Dixie Chopper 2348KO, 2348BR, 2342KO, 2354KO, 2248KW Operation & Maintenance Manual

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2017 ZEE 2 Safety, Operation & Maintenance Manual

700561 2/2017

1 CONTENTS

1Contents

Contents

Introduction

2.1 Important.............................................................................2

2.2 Product Identification...........................................................3

2.3 Serial Numbers ...................................................................3

2.4 Guidelines for the Disposal of Scrap Products....................4

Safety

3.1 How to Operate Safely........................................................5

Specifications

4.1 Engine Specifications........................................................10

4.2 Dimensions and Weights ..................................................11

4.3 Mower Specification..........................................................13

4.4 Cutting Unit Specification..................................................13

4.5 Belt Specification...............................................................13

4.6 Recommended Lubricants ................................................14

4.7 Accessories.......................................................................14

4.8 Support Literature .............................................................15

Decals

5.1 Safety Decals....................................................................16

5.2 Instruction Decals..............................................................17

Controls

6.1 Mower Controls.................................................................19

6.2 Control Panel ....................................................................20

6.3 Steering Control Levers ....................................................22

6.4 Parking Brake....................................................................22

6.5 Cutting Unit HOC Pedal ....................................................23

6.6 Lift Stop Lever...................................................................23

Operation

7.1 Daily Inspection.................................................................24

7.2 Interlock System................................................................25

7.3 Operating Procedure.........................................................26

7.4 Starting The Engine ..........................................................27

7.5 To Stop The Engine ..........................................................27

7.6 Driving...............................................................................28

7.7 Height of Cut .....................................................................29

7.8 Mowing..............................................................................29

7.9 Mowing On Slopes............................................................30

7.10 Towing The Mower..........................................................32

Maintenance and Lubrication Charts

8.1 Maintenance Chart............................................................33

8.2 Fluid Requirements...........................................................34

Maintenance

9.1 General Precautions .........................................................35

9.2 Engine...............................................................................35

9.3 Engine Oil .........................................................................36

9.4 Engine Air Filter ................................................................37

9.5 Engine Exhaust.................................................................37

9.6 Fuel ...................................................................................38

9.7 Charge the battery ............................................................38

9.8 Battery...............................................................................39

9.9 Drive Axle Fluid.................................................................40

9.10 Tires ................................................................................41

9.11 Wheel Mounting Procedure ............................................41

9.12 Folding ROPS Accessory ...............................................42

9.13 Air Cooling System .........................................................43

9.14 Inspecting Blades............................................................43

9.15 Sharpening Blades..........................................................44

9.16 Electrical System ............................................................44

9.17 Belts ................................................................................45

9.18 Care and Cleaning ..........................................................46

9.19 Mower Storage................................................................47

Adjustments

10.1 General Precautions .......................................................48

10.2 Steering Lever Adjustment..............................................48

10.3 Forward Speed Limit Screws ..........................................49

10.4 Torque Specification .......................................................50

Problem Solving

11.1 General ...........................................................................51

Notes

reserved, including the right to reproduce this material or portions

thereof in any form.”

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Proposition 65 Warning

This product contains or release chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Litho In U.S.A. 2-2017

INTRODUCTION 2

2Introduction

2.1 IMPORTANT ______________________________________________________________

The Dixie Chopper Zee 2 2348, 2354, 2348BR, 2354 BR, 2342KO, 2348KO and 2354KO with a Gasoline engine is a self propelled rotary mower.

If you follow all instructions in this manual, you increase the life of your mower and keep its maximum performance. Adjustments and maintenance must always be done by an approved technician.

IMPORTANT: Do the maintenance included in this manual to make sure that the quality of cut is kept at a high level.

This SAFETY, OPERATION AND MAINTENANCE MANUAL is part of the mower and must stay with the mower always. Suppliers of both original and used mowers need to keep the documentation that comes with the mower.

You must use the mower to cut the grass and not for any other purpose. Compliance with the conditions or operation, service and repair specified by the manufacturer, are understood to be part of the correct use.

ALL operators MUST read through this manual and understand the Safety Instructions, controls, lubrication and maintenance procedures.

Make sure that you obey all safety and road traffic regulations.

You must not make any changes to the mower that the manufacturer does not approve. This type of change can release the manufacturer from the liability for any damage or injury.

When you discard worn parts, know the environmental result and use the systems available in the country where the mower is used. When the mower is at its end of life, there are guidelines in this manual for the removal of the mower from use.

Use only Dixie Chopper approved parts.

2006/42/EC The instructions recorded here are the original instructions confirmed by Dixie Chopper, A Textron Company.

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2 INTRODUCTION

Eight digit serial number

17XXXXXX

BARCODE

2.2 PRODUCT IDENTIFICATION_________________________________________________

Mower Serial number plate

A Product code and Serial number

Location of Mower Serial number plate

The serial number plate (A) is found on the right frame tube near the front caster wheel mount.

Engine Identification Number

The engine serial number is found on a label on the side of the engine.

Drive Axle Identification Numbers

The drive axle serial number is found on a plate on the drive axle. There will be a separate serial number for each drive axle.

2.3 SERIAL NUMBERS ________________________________________________________

Record the mower, engine and drive axle serial numbers below:

Mower Number:_________________________

Engine Number:__________________________

Left Drive Axle:__________________________

Right Drive Axle:_________________________

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INTRODUCTION 2

2.4 GUIDELINES FOR THE DISPOSAL OF SCRAP PRODUCTS _______________________

2.4.1 DURING SERVICE LIFE _____________________________________________________

The used oil, oil filters and engine coolant are hazardous materials. Follow the recommended procedures for their safe removal.

If a fluid leaks, contain the spill to make sure that the leak does not flow into the ground or drainage system. Follow the local laws to make sure that leaks are controlled safely.

The maintenance procedures in this manual make sure that the damage that the mower can cause in the local environment is controlled safely.

Take these actions after the mower complete its full service life.

2.4.2 END OF SERVICE LIFE _____________________________________________________

Use these guidelines with applicable Health, Safety and Environmental laws. Always use the approved local waste disposal and agencies for recycled materials.

• Park the mower in a location to use all of the necessary lifting equipment.

• Use the correct tools and Personal Protective Equipment (PPE) and take instruction from the technical manuals applicable to the mower.

• Remove and keep correctly

1. Batteries

2. Fuel

3. Engine coolant

4. Oils

• Disassemble the structure of the mower and refer to the technical manuals. Give attention to parts that have mechanical pressure or tension applied to the part in the mower, including springs.

• Separate items that continue to have service life and returned to storage.

• Separate items that are worn into the material groups and removed according to the agencies for the recycled materials that are available. Common types are as shown:

• Steel

• Non ferrous metals

• Aluminum

• Brass

• Copper

• Plastic Materials

• Identified

• Can be recycled

• Can not be recycled

• Not Identified

• Rubber

• Electrical and Electronic Components

• Add items that can not be easily separated into different materials to the “General discarded materials” area.

• Do not burn the discarded materials

Change the mower records to show that the mower is not in service and is discarded. Supply this serial number to Dixie Chopper Warranty Department to close their records.

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3 SAFETY

3Safety

3.1 HOW TO OPERATE SAFELY ______________________________________________________

WARNING

EQUIPMENT OPERATED INCORRECTLY OR WITHOUT TRAINING CAN BE DANGEROUS.

Know the location and correct operation of controls. Operators without experience must receive instruction from another person that knows the correct operation of the equipment before you operate the mower.

Only use parts, accessories and attachments approved by Dixie Chopper.

3.1.1 SAFE OPERATION

a Read the Operator’s Manual and other training material. If the operator or technician can not read this manual,

the owner is responsible to describe this material to the operators and technicians.

a Read all of the instructions for this mower carefully. Know the controls and the correct operation of the

equipment.

b Children or persons who do not understand these instructions must not use the mower. The local regulations can

limit the age of the operator.

c Never use a mower near persons, including children or animals.

d Remember that the operator or owner is responsible for accidents or hazards that occur to other persons or their

property.

e Never carry passengers.

f Never allow persons to operate or service the mower or its attachments without correct instructions.

g Do not operate equipment while tired, sick or after you use alcohol or drugs.

3.1.2 PREPARATION

a When you operate the mower, wear correct clothing, slip resistant work shoes or boots, work gloves, hard hat,

safety glasses and hearing protection. Long hair, loose clothing or jewelry can be caught in moving parts.

b Do not operate the equipment with the Interlock System disconnected or the system does not operate correctly.

Do not disconnect or prevent the operation of any switch.

c Never operate equipment that is not in correct order or without decals, guards, shields, deflectors or other

protective devices fastened.

d Inspect the mower before you operate the mower. Check the tire pressure, the engine oil level, and the fuel level.

Fuel is flammable. Use caution when you add the fuel to the mower.

e Operate the mower in daylight or in good artificial light. Use caution when you operate the mower during bad

weather. Never operate the mower with lightning in the area.

f Inspect the area to select the accessories and attachments that are needed to correctly and safely do the job.

Only use parts, accessories and attachments approved by Dixie Chopper.

g Be careful of holes in the terrain and other hazards that are not visible.

h Inspect the area where the equipment is operated. Remove all objects you can find before you operate. Be

careful of obstructions above the ground (low tree limbs, electrical wires) and also underground obstacles (sprinklers, pipes, tree roots). Enter a new area carefully. Look for possible hazards.

i Inspect the cutting system before you start the mower. Make sure the blades are free to rotate. When you rotate

one blade, other blades can rotate.

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SAFETY 3

3.1.3 OPERATION

a Never operate the engine without enough ventilation or in an enclosed area. The carbon monoxide in the exhaust

fumes can increase to dangerous levels.

b Never carry passengers. Keep other persons or animals away from the mower.

c Disengage all drives and engage the parking brake before you start the engine. Only start the engine with the

operator in the seat. Never start the engine with persons near the mower.

d Keep your legs, arms and body inside the operator compartment while the mower is in operation. Keep your

hands and feet away from the cutting units.

e Do not use on the slopes greater than the safe slope limit for the equipment.

f To guard against over turning or loss of control:

– Operate the mower up and down on the face of slopes (vertically), but not across the face (horizontally).

– Do not start or stop suddenly on slopes.

– Decrease the speed when you operate on slopes or when you must turn. Use caution when you change

direction. Turf condition can change the mower stability.

– Use caution when you operate the mower near drop-offs, ditches or embankments.

– Be careful of holes in the terrain and other hazards that are not visible.

g When you drive in the reverse direction, look behind you and down to make sure the path is clear. Do not operate

the cutting unit when you drive in the reverse direction.

h Use caution when you go near corners, trees or other objects that can prevent a clear view.

i Equipment must meet the current regulations to be driven on the public roads.

j Before you move across or operate on the paths or roads, turn off the PTO switch, lift the cutting unit and travel at

decreased speed. Look for traffic.

k Stop the blades when the mower is on any surface that is not grass.

l Do not release the cut grass in the direction of persons or allow persons near the mower while in operation.

m Do not operate the mower with damaged guards or without safety devices in position.

n Do not change the engine governor setting or over-speed the engine. Never change or tamper with adjusters that

are closed with a seal for the engine speed control.

o Before you leave the operator compartment, for any reason:

– Disengage all the drives and lower the cutting unit to the ground.

– Engage the parking brake.

– Stop the engine and remove the key.

p When you hit an object or mower starts to cause the vibration that is not normal, inspect the mower for damage

and make repairs.

q Decrease the throttle setting before you stop the engine.

r Do not use this equipment for uses that the mower was not made for.

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3 SAFETY

3.1.4 OPTIONAL ROPS ACCESSORY

a The ROPS is a safety device. Keep the ROPS in the vertical and locked position. Always use the seat belt when

you operate the mower. Make sure the seat belt can be released quickly in an emergency.

b Only operate the mower with the ROPS in the folded position on flat and level surfaces when necessary. Do not

operate the mower with the ROPS in the folded position on slopes, near sharp edges or near water. There is no roll over protection with the ROPS in the folded position.

c Check for clearance before you drive below objects. Do not contact tree branches, electrical wires or other

objects with the ROPS.

d Do not use the seat belt with the ROPS in the folded position.

e Inspect the ROPS for damage. Keep the ROPS hardware fastened.

f Do not weld, drill, change or bend the ROPS. Replace a damaged ROPS. Do not try to correct a damaged

ROPS.

g Do not remove the ROPS from the mower.

h Dixie Chopper must approve any changes to the ROPS.

3.1.5 SAFE HANDLING OF FUELS

a The fuel and the fuel vapors are flammable. Use caution when you add the fuel to the mower. The fuel vapors

can cause an explosion.

b Never use the containers that are not approved to keep or transfer fuel.

c Never keep the mower or fuel containers near an open flame or any device that can cause the ignition of fuel or

fuel vapors.

d Never fill the fuel containers inside a vehicle or on a truck or trailer with a plastic liner. Always put the fuel

container on the ground away from your vehicle before you fill the container.

e Refuel the mower before you start the engine. When the engine is in operation or while the engine is hot, never

remove the fuel cap or add fuel to the mower.

f Refuel outdoors only and do not smoke when you add fuel. Extinguish all types of ignition.

g The fuel nozzle must touch the rim of the fuel tank when you add fuel to the mower. Do not use a device to lock

the fuel nozzle in the open position.

h Do not over fill the fuel tank. Leave at least 1 inch (2.5 cm) below the filler neck.

i Always tighten the fuel tank cap and container cap after you add fuel.

j If the fuel spills on your clothing, change your clothing immediately.

3.1.6 MAINTENANCE AND STORAGE

a Before you clean, adjust or repair this equipment, push PTO switch to the OFF position, lower the cutting unit to

the ground, engage the parking brake, stop the engine and remove the key.

b Make sure the mower is parked on a solid and level surface.

c Never work on a mower that is lifted only by the jack. Always use the jack stands.

d Never allow persons to service the mower or its attachments without correct instructions.

e When the mower is parked, put into storage or left without an operator, lower the cutting device unless a positive

mechanical lock is used.

f When you put the mower on a trailer or put the mower in storage, close the fuel valve. Do not keep fuel near

flames or drain the fuel inside a building.

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SAFETY 3

g Disconnect the battery before you service the mower. Always disconnect the negative battery cable before the

positive battery cable. Always connect the positive battery cable before the negative battery cable.

h Charge the battery in an area with good airflow. The battery can release hydrogen gas that is explosive. To

prevent an explosion, keep any device that can cause sparks or flames away from the battery.

i Disconnect the battery charger from the power supply before you connect or disconnect the battery charger to

the battery. Wear protective clothing and use insulated tools when you service the battery.

j Be careful and wear gloves when you check or service the cutting unit blades. Replace any damaged blades, do

not try to correct a damaged blade.

k Keep your hands and feet away from parts that move. Do not adjust the mower with the engine in operation,

unless the adjustment needs the engine in operation.

l Carefully release the pressure from components with stored energy.

m To prevent injury from the hot, high pressure oil, never use your hands to check for oil leaks. Use the paper or

cardboard to find leaks.

n The hydraulic fluid pressure can have enough force to enter your skin. If hydraulic fluid has entered your skin, a

doctor must remove the hydraulic fluid surgically within a few hours or gangrene can occur.

o When you service the hydraulic system, make sure the hydraulic fittings, tubes and hoses are tightened to the

correct torque. Make sure the hydraulic system is in good condition before you start the engine.

p Keep the mower and the engine clean.

q Allow the engine to become cool before storage and always remove the ignition key.

r Keep all nuts, bolts and screws tight to make sure the equipment is in safe condition.

s Replace worn or damaged parts for safety. Replace damaged or worn decals. Only use parts, accessories and

attachments approved by Dixie Chopper.

t To decrease the fire hazard, remove materials that burn from the engine, muffler, battery tray and fuel tank area.

u Disconnect the battery and controller connectors before you weld on this mower.

3.1.7 WHEN YOU PUT THE MOWER ON A TRAILER

a Be careful when you load or unload the mower on a trailer. Trailer must be wider than the mower and can carry

the weight of the mower.

b Use a full-width ramp to load or unload the mower on a trailer.

c Use straps, chains, cables or ropes to fasten the mower to the trailer. Both front and rear straps must be sent

down and toward sides of trailer.

d Make sure that all latches are correctly fastened.

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3 SAFETY

3.1.8 IMPORTANT SAFETY NOTES _______________________________________________

This safety alert symbol gives a warning of possible hazards.

DANGER - Indicates a dangerous condition that WILL cause death or injury unless it is prevented.

WARNING - Indicates a dangerous condition that CAN cause death or injury unless it is prevented.

CAUTION - Indicates a dangerous condition that can cause injury and property damage unless it is prevented. The

label can indicate work procedures that are not safe.

NOTICE - Indicates a condition that can cause damage to the property unless it is prevented. The label can indicate

work procedures that are not safe.

Some illustrations in this manual show the shields, guards or plates, removed. Do not operate this equipment without these devices correctly fastened in position.

WARNING

The Interlock System on this mower prevents the operation of the mower unless a.) The parking brake is engaged. b.) The PTO switch is in the OFF position and c.) The steering control levers are in the Neutral position. The system will stop the engine if the operator leaves the operator position without: a.) The parking brake engaged b.) The steering control levers in the Neutral position and b.) the PTO switch in the OFF position.

NEVER operate the mower unless the Interlock System operates correctly.

WARNING

1. Before you leave the operator position, for any reason:

a. Return the steering control levers to Neutral. b. Disengage all drives. c. Lower the cutting unit to the ground. d. Engage the parking brake. e. Stop the engine and remove the ignition key.

2. Keep your hands, feet and clothing away from moving parts. Wait for all movement to stop before you clean, adjust or service the mower.

3. Keep persons and animals away from the area of operation.

4. Never carry passengers.

5. Never operate the equipment without a correctly fastened grass deflector in position.

If additional information or service is needed, contact your Authorized Dixie Chopper Dealer. Your Dealer knows the current methods to service this equipment.

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SPECIFICATIONS 4

4Specifications

4.1 ENGINE SPECIFICATIONS __________________________________________________

ZEE 2 2348 / 2354 2348BR / 2354BR 2342KO / 2348KO / 2354KO

Make Kawasaki Briggs & Stratton Kohler

Model FR691V 44T777 KT730

Type Four cycle, air cooled, V-Twin,

OHV

Four cycle, air cooled, V-Twin,

OHV

Four cycle, air cooled, V-Twin,

OHV

Number of Cylinders 2 2 2

Bore and Stroke 3.07 x 2.99 in.

(7.8 x 7.6 cm)

Total Displacement

44.3 in

(0.726 l) 44.2 in3 (0.724 l) 44.2 in3 (0.725 l)

3.12 x 2.89 in.

(7.92 x 7.34 cm)

3.27 x 2.64 in. (8.3 x 6.7 cm)

Intake System Naturally Aspirated Naturally Aspirated Naturally Aspirated

Gross Intermittent Power

23.0 hp (17.2 kW) @ 3600 RPM

23 hp (17.2 kW) @ 3600 RPM

Compression Ratio 8.2:1 8.5:1 9.1:1

Maximum Speed 3600 ± 100 rpm (No Load) 3600 ± 100 rpm (No Load) 3600 ± 100 rpm (No Load)

Low Idle 1550 ± 100 rpm (No Load) 1750 ± 100 rpm (No Load) 1750 ± 100 rpm (No Load)

Rotation Clockwise viewed at flywheel Clockwise viewed at flywheel Clockwise viewed at flywheel

Fuel System Single Barrel Float Feed

Carburetor

Fuel 87 Octane Gasoline

Maximum 10% Ethanol

Ignition System Two magnetos triggered by

flywheel magnets

Single Barrel Float Feed

Carburetor

87 Octane Gasoline

Maximum 10% Ethanol

Two magnetos triggered by

flywheel magnets

Single Barrel Float Feed

Carburetor

87 Octane Gasoline

Maximum 10% Ethanol

Two magnetos triggered by

flywheel magnets

Spark Plug NGK BPR4ES B&S 491055 Kohler 12 132 02

Spark Plug Gap 0.030 Inch (0.76 mm) 0.030 Inch (0.76 mm) 0.030 Inch (0.76 mm)

Engine Oil (API

SF, SG, SH, SJ or SL SF, SG, SH, SJ or higher SJ or higher

Class)

Oil Pan Capacity 2.3 quarts (2.2 l) 2.0 quarts (1.9 l) 2.0 quarts (1.9 l)

Starter 12 Volt Electric Start 12 Volt Electric Start 12 Volt Electric Start

Alternator 12 Volt, 15 Amp 12 Volt, 15 Amp 12 Volt, 15 Amp

Dry Weight 88 lb. (39.9 kg) 84 lb. (38.1 kg) 85 lb. (38.6 kg)

Dimensions (Length x Width x

19.6 x 17.99 x 15.08 in. (49.8 x 45.7 x 38.3 cm)

19.3 x 19.4 x 15.7 in.

(49.0 x 49.2 x 39.9 cm)

18.7 x 17.5 x 13.9 in.

(47.5 x 44.45 x 35.31 cm)

Height)

Emission Regulation

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4 SPECIFICATIONS

4.2 DIMENSIONS AND WEIGHTS________________________________________________

2342KO 2348 / 2348BR / 2348KO 2354 / 2354BR / 2354KO

A - Width of Cut 42 inch (106.7 cm) 48 inch (121.9 cm) 54 inch (137.2 cm)

B - Maximum Width

C - Height 47 inch (119.4 cm)

D - Total length 76 inch (193.0 cm)

E - Wheel Base 43.4 inch (110.2 cm)

F - Front Wheel Track

G - Rear Wheel Track

Weight of unit 730 lb. (331.1 kg) 750 lb. (340.2 kg) 763 lb. (346.1 kg)

Tire Size Type Tire Pressure Tire Size Type Tire Pressure

13 x 6.5-6 N/A 42 in. Mower

51.5 inch (130.8 cm) 57.5 inch (146.0 cm) 64 inch (162.6 cm)

31.63 inch 34.38 inch (87.6 cm)

35.88 inch (91.1 cm)

Tire Specifications

Front Wheel Rear Wheel

20 x 8-10

48 and 54 in.

20 x 10-8

Grass

Master

8-10 psi (0.55-0.69 BAR)

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SPECIFICATIONS 4

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4 SPECIFICATIONS

4.3 MOWER SPECIFICATION ___________________________________________________

Battery: 12V, 300 CCA

Service Brake: Dynamic braking through the traction circuit

Parking Brake: Hand lever connected to brake in both drive axles

Fuel Tank: 4 U.S. Gallons (15.1 l)

Steering: Hand lever speed and direction controls for left and right rear wheel

Traction Drive: Belt driven dual hydrostatic Hydro-Gear ZT-2800 drive axle

Cutting Unit Drive: Belt drive with electric clutch

Ground Speed: 0-7 mph (0-11.27 kph)

42 in. Deck Cutting Performance: Up to 2.4 acres/hr. (1.64 hectares/hr) @7 mph (11.27 km/hr)

48 in. Deck Cutting Performance: Up to 2.7 acres/hr. (1.96 hectares/hr) @7 mph (11.27 km/hr)

54 in. Deck Cutting Performance: Up to 3.1 acres/hr. (2.35 hectares/hr) @7 mph (11.27 km/hr)

4.4 CUTTING UNIT SPECIFICATION _____________________________________________

2342KO 2348 / 2348BR / 2348KO 2354 / 2354BR / 2354KO

Blade Length 15-1/4 inch (38.7 cm) 17-1/4 inch (43.8 cm) 19-1/4 inch (48.9 cm)

Number of blades 3

Height of cut 1-1/2 to 4-1/2 in. (3.8 to 11.4 cm) in 1/2 in. (1.27 cm) increments

Height of cut

adjustment

Blade Tip Speed

@ 3600 rpm engine

speed

A foot lever to lift or lower the cutting unit with a HOC pin installed in different holes for

specified HOC.

290.5 feet/second (88.5 meters/second)

287.4 feet/second (87.6 meters/second)

269.4 feet/second (82.1 meters/second)

4.5 BELT SPECIFICATION _____________________________________________________

Traction Belt Part Number 200572, A-Section, Raw, 64 in. EL Belt

42 in. Deck Belt Part Number 300996, A-Section, Wrapped, 133 in. EL Belt

48 in. Deck Belt Part Number 300995, B-Section, Wrapped, 146 in. EL Belt

54 in. Deck Belt Part Number 300997, B-Section, Wrapped, 159 in. EL Belt

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SPECIFICATIONS 4

4.6 RECOMMENDED LUBRICANTS ______________________________________________

Engine Oil:

Kawasaki Engine: API Classification grades SF, SG, SH, SJ or SL

Temperature Viscosity

Above 95° F (35° C) SAE 40

68° to 95° F (20° to 35° C) SAE 30 or SAE 10W-30 or SAE 10W-40 or SAE 40

32° to 68° F (0° to 20° C) SAE 30 or SAE 10W-30 or SAE 10W-40

-4° to 32° F (-20° to 0° C) SAE 5W-20 or SAE 10W-30 or SAE 10W-20

Below -4° F (-20° C) SAE 5W-20

Briggs & Stratton Engine: API Classification grades SF, SG, SH, SJ or higher

Temperature Viscosity

Above 95° F (35° C) SAE 30 or Synthetic SAE 5W-30

40° to 95° F (4° to 35° C) SAE 30 or SAE 10W-30 or Synthetic SAE 5W-30

-0° to 40° F (-18° to 4° C) SAE 5W30 or SAE 10W-30 or Synthetic SAE 5W-30

Below -0° F (-18° C) SAE 5W30 or Synthetic SAE 5W-30

Kohler Engine: API Classification grades SJ or higher

Temperature Viscosity

Above 50° F (10° C) SAE 30 or SAE 10W-30

32° to 50° (0° to 10° C) SAE 10W-30

0° to 32° F (-18° to 0° C) SAE 5W-30 or SAE 10W-30

Below 0° F (-18° C) SAE 5W-30

Drive Axle Fluid:

The standard drive axle fluid is SAE 20W50 API Classification SL.

Grease:

Texaco Starplex 2EP Moly (NLGI Grade 2-EP Lithium Complex Grease containing Molybdenum Disulfide) or equivalent.

4.7 ACCESSORIES____________________________________________________________

4.7.1 STRIPING KIT _____________________________________________________________

Kit Number 902773

4.7.2 ROLL BAR HARDWARE KIT _________________________________________________

Kit Number 902782

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4 SPECIFICATIONS

4.7.3 COMPLETE ROPS KIT _____________________________________________________

Kit Number 902676

4.7.4 SEAT BELT KIT ___________________________________________________________

Kit Number 902784

4.7.5 SEAT CABLE KIT _________________________________________________________

Kin Number 902827

4.7.6 QUICK LIFT KIT ___________________________________________________________

Kit Number 902935

4.7.7 REPLACMENT BLADES ____________________________________________________

Standard 15-1/4 inch (38.7 cm) High Lift Blade Part Number 301067E (For 42 inch (106.7 cm) cutting unit) Standard 17-1/4 inch (43.8 cm) High Lift Blade Part Number 301068E (For 48 inch (121.9 cm) cutting unit) Standard 19-1/4 inch (48.9 cm) High Lift Blade Part Number 301069E (For 54 inch (137.2 cm) cutting unit

4.7.8 COMPLETE DECK ASSEMBLY ______________________________________________

42 inch (106.7 cm) Kit Number 300945 48 inch (121.9 cm) Kit Number 300946 54 inch (137.2 cm) Kit Number 300947

4.7.9 MULCHER KIT ____________________________________________________________

42 inch (106.7 cm) Kit Number 903010 48 inch (121.9 cm) Kit Number 903011 54 inch (137.2 cm) Kit Number 903012

4.7.10 OCDC KIT _______________________________________________________________

42 inch (106.7 cm) Kit Number 301428 48 inch (121.9 cm) Kit Number 301429 54 inch (137.2 cm) Kit Number 301430

4.8 SUPPORT LITERATURE ____________________________________________________

Contact your Dixie Chopper Dealer for a complete listing of literature available for your mower.

Operator’s Manual: 700561 Mower Parts Manual: 700583

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DECALS 5

800817

Read the manual before you operate the mower

Pick up sticks, stones and other debris that can be thrown by the mower.

Wear eye protection when you operate the mower.

Wear ear protection when you operate the mower.

Keep bystanders away from the mower.

Be careful of debris thrown by the mower.

Use caution when you operate on slopes. Only operate on slopes with the ROPS in the vertical position.

Do not carry passengers.

Serious injury or death can result from blade contact or from contacting the belts or pulleys with the engine running. Deck spindles may have a fan installed above or below the pulleys.

Do not operate the mower with the discharge chute or belt guards removed. Make sure the Interlock System is operates correctly.

800848

DO NOT OPERATE WITHOUT OPERATOR CONTROLLED DISCHARGE CHUTE (OCDC), DISCHARGE DEFLECTOR, ENTIRE GRASS COLLECTION SYSTEM, OR MULCHING KIT IN PLACE. DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED.

800818

MAX. FILL

Only fill the fuel tank to the bottom of the fuel filler neck. Do not overfill the fuel tank.

5Decals

5.1 SAFETY DECALS__________________________________________________________

Understand the purpose of these decals. The decals are important to the safe operation of the mower. REPLACE THE DAMAGED DECALS IMMEDIATELY.

30229

WARNING

MAXIMUM TONGUE WEIGHT

100 lbs.

800208

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5 DECALS

WHEN ADDING OIL FOR TRANSAXLES,

USE MULTIVISCOSITY SAE 20W-50 OIL

DO NOT ADD AUTOMATIC TRANSMISSION FLUID

OR HYDRAULIC FLUID!

THIS WILL VOID WARRANTY

MAINTAIN OIL LEVEL TO THE COLD FILL

CHECK OIL WHEN COLD.

LINE ON THE DRIVE OIL EXPANSION TANK (APPROXIMATELY 1/4”

FROM BOTTOM) DO NOT TOP OFF !

OIL/FILTER CHANGE TO BE PERFORMED

BY AUTHORIZED DIXIE CHOPPER SERVICE DEALER ONLY!

DRIVE OIL EXPANSION TANK

CAUTION

800192

Transaxle service interval: Initial 75 hrs., every 400 hrs thereafter

Fast Reverse

Slow Reverse

Slow Forward

Fast Forward

Neutral

Neutral Lock

Position

Neutral Lock

Position

Left Side

Steering Lever

Right Side

Steering Lever

Height of Cut

5.2 INSTRUCTION DECALS ____________________________________________________

800842

800843

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DECALS 5

Engaged

Position

Disengaged

Position

Fast

Slow

Engine

Throttle

PARKING

BRAKE

800845

REAR

1.) Engine to Transmission Belt

2.) Engine to Deck Belt

FRONT800903

No Step

800846

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6 CONTROLS

6Controls

6.1 MOWER CONTROLS_______________________________________________________

6.3

6.2

6.6

6.5

6.4

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CONTROLS 6

STOP

CHOKE

6.2.1

6.2.2

6.2.4

6.2.5

6.2.3

6.2.6

12V

OFF

RUN

START

6.2 CONTROL PANEL _________________________________________________________

6.2.1 IGNITION SWITCH _________________________________________________________

The ignition switch has three positions, OFF, RUN and START.

STOP

6.2.2 PTO SWITCH _____________________________________________________________

The PTO switch is a 2-position knob type switch to engage and to disengage the cutting unit. The PTO switch must be in the OFF (down) position to start the engine.

Pull on the red knob to move the switch to the ON position. When the PTO switch is in the ON position, the cutting unit is engaged.

Always mow with the throttle lever in the fast position.

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6 CONTROLS

Mode Button

CHOKE

Choke Position

Run Position

12V

6.2.3 HOUR METER ____________________________________________________________

The hour meter shows the hours of operation and engine speed.

Press and release the mode button to toggle between functions.

6.2.4 THROTTLE LEVER ________________________________________________________

The throttle lever controls the engine speed. Always operate the mower at full throttle during normal operation.

6.2.5 CHOKE CONTROL ________________________________________________________

When you start a cold engine, pull the choke control to the choke position. Slowly push the choke lever to the RUN position when the engine becomes

warm.

NOTICE

The choke control is not necessary to start a warm engine.

6.2.6 12 VOLT ACCESSORY OUTLET _____________________________________________

The 12 Volt accessory outlet supplies power to 12 Volt accessories. Only use the 12 Volt outlet with the engine started to prevent a drained battery.

CAUTION

Do not use attachments with a power rating greater than 120 watts.

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CONTROLS 6

Operation Position

Neutral Position

Left Side Right Side

Engaged Position

Disengaged Position

6.3 STEERING CONTROL LEVERS ______________________________________________

The mower has separate drive axles for each rear wheel. The right-side control lever controls the operation of the right-side drive axle. The left-side control lever controls the operation of the left-side drive axle. See 7.6 for the operation of the steering

control levers.

DANGER

To prevent personal injury or death, do not quickly move the steering control levers or suddenly start and stop the mower. You must use more caution when you turn the mower or when you operate on slopes.

To put the steering control levers in the Neutral position, move the steering control levers toward the left and right sides.

The steering control levers must be in the Neutral position, the PTO switch must be in the OFF (down) position and the parking brake engaged to start the mower.

6.4 PARKING BRAKE _________________________________________________________

The parking brake lever engages the drive axle brakes to prevent movement of the mower. The parking brake should be engaged when the mower is stationary and/or unoccupied.

When the steering control levers are in the Neutral position, pull the parking brake lever back to the engaged position to engage the parking brake. Push the parking brake lever forward to the disengaged position to disengage the parking brake.

The steering control levers must be in the Neutral position, the PTO switch must be in the OFF (down) position and the parking brake engaged to start the mower.

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6 CONTROLS

Lift Stop Lever

HOC Pin

HOC Pedal

Slot

6.5 CUTTING UNIT HOC PEDAL_________________________________________________

The cutting unit height of cut (HOC) pedal lifts and lowers the cutting unit.

Install the HOC pin in the correct position for the cutting height. To lower the cutting unit, press the pedal down, pull the lift stop lever back and slowly allow the pedal to lift until the lift bracket touches the

HOC pin. See 7.7 for the HOC pin position chart.

NOTICE

To prevent damage to the HOC mechanism or the cutting unit, slowly allow the pedal to lift until the lift bracket touches the HOC pin. Do not allow the cutting unit to drop from the lifted position against the HOC pin.

To lift the cutting unit, fully push the HOC pedal. The lift stop lever pin will drop into the slot. Release the lift pedal.

6.6 LIFT STOP LEVER_________________________________________________________

The lift stop lever is used to hold the cutting unit in the fully raised position.

To lift the cutting unit, fully push the HOC pedal. The lift stop lever pin will drop into the slot. Release the lift pedal. The pin part of the lift stop lever will hold the cutting unit in the fully raised position.

To lower the cutting unit, push on the pedal to release the pressure on the lift stop lever and pull the lift stop lever back. When the cutting unit is lowered, the lift bracket will contact the HOC pin.

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OPERATION 7

7Operation

7.1 DAILY INSPECTION ________________________________________________________

CAUTION

The inspection must be done each day when the engine is turned off and all fluids are cold. Lower the cutting units to the ground, engage the parking brake, stop the engine and remove the ignition key.

Do a visual inspection of the mower. Look for indications of wear or loose hardware. Look for any components that are not included on the mower or damaged components. Check for fuel and oil leaks to make sure the connections are tight. Make sure that all hoses are in good condition.

Check the fuel supply and crankcase oil level. When the engine is cold, all fluids must be at the full level mark.

Check the engine oil cooler fins for dirt or grass. Clean with compressed air as required before you operate the mower.

Check all tires for the correct pressure.

Test the Interlock system.

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7 OPERATION

7.2 INTERLOCK SYSTEM ______________________________________________________

The Interlock System prevents the engine to start unless the steering control levers are in the Neutral position, the parking brake is engaged and the PTO switch is in the OFF (Down) position. The system stops the engine if the operator leaves the seat with the PTO switch in the ON position, steering control levers out of the NEUTRAL position or

the parking brake disengaged.

WARNING

Do not operate the equipment with the Interlock System disconnected or the system does not operate correctly. Do not disconnect or prevent the operation of any switch.

Do each of these tests to make sure the Interlock System operates correctly. If any of the tests fail, stop the test and have the system inspected and repaired as shown below:

• The engine does not start during test 1

• The engine does start during tests 2, 3 and 4

• The engine continues to run during tests 5 and 6

Refer to the chart below for each test and follow the check () marks across the chart. Turn off the engine between each test.

TEST 1: The test shows the normal engine start procedure. The operator is in the seat, parking brake is engaged, the steering control levers are in the NEUTRAL position and the PTO switch is in the OFF (down) position. The engine will start.

TEST 2: The engine must not start if the PTO switch is in the ON position.

TEST 3: The engine must not start if the parking brake is disengaged.

TEST 4: The engine must not start if the steering control lever(s) is out of the NEUTRAL position.

TEST 5: Start the engine with the normal procedure. Turn on the PTO switch and lift your weight off the seat. The engine must stop. The cutting unit blades must not rotate after seven (7) seconds.

TEST 6: Start the engine with the normal procedure. Disengage the parking brake and lift your weight off the seat. The engine must stop. The cutting unit blades must not rotate after seven (7) seconds.

Test

1 

2 

3   

4  

Operator Seated

Yes No Yes No Yes No Yes No Yes No

PTO Switch OFF Parking Brake

Engaged

Steering Control

Levers in Neutral

Engine Starts

5   

6   

 Start the engine with the normal procedure, move position of the switch and lift your weight off the seat.

The engine must stop immediately and the cutting unit blades must not rotate after seven (7) seconds.

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OPERATION 7

7.3 OPERATING PROCEDURE __________________________________________________

WARNING

This mower has an optional folding Roll Over Protection Structure (ROPS). Always wear the seat belt with the ROPS frame in the vertical and locked position. Never wear the seat belt with the ROPS in the folded position or when ROPS is not installed.

If the mower is over turning and the ROPS is in the vertical and locked position, hold the steering wheel. Do not try to move off the mower or leave the seat.

CAUTION

To prevent injury, always wear the safety glasses, leather work shoes or boots, a hard hat and ear protection.

1. Always start the engine with the operator in the seat, never while next to the mower. Never start the engine with persons near the mower.

2. Never operate the engine without enough ventilation or in an enclosed area. The carbon monoxide in the exhaust fumes can increase to dangerous levels.

3. Keep your hands and feet away from moving parts and the cutting units. When possible, do not adjust the mower with the engine started.

4. Do not operate the mower with loose or damaged components. All components must be correctly fastened to the mower. Mow when the grass is dry to get the best results.

5. First cut in a test area so that you completely understand the operation of the tractor and controls.

6. Inspect the area to find the safest procedure for the mower. Check the height of the grass, the type of terrain and the conditions of the surface. Each condition needs the correct adjustments and precautions.

7. Do not release the cut grass in the direction of persons or allow persons near the mower while in operation. The owner and operator are responsible for injuries caused to persons near the mower and any damage to their

property.

CAUTION

Remove all objects you can find before you operate the mower. Carefully enter a new area and always operate at speeds that allow you to control the mower safely.

8. Be careful when you operate near to gravel areas (roads, parking areas, cart paths). Stones released from the equipment can cause injuries to persons and cause damage to the equipment.

9. When you are not mowing grass, always turn off the PTO switch.

10. Before you move across or operate on the paths or roads, turn off the PTO switch, lift the cutting unit and travel at decreased speed. Look for traffic.

11. When you hit an object or mower starts to cause vibration that is not normal, inspect the mower for damage and make repairs.

WARNING

Before you clean, adjust or repair this equipment, always turn off the PTO switch, lower the cutting unit to the ground, turn on the parking brake switch, stop the engine and remove the ignition key.

12. Travel at decreased speed and be careful when you operate on slopes or near sharp edges.

13. When you drive in the reverse direction, look behind you and down to make sure the path is clear. Use caution when you go near corners, trees or other objects that can prevent a clear view.

14. Never use your hands to clean the cutting units. Use a brush to remove the grass clippings from the blades. The blades are sharp and can cause injuries.

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7 OPERATION

STOP

CHOKE

12V

Throttle Lever

Hour Meter

Ignition Switch

Choke

PTO Switch

7.4 STARTING THE ENGINE____________________________________________________

Start the engine with the operator in the seat, steering controls levers in the Neutral position, the PTO switch in the OFF position and the parking brake engaged.

Set the throttle lever to half throttle.

If the engine is cold, move the choke to the choke position.

Turn the ignition switch to the RUN position. The hour meter will show the engine operation hours.

Turn the ignition switch to the START position. Release the key when the engine starts. Allow 30 seconds between start tries to

allow the starter motor to become cool.

NOTICE

Do not hold the ignition switch in the START position for more than 5 seconds.

When the engine starts, move the choke to the RUN position. Allow the engine to become warm before you operate the engine at full throttle.

7.5 TO STOP THE ENGINE _____________________________________________________

To stop and park the mower in normal conditions:

1. Turn the PTO switch to the OFF position. Drive the mower to a flat and level area to park the mower.

2. Put the steering control levers in the Neutral position.

3. Lower the cutting unit to the ground. Engage the parking brake.

4. Turn the ignition switch to the OFF position and remove the key before you leave the mower.

If an emergency occurs and you must park the mower in the area of operation, follow the guidelines set by the grounds manager. If the mower is parked on a slope, chock or block the wheels.

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OPERATION 7

Neutral Forward Forward Left

Turn

Forward Right

Turn

Zero Radius

Left Turn

Neutral Reverse Reverse Left

Turn

Reverse Right

Turn

Zero Radius

Right Turn

7.6 DRIVING _________________________________________________________________

Read and follow all safety instructions contained in this manual when you operate the mower. When you operate in the reverse direction, look behind you to make sure you have a clear path. Do not mow in reverse.

Slowly and equally push both the right-side and left-side control levers forward to drive the mower in the forward direction. The more the levers are pressed the more the forward speed is increased.

DANGER

Slowly and equally pull both the right-side and left-side control levers toward you to drive the mower in the reverse direction. The more the levers are pulled the more the reverse speed is increased. Press the levers against the reverse stop for the maximum reverse speed.

To turn the mower to the left, push the right-side drive lever more than the left-side drive lever. The greater the difference in lever position, the sharper the mower will turn. To do a zero radius left turn, press the right-side lever forward and pull the left-side lever toward you.

To turn the mower to the right, push the left-side drive lever more than the right-side drive lever. The greater the difference in lever position, the sharper the mower will turn. To do a zero radius right turn, press the left-side lever forward and pull the right-side lever toward you.

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7 OPERATION

Front

HOC Pin

7.7 HEIGHT OF CUT __________________________________________________________

The height of cut is determined by the position of the HOC pin. Engage the parking brake, stop the engine and remove the key before you change the HOC. Fully lift the deck until it is held with the lift stop lever.

Use the chart to find the correct cutting height pin location for the necessary HOC.

Hole

1 1-1/2 Inch (3.8 cm) 2 2 Inch (5.1 cm) 3 2-1/2 Inch (6.4 cm) 4 3 Inch (7.6 cm) 5 3-1/2 Inch (8.9 cm) 6 4 Inch (10.2 cm) 7 4-1/2 Inch (11.4 cm)

HOC

7.8 MOWING_________________________________________________________________________

WARNING

To prevent injuries, when the blades rotate, keep your hands, feet and clothing away from the cutting unit.

NEVER use your hands to clean the cutting unit. Use a brush to remove grass from the blades. The blades can be sharp and can cause injury.

DO NOT operate the cutting unit with the discharge chute removed.

To mow:

1. Put the PTO switch in the ON position. The blades will start turning.

2. Lower the cutting unit.

3. Push the steering control levers forward to drive the mower. Never mow in the reverse direction.

4. Slow down when you turn the mower or mow on slopes.

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OPERATION 7

0°

2-3/4°

5-3/4

/2°

15%

11-1/4°

20%

4°

25%

16-3/4°

30%

19-1/4°

35%

-3/4°

40%

24-1/4°

45%

26-1/2°

50%

28-3/4°

55%

31°

60%

33°

65%

35°

70%

36-3/4°

75%

38-3/4°

80%

40-1/4°

85%

42°

90%

43-1/2°

95%

45°

100%

General slope of roadway embankment - 45° Steepest Grass Area - 31° Slope of the average roof - 19-1/4° 2nd Class highway maximum grade 4-1/2° Toll road or freeway - 1-3/4°

Grade

Degrees

7.9 MOWING ON SLOPES ______________________________________________________

The mower is made to have good traction and to have good balance. Operate the mower with caution when you drive on a slope. If you drive on wet grass, the traction and steering

control of the mower is decreased.

WARNING

To make sure that the mower does not turn over, the safest method to drive on a slope is to drive vertically. Travel at a slow speed and do not make turns that are not necessary.

Check for hazards on the road that are not visible to the drivers. Keep the cutting unit lowered when you operate on the slopes.

CAUTION

When you are mowing on sides of hills, do not operate the mower on slopes greater than 5° or a 8.7% grade.

When you are mowing going uphill, do not operate the mower on slopes greater than 10° or a 17.6% grade.

When you are mowing going downhill, do not operate the mower on slopes greater than 15° or a 26.8% grade.

1. Always cut the grass with the engine at full throttle. Control the forward speed with the steering control levers to keep the correct performance.

2. If the mower moves to the side or the tires damage the turf, drive the mower on a slope with a decreased angle.

3. If the mower continues to move to the side and damage the turf, the slope is at an angle that is not safe. Do not continue to drive toward the top of the slope. Carefully drive toward the bottom of the slope.

4. When you drive toward the bottom of a slope with a high angle, lower the cutting unit to the ground. This procedure makes sure the mower does not turn upside down.

5. Correct tire pressure is necessary for maximum traction.

Rear - 8-10 psi (0.55-0.69 BAR)

5° Maximum

10° Maximum

15° Maximum

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7 OPERATION

How to calculate a slope:

Tools Required: Level (A), either 1 yard, or 1 meter long. Tape measure (B).

Use the level (A) and position it horizontally to measure the distance (C) with tape measure (B). Use the chart to calculate the slope angle or the percentage grade of the slope (D).

Height (C) Result (D)

Inches with 1 Yard Level (A) Millimeters with 1 Meter Level (A) Slope in Degrees Slope Grade %

100 5.7 10.0

150 8.5 15

200 11.3 20.0

7.5

225 12.7 22.5

9 250 14 25.0

275 15.4 27.5

300 16.7 30.0

325 18.0 32.5

350 19.3 35.0

375 20.6 37.5

400 21.8 40.0

425 23.0 42.5

475 25.4 47.5

18 500 26.6 50.0

600 31.0 60.0

36 1000 45.0 100

800 38.7 80.0

900 42.0 90

4.8 8.3

9.5 16.7

11.8 20.8

15.5 27.8

17.0 30.6

18.4 33.3

19.9 36.1

21.3 38.9

22.6 41.7

24 44.4

29.1 55.6

34.8 69.4

39.8 83.3

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OPERATION 7

Neutral

Position

Operation

Position

7.10 TOWING THE MOWER______________________________________________________

If the mower has a problem and can not drive to the service area, move the neutral release levers to the neutral position and load the mower on a trailer. If a trailer is not available, tow the mower at a slow speed for short distances.

Be careful when you load or unload the mower on the trailer. Fasten the mower to the trailer to prevent the mower to move on the trailer. Engage the parking brake.

If the trailer is moved on the highway, inflate the tires to the maximum pressure recorded on the tire before you fasten the mower to the trailer. Decrease the tire pressure after the mower is removed from the trailer.

Move the neutral release levers (B) to the neutral position on both drive axles before you tow the mower. The neutral release levers lets the mower be moved without the engine started and to prevent possible damage to the drive axles.

The neutral release levers (B) are located behind the drive axles. Pull the levers toward the rear of the mower until they can be lowered into the neutral position.

Before towing, disengage the parking brake and make sure the cutting unit is lifted.

NOTICE

When you tow the mower, do not drive more than 2 mph (3.2 km/hr). Dixie Chopper recommends that you do not tow the mower for long distances.

When the mower gets to the service area, engage the parking brake, lift up and push the neutral release levers to the operation position.

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8 MAINTENANCE AND LUBRICATION CHARTS

8Maintenance and Lubrication Charts

8.1 MAINTENANCE CHART ____________________________________________________

Mower Service Interval Chart

Interval Item Section

First 5 Hours • Replace engine oil

• Replace engine oil filter

• Check electrical wiring

Each day (10 Hours) • Check Safety Interlock System

• Check engine oil level

• Check drive axle oil level

• Clean area around muffler and controls

• Check blades for sharpness and wear

Each 25 Hours • Clean air filter

• Replace cutting blades

Each week (50 Hours) • Check fuel lines and fittings

• Inspect parking brake and steering control lever linkage

• Inspect deck and drive belts

• Check for loose components

• Check engine exhaust system

• Lubricate front wheel pivot grease fittings

First 75 Hours • Replace drive axle fluid and filter (Two per mower) See 9.9

Each Two weeks (100

Hours)

• Clean engine oil cooler fins and cylinder cooling fins

• Replace air filter element1 (Kohler Engine)

• Replace engine oil and filter

• Clean and regap spark plugs (Kawasaki Engine)

• Replace fuel filter (Kohler Engine)

See 9.3 See 9.3

See 9.16

See 7.2 See 9.3 See 9.9

See 9.14

See 9.6

See 9.3

See 9.13

See 9.4 See 9.9 See 9.3

Each month (200 Hours) • Check electrical wiring

• Replace air filter element

300 Hours

• Clean combustion chamber (Kawasaki Engine)

• Check and adjust valve clearance (Kawasaki Engine)

• Clean and lap valve seating surface (Kawasaki Engine)

Each two months (400

Hours

Yearly or 500 Hours

600 Hours

Perform more frequently under severe, dusty, dirty conditions.

Have a Kawasaki authorized dealer perform this service

Have a Kohler authorized dealer perform this service

Not required unless engine performance problems are noted

• Replace fuel filter

• Replace drive axle fluid See 9.9

• Replace air filter element

• Replace spark plugs

• Check and adjust valve lash (Kohler)

(Briggs and Kawasaki Engine)

(Briggs)

See 9.16

See 9.4

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MAINTENANCE AND LUBRICATION CHARTS 8

8.2 FLUID REQUIREMENTS ____________________________________________________

Fluid Requirements

Quantity Type

Engine Oil with Filter

Kawasaki Engine

Briggs & Stratton Engine

Kohler Engine

Drive axle 2.41quarts (2.28 liter) Each

Fuel 4 U.S. Gallons (15.1 l) 87 Octane Gasoline

If SAE 20W-50 oil is not available, you may substitute a motor oil of 55 SUS or better (at 230° F (110° C)), such as a

high grade 10W-50, 15W-40 or 15W-50.

2.3 quarts (2.2 l)

2.0 quarts (1.9 l)

(2 per Mower)

Varies depending on air temperature.

See 4.6

SAE 20W-50 API Classification SL

Maximum 10% Ethanol

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9 MAINTENANCE

9Maintenance

9.1 GENERAL PRECAUTIONS ________________________________________________________

WARNING

Before you clean, adjust or repair this equipment, push PTO switch to the OFF position, lower the cutting unit, engage the parking brake, stop the engine and remove the key.

Make sure the mower is parked on a solid and level surface. Never work on a mower that is lifted only by the jack. Always use the jack stands.

A qualified technician must always do adjustments and maintenance. If the correct adjustments can not be made, contact your Dixie Chopper Dealer.

Inspect the equipment according to the maintenance schedule and keep complete records.

a Keep the equipment clean.

b Keep all moving parts correctly adjusted and lubricated.

c Replace worn or damaged parts before you operate the mower.

d Keep all fluids at the correct level.

e Keep the shields in position and all hardware tight.

f Keep the tires correctly inflated.

When you make the adjustments or repairs, do not wear jewelry or loose fitting clothing.

Refer to the illustrations in the Parts Manual for the removal and assembly of parts.

When you discard hazardous materials (batteries, lubricants, fuel, anti-freeze), follow your local, state or federalrecommended procedures.

9.2 ENGINE _________________________________________________________________

IMPORTANT - The mower includes a separate Engine Manual prepared by the engine manufacturer. Read the Engine

Manual and know the operation and maintenance of the engine. When you follow the engine manufacturer instructions, you will make sure of the maximum service life of the engine. The replacement engine manuals are available from the engine manufacturer.

The operation and maintenance during the first 5 hours of a new engine can make a difference to the performance and life of the engine.

During the first 5 hours of operation, Dixie Chopper recommends the following.

• Allow the engine to reach a temperature of at least 140° F (60° C) before operation at full load.

• Check the engine oil level two times each day. Higher than normal oil use can occur during the first 5 hours.

• Change the engine oil and oil filter after the first 5 hours of operation.

• Refer to the Engine manual for specified maintenance intervals.

NOTICE

The mower operates and cuts correctly at the preset governor setting. Do not change the engine governor setting or over speed the engine.

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MAINTENANCE 9

ADD FULL

Dipstick

Level Indicator

Kohler EngineKawasaki Engine

Level Indicator

Dipstick

Briggs Engine

Drain Plug

Filter

Drain Plug

Filter

Kohler EngineKawasaki Engine

Briggs Engine

Filter

9.3 ENGINE OIL ______________________________________________________________

Check engine oil level

Check the engine oil level before you start the engine or at least five minutes after you stop the engine.

a Park the mower on a level surface.

b The dipstick is found on the engine behind the seat.

Remove the dipstick. Clean the dipstick with a cloth and replace in position.

c Remove the dipstick and check the oil level. The oil

level must be between the two level indicators on the dipstick.

Change Engine Oil and Filter

a Start the engine to increase the temperature, then

stop the engine.

b Place a container capable of holding one gallon under

the engine.

c Remove the oil drain plug and allow the engine oil to

drain into a container.

d Remove the oil filter.

e Let the engine oil flow into a container.

f Clean the filter area on the engine.

g Apply a thin layer of oil to the gasket on new filter.

Install the oil filter.

h Tighten the filter until the gasket contacts the oil filter

adapter, then tighten an additional 1/2 to 3/4 turn. Only use your hand to tighten the filter.

i Replace the oil drain plug and fill the engine with the

correct quantity and grade of oil through the dipstick tube.

j Start the engine and check around the oil filter gasket

for leaks.

k Stop the engine and check the engine oil level.

The engine oil can damage your skin. Use gloves when you use engine oil. If engine oil touches your skin, clean the area immediately.

Discard used engine oil as shown in local regulations.

CAUTION

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9 MAINTENANCE

Latch

Clamp

Filter Cover

Fastener

Filter

Filter Cover

Fastener

Filter

9.4 ENGINE AIR FILTER _______________________________________________________

Do not remove the filter to inspect air cleaner. Removal of the filter that is not necessary increases the risk of dust and other particles to enter the engine.

Clean filter element every 25 hours. Replace the filter every 100 hours (Kohler) or 200 hours (Kawasaki and Briggs).

Clean the inside of the filter housing. Make sure dust and other particles do not get into the engine inlet.

Inspect the new filter. Do not use a damaged filter and never use an incorrect filter.

To service the air filter:

Kawasaki Engine - Lift the filter cover off the engine. Loosen hose clamp and remove the filter. After you install the filter, make sure the hose clamp is tight and holds the filter in position.

Kohler Engine - Release the fasteners and lift the filter cover off the engine. Remove the filter. After you install the filter and filter cover, make sure the fasteners hold the cover in position.

Briggs & Stratton Engine - Release the fasteners and lift the filter cover off the engine. Pull the latch down and remove the filter. After you install the filter and filter cover, make sure the fasteners hold the cover in position.

9.5 ENGINE EXHAUST _______________________________________________________________

WARNING

The exhaust fumes contain carbon monoxide. The carbon monoxide in the exhaust fumes can increase to dangerous levels. To protect you from carbon monoxide poisoning, inspect the complete exhaust system every month and replace damaged components immediately.

NEVER operate the engine without enough ventilation.

The temperature of the exhaust components can be greater than 300° F (149° C). To prevent the burns, do not touch a hot exhaust system.

If you sense a change in the color or sound of the exhaust, stop the engine immediately. Identify the problem and have the system repaired.

Torque all exhaust manifold hardware equally. Tighten or replace the exhaust clamps.

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MAINTENANCE 9

9.6 FUEL ____________________________________________________________________

Gasoline is flammable. Use caution when you add the fuel to the mower. Only use an approved container. The

spout on the container must fit inside the fuel filler neck. Never use the containers that are not approved to keep or transfer fuel.

WARNING

Refuel the mower before you start the engine. When the engine is in operation or while the engine is hot, never remove the fuel cap or add fuel to the mower.

Refuel outdoors only and do not smoke when you add fuel.

If the fuel spills, do not try to start the engine, but move the mower away from the area. Until fuel vapors are removed, do not allow the sparks, open flame or other types of ignition.

Never keep fuel containers near an open flame or any device that can cause the ignition of fuel or fuel vapors.

Always tighten the fuel tank cap and container cap after you add fuel.

Fill the fuel tank to the bottom of the filler neck.

Do not use premium gasoline or an oil-gasoline mixture. Use clean, fresh, regular unleaded gasoline, 85 octane minimum. When using blended fuel, do not use a blend with more than 10% ethanol. Under no circumstances should you use a blend with methanol. Refer to the engine’s operator manual for fuel recommendations when using blended fuel.

Check fuel hoses and clamps every 50 hours. Replace fuel hoses and clamps at first indication of wear or damage.

Keep fuel according to your local, state or federal regulations and instructions from your fuel supplier.

Never allow the tank to become empty.

9.7 CHARGE THE BATTERY __________________________________________________________

WARNING

Charge the battery in an area with good airflow. The battery can release hydrogen gas that is explosive. To prevent an explosion, keep any device that can cause sparks or flames away from the battery.

When the battery charger is turned on, to prevent injury, stay away from the battery. A battery that is damaged can cause an explosion.

Read the battery charger manual for specified instructions on the operation of the charger.

When possible, remove the battery from the mower before you charge the battery. If the battery is not sealed, check and make sure the level of the electrolyte is above the plates in all of the cells.

Make sure the battery charger is turned OFF, then connect the battery charger to the battery terminals as specified in the battery charger manual.

Always turn OFF the battery charger before you disconnect the battery charger from the battery terminals.

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9 MAINTENANCE

9.8 BATTERY ________________________________________________________________

Before you service the battery, make sure the ignition switch is in the OFF position and the key is removed.

CAUTION

When you service the battery, always use the tools with insulation, wear protective glasses and protective clothing.

Discard used batteries as shown in your local regulations.

WARNING

The battery contains corrosive acid. Prevent contact with the battery acid.

Always wash your hands after you service a battery.

WARNING

The battery posts, battery terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and other reproductive harm.

Tighten the battery cables on the battery terminals, To prevent corrosion, apply a layer of silicone dielectric grease to battery terminals and ends of cables. Keep the vent caps and battery terminal covers in position.

Before you do any welding operation on the mower, always disconnect the battery cables from the battery.

Confirm the battery polarity before you connect or you disconnect the battery cables.

When you install the battery, always connect the positive (RED) battery cable before the negative (BLACK) battery cable.

When you remove the battery, always disconnect the negative (BLACK) battery cable before the positive (RED) battery cable.

Jump-Starting the Mower

a Before you try to jump-start the mower, check the condition of the drained battery.

b Connect the positive (+) battery terminal of the charged battery to positive battery terminal of the drained battery.

c Connect the negative (–) battery terminal of the charged battery to frame of vehicle with the drained battery.

WARNING

The battery can release hydrogen gas that is explosive. To decrease the risk of an explosion, prevent sparks near the battery. Always connect the negative jumper cable to the frame of the mower with the drained battery.

d When the cables are connected, start the engine on the vehicle with the good battery, then start the mower.

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MAINTENANCE 9

FULL COLD

Vent Plug

Expansion Bottle

Filter

Filter Guard

9.9 DRIVE AXLE FLUID ________________________________________________________

Drain and replace the drive axle fluid and filter after the first 75 hours and each 400 hours.

Always replace the filter when you replace the drive axle fluid.

a Clean the area around the vent plug, expansion bottle cap and

filter to prevent dirt to enter the drive axle.

b Place a container capable of holding one gallon (4 liters) under the

drive axle.

c Remove the 3 filter guard screws, the filter guard and the filter.

Remove the cap from the expansion bottle. Allow the fluid to drain into the container.

d After the oil has drained, clean the filter mounting surface. Apply a

thin film of oil to the filter gasket and assemble the filter to the drive axle. Tighten the filter until the gasket contacts the filter base, then tighten an additional 3/4 to 1 turn. Only use your hand to tighten the filter.

e Assemble the filter guard and the guard screws. Torque the screws to 65 in. lb. (7.3 Nm). f Remove the vent plug from the drive axle. Add fluid to the expansion bottle until the oil level reaches the bottom

of the vent. Assemble the vent plug. Torque the plug to 180 in. lb. (20.3 Nm)

g Add oil until the fluid is at the FULL COLD line on the expansion bottle. Assemble the expansion bottle cap. h Repeat steps a~f for the other drive axle.

After the drive axle fluid is changed, the air must be removed from the drive axles. Lift the rear wheels off the ground. Support the mower with jack stands.

WARNING

Make sure the mower is parked on a solid and level surface. Never work on a mower that is supported only by the jack. Always use jack stands.

Put chocks in front of and behind the front wheels.

CAUTION

When you remove the air from the drive axles, the rear wheels will turn. To prevent injury, use caution to prevent contact with the wheels.

a Start the engine and disengage the parking brake. b Move the neutral release levers to the Neutral position. Slowly move the steering control levers from the Neutral

Position, to the full forward position, to the full reverse position and return the handles to the Neutral position. Repeat 5 to 6 times.

c Move the neutral release knobs to the Normal Operation position. Slowly move the steering control levers from

the Neutral Position, to the full forward position, to the full reverse position and return the handles to the Neutral position. Repeat 5 to 6 times.

d Stop the engine and add fluid to the expansion bottle until the fluid is at the FULL COLD line. e If needed, repeat steps a~d until the drive axles operate at normal noise levels and the tires move smoothly in the

forward and reverse directions.

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9 MAINTENANCE

9.10 TIRES ___________________________________________________________________

Keep the tires correctly inflated to increase tire life. Inspect the tread wear.

Check the tire pressure each day, while the tires are cool. Use an accurate low-pressure tire gauge.

Keep the rear tires inflated to 8-10 psi (0.55-0.69 BAR).

CAUTION

DO NOT try to put a tire on a rim unless you have the correct training, tools and experience. Incorrect mounting can cause an explosion which can cause injury.

9.11 WHEEL MOUNTING PROCEDURE____________________________________________

WARNING

Make sure the mower is parked on a solid and level surface. Never work on a mower that is supported only by the jack. Always use jack stands.

If only the front or back of the mower is lifted, put the chocks in front of and behind the wheels that are not lifted.

Remove dirt, grease and oil from the stud threads. Do not lubricate threads.

Put the wheel on the hub. Inspect the wheel to make sure of full contact between surface of wheel and hub.

Tighten all hardware with your fingers, then torque hardware in a criss-cross order. When possible, tighten nuts in the top position.

Check and torque hardware each day until torque is kept at 65-75 ft.lb. (88-102 Nm).

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MAINTENANCE 9

ROPS Pin

Hair Pin

Vertical Position

Folded Position

ROPS Pin

Hair Pin

9.12 FOLDING ROPS ACCESSORY _______________________________________________

A folding Roll Over Protective Structure (ROPS) accessory is available for this mower. If installed, inspect the ROPS periodically for loose hardware or damage.

CAUTION

Keep the ROPS hardware correctly fastened. Do not do welding operations, drill, change or bend the ROPS. Replace damaged ROPS. Do not try to correct a damaged ROPS.

Every 400 hours, inspect the seat, seat belt, ROPS mounting hardware and ROPS frame for damage. Replace all damaged parts immediately. All replacement parts for the ROPS must be as specified in the Parts Manual.

Check and torque all ROPS hardware every 100 hours.

Only operate the mower with the ROPS in the folded position on flat and level surfaces. Do not operate the mower with the ROPS in the folded position on the slopes, near sharp edges or near water. There is no roll over protection with

the ROPS in the folded position.

Folding the ROPS.

a Remove the hair pin and ROPS pin from both sides of the ROPS.

b Fold the ROPS toward the back of the mower.

c Assemble the ROPS pin and hair pin to lock the ROPS in the folded

position. Never wear the seat belt with the ROPS in the folded position.

WARNING

To prevent injury when you fold the ROPS, use caution to prevent your fingers crushed between moving and rigid parts of the ROPS.

Always wear the set belt with the ROPS frame in the vertical and locked position.

Never wear the seat belt with the ROPS in the folded position.

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9 MAINTENANCE

Normal

Blade

Bent

Blade

Grooved

Blade

Cracked

Blade

9.13 AIR COOLING SYSTEM ____________________________________________________

The engine on the mower is an air-cooled engine. Dirt and other objects can decrease the air flow and cause the engine to overheat, cause bad performance and decreased engine life.

NOTICE

Do not use water to clean the engine. Water can cause contamination in the fuel system. Use a brush or clean cloth to clean the engine.

Use a brush or a dry cloth to clean the air intake area.

Keep throttle linkage, springs and controls clean.

Use compressed air to remove debris from the engine oil cooler fins.

Refer to the Engine manual for additional information.

9.14 INSPECTING BLADES _____________________________________________________

Every 50 hours of operation or when the cutting unit is removed from the mower, carefully inspect the blades to make sure the blades are in good condition. Replace any blade that has

bends, grooves or cracks.

CAUTION

Be careful when you check blades to prevent pinching hands and fingers between ends of the blades.

WARNING

Never try to correct or repair a damaged blade. Always replaced a damaged blade.

The bends, grooves or cracks can cause a piece of the blade to become loose and be discharged from the mower. The broken blade pieces can cause injury to persons or property damage.

A bent blade can have a small crack that can increase and cause a piece of the blade to break. The bent blades can cause vibration and other stress on the mower.

The dust or sand particles can wear a dangerous groove in the blade between the air vanes and the flat part of the blade. The groove can quickly increase in size and allow a piece of the blade to break.

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MAINTENANCE 9

Maximum 1/2 in. (1.3 cm)

9.15 SHARPENING BLADES _____________________________________________________

Put a wooden block between the blade and cutting unit housing to prevent the blade to rotate.

WARNING

3Be careful and wear gloves when you check or service the

cutting unit blades. Use a brush to remove grass clippings from the blades. The blades are sharp and can cause injuries.

When you remove more than one half inch of material, the blade tip can break and be discharged from the mower. The broken blade pieces can cause injury to persons or property damage.

When you prepare or sharpen the blade, do not follow the original grind pattern. Grind new cutting edges at an angle. If the maximum of one half inch (1.3 cm) blade loss has occurred, do not sharpen more, replace the blade.

To prevent a blade that is not balanced, make sure an equal amount of material is removed from both ends of the blades. A blade that is not balanced will cause vibration and can damage the mower. Use a blade balancer to check the blade after you sharpen.

Torque center blade bolt to 115-130 ft.Lb. (156 to 176 Nm).

9.16 ELECTRICAL SYSTEM ____________________________________________________________

CAUTION

Always turn the ignition switch to the off position and remove the negative (BLACK) battery cable before you inspect or service the electrical system.

General precautions to decrease electrical problems are -

• Make sure that all the connections are clean and correctly fastened.

• Check the Interlock system and fuses at normal intervals. If the Interlock system does not operate correctly and you can not correct the problem, contact an authorized Dixie Chopper Dealer.

• Keep the wiring harness away from hot surfaces and moving parts.

• Check the battery and the charging system.

• Do not wash or pressure spray around electrical connections and components.

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9 MAINTENANCE

48 Inch (122 cm) Deck

Belt Routing

42 Inch (107 cm) Deck

Belt Routing

Deck Belt

Drive Axle Belt

Deck Belt

54 Inch (137 cm) Deck

Belt Routing

9.17 BELTS __________________________________________________________________

Replace the belts if they show signs of cuts, tears, burns caused by slipping or excessive wear.

To remove the belts, reduce belt tension by pulling the idler pulley away from the belt. Note the belt routing and remove the belts from the pulleys. The new belt must use the same belt routing.

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MAINTENANCE 9

9.18 CARE AND CLEANING _____________________________________________________

Clean the mower and cutting units after each use. To prevent damage to the engine, do not wash the mower with the engine in operation. When possible, clean the mower with compressed air.

NOTICE

Do not wash any part of the mower that is hot. Do not use the high-pressure spray or steam. Use cold water and automotive cleaners.

Do not use a pressure washer to clean the deck. Water can get in and under seals and cause damage to the equipment

Use compressed air to clean the engine and the engine oil cooler fins. Do not pressure wash the engine.

Clean the underside of the deck frequently.

Use clean water to wash your equipment.

NOTICE

To use salt water or drain water is known to cause rust and corrosion of metal parts and can cause damage or failure. This damage is not included by the factory warranty.

Do not spray water at the control panel, ignition switch or other electrical components.

Clean all plastic or rubber parts with a weak soap solution or use commercially available rubber cleaners.

Repair damaged metal surfaces and use Dixie Chopper touch-up paint. Apply wax to the equipment for maximum paint protection.

CAUTION

To prevent fire, clean grass clippings and dirt from the cutting unit, drives, engine and exhaust components.

WARNING

Never use your hands to clean cutting units. Use a brush to remove grass clippings from the blades. The blades are

sharp and can cause injuries.

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9 MAINTENANCE

9.19 MOWER STORAGE ________________________________________________________

General

• Clean the mower and lubricate. Repair and paint damaged or open metal.

• Inspect the mower, tighten all hardware, replace worn or damaged components.

• Clean the tires and keep the mower so that the load is not on the tires. If the mower is not on the jack stands, check tires at normal intervals and add air when needed.

• Keep the mower and all accessories clean, dry and protected from the elements. Never keep the mower near an open flame or spark which can cause ignition of the fuel or fuel vapors.

Battery

• Remove, clean and keep the battery in the upright position on a surface that is not metal in a cool dry location. To prevent increased battery discharge, do not keep the battery on a metal surface.

• Check and charge the battery every 60 to 90 days.

• Keep the battery in a cool dry location. To decrease the self discharge rate, the temperature must not be more than 80° F (27° C) or less than 20° F (-7° C).

Engine

• Change the engine oil and filter.

• Clean the outside surface of the engine. Paint bare metal or apply a thin layer of rust preventative oil.

• Add a fuel stabilizer to prevent the fuel to become stale. See your fuel supplier for instructions. Start the engine. Operate the engine for two minutes to circulate the stabilizer throughout the fuel system.

Cutting Units

• Completely clean the cutting units. Repair and paint any damaged or bare metal surfaces.

• Lubricate all grease fittings and friction points.

• Apply a thin layer of rust preventative oil to the sharpened edges of the blades.

CAUTION

The cutting unit blades can have sharp edges. To prevent injury, use caution when you service or hold the blade.

After Storage

• Check and install the battery. If necessary, charge the battery.

• Check or service the fuel filter and air cleaner

• Check the level of engine oil and drive axle fluid.

• Fill the fuel tank with fuel.

• Make sure the tires are correctly inflated.

• Remove all oil from the blades.

• Start the engine at 1/2 throttle. Allow the engine to become warm and lubricated.

WARNING

Never operate the engine without enough ventilation or in an enclosed area. The carbon monoxide in the exhaust

fumes can increase to dangerous levels.

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ADJUSTMENTS 10

10Adjustments

10.1 GENERAL PRECAUTIONS ________________________________________________________

WARNING

Before you clean, adjust or repair this equipment, push PTO switch to the OFF position, lower the cutting unit to the ground, turn on the parking brake switch, stop the engine and remove the key.

Make sure the mower is parked on a solid and level surface. Never work on a mower that is lifted only by the jack. Always use the jack stands.

A qualified technician must always do adjustments and maintenance. If the correct adjustments can not be made, contact your Dixie Chopper Dealer.

Inspect the equipment according to the maintenance schedule and keep complete records.

a Keep the equipment clean.

b Keep all moving parts correctly adjusted and lubricated.

c Replace worn or damaged parts before you operate the mower.

d Keep all fluids at the correct level.

e Keep the shields in position and all hardware tight.

f Keep the tires correctly inflated.

When you make the adjustments or repairs, do not wear jewelry or loose fitting clothing.

Refer to the illustrations in the Parts Manual for the removal and assembly of parts.

When you discard hazardous materials (batteries, lubricants, fuel, anti-freeze), follow your local, state or federalrecommended procedures.

10.2 STEERING LEVER ADJUSTMENT ____________________________________________

The position of the steering levers is adjustable to meet the needs of the operator. Adjust both steering levers to the same position.

To adjust the steering lever neutral position, loosen but do not remove the hardware that secures the steering lever to the steering bar. Move the steering lever to the desired position and tighten the hardware. Make sure that the steering bar does not move when you adjust the neutral position.

There are two height settings for the steering levers. To move the steering levers to the upper or lower position, remove both bolts, lift or lower the steering lever and assemble the bolts. Adjust the steering lever neutral position if needed.

Neutral Adjustment Range

Steering Lever

Upper Position

Steering Lever Hardware

Lower Position

Steering Bar

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10 ADJUSTMENTS

Speed Limit Screws

10.3 FORWARD SPEED LIMIT SCREWS ___________________________________________

The cutting quality is improved at speeds lower than the full transport speed of the mower. The local turf condition may require a different speed.

To adjust the forward speed, adjust the speed limit screws at the base of the steering control lever. Turn the screws to the right-side to decrease the forward speed. Turn the screws toward the left side to increase the forward speed.

Make certain the speed limit screws on both sides of the mower are set to the same adjustment.

Test drive the mower. If the mower steers to the right or left when both steering control levers are pushed all the way forward, tracking adjustment may be required.

• If the mower steers to the right, adjust the speed limit screw on the left side of the mower to decrease the left drive axle speed.

• If the mower steers to the left, adjust the speed limit screw on the right side of the mower to decrease the right drive axle speed.

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ADJUSTMENTS 10

4.6

8.8

10.9

12.9

10.4 TORQUE SPECIFICATION___________________________________________________

NOTICE

The torque values included in these charts are approximate and are for reference only. Use these torque values at your risk. Dixie Chopper is not responsible for any loss, claim or damage caused by these charts. Always use

caution with torque values.

Dixie Chopper uses Grade 5 (Inch) and Grade 8.8 (Metric) Plated bolts, unless a note is given. Always check the marks on the head of the bolts for the bolt grade. For tightening plated bolts, use the value given for lubricated.

AMERICAN NATIONAL STANDARD FASTENERS

SIZE UNITS

GRADE 5 GRADE 8

Lubricated Dry Lubricated Dry Lubri-

#6-32 in-lb (Nm) – 20 (2.3) – – 7/16-14 ft-lb (Nm) 37 (50.1) 50 (67.8) 53 (71.8) 70 (94.9)

#8-32 in-lb (Nm) – 24 (2.7) – 30 (3.4) 7/16-20 ft-lb (Nm) 42 (56.9) 55 (74.6) 59 (80.0) 78 (105)

#10-24 in-lb (Nm) – 35 (4.0) – 45 (5.1) 1/2-13 ft-lb (Nm) 57 (77.2) 75 (101) 80 (108) 107 (145)

#10-32 in-lb (Nm) – 40 (4.5) – 50 (5.7) 1/2-20 ft-lb (Nm) 64 (86.7) 85 (115) 90 (122) 120 (162)

#12-24 in-lb (Nm) – 50 (5.7) – 65 (7.3) 9/16-12 ft-lb (Nm) 82 (111) 109 (148) 115 (156) 154 (209)

1/4-20 in-lb (Nm) 75 (8.4) 100 (11.3) 107 (12.1) 143 (16.1) 9/16-18 ft-lb (Nm) 92 (124) 122 (165) 129 (174) 172 (233)

1/4-28 in-lb (Nm) 85 (9.6) 115 (13.0) 120 (13.5) 163 (18.4) 5/8-11 ft-lb (Nm) 113 (153) 151 (204) 159 (215) 211 (286)

5/16-18 in-lb (Nm) 157 (17.7) 210 (23.7) 220 (24.8) 305 (34.4) 5/8-18 ft-lb (Nm) 128 (173) 170 (230) 180 (244) 240 (325)

5/16-24 in-lb (Nm) 173 (19.5) 230 (26.0) 245 (27.6) 325 (36.7) 3/4-10 ft-lb (Nm) 200 (271) 266 (360) 282 (382) 376 (509)

3/8-16 ft-lb (Nm) 23 (31.1) 31 (42.0) 32 (43.3) 44 (59.6) 3/4-16 ft-lb (Nm) 223 (302) 298 404 315 (427) 420 (569)

3/8-24 ft-lb (Nm) 26 (35.2) 35 (47.4) 37 (50.1) 50 (67.8) 7/8-14 ft-lb (Nm) 355 (481) 473 (641) 500 (678) 668 (905)

METRIC FASTENERS

SIZE UNITS Non Critical

Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry

M4 Nm (in-lb)––––––3.83 (34)5.11 (45)2.0 (18)

M5 Nm (in-lb) 1.80 (16) 2.40 (21) 4.63 (41) 6.18 (54) 6.63 (59) 8.84 (78) 7.75 (68) 10.3 (910 4.0 (35)

M6 Nm (in-lb) 3.05 (27) 4.07 (36) 7.87 (69) 10.5 (93) 11.3 (102) 15.0 (133) 13.2 (117) 17.6 (156) 6.8 (60)

M8 Nm (in-lb) 7.41 (65) 9.98 (88) 19.1 (69) 25.5 (226) 27.3 (241) 36.5 (323) 32.0 (283) 42.6 (377) 17.0 (150)

M10 Nm (ft-lb) 14.7 (11) 19.6 (14) 37.8 (29) 50.5 (37) 54.1 (40) 72.2 (53) 63.3 (46) 84.4 (62) 33.9 (25)

M12 Nm (ft-lb) 25.6 (19) 34.1 (25) 66.0 (48) 88.0 (65) 94.5 (70) 125 (92) 110 (81) 147 (108) 61.0 (45)

M14 Nm (ft-lb) 40.8 (30) 54.3 (40) 105 (77) 140 (103) 150 (110) 200 (147) 175 (129) 234 (172) 94.9 (70)

GRADE 5 GRADE 8

Dry Lubri-

cated

Dry

Fasteners into Aluminum

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11 PROBLEM SOLVING

11Problem Solving

11.1 GENERAL________________________________________________________________

The problem solution chart lists basic problems that can occur during start and operation of the mower. For complete information about the hydraulic and electrical systems, contact your Dixie Chopper Dealer.

Symptoms Possible Causes Action

Engine will not start.

Engine hard to start or runs poorly.

Engine stops. 1. Fuel tank empty. 1. Fill with fresh fuel and bleed fuel lines.

Engine overheating.

Battery not holding charge.

Cutting unit does not cut evenly.

1. Parking brake disengaged,

1. Check Interlock System and start-up procedure. PTO switch ON or steering levers out of neutral position.

2. Battery low on charge or

2. Inspect condition of battery and battery connections. defective.

3. Fuel tank empty or dirty. 3. Fill with fresh fuel. Change fuel filter.

4. Fuse blown. 4. Replace fuse.

5. Relay(s) defective. 5. Test and replace relay.

1. Fuel level low, fuel or fuel

1. Fill with fresh fuel. Change fuel filter. filter dirty.

2. Air cleaner dirty. 2. Inspect, clean and/or replace air filter.

3. Engine problem. 3. Consult engine manual.

2. Interlocks not set before leaving operator’s position.

2. Put steering levers in neutral position, engage parking brake and set PTO switch to OFF.

1. Air intake restricted. 1. Clean engine cooling air intake and fins.

1. Loose or corroded battery

1. Inspect and clean terminals.

terminals.

2. Low electrolyte. 2. Refill to correct level.

3. Charging system defective. 3. See engine manual.

1. Deck not level. 1. Check that decks are level. Check and adjust cutting height.

2. Engine speed too low. 2. Check engine speed with throttle in its fast position.

3. Mow speed not adjusted for

3. Adjust mow speed for best cut.

turf conditions.

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NOTES 12

12Notes

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12 NOTES

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NOTES 12

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Dixie Chopper is a registered trademark of Jacobsen Professional Lawn Care Inc.

any and all use and/or reproductions are strictly prohibited.

DIXIE CHOPPER

6302 E. County Road 100 N.

Coatesville, Indiana 46121

www.dixiechopper.com

Printed In USA

Dixie Chopper 2348KO, 2348BR, 2342KO, 2354KO, 2248KW Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual