil (every 500 hours)

 

 

 

 

Replace the hydraulic oil filter (every 500 hours)

 

 

 

 

Dismantle and inspect starter 3) (every 500 hours)

 

 

 

 

 

Check/adjust the mower deck

 

 

 

 

Check the engine valve clearance 3)

 

 

 

 

Perform the 500-hourservice3)

 

 

 

 

1) First change after5-8hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.2) In dusty conditions, cleaning and replacement are required more often.3) Performed by authorized service workshop.

= Described in this manual

= Not described in this manual

= Refer to the engine manufacturer's manual

WARNING!

Before performing any service or adjustment checklist:

Engage the parking brake.

Place the Blade-switchin the disengaged position.

Turn the ignition switch to “OFF” position and remove the key.

Make sure the blades and all moving parts have completely stopped.

Disconnect the spark plug wire from all spark plugs and place the wire where it cannot come in contact with the plug.

39

maintenance

Battery

The mower is equipped with a maintenance free battery and does not need servicing. However, periodic charging of the battery with an automotive type battery charger will extend its life.

Keep battery and terminals clean.

Keep battery bolts tight.

See chart for charging times.

STANDARD

STATE

APPROXIMATE BATTERY CHARGING TIME*

 

 

TO FULL CHARGE AT 80OF / 27OC

BATTERY

OF

 

 

 

 

 

Maximum Rate at:

 

 

 

 

 

 

CHARGE

 

 

 

 

 

50 Amps

30 Amps

20 Amps

10 Amps

 

 

 

 

 

 

 

 

12.6V

100%

- FULL CHARGE -

 

 

 

 

 

 

12.4V

75%

20 min.

35 min.

48 min.

90 min.

 

 

 

 

 

 

12.2V

50%

45 min.

75 min.

95 min.

180 min.

 

 

 

 

 

 

12.0V

25%

65 min.

115 min.

145 min.

280 min.

 

 

 

 

 

 

11.8V

0%

85 min.

150 min.

195 min.

370 min.

 

 

 

 

 

 

*Charging time depends on battery capacity, condition, age, temperature and efficiency of charger

WARNING!

Always wear eye protection when around batteries.

Battery Removal

Corrosion and dirt on the battery and terminals can cause the battery to “leak” power.

1.Lift the seat and rotate fully forward until supported by the seat rod.

2.Loosen the two wingnuts attached to the side “J” bolts just enough that the battery mount bracket slides down off the battery.

3.Using two ½" wrenches disconnect BLACK battery cable then RED battery cable.

4.Carefully remove the battery from the mower.

For cleaning

5.Rinse the battery with plain water and dry.

6.Clean terminals and battery cable ends with wire brush until shiny.

For replacing

7.Install new battery with terminals in the same position as the old battery.

8.Connect RED battery cable first to positive (+) battery terminal.

9.Connect BLACK grounding cable to negative (-)battery terminal.

10.Slide mount bracket back up over battery and retighten wingnuts.

11.Lower seat.

IMPORTANT INFORMATION

Do not attempt to open or remove caps or covers. Adding or checking level of electrolyte is not necessary.

Always use two wrenches for the terminal screws.

WARNING!

Do not short battery terminals by allowing a wrench or any other object to contact both terminals at the same time. Before connecting battery, remove metal bracelets, wristwatch bands, rings, etc.

Positive terminal must be connected first to prevent sparks from accidental grounding.

1

2

8065-020

1.Mount bracket

2.Battery bracket

Battery cleaning and installation

40

maintenance

Safety System

This machine is equipped with a safety system that prevents starting or driving under the following conditions.

The engine can only be started when:

1.The mower deck is disengaged.

2.The steering controls are in the outer, locked neutral position.

3.The parking brake is on.

Make daily inspections to ensure that the safety system works by attempting to start the engine when one of the conditions is not met. Change the conditions and try again.

If the machine starts when one of these conditions is not met, turn the machine off and repair the safety system before using the machine again.

Make sure the engine stops when the park brake is not engaged and the operator leaves the seated position.

Check that the engine stops if the mower blades are engaged and the driver temporarily moves off the driver's seat.

8065-021

Conditions for starting

IMPORTANT INFORMATION

To be able to drive, the driver must sit in the seat and release the parking brake before the steering controls can be moved into the neutral position, otherwise the engine will stop.

Fuel Filter

Replace the line-mountedfuel filter every 100 hours (once per season) or more often if it becomes clogged.

1.Move the hose clamps away from the filter. Use flat-nosedpliers.

2.Pull the filter loose from the hose ends.

3.Check hoses for brittleness or damage. Replace if necessary.

4.Push the new filter into the hose ends. Position the filter with the FLOW arrow pointing toward the fuel pump. If necessary, a soap solution can be applied to the filter ends to ease mounting.

5.Move the hose clamps back toward the filter.

8065-026

Fuel filter

Tire Pressures

Fill tire pressures to 15 psi / 103 kPa / 1 bar.

IMPORTANT INFORMATION

DO NOT add any type of tire liner or foam fill material to the drive tires. Excessive loads created by foam filled tires will cause premature failures.

Only use O.E.M. specified tires.

41

maintenance

Parking Brake

Visually check that no damage is found on the lever, links, or switch belonging to the parking brake. Perform a standstill test and check that there is sufficient braking action.

WARNING!

Faulty adjustment results in reduced braking ability and can cause an accident.

IMPORTANT INFORMATION

The machine must be standing still when applying the parking brake.

Parking Brake Adjustments

1.Using a jack stand, raise the rear of the mower up off the ground. Make sure the machine is securely supported.

2.Remove the rear tire assemblies.

3.Release the park brake.

4.Measure the distance from the swivel to the washer. (See Illustration). The measurement should be 1¾" on both the right and left side brake linkage assemblies.

5.If adjustments are needed, loosen B jam nut and turn A jam nut until the correct distance is achieved. Retighten B jam nuts against A jam nuts.

8065-006

Parking brake

1¾"

1

2

8065-051

1.Swivel

2.Washer

Parking brake adjustment

D

B

 

 

A

 

C

 

8065-052

Parking brake adjustment

42

maintenance

6.Engage the park brake. Measure the distance between the D brake bolt and the brake swivel. The distance should be 1/8"-¼".

7.If adjustments are needed, loosen C jam nut. Turn the brake bolt until the distance is correct. Retighten C jam nuts.

Neutral Adjustments

WARNING!

Neutral adjustments are made with the rear tires able to rotate. Do not wear loose clothing or jewelry and keep hands and feet away from tires.

Neutral adjustments are made with the rear wheels off the ground and able to rotate, which is done with the engine running.

1.Using a jack stand, raise the rear of the mower up off the ground enough so the tires can rotate freely. Make sure the machine is securely supported.

2.Lift the seat and rotate fully forward until supported by the seat rod.

3.Unplug the safety switch and harness from the seat.

4.Using two 9/16" wrenches, loosen the jam nut next to the turnbuckle. (See illustration.)

5.Hold down the safety switch plunger and start the engine. Continue to hold the plunger down during the next two steps.

6.Keeping the drive levers in the neutral lock position, release the parking brake. The drive wheels should NOT rotate.

7.If the drive wheels rotate, turn the turnbuckle until the wheels stop. Release plunger to stop the engine.

8.Retighten the jam nut against the turnbuckle while holding the turnbuckle.

9.Duplicate procedure for the opposite wheel.

10.After adjustments are made, secure the safety switch and lower the seat.

1/8"-¼"gap with park

brake engaged

8065-049

Measure gap

8065-050

Seat safety switch

1

2

8065-049

1.Jam Nut

2.Turnbuckle

Neutral adjustment

43

maintenance

Deck Belt

Deck Belt Removal

Park on a level surface. Apply park brake. Lower the deck into the lowest cutting position.

1.Remove foot plate and belt shields.

2.Remove any dirt or grass that may have accumulated around the cutter housings and entire deck surface.

3.With a ½" breaker bar and using the square opening in the idler arm, shift the arm counter clockwise to relieve the tension on the belt.

4.Carefully roll the belt over the top of the cutter housing pulleys.

5.Remove the belt guide hardware with a ½" wrench and set belt guide aside.

6.Remove the belt from around the electric clutch on the engine shaft.

Deck Belt Installation

NOTE: For ease in installing the deck belt, refer to the routing decal on the cutting deck.

1.Place the belt around all the pulleys except the center spindle pulley.

2.With a ½" breaker bar, shift the idler arm counter clockwise. When there is enough slack, slip the belt onto the center spindle pulley.

3.Reinstall the belt guide removed in Step 5 above.

8065-040

Release the belt tension

8065-045

Remove belt guide

8065-047

Refer to belt routing decal

44

maintenance

4.Double check belt routing to make sure it matches the routing decal, and that the belt does not have any twist. Correct if needed.

5.Adjust belt tension by turning the eyebolt until there is approximately 7/8"-1"of threads showing outside the nut.

6.Belt tension should be set to 60-70lbs.

7.Replace belt shields on both mandrel housings and secure with fasteners.

Pump Belt

The belts are not adjustable. Replace belts if they begin to slip from wear.

Replacing Pump Belt

Park the mower on a level surface. Engage the parking brake.

Belt Removal

1.Remove the deck belt (see Deck Belt Removal in this section of the manual).

2.Remove clutch stop to access the belt.

3.Disconnect clutch wire.

4.With a ½" breaker bar and using the square opening in the idler arm, shift the arm to create slack in the belt.

5.Remove belt from the engine and pump pulleys.

Belt Installation

1.Wrap the belt around the engine pulley.

2.Wrap the belt around the left pump pulley.

3.Route the belt around the inside of the idler pulley.

4.With a ½" breaker bar and using the square opening in the idler arm, shift the arm to create slack in the belt.

While holding the idler back with the breaker bar, wrap the belt around the right pump pulley.

5.Replace and secure clutch stop.

6.Reinstall the deck belt. (See Deck Belt Installation in this section of the manual).

V-belts

Check every 100 hours of operation. Check for severe cracking and large nicks.

NOTE: The belt will show some small cracks in normal operation.

8065-054

Adjust belt tension

3

1

2

8065-041

Electric clutch

Idler arm release placement

Clutch stop

Pump belt removal

45

maintenance

Cutting Blades

To attain the best mowing effect, it is important that the blades are well sharpened and not damaged.

Bent or cracked blades or blades with large nicks should be replaced.

Blades damaged from hitting obstacles that result in a breakdown should be replaced. The service workshop should decide whether the blade can be repaired/ground or must be replaced. Balance the blades after sharpening.

Check the blade mounts.

Blade Replacement

WARNING!

Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling.

1.Remove blade bolt by turning counterclockwise.

2.Install new or re-sharpenedblade with stamped “GRASS SIDE” facing towards ground/grass (down) or “THIS SIDE UP” facing deck and cutter housing.

3.Install and tighten blade bolt securely.

4.Torque blade bolt to 90 ft-lbs(122 Nm).

IMPORTANT INFORMATION Special blade bolt is heat treated.

Replace with a Dixon bolt if required.

Do not use lower grade hardware than specified.

WARNING!

Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling.

IMPORTANT INFORMATION

The sharpening of blades should be carried out by an authorized service workshop.

3

1

2

8065-028

1.Blade

2.Blade bolt (special)

3.Cutter housing

Blade attachment

46

maintenance

Adjusting the Mower Deck

Leveling Deck

Adjust the deck while the mower is on a level surface. Make sure the tires are inflated to the correct pressure. See Tire Pressures inMaintenance section. If tires are under or over inflated, the deck cannot be properly adjusted. Faulty mower deck adjustments will cause an uneven mowing result.

Four bolts control the height and pitch of the mower deck. The deck should be adjusted slightly higher in the rear.

NOTE: To insure accuracy of leveling procedure, mower deck drive belt must be installed prior to leveling the deck.

1.Wear heavy gloves. Turn each outer blade tip to align the deck in a side-to-sidemanner.

2.Measure from the floor surface up to the bottom of the blade tip on the discharge side of the mower deck. Retain this measurement. Move to the opposite side; check that measurement is the same. If adjustment is required, loosen the locknut and adjust bolt up until both side-to-sidemeasurements are equal. Retain measurement.

3.Turn both outer blades to align with the deck in front-to-rearmanner. Reposition rear mounting bolts up or down until rear blade tips are positioned1/8" to3/8" higher in the rear than the front blade tips.

4.Confirm measurements once again. Blade tip height should be equal in a side-to-sidemanner. In the rear, blade tips should be1/8" to3/8" higher than the front measurement. In the front, blade tips should be equal fromside-to-side.

NOTE: This will place the mower deck in a base measurement position. Additional adjustment may be required to achieve desired cut for the type of grass or conditions being mowed.

WARNING!

Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling.

1

2

8065-037

1.Adjustment bolt

2.Locknut

Leveling the mower deck

47

maintenance

Anti-scalpRollers

Anti-scalprollers keep the deck in the proper position to help prevent scalping in most terrain conditions. Do not adjust the rollers to support the deck.

IMPORTANT INFORMATION

Adjust anti-scalprollers with the mower on a flat level surface.

The anti-scalp rollers can be set in three positions:

Upper position 1 to 2½" (25 to 63 mm) grass.

Middle position 2½" to 4" (63 to 102 mm) grass.

Lower position 4" to 5" (102 to 127 mm) grass.

8065-029

Anti-scalprollers

Deck Lift Spring

When mowing 2" or lower, it may be necessary to adjust the deck lift springs. Access the springs by tilting the seat forward.

Loosen the nut to adjust the spring tension.

IMPORTANT INFORMATION

The anti-scalprollers must not be used for gauge wheels or the roller and deck may be damaged.

8065-062

Deck lift spring

48

maintenance

Caster Wheels

Check every 200 hours. Check that wheels rotate freely.

Removal and Installation

Remove nut and caster bolt. Pull the wheel out of the fork. Install in reverse order. Tighten caster bolt. Torque to 45 ft-lbs(61 Nm), then back nut off ½ turn.

NOTE: Tire should rotate freely but axle spacers should not.

If wheels do not rotate freely take the unit to the dealer for service.

Hardware

Check daily. Inspect the entire machine for loose or missing hardware.

Cleaning

Regular cleaning and washing, especially under the mower deck, will increase the machine’s life-span.Make it a habit to clean the machine directly after use (after it is cooled), before the dirt sticks.

Do not spray water on the top of the mower deck. Use compressed air to clean the top side of mower deck. Regularly clean deck and underside of the deck with normal water pressure. Do not use a high pressure washer or steam cleaner. Avoid spraying engine and electrical components with water.

Do not rinse hot surfaces with cold water. Let unit cool before washing.

2

1

8065-030

1.Caster bolt

2.Axle spacer

Caster wheel

Use protective glasses when cleaning and washing.

49

LUBRICATION

Lubrication Schedule

8065-035

12/12 Every year

Lubricate with grease gun

Level check

1/52 Every Week

Oil change

 

1/365 Every day

Filter change

 

 

 

 

*Change hydraulic drive filters.

p Change engine oil every 50 hours.

General

Remove the ignition key to prevent unintentional movements during lubrication.

When lubricating with an oil can, it must be filled with engine oil.

When lubricating with grease, unless otherwise stated, use high grade molybdenum disulphide grease.

For daily use, the machine should be lubricated twice weekly.

Wipe away excess grease after lubrication.

It is important to avoid getting lubricant on the belts or the drive surfaces on the belt pulleys. Should this happen, attempt to clean them with spirits. If the belt continues to slip after cleaning, it must be replaced. Gasoline or other petroleum products must not be used to clean belts.

50

LUBRICATION

Wheel and Deck Zerks

Use only good quality bearing grease.

Grease from well-knownbrand names (petrochemical companies, etc.) usually maintains a good quality.

Front Wheel Mount

Remove dust cap to expose zerk. Lubricate with a grease gun until the grease is forced out around the top washer.

Front Wheel Bearings

Lubricate 3-4strokes with a grease gun on each set of wheel bearings.

Deck Spindle

Lower the cutting deck completely.

If a grease gun without rubber hose is used, the foot plate must be removed.

Lubricate with a grease gun, 2-3strokes per spindle.

Cables

If possible, grease both ends of the cables and move the controls to end stop positions when lubricating. Refit the rubber covers on the cables after lubrication. Cables with sheaths will bind if they are not lubricated regularly. If a cable binds, it can disrupt operation.

If a cable binds, remove the cable and hang it vertically. Lubricate it with light engine oil until the oil begins to escape from the bottom.

8065-032

Lubricating front wheels

8065-033

Deck spindle

51

LUBRICATION

Hydraulic Drive

Fluid Change

The hydraulic drive is designed with an external filter for ease of maintenance. To ensure constant fluid quality levels and longer life, an oil filter change interval of every 500 hours is recommended.

The following procedure can be performed with the pump installed in the vehicle, and the vehicle on level ground.

1.Lock the vehicle parking brake.

2.Place an oil drain pan with a 2 gallon capacity beneath the oil reservoir. Remove the drain port and drain oil. Remove the oil filter from the pump.

Drain old oil filters of all free-flowingoil prior to disposal. Place used oil in appropriate containers and dispose of it in accordance with laws in your area.

2

3

1

8065-036

1.Pump filter

2.Oil reservoir

3.Drain port

Changing the hydraulic pump oil and filter

3.

After the oil has drained, wipe the filter base

 

 

 

surface off and apply a film of new oil to the

 

 

 

gasket of the new replacement filter.

 

 

4.

Prefill the oil filter with new oil and install the new

 

 

 

filter by hand. Turn ¾ to one full turn after the

 

 

 

filter gasket contacts the filter base surface.

 

 

5.

Fill reservoir with synthetic 15W 50 oil to the

 

 

 

level of the lower hole in the fill tube. DO NOT

 

 

 

fill above the level of the upper hole. After

 

 

 

purging, check levels and add oil if necessary.

 

 

6.

Reinstall the reservoir cap by hand. Do not

 

 

 

overtighten.

Do not fill above

 

7.

Proceed to the purge procedure.

 

this level

Minimum fill level

 

 

 

52

LUBRICATION

Purging Procedures

Due to the effects air has on efficiency in hydrostatic drive applications, it is critical to purge the system.

These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system.

Resulting symptoms in hydrostatic systems may be:

Noisy operation.

Lack of power or drive after short term operation.

High operation temperature and excessive expansion of oil.

Shortened component life.

Before starting, make sure the oil tank is at the proper oil level. If not, fill to the specifications outlined above.

The following procedures are best performed with the vehicle drive wheels off the ground, then repeated under normal operating conditions.

1.Disengage the brake if activated.

2.With the bypass valve open and the engine running at fast idle, slowly move the directional control in both forward and reverse directions (5 or 6 times). As air is purged from the unit, the oil level will drop.

3.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 required after stopping the engine.

4.It may be necessary to repeat Steps 2 and 3 until all the air is completely purged from the system. When the hydraulic drive operates at normal noise levels and moves smoothly forward and reverse at normal speeds, the hydraulic drive is considered purged.

5.After the vehicle has been used two times, the oil level should be checked while the oil is cold and adjusted accordingly.

53

troubleshooting guide

Problem

Cause

 

 

 

Engine will not start.

Blade switch is engaged.

 

• Steering controls are not locked in the neutral

 

 

position.

 

• Parking brake is not activated.

 

Battery is dead.

 

• Contamination in the carburetor or fuel line.

 

• Fuel supply is closed.

 

• Clogged fuel filter or fuel line.

 

Faulty ignition system.

 

 

 

Starter does not turn the engine over.

Dead battery.

 

• Poor contacts on the battery terminal cable

 

 

connections.

 

Fuse blown.

 

Ignition system faulty.

 

• Fault in the starter safety circuit. See Safety

 

 

System in theMaintenance Section

 

 

 

Engine runs rough.

Faulty carburetor.

 

• Choke control is pulled out with warm engine.

 

• Clogged fuel filter or jet.

 

• Clogged ventilation valve on the fuel cap.

 

• Fuel tank nearly empty.

 

Fouled spark plug.

 

• Spark plug is loose.

 

• Rich fuel mixture or fuel-airmixture.

 

Wrong fuel type.

 

• Water in the fuel.

 

Clogged air filter.

 

 

 

Engine seems weak.

Clogged air filter.

 

Fouled spark plugs.

 

Carburetor incorrectly adjusted.

54

troubleshooting guide

 

Problem

Cause

 

 

 

 

 

Machine vibrates.

Blades are loose.

 

 

• Blades are incorrectly balanced.

 

 

Engine is loose.

 

 

 

 

Engine overheats.

Clogged air intake or cooling fins.

 

 

Engine overloaded.

 

 

• Poor ventilation around engine.

 

 

• Defective engine speed regulator.

 

 

• Too little or no oil in the engine.

 

 

Fouled spark plug.

 

 

 

 

Battery not charging.

Poor contact with battery terminal cable

 

 

 

connectors.

 

 

• Charging lead is disconnected.

 

 

• Fault in engine charging system.

 

 

 

 

Machine moves slowly, unevenly, or not at all.

Parking brake on.

 

 

• Bypass valve on pump open.

 

 

• Drive belt for the transmission gears slack or has

 

 

 

come off.

 

 

• Air in hydraulic system.

 

 

 

 

Mower deck not engaging.

Drive belt for the mower deck has come loose.

 

 

• Contact for the electromagnetic coupling has

 

 

 

loosened.

 

 

• The blade switch is faulty or has come loose, from

 

 

 

the cable contact.

 

 

• The fuse has blown.

 

 

 

 

Hydraulic drive leaks oil.

Damaged seals, housing, or gaskets.

 

 

• Air trapped in hydraulic system.

 

 

 

 

Uneven mowing results.

Unequal tire pressure on the left and right sides.

 

 

Bent blades.

 

 

• Suspension for the mower deck is uneven.

 

 

Blades are dull.

 

 

• Driving speed too high.

 

 

• The grass is too long.

 

 

• Grass collected under the mower deck.

55

STORAGE

Winter Storage

At the end of the mowing season, the machine should be readied for storage (or if it will not be in use for longer than 30 days).

Fuel allowed to stand for long periods of time (30 days or more) can leave sticky residues that can plug the carburetor and disrupt engine function.

Fuel stabilizers are an acceptable option as regards to the sticky residues that can occur during storage.

Add stabilizer to the fuel in the tank or in the storage container. Always use the mixing ratios specified by the manufacturer of the stabilizer. Run the engine for at least 10 minutes after adding the stabilizer so that it reaches the carburetor. Do not empty the fuel tank and the carburetor if a stabilizer has been added.

WARNING!

Never store an engine with fuel in the tank indoors or in poorly

ventilated spaces where fuel vapor can come in contact with open flames, sparks, or a pilot light such as in a boiler, hot water tank, clothes drier, etc. Handle the fuel with care. It is very flammable and can cause serious personal injury and property damage. Drain the fuel into an approved container outdoors and far away from open flame. Never use gasoline for cleaning. Use

a degreaser and warm water.

To ready the machine for storage, follow these steps:

1.Thoroughly clean the machine, especially under the mower deck. Touch up damage to the paint and spray a thin layer of oil on the underside of the mower deck to avoid corrosion.

2.Inspect the machine for worn or damaged parts and tighten any nuts or screws that may have become loose.

3.Change the engine oil; dispose of properly.

4.Empty the fuel tanks or add a fuel stabilizer. Start the engine and allow it to run until the carburetor is drained of fuel or the stabilizer has reached the carburetor.

5.Remove the spark plug and pour about a tablespoon of engine oil into the cylinder. Turn over the engine so that the oil is evenly distributed and then refit the spark plug.

6.Lubricate all grease zerks, joints, and axles.

7.Remove the battery. Clean, charge, and store the battery in a cool place, but protect it from direct cold.

8.Store the machine in a clean, dry place and cover it for extra protection.

Service

When ordering spare parts, please specify the purchase year, model, type, and serial number.

Always use genuine Dixon spare parts.

An annual check-upat an authorized service workshop is a good way to ensure that the machine performs its best the following season.

56

WIRING DIAGRAM

TIMER SCHEMATIC

57

TECHNICAL DATA

 

6029FX, 6029FX BF

7234FX, 7243FX BF

 

 

 

Engine

 

 

 

 

 

Manufacturer

Kawasaki

Kawasaki

 

 

 

Type

FX801V

FX921V

 

 

 

Power

29 HP (21.6 Kw) @ 3600 rpm

34 HP (25.4 Kw) @ 3600 rpm

 

 

 

Lubrication

Pressure w/ Oil Filter

Pressure w/ Oil Filter

 

 

 

Oil capacity excluding filter

1.9 qts (1.8 liters)

1.9 qts (1.8 liters)

 

 

 

Oil capacity including filter

2.0 qts (2.0 liters)

2.0 qts (2.0 liters)

Engine oil (See viscosity diagram)

SAE 10W30 API SG-SJ

SAE 10W30 API SG-SJ

 

 

 

Fuel

Min 87 octane unleaded (Max

Min 87 octane unleaded (Max

 

ethyl alcohol 10%, Max MTBE 15%)

ethyl alcohol 10%, Max MTBE 15%)

 

 

 

Fuel tanks capacity

12 gallons / 45.4 liters

12 gallons / 45.4 liters

 

 

 

Spark plugs / gap

NGK - BPR4ES

NGK - BPR5ES

 

.030" / 0.75 mm

.030" / 0.75 mm

 

 

 

Cooling

Air cooled

Air cooled

 

 

 

Air filter

Heavy duty canister

Heavy duty canister

Alternator

12v 15 amp @ 3600 rpm

12v 15 amp @ 3600 rpm

 

 

 

Starter

Electric

Electric

 

 

 

Transmission

 

 

 

 

 

Transmission

Dual pump and wheel motor

Dual pump and wheel motor

 

 

 

Speed and direction controls

Dual levers, foam gripped

Dual levers, foam gripped

 

 

 

Speed forward

0-11mph -0-17.7Km/h

0-12mph -0-19.3Km/h

Speed reverse

0-6mph -0-9.7Km/h

0-6mph -0-9.7Km/h

 

 

 

Brakes

Disc

Disc

 

 

 

Front caster tires, smooth tread

13 x 6.5 Flat Free

13 x 6.5 Flat Free

 

 

 

Rear tires, turf pneumatic

24 x 12-124 ply

24 x 12-124 ply

 

 

 

Tire pressures

15 PSI / 103 kPa / 1 bar

15 PSI / 103 kPa / 1 bar

 

 

 

58

TECHNICAL DATA

 

6029FX, 6029FX BF

7234FX, 7243FX BF

 

 

 

Frame

 

 

 

 

 

Cutting Width

60" (152.4 cm)

72" (183 cm)

 

 

 

Cutting Height

1"-5"(2.5-12.7cm)

1"-5"(2.5-12.7cm)

 

 

 

Uncut Circle

0

0

 

 

 

Number of Blades

3

3

 

 

 

Blade Length

21" / 53.3 cm

25" / 63.5 cm

 

 

 

Nose Rollers

5 adjustable

6 adjustable

Sprung Seat

Suspension

Suspension

 

 

 

Hinged Arm Rests

Yes

Yes

 

 

 

Hour Meter

Yes

Yes

 

 

 

Blade Engagement

250 ft-lbOgura

250 ft-lbOgura

 

 

 

Deck Construction

7 gauge

7 gauge

 

 

 

Productivity

6 acres/h / 24,280 m2/h

7.2 acres/h / 29,137 m2/h

Dimension

 

 

 

 

 

Weight

1320 lbs / 599 kg

1400 lbs / 635 kg

 

 

 

Base Machine Length

82½" / 210 cm

86" / 218 cm

 

 

 

Base Machine Height

47½" / 121 cm

47½" / 121 cm

 

 

 

Base Machine Width

55" / 140 cm

57" / 145 cm

 

 

 

Overall Width, Chute Up

61½" / 156 cm

73½" / 187 cm

Overall Width, Chute Down

73" / 185 cm

86" / 218 cm

 

 

 

Overall Height, ROPS Up

72" / 183 cm

72" / 183 cm

 

 

 

59

TECHNICAL DATA

Torque Specifications

Hex Head Cap Screws

Shank Size (Diameter in inches, fine or coarse thread)

The torque values shown should be used as a general guideline when specific torque values are not given.

U.S. Standard Hardware

 

Grade

SAE Grade 5

SAE Grade 8

 

Flangelock Screw

 

 

 

 

 

 

 

 

 

w/Flangelock Nut

 

ft./lbs

 

ft./lbs

 

Nm

ft./lbs

 

Nm

ft./lbs

 

Nm

 

 

 

 

 

 

¼

 

9

 

12

13

 

18

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5/16

 

18

 

24

28

 

38

24

 

33

 

3/8

 

31

 

42

46

 

62

40

 

54

 

7/16

 

50

 

68

75

 

108

 

 

 

 

½

 

75

 

102

115

 

156

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9/16

 

110

 

150

165

 

224

 

 

 

 

5/8

 

150

 

203

225

 

305

 

 

 

 

¾

 

250

 

339

370

 

502

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7/8

 

378

 

513

591

 

801

 

 

 

 

11/8

 

782

 

1060

1410

 

1912

 

 

 

** Grade 5 - Minimum commercial quality (lower quality not recommended)

Metric Standard Hardware

 

Grade

Grade 8.8

 

Grade 10.9

 

Grade 12.9

 

 

 

 

 

 

 

 

 

 

 

ft./lbs

ft./lbs

 

Nm

ft./lbs

 

Nm

ft./lbs

Nm

 

 

 

 

 

 

 

 

 

 

 

M4

1.5

 

2

2.2

 

3

2.7

3.6

 

 

 

 

 

 

 

 

 

 

 

M5

3

 

4

4.5

 

6

5.2

7

 

 

 

 

 

 

 

 

 

 

thread)

M6

5.2

 

7

7.5

 

10

8.2

11

 

 

 

 

 

 

 

 

 

M7

8.2

 

11

12

 

16

15

20

coarse

 

 

 

 

 

 

 

 

 

 

 

M8

13.5

 

18

18.8

 

25

21.8

29

fine or

 

 

 

 

 

 

 

 

 

M10

24

 

32

35.2

 

47

43.5

58

millimeters,

 

 

 

 

 

 

 

 

 

M14

70.5

 

94

100

 

133

119

159

 

M12

43.5

 

58

62.2

 

83

75

100

in

 

 

 

 

 

 

 

 

 

(Diameter

M16

108

 

144

147

 

196

176

235

 

 

 

 

 

 

 

 

 

M18

142

 

190

202

 

269

242

323

Size

 

 

 

 

 

 

 

 

 

M20

195

 

260

275

 

366

330

440

Shank

 

 

 

 

 

 

 

 

 

 

 

M22

276

 

368

390

 

520

471

628

 

 

 

 

 

 

 

 

 

 

 

 

 

 

M24

353

 

470

498

 

664

596

794

 

 

 

 

 

 

 

 

 

 

 

M27

530

 

707

474

 

996

904

1205

 

 

 

 

 

 

 

 

 

 

60

WARRANTY

DIXON® ZTR® PRO SERIES COMMERCIAL / RESIDENTIAL

Black Bear™, Kodiak® & Grizzly™ Mowers

DIXON WARRANTS ITS ZTR MOWERS AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP FOR THE PERIODS SET FORTH BELOW. THE SOLE REMEDY UNDER THIS WARRANTY IS REPLACEMENT OR REPAIR OF PARTS INCLUDING LABOR COSTS.

THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:

1.COMMERCIAL WARRANTY (use other than, or in addition to, mowing at owner’s primary place of residence):

a.First two years - 100% parts and labor subject to the conditions and limitations described herein with the exception of non-covereditems specified below.

b.Third year - limited to 100% parts cost as shown in the current Dixon Parts Price List and subject to the conditions and limitations as described herein.

c.Attachments marketed through or approved by Dixon are warranted for one year parts and labor in commercial use applications.

d.Pro Series Models are not subject to hour meter restrictions.

e.Warranty applies to new mowers.

2.RESIDENTIAL WARRANTY (used only at owner’s primary place of residence):

a.Three years - 100% parts and labor subject to the conditions and limitations described herein for a period of three years from date of purchase by the original owner.

b.Attachments marketed through or approved by Dixon are warranted for two years parts and labor in residential use applications.

c.Warranty applies to new mowers.

3.All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon warranty policy and allowances. All warranty claims must be submitted to Dixon for approval.

4.Warranty labor reimbursement to dealers based on published Dixon flat rate schedule.

5.Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or alteration. The use of parts or components other than those supplied by Dixon VOIDS ALL WARRANTY.

6.Battery warranty is limited to 1 year from mower manufacture date.

7.The following items are not covered by this warranty policy:

a.Routine maintenance or adjustments to include any oils, filters or other fluids used.

b.Belts, blades, tires and cosmetic appearance (paint, seat fade, etc.)

c.Pick up and delivery charges for transportation of mower to and from an authorized Dixon dealer’s place of business.

d.Engines. These are covered under a separate warranty by each individual engine manufacturer. Consult engine manual for warranty details.

e.Any costs or expense of providing substitute equipment while repair work is being performed on a warranted mower.

8.THERE IS NO OTHER EXPRESS WARRANTY. TO THE EXTENT PERMITTED BY LAW, ALL IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED, OTHERWISE, ALL SUCH IMPLIED WARRANTIES ARE LIMITED TO THE SAME DURATION AND REMEDIES AS THE EXPRESS WARRANTY. ALL LIABILITIES FOR CONSEQUENTIAL DAMAGES UNDER ANY EXPRESS OR IMPLIED WARRANTY ARE EXCLUDED.

61

conformity certificates

USA requirements

Labels are placed on the engine and/or in the engine compartment stating that the machine will fulfill the requirements. This is also applicable to special requirements for any of the states, (California emission rules etc.). Do not remove any of these labels. Certificates can also be supplied with the machine at delivery or written in the Engine manual. Take care of them as they are valuable documents.

CE requirements

The Declaration of Conformity is included in the literature packet.

62

SERVICE JOURNAL

Action

Date, mtr reading,

 

stamp, sign

Delivery Service

 

1.

Charge and connect the battery.

 

2.

Adjust the tire pressure of all wheels to 15 PSI (1 bar).

 

3.

Check hydraulic oil level.

 

4.

Check hydraulic hoses for kinking or leaks.

 

5.

Check neutral position.

 

6.

Fill with fuel and open the fuel shut off valve.

 

7.

Start the engine.

 

8.

Check that there is drive to both wheels.

 

9.

Check the mower deck pitch and adjustment.

 

10.

Check:

 

 

Safety switch for the parking brake.

 

 

Safety switch for the mower deck.

 

 

Safety switch in the seat.

 

 

Safety switch in the steering controls.

 

 

Parking brake functionality and adjustment.

 

 

Driving forward.

 

 

Driving backward.

 

 

Engaging the blades.

 

11.

Check idle speed

 

12. Check engine high idle speed

 

13. Inform the customer about:

 

 

Need and advantages of following the service schedule.

 

 

Need and advantages of leaving the machine for service.

 

 

Effects of service and maintaining a service journal on the machine’s

 

 

resale value.

 

 

Application areas for mulching.

 

14.

Fill in the sales papers, etc.

Delivery service has

 

 

been carried out.

 

 

No remaining notes.

 

 

Certified:

63

SERVICE JOURNAL

Action

Date, mtr reading,

 

stamp, sign

After 10 hours

1. Change the engine oil.

2. Change the oil filter.

3. Check hydraulic oil level.

4. Inspect hydraulic hoses.

5. Inspect hydraulic belt

6. Inspect hydraulic filter.

7. Check neutral position.

8. Check safety system.

9. Check seat belt.

10. Check ROPS.

11. Check fuel system for leaks.

12. Inspect safety guards and shields.

13. Check brake adjustment.

64

SERVICE JOURNAL

Action

Date, mtr reading,

 

stamp, sign

Daily Service

1. Clean debris from mower.

2. Check engine oil level.

3. Check the tire pressures.

4. Check underside of deck.

5. Inspect deck pulleys.

6. Check/clean the engine’s cooling air intake.

7. Check safety system.

8. Check seat belt.

9. Check ROPS.

10. Check fuel system for leaks.

11. Inspect safety guards and shields.

12. Check brake adjustment.

65

SERVICE JOURNAL

Action

Date, mtr reading,

 

stamp, sign

50-HourService

1. Clean debris from mower.

2. Change the engine oil and filter.

3. Check the tire pressures.

4. Clean the air filter.

5. Grease blade spindles.

6. Inspect deck belt and blades.

7. Check hydraulic oil level.

8. Check safety system.

9. Check seat belt.

10. Check ROPS.

11. Check fuel system for leaks.

12. Inspect safety guards and shields.

13. Check brake adjustment.

66

SERVICE JOURNAL

Action

Date, mtr reading,

 

stamp, sign

250-HourService

1. Grease fittings (caster pivots and caster wheels)

2. Inspect dampeners

3. Inspect frame

4. Inspect throttle and choke cables

5. Inspect hardware

6. Check the tire pressures

7. Change the engine oil and filter

8. Change air filter

9. Inspect spark plug

10. Inspect fuel filter

11. Check engine RPM

12. Clean underside of deck

13. Check blade pitch

14. Grease blade spindles

15. Inspect spindle bearings

16. Inspect deck belt and blades

17. Inspect idler arm bearings

18. Inspect deck idler pulleys

19. Check hydraulic oil level

20. Inspect hydraulic filter

21. Inspect hydraulic drive belt

22. Inspect hydraulic hoses

23. Check neutral position

24. Inspect battery connections

25. Check safety system

26. Check seat belt

27. Check ROPS

28. Check fuel system for leaks

29. Inspect safety guards and shields

30. Check brake adjustment

67

SERVICE JOURNAL

Action

Date, mtr reading,

 

stamp, sign

500-HourService

1. Grease fittings (caster pivots and caster wheels)

2. Inspect dampeners

3. Inspect frame

4. Inspect throttle and choke cables

5. Inspect hardware

6. Check the tire pressures

7. Change the engine oil and filter

8. Change air filter

9. Inspect spark plug

10. Inspect fuel filter

11. Check engine RPM

12. Clean underside of deck

13. Check blade pitch

14. Grease blade spindles

15. Inspect spindle bearings

16. Inspect deck belt and blades

17. Inspect idler arm bearings

18. Inspect deck idler pulleys

19. Change hydraulic oil

20. Change hydraulic filter

21. Replace hydraulic drive belt

21. Inspect hydraulic hoses

22. Check neutral position

23. Inspect battery connections

24. Load test battery

25. Clean electrical connections

26. Inspect the clutch

24. Check safety system

25. Check seat belt

26. Check ROPS

27. Check fuel system for leaks

28. Inspect safety guards and shields

29. Check brake adjustment

68

SERVICE JOURNAL

Action

Date, mtr reading,

 

stamp, sign

At least once each year

1. Clean the engine’s cooling air intake.

2. Replace the air cleaner’s pre-filter(foam). 3. Replace the air filter’s paper cartridge. 4. Change the engine oil.

5. Replace the engine oil filter

6. Check/adjust the cutting height

7. Check/adjust the parking brake

8. Clean/Change the spark plugs

9. Inspect spark plug

10. Check the engine valve clearance

69

SERVICE JOURNAL

Action

Date, mtr reading,

 

stamp, sign

 

 

 

 

70

P/N 115 276826R1

09/21/09