Dixon D25K48YT, 435068 User Manual

D25K48YT

Operator's Manual

435068 02.10.10 AP Printed in the U.S.A.

SAFETY RULES

Safe Operation Practices for Ride-On Mowers

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

WARNING: In order to prevent ac ci den tal starting when setting up, trans port ing, ad just ing or making repairs, al ways dis con nect spark plug wire and place wire where it can not contact spark plug.

WARNING: Do not coast down a hill in neutral, you may lose control of the tractor.

WARNING: Tow only the attachments that are rec om mend ed by and comply with spec i fi ca tions of the man u fac tur er of your tractor. Use common sense when towing. Operate only at the low est possible speed when on a slope. Too heavy of a load, while on a slope, is dan ger ous. Tires can lose trac tion with the ground and cause you to lose control of your tractor.

WARNING

Engine exhaust, some of its con stit u ents, and cer tain vehicle com po nents contain or emit chem i cals known to the State of Cal i for nia to cause can cer and birth de fects or oth er re pro duc tive harm.

WARNING

Battery posts, terminals and related ac ces so ries contain lead and lead compounds, chem i cals known to the State of Cal i for nia to cause can cer and birth defects or oth er re pro duc tive harm. Wash hands after handling.

I. GENERAL OPERATION

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

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

• Only allow responsible adults, who are familiar with the in struc tions, to operate the machine.

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

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

• Never carry passengers.

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

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

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

• Slow down before turning.

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

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

• Operate machine only in daylight or good artificial light.

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

• Watch for traffic when operating near or crossing road ways.

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

• Always wear eye protection when operating machine.

• Data indicates that operators, age 60 years and above, are involved in a large percentage of riding mowerrelated injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect them selves and others from serious injury.

• Follow the manufacturer's recommendation for wheel weights or counterweights.

• Keep machine free of grass , leaves or other debris build-up which can touch hot exhaust / engine parts and burn. Do not allow the mower deck to plow leaves or other debris which can cause build-up to occur. Clean any oil or fuel spillage before operating or storing the machine. Allow machine to cool before storage.

II. SLOPE OPERATION

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

• Mow up and down slopes, not across.

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

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

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

Always keep the machine in gear when going down

slopes. Do not shift to neutral and coast downhill.

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

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

• Use extra care while operating machine with grass catchers or other at tach ments; they can affect the stability of the machine. Do no use on steep slopes.

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

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

SAFETY RULES

Safe Operation Practices for Ride-On Mowers

III. CHILDREN

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the ma chine and the mowing activity. Never assume that children will remain where you last saw them.

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

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

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

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

• Never allow children to operate the machine.

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

IV. TOWING

• Tow only with a machine that has a hitch designed for towing. Do not attach towed equipment except at the hitch point.

• Follow the manufacturer's recommendation for weight limits for towed equipment and towing on slopes.

• Never allow children or others in or on towed equipment.

• On slopes, the weight of the towed equipment may cause loss of traction and loss of control.

• Travel slowly and allow extra distance to stop.

V. SERVICE

SAFE HANDLING OF GASOLINE

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

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

• Use only approved gasoline container.

• Never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling.

• Never fuel the machine indoors.

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

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

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

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

• If fuel is spilled on clothing, change clothing immediately.

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

GENERAL SERVICE

• Never operate machine in a closed area.

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

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

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

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

• Never make any adjustments or repairs with the engine run ning.

• Check grass catcher components and the discharge chute frequently and replace with manufacturer's recommended parts, when necessary.

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

• Check brake operation frequently. Adjust and service as required.

• Maintain or replace safety and instruction labels, as necessary.

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

• Never carry passengers.

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

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

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

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

• Mow up and down slopes (15° Max), not across.

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

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

• If machine stops while going uphill, disengage blades, shift into reverse and back down slowly.

• Do not turn on slopes unless necessary, and then, turn slowly and gradually downhill, if possible.

PRODUCT SPECIFICATIONS

Gasoline Capacity 3 Gallons and type: Unleaded Regular

Oil Type (API-SG-SL): SAE 10W30 (above 32°F) SAE 5W-30 (below 32°F)

Oil Capacity: 64 oz Spark Plug: Champion RC12YC

(Gap: .030") Ground Speed (MPH): Forward: 0 - 5.2

Reverse: 0 - 2.9 Charging System: 15 AMPS @ 3600 RPM Battery: AMP/HR: 28

MIN. CCA: 230 Case Size: U1R

Blade Bolt Torque: 45-55 FT. LBS.

CONGRATULATIONS on your purchase of a new tractor. It has been designed, engineered and manu fac tured to give you the best possible dependability and performance.

Should you experience any problem you cannot easily remedy, please contact your nearest authorized servicecenter/ de part ment We have competent, well-trained tech ni cians and the proper tools to service or repair this tractor.

Please read and retain this manual. The instructions will enable you to assemble and maintain your tractor prop erly. Always observe the “SAFETY RULES”.

CUSTOMER RESPONSIBILITIES

• Read and observe the safety rules.

• Follow a regular schedule in maintaining, caring for and using your tractor.

• Follow the instructions under “Maintenance” and “Stor age” sec tions of this manual.

WARNING: This tractor is equipped with an internal com bus tion engine and should not be used on or near any un im proved forest-covered, brush-covered or grass-cov ered land unless the en gine’s exhaust system is equipped with a spark arrester meeting ap pli ca ble local or state laws (if any). If a spark arrester is used, it should be maintained in effective working order by the operator.

In the state of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands.

A spark arrester for the muffler is available through your nearest authorized service center/department (See RE PAIR PARTS section of this manual).

TABLE OF CONTENTS

SAFETY RULES .........................................................2-3

PRODUCT SPECIFICATIONS ....................................... 4

CUSTOMER RESPONSIBILITIES ................................. 4

ASSEMBLY ................................................................. 6-9

OPERATION ...........................................................10-16

MAINTENANCE SCHEDULE ...................................... 17

MAINTENANCE ..................................................... 17-20

SERVICE AND AD JUST MENTS ............................ 21-25

STORAGE .................................................................... 26

TROU BLE SHOOT ING ............................................ 27-28

WARRANTY ................................................................. 30

UNASSEMBLED PARTS

(5) Large Retainer

Springs - 7/16

(2) Smaller Retainer

Springs - 5/16

Mower

(1) 3/4 O.D. Washers

(5) 1-3/16 O.D. Washers

Mower Front Wheel

(1) Wheel

(1) Shoulder Bolt

(1) Oil Drain Tube For Future Use

Keys

(1) 1-1/4 O.D. Washer

(1) Locknut

3/8-16

Slope Sheet

(1) Anti-Sway Bar

(2) Rear Lift Link

Assemblies

(2) Keys

ASSEMBLY

Your new tractor has been assembled at the factory with exception of those parts left unassembled for shipping purposes. To ensure safe and proper operation of your tractor all parts and hardware you assemble must be tightened securely. Use the correct tools as necessary to ensure proper tightness.

TOOLS REQUIRED FOR ASSEMBLY

A socket wrench set will make assembly easier. Stan dard wrench sizes are listed.

(2) 7/16" wrenches Utility knife (1) 1/2" wrench Tire pressure gauge (1) 3/4" wrench Pliers (1) 3/4" socket w/drive ratchet

When right or left hand is mentioned in this man ual, it means when you are in the operating po si tion (seated be hind the steer ing wheel).

TO REMOVE TRACTOR FROM CARTON

UNPACK CARTON

• Remove all accessible loose parts and parts cartons from carton .

• Cut along dotted lines on all four panels of carton. Remove end panels and lay side panels flat.

• Remove mower and packing materials.

• Check for any additional loose parts or cartons and remove.

BEFORE REMOVING TRACTOR FROM SKID

TO CHECK BATTERY (See Fig. 1)

• Lift hood to raised position.

NOTE: If this battery is put into service after month and year indicated on label (label is located between terminals) charge battery for minimum of one hour at 6-10 amps. (See "BATTERY" in Maintenance section of this manual for charging instructions).

• For battery and battery cable installation see "REPLACING BATTERY" in the "Service and Adjustments" section in this manual.

ADJUST SEAT (See Fig. 2)

• Sit in seat.

• Lift up adjustment lever (A) and slide seat until a comfortable position is reached which allows you to press clutch/brake pedal all the way down.

• Release lever to lock seat in position.

Fig. 2

NOTE: You may now roll your tractor off the skid. Follow the

instructions below to remove the tractor from the skid.

WARNING: Before start ing, read, un der stand and fol low all in struc tions in the Op er a tion section of this man u al. Be sure tractor is in a well-ventilated area. Be sure the area in front of tractor is clear of other peo ple and objects.

TO ROLL TRACTOR OFF SKID (See Op er a tion section for location and function of con trols)

• Raise attachment lift lever to its highest po si tion.

• Release parking brake by de press ing clutch/brake

ped al.

• Place freewheel control in "trans mis sion dis en gaged"

position (See “TO TRANS PORT” in the Op er a tion section of this manual).

• Roll tractor forward off skid. Continue with the instructions that follow.

TO INSTALL MOWER AND BLADE DRIVE BELT (See Figs. 3 - 16)

1. SET PARKING BRAKE LEVER AND LOWER AT-

TACHMENT LIFT LEVER (See Fig. 3 and 4)

• Depress clutch/brake pedal all the way down and hold.

• Pull parking brake lever up and hold, re lease pres sure

from clutch/brake pedal, then release parking brake lever. Pedal should re main in brake position. Ensure parking brake will hold tractor secure.

LABEL

Fig. 1

PARKING BRAKE LEVER

Fig. 3

CAUTION: Lift lever is spring loaded. Have a tight grip on lift lever, lower it slowly and engage in lowest position. Lift lever is located on left side of fender.

LIFT LEVER

Fig. 4

ASSEMBLY

4. SLIDE MOWER UNDER TRACTOR (See Fig. 8)

• Bring belt forward and check belt for proper routing in all mower pulley grooves.

NOTE: Be sure mower side suspension arms (A) are pointing forward before sliding mower under tractor.

• Slide mower under tractor until it is centered under tractor.

2. ASSEMBLE FRONT GAUGE WHEEL (W) TO FRONT OF MOWER (See Fig. 5)

H. FRONT MOWER

BRACKET

W. FRONT GAUGE

WHEEL

X. SHOULDER

BOLT

Y. 1-1/4 O.D.

WASHER

Z. 3/8-16 LOCKNUT

Fig. 5

3. TURN STEERING WHEEL LEFT AND POSITION

MOWER (See Fig. 6)

• Turn steering wheel to the left as far as it will go and

position mower on right side of tractor with deflector shield (Q) to the right.

FRONT

ENGINE

TRANSAXLE

02965

BACK

Q. DEFLECTOR

SHIELD

Fig. 6

A. MOWER SIDE

02965

SUSPENSION ARMS

Q. DEFLECTOR

SHIELD

Fig. 8

5. INSTALL ANTI-SWAY BAR (S) (IF EQUIPPED) (See Fig. 9 - 11)

ANTI-SWAY BAR (S)

TOWARDS TOWARDS TRANSAXLE MOWER DECK

90° END INTEGRATED WASHER END

Fig. 9

• From right side of mower, first insert 90° end of anti-sway bar (S) into hole in transaxle bracket (T), located near left rear tire in front of transaxle.

NOTE: Flashlight may be helpful.

A. MOWER SIDE SUSPENSION

ARMS

B. RETAINER SPRING C. REAR LIFT LINK(S) D. RIGHT SIDE REAR MOWER

BRACKET E. FRONT LIFT LINK ASSEMBLY F. FRONT SUSPENSION BRACKET H. FRONT MOWER BRACKET I. LEFT SIDE REAR MOWER

BRACKET K. BELT TENSION ROD L. LOCKING BRACKET M. ENGINE CLUTCH PULLEY Q. DEFLECTOR SHIELD S. ANTI-SWAY BAR W. FRONT GAUGE WHEEL

Fig. 7

ANTI-SWAY BAR

PLACE 90° END INTO HOLE

(S) LOCATION

ASSEMBLY

TRANSAXLE

BRACKET (T)

LOCATED

BETWEEN REAR

TIRES

7. ATTACH REAR LIFT LINKS (C) (See Fig. 13)

• Insert rod end of rear lift link (C) into hole (U) in tractor lift shaft suspension arm and pivot link down to mower.

• Lift rear corner of mower and position slot in link assembly over pin on rear mower bracket (D) and secure with large washer and large retainer spring.

• Repeat on opposite side of tractor.

PLACE 90° END INTO HOLE

S. ANTI-SWAY BAR T. TRANSAXLE BRACKET

Fig. 10

NOTE: Depending on model, bracket (T) may be differ-

ent than shown but hole for anti-sway bar will be in same position/location.

• Pivot the integrated washer end of anti-sway bar (S) towards mower deck bracket on right side of mower. Insert integrated washer end of bar into hole in rear mower bracket (D). Move mower as needed to insert integrated washer end of bar into rear mower bracket (D).

• Secure with small washer and small retainer spring as shown.

C. REAR LIFT LINK(S) D. RIGHT SIDE REAR

MOWER BRACKET

U. HOLE

Fig. 13

8 ATTACH FRONT LINK (E) (See Fig. 14)

• Turn steering wheel to position wheels straight forward.

• From front of tractor, insert rod end of front link (E) through front hole in tractor front suspension bracket (F).

• Move to left side of mower and and insert large retainer spring (G) through hole in front link (E) behind front suspension bracket (F).

• Insert other end of link (E) into hole in front mower bracket (H) and secure with washer and small retainer spring (J).

NOTE: Requires deck lifting.

FRONT LINK

LOCATION

D. RIGHT SIDE

REAR MOWER

BRACKET S. ANTI-SWAY BAR T. TRANSAXLE

BRACKET

Fig. 11

6. ATTACH MOWER SIDE SUSPENSION ARMS (A) TO CHASSIS (See Fig. 12)

• Position front hole in side suspension arm (A) over pin on outside of tractor chassis and secure with large washer and large retainer spring (B).

• Repeat on opposite side of tractor.

A. MOWER SIDE

SUSPENSION ARMS

B. RETAINER

SPRING

D. RIGHT

SIDE REAR

MOWER BRACKET

Fig. 12

E. FRONT LIFT LINK ASSEMBLY F. FRONT SUSPENSION BRACKET G. LARGE RETAINER SPRING H. FRONT MOWER BRACKET J. SMALL RETAINER SPRING M. ENGINE CLUTCH PULLEY

Fig. 14

ASSEMBLY

9 INSTALL BELT ON ENGINE CLUTCH PULLEY (M)

(See Fig. 7 & 15)

• Disengage belt tension rod (K) from locking bracket (L).

• Install belt onto engine clutch pulley (M).

✓CHECKLIST

BEFORE YOU OPERATE YOUR NEW TRAC TOR, WE WISH TO ASSURE THAT YOU RECEIVE THE BEST PERFORMANCE AND SATISFACTION FROM THIS QUALITY PRODUCT.

PLEASE REVIEW THE FOLLOWING CHECKLIST:

✓ All assembly instructions have been com plet ed. ✓ No remaining loose parts in carton. ✓ Battery is properly prepared and charged.

M. ENGINE

CLUTCH PULLEY

Fig. 15

IMPORTANT: Check belt for proper routing in all mower

pulley grooves and under mandrel covers.

• Engage belt tension rod (K) on locking bracket (L).

CAUTION: Belt tension rod is spring loaded. Have a tight grip on rod and engage slowly.

• Raise attachment lift lever to highest position.

• If necessary, adjust gauge wheels before op er at ing mower as shown in the Operation section of this manual.

MOWER DRIVE BELT INSTALLATION

Follow procedure described in “TO REPLACE MOWER BLADE DRIVE BELT ” in the "Service and Adjustments" section of this manual.

CHECK TIRE PRESSURE

The tires on your tractor were overinflated at the factory for shipping purposes. Correct tire pressure is important for best cutting performance.

• Reduce tire pressure to PSI shown on tires.

CHECK DECK LEVELNESS

For best cutting results, mower housing should be properly leveled. See “TO LEVEL MOWER HOUSING” in the Service and Adjustments section of this manual.

CHECK FOR PROPER POSITION OF ALL BELTS

See the figures that are shown for replacing motion and mower blade drive belts in the Service and Adjustments sec tion of this manual. Verify that the belts are routed cor rect ly.

✓ Seat is adjusted comfortably and tightened securely. ✓ All tires are properly inflated. (For shipping purposes,

the tires were overinflated at the factory).

✓ Be sure mower deck is properly leveled side-to-side/

front-to-rear for best cutting results. (Tires must be properly inflated for leveling).

✓ Check mower and drive belts. Be sure they are routed

properly around pulleys and inside all belt keepers.

✓ Check wiring. See that all connections are still secure

and wires are properly clamped.

✓ Before driving tractor, be sure free wheel control is in

“transmission engaged” position (see “TO TRANS PORT” in the Operation section of this man u al).

WHILE LEARNING HOW TO USE YOUR TRACTOR, PAY EXTRA ATTENTION TO THE FOLLOWING IMPORTANT ITEMS:

✓ Engine oil is at proper level. ✓ Fuel tank is filled with fresh, clean, regular unleaded

gasoline.

✓ Become familiar with all controls, their location and

function. Operate them before you start the engine.

✓ Be sure brake system is in safe operating condition. ✓ Be sure Operator Presence System and Reverse Op-

eration System (ROS) are working properly (See the Operation and Maintenance sections in this manual).

✓ It is important to purge the transmission before op er at-

ing your tractor for the first time. Follow proper starting and transmission purging instructions (See “TO START EN GINE” and “PURGE TRANSMISSION” in the Op er a tion section of this manual).

CHECK BRAKE SYSTEM

After you learn how to operate your tractor, check to see that the brake is operating properly. See “TO CHECK BRAKE” in the Service and Adjustments section of this manual.

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