Dixon Kohler Ram Ultra 50 User Manual

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Operator’s Manual

Ram Ultra 50, 25 KOH / 968999722 Ram Ultra 60, 25 KOH / 968999723 Ram Ultra 72, 27 KOH / 968999724 Ram Ultra 50, 25 KOH BF / 968999725 Ram Ultra 60, 25 KOH BF / 968999726 Ram Ultra 72, 27 KOH BF / 968999773

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

©2008 HTC. All rights reserved. Beatrice, NE. Printed in U.S.A.

Contents

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

5

General........................................................................

5

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

5

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

5

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

5

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

6

Symbols and Decals..................................................

7

Safety.............................................................................

9

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

9

General Operation.............................................

9

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

11

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

11

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

13

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

14

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

16

Roll over Protection system (ROPS).........................

17

Controls.....................................................................

18

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

18

Steering Control Levers.............................................

19

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

20

Throttle Control..........................................................

20

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

20

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

21

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

21

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

21

Fuel Tank...................................................................

22

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

23

Cutting Height Adjuster..............................................

23

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

24

Operation....................................................................

25

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

25

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

25

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

26

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

26

Starting With a Weak Battery....................................

28

Jumper cables.................................................

28

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

29

Operating On Hills.....................................................

30

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

31

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

32

Moving by Hand........................................................

33

Maintenance...............................................................

34

Maintenance Schedule..............................................

34

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

36

Ignition System..........................................................

37

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

37

Engine Cooling Air Intake..........................................

38

Throttle Cable............................................................

38

Choke Cable .............................................................

38

Air Filter.....................................................................

39

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

40

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

41

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

41

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

41

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

42

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

43

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

43

Blade replacement..........................................

44

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

45

Leveling...........................................................

45

Cutting Height..................................................

45

Anti-scalprollers..............................................

46

Cleaning and Washing..............................................

47

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

47

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

47

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

48

Lubricating the Cables.....................................

49

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

49

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

49

Deck spindle....................................................

49

Deck outer spindle...........................................

50

Engine Oil..................................................................

50

Changing the Engine Oil.................................

51

Engine Oil Levels............................................

51

Hydraulic Pump ........................................................

52

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

52

Purging ...........................................................

52

TROUBLESHOOTING.....................................................

53

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

55

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

55

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

55

schematics.................................................................

56

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

57

Accessories...............................................................

61

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

61

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

62

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

63

English-3

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.

English-4

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

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

Do not tow any trailers with this mower. They may jackknife or overturn causing damage to the mower and possible serious injury to the operator.

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 judgement, 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.

Dixon-5

INTRODUCTION

Good Service

Dixon’s products are sold all over the world and 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 left 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 on one of the valve covers.

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-Dixon

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

P

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.

Use protective glasses

Use protective gloves

Only machines for European

market

Dixon-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-Dixon

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.

8011-512

Read the operator’s manual before starting the machine

8011-513

Clear the area of objects before mowing

Dixon-9

SAFETY

Operate machine only in daylight or good artificial light.

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

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 hot exhaust / engine part and burn. Do not allow the mower deck to plow leaves or other debris which can cause 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 a odorless, colorless, poisonous gas. Do not use the machine in enclosed spaces.

10-Dixon

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

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

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. And do not drive across any slopes.

Dixon-11

SAFETY

Do not use on steep slopes.

Do not try to stabilize the machine by putting your 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.

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 where you last saw them.

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 your view of a child.

8011-509

Be extra cautious when driving on slopes

8011-517

Never allow children to operate the machine

8011-518

Keep children away from work area

12-Dixon

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 you begin refueling, 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.

Dixon-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 you strike 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 you run the engine too fast, you risk damaging the machine components.

Be very careful when handling battery acid. Acid on skin can cause serious corrosive burns. If you spill battery acid on your 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/damage.

8011-515

Never drive the machine in an enclosed space

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-Dixon

SAFETY

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

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 you run the engine too fast, you risk damaging the machine components.

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 chassis 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 and inspect the equipment if you run 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.

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

Dixon-15

SAFETY

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.

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.

Do not tow with this mower. They may jackknife or overturn causing damage to the mower and possibly serious injury to the operator.

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.

8011-514

Regularly clean deck

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-Dixon

SAFETY

Roll over Protection system (ROPS)

The ROPS increases the basic weight of the unit by 42 lbs/19 kg. The ROPS is an accessory.

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 operator´s manual before each use.

Securely fasten your 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). If a spark arrester is used, it should be maintained in effective working order by the operator.

Dixon-17

CONTROLS

This operator’s manual describes the Dixon Zero

Turn Rider. The rider is fitted with a Kohler fourstroke overhead valve engine developing 25-27horse power*.

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

Control Locations

 

9

8

7

 

 

2

 

 

 

 

 

 

1

 

 

 

 

 

 

10

 

 

 

 

 

 

11

6

12

3

5

4

 

 

 

 

1.

Motion control levers

7.

Fuses

2.

Parking brake

8.

Fuel tank cap

3.

Throttle control

9.

Fuel shut off valve

4.

Blade switch

10.

Deck lift

5.

Ignition switch

11.

Seat adjustment lever

6.

Choke control

12.

Hour meter

*As rated by the engine manufacturer.

18-Dixon

CONTROLS

Steering 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.

In order, 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.

If the steering controls are in uneven positions when standing still or do not fit in the slots for moving the controls outward, they can be adjusted.

8011-789

Steering controls

WARNING!

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

1

 

2

3

4

 

 

8011-7912

1.Forward

2.Neutral

3.Neutral slot, Neutral lock

4.Reverse

Motion control lever, right side

Dixon-19

CONTROLS

Parking Brake

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.

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

Throttle Control

The throttle control regulates the engine speed and thereby the rate of rotation of the blades, assuming the blade switch is pulled out, see Engaging the Mower Deck.

In order to increase or decrease the engine speed, the control is moved forward or back respectively.

Avoid idling the engine for long periods, as there is a risk of fouling the spark plugs.

USE FULL THROTTLE WHEN MOWING, for best mower performance and battery charging.

Blade Switch

In order to engage the mower deck, pull the knob out; the mower blades are disengaged when the knob is depressed.

8061-019

Parking brake not activated

BLADES

THROTTLE

ON

CHOKE

OFF

8061-017

Throttle control

BLADES

THROTTLE

ON

CHOKE

OFF

8061-017

Blade switch

20-Dixon

CONTROLS

Ignition Switch

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

Choke Control

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

For cold starts the control should be pushed to the ON position.

Fuses

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

There are two fuses with ratings and functions:

20 A, Primary fuse.

7.5 A, Mower deck coupling.

BLADES

THROTTLE

ON

CHOKE

OFF

8061-017

Ignition switch

BLADES

THROTTLE

ON

CHOKE

OFF

8061-017

Choke control

8011-420

Fuses

Dixon-21

CONTROLS

Fuel Tank

Read the safety instructions before refueling. The machine has one fuel tank, just behind the seat. The tank capacity is 5.7 gallons (22 liters).

Make sure the fuel cap is properly tightened and the cap gasket is not damaged.

The engine will run on a minimum of 85-octaneunleaded gasoline (no oil mix). Environmentally adapted alkylate gasoline can be used. See also Technical Data concerning ethanol fuel. Methanol fuel is not allowed. Do not use E85 alcohol based fuel. Damage to engine and components may occur.

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.

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

8011-625

Fuel tank

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.

22-Dixon

CONTROLS

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.

8011-419

Fuel shut off valve in the CLOSED position

Cutting Height Adjuster

The deck cutting height is obtained by pressing the foot pedal forward to lift the deck. To lower the deck, apply pressure to the top side of the foot pedal and allow it to pivot while the lift arm rotates to the rear of the unit. To stop in the desired cutting position, rotate the foot pedal down into the notch in the height plate. The cutting height range is from 1½" (38mm) to 4½" (114mm) in ¼ (6mm) increments. The heights are measured from the ground up to the blade tip with the engine not running.

The mower deck’s lifting lever

8050-117

 

IMPORTANT INFORMATION

In order to obtain an even cutting height, it is important that the air pressure in the front tires is 15 psi and the rear tires is 10 psi.

IMPORTANT INFORMATION

Always use the high position to transport.

Dixon-23

CONTROLS

Seat Adjustment Lever

The seat can be adjusted lengthways. When making adjustments, the lever under the front edge of the seat is moved to the left (as seen by the driver in the seat), after which the seat can be moved backward or forward.

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.

8011-441

Lengthways adjustment

BLADES

THROTTLE

ON

CHOKE

OFF

8011-441

Hour meter

24-Dixon

operation

Read “Safety Instructions” section and 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.

IMPORTANT INFORMATION

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

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.

First time users should push mower (see “Moving by Hand” in the Operation section) to an open, flat area, without other people or vehicles/obstacles nearby. In order to move unit under its own power, the operator must be in the seat, start engine (see “Before Starting” inOperation 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, 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.

Dixon-25

operation

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:

The driver must be seated on the seat.

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

The parking brake must be on.

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

Starting the Engine

1.Sit on the seat.

2.Raise the mower deck by pulling the lifting lever backward to the locked position (transport position).

3.Activate the parking brake.

The mower deck’s lifting lever

8050-117

 

8061-019

Parking brake not activated

Disengage the mower blades by pressing the blade switch downwards.

BLADES

THROTTLE

ON

CHOKE

OFF

8011-441

Hour meter

26-Dixon

operation

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

8061-012

Place controls in neutral position

Move the throttle to the middle position.

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 a odorless, colorless, poisonous gas. Do not use the machine in enclosed spaces.

If the engine is cold, the choke lever should be pushed to the ON position.

BLADES

THROTTLE

ON

CHOKE

OFF

8061-001

Set the throttle

BLADES

THROTTLE

ON

CHOKE

OFF

8061-004

Set the choke control

Dixon-27

operation

Starting the engine with a weak battery

WARNING!

Lead-acidbatteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries.

IMPORTANT INFORMATION

Your mower is equipped with a 12-voltnegative grounded system. The other vehicle must also be a12-voltnegative grounded system. Do not use your mower to start other vehicles.

If your battery is too weak to start the engine, it should be recharged. (See “Battery” in the Maintenance Section.)

If “jumper cables” are used for emergency starting, follow this procedure:

Jumper cables

8011-642

Jumper cable connection

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 NEGATIVE (-)terminal of the fully charged battery.

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.

28-Dixon

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.Select the cutting height with the cutting height adjustment pedal.

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

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

WARNING!

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

6.Move throttle control to full throttle.

7.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.

In order, 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.

Turning on the spot (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.

8061-019

Released parking brake

The mower deck’s lifting lever

8050-117

 

BLADES

THROTTLE

ON

CHOKE

OFF

8061-017

Set blade engagement and throttle control

Dixon-29

operation

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.

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.

IMPORTANT INFORMATION

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

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.

8061-020

Place controls in neutral position to stop

8061-019

Released parking brake

30-Dixon

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.

WARNING!

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

8011-603

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.

Dixon-31

operation

Stopping the Engine

Allow the engine to idle a minute in order to attain normal operating temperature before stopping it, if it has been worked hard. Avoid idling the engine for longer periods, as there is a risk of the spark plugs fouling.

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.

Move the throttle to the minimum position (tortoise symbol). Turn the ignition key to the stop position.

Move the steering controls outward.

Remove key. Always remove key when leaving the mower to prevent unauthorized use.

IMPORTANT INFORMATION

Leaving the ignition switch in any other position than “OFF” will cause the battery to be discharged and the hour meter to accumulate hours.

BLADES

THROTTLE

ON

CHOKE

OFF

8061-017

Disengage the mower deck and move throttle to minimum

The mower deck’s lifting lever

8050-117

 

8061-020

Place controls in neutral position to stop

32-Dixon

operation

Moving by Hand

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 front and rear of the pump. They are used to release the system so the machine may be moved by hand when not running. Tilt seat forward to gain access to the pump. The rear bypass valve sits directly opposite the front valve, below the seat support. It is not visible in the illustration.

Use a 17 mm open end wrench or socket and ratchet. Turn the outer locknut 2-3turns. Using an 8mm wrench or socket, turn the inner nut one turn.

Reverse the procedure to reset the pump.

8011-507

Pump release valve

English-33

Dixon-33

MAINTENANCE

Maintenance Schedule

The following is a list of maintenance procedures that must be performed on the machine. For those points not described in this manual, visit an authorized service workshop. An annual service carried out by an authorized service workshop is recommended to maintain your machine in the best possible condition and to ensure safe operation.

Read “Maintenance” in the Safety Instructions section.

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) For daily use, the machine should be lubricated twice weekly.4) Performed by authorized service workshop.

 

= Described in this manual

 

 

 

 

 

 

 

 

 

= Not described in this manual

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Daily

 

Weekly

At

Maintenance interval

 

 

 

 

 

least

in hours

 

 

 

 

 

once

 

 

 

 

 

 

 

 

 

each

 

 

 

 

 

Maintenance

Before

After

 

 

 

 

 

 

 

 

 

 

 

 

 

year

25 50 100 300

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

Sharpen/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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

34-Dixon

MAINTENANCE

 

Daily

 

Weekly At

Maintenance interval

 

 

 

least

in hours

 

 

 

 

 

once

 

 

 

 

Maintenance

Before

After

each

 

 

 

 

 

 

 

 

year

25

50

100

300

 

 

 

Check/adjust throttle and choke cables

 

 

 

 

 

 

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 the air filter (paper filter) 2)

 

 

 

 

 

Check the caster wheels (every 200 hours)

 

 

 

 

 

 

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

 

 

 

 

 

 

Check/adjust the mower deck

 

 

 

 

 

Check the engine valve clearance 3)

 

 

 

 

 

Perform the 300-hourservice3)

 

 

 

 

 

Lubricate according to Lubrication Schedule

 

 

Check hydraulic oil at reservoir

 

 

 

 

 

 

Change hydraulic oil & filter (200 hours)

 

 

 

 

 

 

 

 

 

 

 

 

 

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

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.

Dixon-35

MAINTENANCE

Battery

Your 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.

Recharge at 6-10amperes for 1 hour

To clean battery and terminals

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

1.Open the terminal access doors.

2.Disconnect BLACK battery cable first, then the

RED battery cable and remove the battery from the machine.

3.Rinse the battery with plain water and dry.

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

5.Coat terminals with grease or petroleum jelly

6.Reinstall battery.

Replacing battery

1.Lift seat and rotate forward.

2.Open terminal access doors

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

4.Using a 7/16 wrench, remove the bolts on either side of the terminal guard and lift off guard.

5.Carefully remove the battery from the mower.

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

7.Reinstall battery terminal guard.

8.First connect RED battery cable to positive (+) battery terminal with hex bolt and hex nut.

9.Connect BLACK grounding cable to negative (-)battery terminal with remaining hex bolt and hex nut.

10.Close access doors.

11.Lower seat.

Always use protective glasses when handling the battery.

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.

2

1

CZ-22

1.Terminal guard

2.Access doors

Battery cleaning and installation

36-Dixon

MAINTENANCE

Ignition System

The engine is equipped with an electronic ignition system. Only the spark plugs require maintenance.

For recommended spark plugs, see Technical Data.

1.Remove the ignition cable boot and clean around the spark plug.

2.Remove the spark plug with a spark plug socket wrench.

3.Check the spark plug. Replace the spark plug if fouled, the electrodes are burned and if the

insulation is cracked or damaged. Clean the spark plug with a steel brush if it is to be reused.

4.Measure the electrode gap with a gapping tool. The gap should be .030" (0.75 mm). Adjust as necessary by bending the side electrode.

5.Reinsert the spark plug, turning by hand to avoid damaging the threads.

6.After the spark plug is seated, tighten it using a spark plug wrench so that the washer is

compressed. A used spark plug should be turned

1/8 of a turn from the seated position. A new spark plug should be turned a ¼ turn from the seated position.

7. Replace the ignition cable.

IMPORTANT INFORMATION

Fitting the wrong spark plug type can damage the engine.

Inadequately tightened spark plugs can cause overheating and damage the engine. Tightening the spark plugs too hard can damage the threads in the cylinder head.

8011-054

Measure the electrode gap

Safety System

The 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 driver is sitting in the driver’s seat.

4.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 drivers seat.

Conditions for starting

8061-018

 

IMPORTANT INFORMATION

In order 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.

Dixon-37

MAINTENANCE

Engine Cooling Air Intake

Check that the engine’s cooling air intake is free from leaves, grass, and dirt.

If the cooling air intake is clogged, engine cooling deteriorates, which can lead to engine damage.

The cooling air intakes rotates when the engine is running. Mind your fingers.

Throttle Cable

Check that the engine responds to throttle increases and that a good engine speed is attained at full throttle.

If doubts arise, contact the service workshop.

If adjustments are necessary, they can be made as follows for the lower cable:

1.Loosen the clamping screw for the cable’s outer casing and move the throttle to the full throttle position.

2.Check that the throttle cable is mounted in the correct hole in the lower lever, see illustration.

3.Push the throttle cable’s outer casing as far to the right as possible and tighten the clamping screw.

Choke Cable

If the engine produces black smoke or is difficult to start, this can be because the choke cable is incorrectly adjusted (upper cable).

If doubts arise, contact the service workshop.

If adjustments are necessary, they can be made as follows:

1.Loosen the clamping screw for the cable’s outer casing and push the choke control fully in.

2.Check that the choke cable is mounted in the upper lever, see illustration. Push the choke cable’s outer casing as far to the left as possible and tighten the clamping screw.

8061-014

Check and clean the cooling air intake

8011-605

Adjusting the throttle cable

8011-605

Adjusting the choke cable

38-Dixon

MAINTENANCE

Air Filter

If the engine seems weak or runs unevenly, the air filter may be clogged. If running with a dirty air filter, the spark plugs can become fouled.

For this reason, it is important to replace the air filter regularly (see the heading Maintenance Schedule for the proper service interval).

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.

IMPORTANT INFORMATION

Do not use compressed air to clean the air filter.

Do not wash the paper filter. Do not oil the paper filter.

Do not tap filter to clean this could cause damage to the sealing.

Replacing Air Filter

The engine is equipped with a replaceable, high density paper air cleaner element and an oiled, foam precleaner which surrounds the paper element.

Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.

IMPORTANT INFORMATION

Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure.

Servicing Precleaner

Wash and re-oilthe precleaner every25 hours of operation (more often under extremely dusty or dirty conditions). Replace the precleanerannually, or every

100hours.

1.Open the door on the blower housing to access the air cleaner element and precleaner.

2.Unhook the latch and remove the precleaner from the air cleaner element, or remove as an assembly for servicing. Make sure the base and the sealing area is clean before reassembly is performed.

3.Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry.

4.Saturate the precleaner with new engine oil. Squeeze out all excess oil.

5.Reinstall the precleaner over the paper element and secure with the latch.

6.Close and latch the door.

Servicing Paper Element

Check the paper element every 50 hours of operation, (more often under extremely dusty or dirty conditions). Clean or replace the element as necessary. Replace the air cleaner elementannually, or every 100 hours.

1.Open the door on the blower housing to access the air cleaner element.

2.Unhook the latch and remove the air cleaner element and precleaner.

3.Remove the precleaner (if so equipped) from the paper element. Service the precleaner as described in Precleaner Service.

4.Gently tap the paper element to dislodge dirt. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element with a new one. Handle the new element carefully; do not use if the sealing surfaces are bent or damaged.

5.Clean the air cleaner base as required and check condition.

6.Reinstall the precleaner over the paper air cleaner element and install on the base. Secure with the latch.

7.Close and latch the door.

Dixon-39

MAINTENANCE

Fuel Filter

Replace the line-mountedfuel filter every 100 hours

(once per season) or more regularly if it is clogged.

Replace the filter as follows:

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

2. Pull the filter loose from the hose ends.

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

4. Move the hose clamps back toward the filter.

Fuel filter

Fuel Pump Air Filter

Regularly check that the fuel pump’s air filter is free from dirt.

Remove the screws and open the pump, no hoses need be removed.

The filter can be cleaned with a brush if necessary. Replace the filter on the console.

The fuel pump’s air filter

8011-468

8009-147

40-Dixon

MAINTENANCE

Tire Pressures

Rear tires should have a pressure of 10 psi / 69 kPa /.7 bar. Front tires should be at 15 psi / 103 kPa / 1 bar.

Parking Brake

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

To adjust the parking brake, contact the Dixon service workshop.

WARNING!

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

8011-564

Tire pressures

8061-019

Parking brake

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.

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

IMPORTANT INFORMATION

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

Dixon-41

 

MAINTENANCE

Deck Belt

 

1.

Park on a level surface. Apply parking brake.

 

2.

Lower the deck into the lowest cutting

 

 

position.

 

3.

Remove bolts from belt shields and remove

 

 

shields.

 

4.

Remove any dirt or grass that may have

Belt Shields

 

accumulated around the cutter housings and

 

 

entire deck surface.

 

5.

Carefully roll the belt over the top of the

 

 

cutter housing pulleys and remove belt.

2

 

 

Deck belt installation

 

NOTE: For ease in installing the deck belt, refer to

front deck2

the routing decal on bottom of seat.

Removing deck belt

1.Wrap the deck belt around the electric clutch pulley that is located on the engine shaft.

2.Route the belt forward between the EZT (E-SeriesZeroturn Transaxles) and up onto the deck.

3.Place belt around spring loaded idler pulley.

4.Wrap the belt around the stationary idler pulley and around the mandrel housings.

5.Push inward on the idler arm and carefully route belt over stationary idler pulley. Once belt is properly routed, slowly release idler arm to tension belt.

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

7.Adjust tension with deck eyebolt.

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

1

2

8061-021

1.Clutch pulley

2.Deck belt

Belt routing, deck belt

42-Dixon

 

MAINTENANCE

Pump Belt

 

 

Replacing pump belt

 

 

Park the mower on a level surface. Engage the

 

 

parking brake.

 

 

Belt removal

 

 

1.

Remove the deck belt (see Deck Belt

 

1

 

Removal in this section of the manual).

 

2

2.

Remove clutch stop to access the belt.

 

 

3

3.

Disconnect clutch wire.

 

4.

Create slack in the belt by removing the

 

 

 

spring on the pump idler arm.

 

 

5.

The belt should now be able to be removed

 

8054-002

 

from the engine pulley and pump pulleys.

 

 

1.

Electric clutch

Belt installation

2.

Idler spring

3.

Clutch stop

1.

Wrap the belt around the pulley

Pump belt removal

2.

Route the belt around the inside of the idler

 

 

 

pulley.

 

 

3.

Wrap the belt around the engine pulley.

 

 

4.

Reattach the spring on the pump idler arm.

 

 

5.

Reconnect clutch wire.

 

 

6.

Replace and secure clutch stop.

 

 

7.

Reinstall the deck belt. (see Deck Belt

 

 

 

Removal in this section of the manual).

 

 

Cutting Blades

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

WARNING!

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

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

Damaged blades should be replaced when hitting obstacles that result in a breakdown. Let the service workshop decide whether the blade can be repaired/ ground or must be replaced.

Balance the blades after sharpening. Check the blade mounts.

8011-604

Check the blades

IMPORTANT INFORMATION

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

Dixon-43

MAINTENANCE

Blade replacement

WARNING!

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

Remove blade bolt by turning counterclockwise.

IMPORTANT INFORMATION

To ensure proper assembly, center hole in blade must align with star on cutter housing.

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

Install and tighten blade bolt securely.

Torque blade bolt to 45-55ft/lbs(60-75Nm).

IMPORTANT INFORMATION Special blade bolt is heat treated.

Replace with a Dixon bolt if required.

Do not use lower grade hardware than specified.

3

50" /

60"

1

 

 

2

 

 

 

 

3

 

 

1

72"

2

 

 

 

1.Blade

2.Blade bolt (special)

3.Cutter housing

Blade attachment

44-Dixon

MAINTENANCE

Adjusting the Mower Deck

WARNING!

Before performing any service or adjustment checklist:

1.Engage the parking brake.

2.Place the Blade switch in the disengaged position.

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

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

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

Check the tire pressure before adjustment of the mower deck. See “Checking Tire Pressure” in Maintenance section. Faulty mower deck adjustments will cause an uneven mowing result.

Leveling

1.Position the mower on a level, preferably concrete, surface.

2.Check the pressure in all four tires. See “Technical Data”.

3.Rotate blades to align front to back.

4.Set the cutting height to 4" (10cm).

5.Measure front blade tip. It should be 4" from ground. If not, turn locknut on top of front L bolt until measurement is achieved. Check blade tip at front on opposite front blade. Adjust locknut on front L bolt as necessary.

6.Check that the rear blade measurement is 4¼" (11.4cm) from ground. If not, turn locknut on top of rear L bolt to achieve measurement. Repeat procedure on opposite side.

Cutting Height

1.Raise and secure the deck height lever to the transport position (4½" / 11.5cm).

2.Position blade tip so it is straight forward.

3.Measure from the cutting edge of the blades to a flat level surface. The distance should be 4½"

(11.4cm).

4.Drop the level to (for example) the 2" (5cm) cutting height. Measure as above. Distance should be 2".

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.

3

4

2

1

8050-808

1.Front L bolt

2.Front locknut

3.Rear locknut

4.Rear L bolt

Leveling the mower deck

Dixon-45

MAINTENANCE

Anti-scalprollers

Anti-scalp rollers are properly adjusted when they are just slightly off of the ground when the deck is at the desired cutting height in the operating position.

Anti-scalp rollers then keep the deck in the proper position to help prevent scalping in most terrain conditions.

IMPORTANT INFORMATION

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

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

Anti-scalprollers

Upper position 1½ to 3" (38 to 76 mm) grass.

Middle position 3" to 4½" (76 to 114 mm) grass.

Lower position 4½" to 6" (114 to 152 mm) grass.

The rollers should be approximately ¼" (6.5 mm) from ground. Do not adjust the rollers to support the deck.

IMPORTANT INFORMATION

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

CZ-9

46-Dixon

MAINTENANCE

Cleaning and Washing

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

Use protective glasses when cleaning and washing.

8050-092

Clean regularly

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

Caster Wheels

Check every 200 hours. Check that wheels rotates freely. If wheels do not rotate freely take the unit to your dealer for service.

IMPORTANT INFORMATION

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

Only use O.E.M. specified tires.

Foam filled tires or solid tires will void the warranty.

Removal and installation of caster wheel

Remove nut and caster bolt.

Pull the wheel out of the fork and take care of the sleeve.

Install in reverse order. Tighten caster bolt.

Hardware

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

8011-619

Caster wheels

Dixon-47

LUBRICATION

1

23

4

5

*

 

 

6

8011-672-6

12/12 Every year

Lubricate with grease gun

Lubricate with oil can

1/52 Every Week

Oil change

Level check

1/365 Every day

Filter change

 

 

 

 

*Change transaxles (transmission) filters.

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 a 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.

48-Dixon

LUBRICATION

Lubricating the 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.

Tip: Fill a small plastic bag with oil and tape it so that it seals against the sheath and allow the cable to hang vertically from the bag overnight. If you do not succeed in lubricating the cable, it must be replaced.

Front Wheel Mount

Lubricate with a grease gun, one zerk for each wheel mount, until the grease is forced out.

Use only good quality bearing grease.

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

Front Wheel Bearings

Lubricate with a grease gun, one zerk for each set of wheel bearings, until the grease is forced out.

Use only good quality bearing grease.

Deck spindle

Lower the cutting deck completely.

If you use grease gun without rubber hose, the foot plate must be removed.

Lubricate with a grease gun, one zerk, 2-3strokes.

Use only good quality bearing grease.

IMPORTANT INFORMATION

Use minimal lubrication and remove excess lubricant so that is does not come into contact with belts or belt pulley drive surfaces.

8011-731

Lubricating the front wheels

8011-732

Deck spindle

Dixon-49

LUBRICATION

Deck outer spindle

Lubricate using a grease gun, one zerk, each side 2-3strokes. Use only good quality bearing grease.

WARNING!

Engine oil can be very hot if it is drained directly after stopping the engine. Allow the engine to cool to a safe temperature first.

Engine Oil

Engine Oil Filter

Drain the engine oil in accordance with the work description under the heading Engine Oil/Change Engine Oil.

Remove the oil filter. If necessary, use a filter remover.

Wipe new, clean engine oil onto the seal for the new filter.

Mount the filter by hand with +¾ turn.

Run the engine warm, then check that there are no leaks around the oil filter seal.

Check the oil level in the engine, fill

if necessary. The oil filter holds 0.1 qt (0.1 liters) of oil.

8011-733

Deck outer spindle (with belt shield removed)

Changing the oil filter

8011-734

IMPORTANT INFORMATION

Used engine oil is a health hazard and must not be disposed of on the ground or in nature; it should always be disposed of at a workshop or appropriate disposal location.

Avoid skin contact; wash with soap and water in case of spills.

50-Dixon

LUBRICATION

WARNING!

Engine oil can be very hot if it is drained directly after stopping the engine. Allow the engine to cool to a safe temperature first.

Changing the Engine Oil

The engine oil should be changed for the first time after 5-8hours of operation. Thereafter, it should be changed every 50 hours. The oil drain valve is located at the rear of the unit, to the right of the oil filter.

Place the machine on a flat surface.

Place a container under the engine where the oil drain valve exits.

Remove the valve cap.

Allow the oil to run out into the container.

Reinstall the oil drain valve cap.

Replace the oil filter if necessary.

Fill with new engine oil in accordance with Checking the Oil Level.

Start the engine. Run it for 3-5minutes. Stop and recheck the oil level.

Engine Oil Levels

Check the oil level in the engine when the machine is standing level and the engine is stopped.

Remove the dipstick, wipe it clean, and then replace it. The dipstick should be screwed into place.

Take the dipstick out again and read the oil level.

The oil level should lie between the markings on the dipstick. If the level is approaching the “ADD” mark, fill the oil to the “FULL” mark on the dipstick.

Never fill to above the “FULL” mark.

The oil is filled through the hole for the dipstick.

API class SF, SG, SH, SJ or higher must be used. Synthetic oil SAE 5W-30or10W-30is recommended at all temperatures. Mineral oil SAE5W-30,10W-30can be used between

-18°C/0 °F and +5 °C/40 °F. At temperature above +5 °C/40 °F single grade SAE 30 must be used.

The engine holds 0.88 qt (1.0 liters) of oil excluding the filter, including filter 2 qt (1.9 liters).

Oil drain valve

8011-500

Remove the dipstick

The dipstick markings

Dixon-51

8009-159

LUBRICATION

*Hydraulic Pump

Fluid Change

This transaxle 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 200 hours is recommended.

The following procedure can be performed with the pump installed in the vehicle, and the vehicle on level ground. Apply the bypass valve and lock the vehicle parking brake.

1.Place an oil drain pan with a two gallon capacity beneath the oil filter. Remove the oil filter from the pump.

2.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.

3.Install the new filter by hand, turn ¾ to one full turn after the filter gasket contacts the filter base surface.

4.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.

5.Remove the cap from the pump’s expansion tank located on the vehicle frame.

6.Fill reservoir with SAE 10W30 oil to just above the MIN-ADDline on the reservoir. After purging, check levels and add oil if necessary.

7.Reinstall the tank cap by hand. Do not overtighten.

8.Proceed to the purge procedure.

Purging

Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it is purged from 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.

The resulting symptoms in hydrostatic systems may be:

1.Noisy operation.

2.Lack of power or drive after short term operation.

3.High operation temperature and excessive expansion of oil.

52-Dixon

2

3

1

8061-016

1.Pump filter

2.Pump reservoir

3.Fluid fill lines

Changing the hydraulic pump oil filter

Before starting, make sure the pump is at the proper oil level. If it is not, fill to the specifications outlined earlier.

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 transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds, then the transaxle 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.

TROUBLESHOOTING

Problem

Cause

 

 

The engine will not start.

The blade switch is engaged.

The steering controls are not locked in the neutral position.

The driver is not sitting in the driver’s seat.

The parking brake is not activated.

The battery is dead.

Contamination in the carburetor or fuel line.

The fuel supply is closed or the shutoff valve for the fuel tank is in the wrong position.

Clogged fuel filter or fuel line.

Ignition system faulty.

The starter does not turn the engine over.

Dead battery.

 

 

 

• Poor contact of the battery terminal cable connections.

 

 

 

Fuse blown.

 

 

 

• Fault in the starter safety circuit.

 

 

 

 

See Checking the Safety System in the

 

 

 

 

“Maintenance Section”

 

 

 

 

 

 

The engine runs rough.

Faulty carburetor.

 

 

 

• The choke control is pulled out with a warm engine.

 

 

 

• Clogged fuel filter or jet.

 

 

 

• Clogged ventilation valve on the fuel cap.

 

 

 

• Fuel tank nearly empty.

 

 

 

Fouled spark plugs.

 

 

 

• Rich fuel mixture or fuel-airmixture.

 

 

 

Wrong fuel type.

 

 

 

• Water in the fuel.

 

 

 

Clogged air filter.

 

 

 

 

 

The engine seems weak.

Clogged air filter.

 

 

 

Fouled spark plugs.

 

 

 

Carburetor incorrectly adjusted.

 

 

 

• Air trapped in hydraulic system.

 

 

 

 

The machine vibrates.

The blades are loose.

 

 

 

• The blades are incorrectly balanced.

 

 

 

• The engine is loose.

Dixon-53

TROUBLESHOOTING

Problem

Cause

The 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 plugs.

 

 

 

Battery not charging.

Poor contact with battery terminal cable connectors.

 

• Charging lead is disconnected.

 

 

 

The machine moves slowly, unevenly, or not at all.

Parking brake on.

 

• Bypass valve on pump open.

 

• Drive belt for the transmission slack or

 

 

has come off.

 

• Air trapped 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.

 

 

 

Transaxle leaks oil.

Damaged seals, housing, or gaskets.

 

• Air trapped in hydraulic system.

 

 

 

Uneven mowing results.

Different air pressure in the tires on the left and right

 

 

sides.

 

Bent blades.

 

• The suspending for the mower deck is uneven.

 

• The blades are dull.

 

• Driving speed too high.

 

• The grass is too long.

 

• Grass collected under the mower deck.

54-Dixon

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 you have added stabilizer

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 dryer, 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 instead.

To ready the machine for storage:

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 your machine performs its best the following season.

Dixon-55

schematics

 

 

 

 

NOTES:

 

 

 

 

 

 

 

 

1. SEAT UNOCCUPIED

 

 

 

 

 

 

2. BRAKE SWITCH IN OFF POSITION

 

 

SOlENOID

 

3. MOTION CONTROl lEVERS OUT

 

 

yEl

4. PTO IN OFF POSITION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

yEl

 

GRN

 

 

 

 

 

RED/BlK

BRN

 

BRAKE

 

 

 

yEl

 

RED/BlK

 

 

 

 

 

 

 

 

SWITCH

GRN

 

 

TO

 

20 AMP

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE

S

B

RIGHT MOTION

 

 

WHT

 

 

PIGTAIl

A2

 

 

 

 

PUR

A1

l

CONTROl lEVER

 

 

 

GRy

 

 

 

 

 

 

 

 

 

 

 

 

 

M

G

BRN

 

 

 

 

 

 

 

 

 

WHT

 

 

 

 

 

 

 

 

 

 

 

RED

 

 

 

 

 

 

 

 

 

 

 

BlK

 

 

 

 

yEl

 

 

 

 

WHT

 

 

BlU

 

 

 

 

GRN

 

BlK

 

 

 

 

GRN

 

lEFT MOTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROl lEVER

 

 

 

 

 

PUR

 

BlK

 

 

 

 

 

 

 

yEl

 

 

 

 

 

 

 

yEl/RED

 

 

 

 

 

BRN

 

 

BRN

 

BRN

 

 

 

 

 

 

 

HOURMETER

SEAT

 

 

 

 

PUR

 

 

BlU

 

 

 

 

SW.

 

 

 

 

 

 

 

 

 

 

 

7.5 AMP

 

 

 

 

 

 

PTO

 

 

 

 

ElECTRIC

 

SWITCH

PUR

 

 

 

 

 

 

 

HOURMETER

 

 

ClUTCH

BlK

BlK

 

 

 

 

 

 

 

 

 

 

 

 

 

BlK

 

ACCESSORy

 

 

 

 

 

 

OUTlET

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE

 

 

 

 

 

 

 

 

GROUND

 

 

 

 

 

 

 

KEy SWITCH POSITIONS

 

 

 

POSITION 1 - OFF

POSITION 2 - RUN1

POSITION 3 - RUN2

POSITION 4 - START

S

B

 

S

B

S

B

S

B

 

A2

A2

A2

 

A2

 

 

 

 

A1

 

l

A1

l

A1

l

A1

l

 

M

G

M

G

M

G

 

M G

56-Dixon

TECHNICAL DATA

 

968999722

968999723

Engine

968999726

968999726

 

 

Manufacturer

Kohler

Kohler

Type

Courage Pro

Courage Pro

Power

25 hp*

25 hp*

Lubrication

Pressure with oil filter

Pressure with oil filter

Oil capacity excluding filter

1.6 qt / 1.7 liter

1.6 qt / 1.5 liter

Oil capacity including filter

1.7 qt / 1.9 liter

1.7 qt / 1.6 liter

Engine oil

10W30, 5W30

10W30, 5W30

(See viscosity diagram)

SG, SH, SJ

SG, SH, SJ

Fuel

Min 87 octane unleaded (Max

Min 87 octane unleaded (Max

 

ethanol 10%, Max MTBE 15%)

ethanol 10%, Max MTBE 15%)

Fuel tank capacity

5.2 gallons / 19.7 liters

5.2 gallons / 19.7 liters

Spark plugs / gap

Champion RCY12YC

Champion RCY12YC

 

.030" / 0.75 mm

.030" / 0.75 mm

Cooling

Air cooled

Air cooled

Air filter

Standard

Standard

Alternator

12V

12V

Starter

Electric

Electric

Transmission

 

 

Transmission

Hydraulic pump

Hydraulic pump

Speed and direction controls

Dual levers, foam gripped

Dual levers, foam gripped

Speed forward

8 mph / 12.9 km/h

8 mph / 12.9 km/h

Speed reverse

4 mph / 6.45 km/h

4 mph / 6.45 km/h

Brakes

Mechanical parking brake

Mechanical parking brake

Front caster tires, smooth tread

13 x 5.0-6,4 ply

13 x 5.0-6,4 ply

Rear tires, turf pneumatic

23 x 10.5-12

23 x 10.5-12

Tire pressure, front

15 PSI / 103 kPa / 1 bar

15 PSI / 103 kPa / 1 bar

Tire pressure, rear

10 PSI / 69 kPa / .7 bar

10 PSI / 69 kPa / .7 bar

 

 

 

*As rated by the engine manufacturer.

Dixon-57

TECHNICAL DATA

 

968999722

968999723

 

968999725

968999726

Cutting Width

52" / 127cm

60" / 152cm

Cutting Height

1.5 - 4.5" / 3.8 - 11.4 cm

1.5 - 4.5" / 3.8 - 11.4 cm

Uncut Circle

0

0

Number of Blades

3

3

Blade Length

17" / 435 mm

20" / 510 mm

Nose Rollers

Yes

Yes

Sprung Seat

Standard

Standard

Hinged Arm Rests

Yes

Yes

Hour Meter

Standard

Standard

Blade Engagement

Electromagnetic clutch

Electromagnetic clutch

Deck Construction

11 gauge fabricated

11 gauge fabricated

Productivity

 

 

Productivity

4.0 acres /h 16187 m2/h

4.8 acres /h 19425 m2/h

Overall Dimensions

 

 

Weight

760 lbs / 345 kg

780 lbs / 354 kg

Base Machine Length

76" / 193 cm

76" / 193 cm

Base Machine Height (ROPS up)

42" / 107 cm

42" / 107 cm

Base Machine Height (ROPS dwn)

51" / 130 cm

61" / 155 cm

Base Machine Width

60" / 152 cm

72" / 183 cm

Overall Width, Chute Up

54" / 137 cm

63" / 157 cm

Overall Width, Chute Down

67" / 170 cm

76" / 193 cm

58-Dixon

 

TECHNICAL DATA

 

 

 

 

 

 

 

968999724

 

Engine

968999773

 

 

 

Manufacturer

Kohler

 

Type

Courage Pro

 

Power

27 hp*

 

Lubrication

Pressure with oil filter

 

Oil capacity excluding filter

1.6 qt / 1.7 liter

 

Oil capacity including filter

1.7 qt / 1.9 liter

 

Engine oil

10W30, 5W30

 

(See viscosity diagram)

SG, SH, SJ

 

Fuel

Min 87 octane unleaded (Max

 

 

ethanol 10%, Max MTBE 15%)

 

Fuel tank capacity

5.2 gallons / 19.7 liters

 

Spark plugs / gap

Champion RCY12YC

 

 

.030" / 0.75 mm

 

Cooling

Air cooled

 

Air filter

Standard

 

Alternator

12V

 

Starter

Electric

 

Transmission

 

 

Transmission

Hydraulic pump

 

Speed and direction controls

Dual levers, foam gripped

 

Speed forward

8 mph / 12.9 km/h

 

Speed reverse

4 mph / 6.45 km/h

 

Brakes

Mechanical parking brake

 

Front caster tires, smooth tread

13 x 5.0-6,4 ply

 

Rear tires, turf pneumatic

23 x 10.5-12

 

Tire pressure, front

15 PSI / 103 kPa / 1 bar

 

Tire pressure, rear

10 PSI / 69 kPa / .7 bar

 

*As rated by the engine manufacturer.

Dixon-59

 

TECHNICAL DATA

 

 

 

 

 

 

 

968999724

 

 

968999773

 

Cutting Width

72" / 183cm

 

Cutting Height

1.5 - 4.5" / 3.8 - 11.4 cm

 

Uncut Circle

0

 

Number of Blades

3

 

Blade Length

25" / 635 mm

 

Nose Rollers

No

 

Sprung Seat

Standard

 

Hinged Arm Rests

Yes

 

Hour Meter

Standard

 

Blade Engagement

Electromagnetic clutch

 

Deck Construction

11 gauge fabricated

 

Productivity

 

 

Productivity

5.8 acres /h 23472 m2/h

 

Overall Dimensions

 

 

Weight

797 lbs / 362 kg

 

Base Machine Length

78" / 201 cm

 

Base Machine Height (ROPS up)

42" / 107 cm

 

Base Machine Height (ROPS dwn)

73" / 187 cm

 

Base Machine Width

87" / 221 cm

 

Overall Width, Chute Up

73" / 187 cm

 

Overall Width, Chute Down

87" / 221 cm

 

60-Dixon

 

 

TECHNICAL DATA

 

 

Accessories

 

Collection system

 

Torque Specifications

 

Engine crankshaft bolt

50 ft/lb (67 Nm)

Deck pulley bolts

45 ft/lb (61 Nm)

Lug nuts

75 ft/lb (100 Nm)

Blade bolt

45-55ft/lb(60-75Nm)

Standard ¼" fasteners

9 ft/lb (12 Nm)

Standard 5/16" fasteners

18 ft/lb (25 Nm)

Standard 3/8" fasteners

33 ft/lb (44 Nm)

Standard 7/16" fasteners

52 ft/lb (70 Nm)

Standard ½” fasteners

80 ft/lb (110 Nm)

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

In order 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.

Dixon-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

Vibration data corresponding to Directive 2002/44/EC is given in the Technical Data Section. The Declaration of Conformity is included in the literature packet.

62-Dixon

SERVICE JOURNAL

Action

Date, mtr reading, stamp, sign

Delivery Service

1.Charge the battery.

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

3.Mount the steering controls in the normal position.

4.Connect the contact box to the cable for the seat’s safety switch.

5.Check that the right amount of oil is in the engine.

6.Adjust the position of the steering controls.

7.Fill with fuel and open the fuel shut off valve.

8.Start the engine.

9.

Check that there is drive to both wheels.

 

10.

Check the mower deck adjustment.

 

11.

Check:

 

 

The safety switch for the parking brake.

 

 

The safety switch for the mower deck.

 

 

The safety switch in the seat.

 

 

The safety switch in the steering controls.

 

 

Parking brake functionality.

 

 

Driving forward.

 

 

Driving backward.

 

 

Engaging the blades.

 

12.

Check the idle speed

 

13.

Check the engine high idle speed

 

14.

Inform the customer about:

 

 

The need and advantages of following the service schedule.

Delivery service has been carried out.

 

The need and advantages of leaving the machine for service

 

No remaining notes.

 

every 300 hours.

 

Certified:

 

The effects of service and maintaining a service journal on the

 

 

 

machine’s resale value.

 

 

Application areas for mulching.

 

15.

Fill in the sales papers

 

Dixon-63

SERVICE JOURNAL

Action

Date, mtr reading, stamp, sign

After the First 5-8Hours

1. Change engine oil.

64-Dixon

SERVICE JOURNAL

Action

Date, mtr reading, stamp, sign

25-HourService

1.Check the engine air filter.

2.Sharpen/Replace mower blades if required.

3.Check the tire pressures.

4.Check battery with cables.

5.Lubricate according to lubrication chart.

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

7.Clean the air cleaner’s prefilter (foam).

Dixon-65

SERVICE JOURNAL

Action

Date, mtr reading, stamp, sign

50-HourService

1.Perform the 25-hourservice.

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

(shorter intervals for dusty operating conditions).

3.Change engine oil.

4.Lubricate according to lubrication chart.

5.Check/adjust the parking brake.

6.Change hydraulic pump oil and filter.

66-Dixon

SERVICE JOURNAL

Action

Date, mtr reading, stamp, sign

100-HourService

1.Perform the 25-hourservice.

2.Perform the 50-hourservice.

3.Change the engine oil filter.

4.Clean/replace the spark plugs.

5.Replace the fuel filter.

6.Check V-belts.

7.Check tighten caster wheel axle bolts (every 200 hours).

8.Change the air filter’s paper cartridge.

9.Change hydraulic pump oil and filter. (200 hours)

Dixon-67

SERVICE JOURNAL

Action

Date, mtr reading, stamp, sign

300-HourService

1.Perform the 25-hourservice.

2.Perform the 50-hourservice.

3.Perform the 100-hourservice.

4.Check/adjust the mower deck.

5.Clean the combustion chamber and grind the valve seats.

6.Check the engine valve clearance.

7.Replace the air cleaner’s prefilter (foam).

68-Dixon

SERVICE JOURNAL

Action

Date, mtr reading, stamp, sign

At Least Once Each Year

1.Clean the engine’s cooling air intake (25 hours).

2.Replace the air cleaner’s pre-filter(foam) (300 hours).

3.Replace the air filter’s paper cartridge.

4.Change the engine oil (50 hours).

5.Replace the engine oil filter (100 hours).

6.Check/adjust the cutting height.

7.Check/adjust the parking brake (50 hours).

8.Clean/change the spark plugs (100 hours).

9.Change the fuel filter (100 hours).

10.Check the engine valve clearance.

Dixon-69

 

 

 

P/N 539 132404 R02

04/01/08