Dixon SpeedZTR 965883101, SpeedZTR 42BF, SpeedZTR 54BF, SpeedZTR 46BF, SpeedZTR 966496201 User Manual

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Operator Manual
SPEEDZTR 42BF / 966496201
SPEEDZTR 42 / 966496301 SPEEDZTR 46BF / 965883101 SPEEDZTR 54BF / 965883201
Please read the operator’s manual carefully and make sure you
understand the instructions before using the machine.
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Note that no legal demands can be placed based on the information contained in these instructions.
Use only original parts for repairs. The use of other parts voids the warranty.
Do not modify or install non-standard equipment to the unit without consent from the manufacturer. Modications to the unit may cause unsafe operations or damage the unit.
When this product is worn out and no longer used, it should be returned to the reseller or other party for recycling.
©2009 HTC. All rights reserved.
Beatrice, NE. Printed in U.S.A.
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TABLE OF CONTENTS
INTRODUCTION ........................................................5
Driving and Transport on Public Roads ................5
Towing ...................................................................5
Operating ..............................................................5
Good Service.........................................................6
SYMBOLS AND DECALS ..........................................7
SAFETY ......................................................................9
Safety Instructions .................................................9
Personal Safety Equipment .................................11
Slope Operation ..................................................11
Safe Handling of Gasoline...................................13
General Maintenance ..........................................14
Transport .............................................................16
Towing .................................................................16
Spark Arrestor .....................................................16
CONTROLS .............................................................17
Control Locations ................................................17
Motion Control Levers .........................................18
Seat Adjustment Lever ........................................19
Bypass Linkage ...................................................19
Fuel Tank .............................................................20
Ignition Switch .....................................................21
Choke Control ......................................................21
Throttle Control ....................................................21
Blade Switch........................................................22
Parking Brake ......................................................22
Cutting Height Adjuster .......................................22
Fuses ...................................................................23
Fuel Shut Off Valve ..............................................23
OPERATION ............................................................24
Training ................................................................24
Steering ...............................................................24
Before Starting.....................................................25
Starting the Engine ..............................................25
Weak Battery .......................................................28
Jumper Cables ..............................................28
Running ...............................................................29
Operating On Hills ...............................................30
Mowing Tips ........................................................31
Stopping the Engine ............................................32
Manual Transport .................................................33
MAINTENANCE .......................................................34
Maintenance Schedule........................................34
Battery .................................................................36
Safety System ......................................................37
Tire Pressures ......................................................37
Parking Brake ......................................................38
Deck Belt .............................................................38
Pump Belt ............................................................39
Cutting Blades .....................................................40
Blade replacement ........................................40
Anti-scalp Rollers ................................................40
Adjusting the Mower Deck ..................................41
Deck Leveling ...............................................41
Caster Wheels .....................................................42
Hardware .............................................................42
Cleaning ..............................................................42
LUBRICATION .........................................................43
Wheel and Deck Zerks ........................................44
Front Wheel Mount ........................................44
Front Wheel Bearings ....................................44
Deck Spindles ...............................................44
TROUBLE SHOOTING ............................................45
Winter Storage .....................................................47
Service ................................................................47
SCHEMATIC ............................................................48
TECHNICAL DATA ...................................................49
Torque Specications ..........................................49
CONFORMITY CERTIFICATES ................................54
WARRANTY .............................................................55
SERVICE JOURNAL ................................................56
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WARNING!
Failure to follow cautious operating practices can result in serious injury to the operator or other persons. The owner must understand these instructions, and must allow only trained persons who understand these instructions to operate the mower.
Each person operating the mower must be of sound mind and body and must not be under the inuence of any mind altering substance.
WARNING!
Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
WARNING!
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
Page 5

INTRODUCTION

Congratulations
Thank you for purchasing a Dixon ride-on mower. This machine is built for superior efciency to rapidly mow primarily large areas. A control panel easily accessible to the operator and a hydrostatic transmission regulated by steering controls both contribute to the machine’s performance.
This manual is a valuable document. Read the contents carefully before using or servicing the machine. The following of instructions (use, service, maintenance, etc.) by all who operate this machine is important for the safety of the operator and others. It can also considerably increase the life span of the machine and increase its resale value.
If you sell your machine, be sure to give the operator’s manual to the new owner.
The nal chapter of this operator’s manual provides a Service Journal. Ensure that service and repair work are documented. A well-kept service journal reduces service costs for the maintenance and affects the machine’s resale value. Please contact your dealer for more information. Take the operator’s manual along when the machine is taken to your dealer for service.
General
In this operator’s manual, left and right, backward and forward are used in relation to the machine’s normal driving direction.
Continuous dedication to improve our products require that specications and design are subject to change without notice.

Driving and Transport on Public Roads

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

Towing

If machine is equipped with a tow hitch, use extreme caution when towing. Never allow children or others in or on the towed equipment. Make wide turns to avoid jack-kning. Travel slowly and allow extra distance to stop.
Do not tow on sloped ground. The weight of the towed equipment may cause loss of traction and loss of control.
Follow the manufacturer's recommendation for weight limits for towed equipment. Do not tow near ditches, canals, and other hazards.

Operating

This machine is constructed only for mowing grass on lawns and even ground without obstacles such as stones, tree stumps, etc. The machine can also be used for other tasks when equipped with special accessories provided by the manufacturer. Operating instructions for the accessories are provided with delivery. All other types of uses are incorrect. The manufacturer’s directions concerning operation, maintenance, and repairs must be carefully followed.
Lawn mowers and all power equipment, can be potentially dangerous if used improperly. Safety requires good judgement, careful use in accordance with these instructions and common sense.
The machine must only be operated, maintained, and repaired by persons familiar with the machine’s special characteristics and who are also knowledgeable about the safety instructions. Use only approved repair parts to maintain this machine.
Accident prevention regulations, other general safety regulations, occupational safety rules, and trafc regulations must be followed without fail.
Unauthorized modications to the design of the machine may absolve the manufacturer from liability for any resulting personal injury or property damage.
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INTRODUCTION

Good Service

Dixon’s products are sold only in specialized retail stores with complete service. This ensures that you as a customer receive only the best support and service. Before the product is delivered, the machine has, for example, been inspected and adjusted by your
retailer. See the certicate in the Service Journal in this operator’s manual.
When you need spare parts or support in service questions, warranty issues, etc., please consult the following professional:
This Operator’s Manual belongs to the machine with the manufacturing number:
Manufacturing Number
The machine’s manufacturing number can be found on the printed plate afxed to the right in the engine compartment. Stated on the plate, from the top are:
The machine’s type designation (I.D.).• The manufacturer’s type number (Model).• The machine’s serial number (Serial no.)
Please have the type designation and serial number available when ordering spare parts.
The engine’s manufacturing number is stamped on one of the valve covers.
The plate states:
The engine’s model.• The engine’s type.• Code
Please have these available when ordering spare parts.
Engine Transmission
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SymBOLS AND DECALS

These symbols are found on the machine and in the operator’s manual.
Study them carefully so that you know what they mean.
WARNING!
Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx.
Used in this publication to notify the reader of a risk of personal injury or death, particularly if the reader should neglect to follow instructions given in the manual.
IMPORTANT INFORMATION
Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxx.
Used in this publication to notify the reader of a risk of material damage, particularly if the reader should neglect to follow instructions given in the manual. Used also when there is a potential for misuse or misassembly.
R N
Reverse Neutral Fast Slow Choke Fuel
Warning! Parking Brake CE conformity Warning! Rotating blades, Do not touch parts marking. Only for keep away from the European market discharge deck
Battery acid is corrosive, explosive and ammable Do not stand here
Noise emissions to the surroundings in accordance with the European Union’s directive. The machine’s emission is stated in the chapter TECHNICAL DATA and on the decals.
Only machines for European market
Use protective glasses Use protective gloves
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SymBOLS AND DECALS
Read Shut off engine and Keep a safe Use on slopes No passengers Operator’s remove key before distance from no greater Manual performing any the machine than 10° maintenance or repair work
Whole body Severing of ngers Do not open or Careful backing up, Careful going exposure to and toes remove safety watch for other forward, watch for thrown objects shields while people other people engine is running
Moving sharp blades under cover
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SAFETy

Safety Instructions

These instructions are for your safety. Read them carefully.
WARNING!
This symbol means that important safety instructions need to be emphasized. It concerns your safety.
IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING
OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.
General Operation
Read, understand, and follow all instructions on • the machine and in the manual before starting.
Do not put hands or feet near rotating parts or • under the machine. Keep clear of the discharge opening at all times.
Only allow responsible adults, who are familiar • with the instructions, to operate the machine.
Clear the area of objects such as rocks, toys, wire, • etc., which could be picked up and thrown by the blades.
Be sure the area is clear of bystanders before • operating. Stop machine if anyone enters the area.
Never carry passengers. The machine is only • intended for use by one person.
Do not mow in reverse unless absolutely • necessary. Always look down and behind before and while backing.
Never direct discharged material toward anyone. • Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blades when crossing gravel surfaces.
Do not operate machine without the entire grass • catcher, discharge guard, or other safety devices in place and working
Slow down before turning.• Never leave a running machine unattended.
Always turn off blades, set parking brake, stop engine, and remove keys before dismounting.
Disengage blades when not mowing. Shut • off engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher, or unclogging the discharge guard.
Operate machine only in daylight or good articial • light.
Do not operate the machine while under the • inuence of alcohol or drugs.
Read the operator’s manual before starting the machine
Clear the area of objects before mowing
8011-512
8011-513
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SAFETy
Watch for trafc when operating near or crossing • roadways.
Use extra care when loading or unloading the • machine into a trailer or truck.
Always wear eye protection when operating • machine.
Data indicates that operators age 60 years and • above are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.
Follow the manufacturer’s recommendation for • wheel weights or counterweights.
Anyone who operates this machine must rst read • and understand this Operation Manual. Local laws may regulate the age of the user.
Keep machine free of grass, leaves or other • debris buildup which can touch the hot exhaust or engine parts and burn. Do not allow the mower deck to plow leaves or other debris, causing buildup to occur.
Clean any oil or fuel spillage before operating or • storing the machine.
Allow machine to cool before storage.
8011-520
Never take passengers
WARNING!
Engine exhaust and certain vehicle components contain or emit chemicals considered to cause cancer, birth defects, or other reproductive system damage. The engine exhaust contains carbon monoxide, which is an odorless, colorless, poisonous gas. Do not use the machine in enclosed spaces.
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Personal Safety Equipment

WARNING!
When using the machine, approved personal protective equipment (shown in illustrations) shall be used. Personal protective equipment cannot eliminate the risk of injury but it will reduce the degree of injury if an accident does happen. Ask your retailer for help in choosing the right equipment.
Make sure that you have rst aid equipment close • at hand when using the machine.
Never use the machine when barefoot.• Always wear protective shoes or boots, preferably
with steel toe caps. Always wear approved protective glasses or a full
visor when assembling or driving. Always wear gloves when handling the blades.• Never wear loose clothing that can get caught in
moving parts. Use ear protectors to avoid damage to hearing.
SAFETy

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 (10 degrees maximum), • not across.
Watch for holes, ruts, bumps, rocks, or other • hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.
Choose a low ground speed so that you will not • have to stop while on the slope.
Do not mow on wet grass. Tires may lose traction.• Avoid starting, stopping, or turning on a slope. If
the tires lose traction, disengage the blades and proceed slowly straight down the slope.
Keep movement on the slopes slow and gradual. • Do not make sudden changes in speed or direction, which could cause machine to roll over.
Use extra care while operating machine with • grass catchers or other attachments; they can affect the stability of the machine.
Do not use on steep slopes.• Do not try to stabilize the machine by putting a
foot on the ground. Do not mow near drop-offs, ditches, or
embankments. The machine could suddenly roll over if a wheel is over the edge or if the edge caves in.
8011-670a
Personal protective equipment
6003-004
Mow up and down, not side to side
WARNING!
Do not drive up or down hills with slopes greater than 10 degrees. Do not drive across any slopes.
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SAFETy
Children
Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain out of the path of danger.
Keep children out of the mowing area and in the • watchful care of a responsible adult other than the operator.
Be alert and turn machine off if a child enters the • area.
Before and while backing, look behind and down • for small children.
Never carry children, even with the blades shut • off. They may fall off and be seriously injured or interfere with safe machine operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine.
Never allow children to operate the machine.• Use extra care when approaching blind corners,
shrubs, trees, or other objects that may block the view of a child.
8011-518
Keep children away from work area
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8011-517
Never allow children to operate the machine
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SAFETy
WARNING!
The engine must not be started when the driver’s oor plate or any protective plate for the mower deck’s drive belt is removed.

Safe Handling of Gasoline

To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely ammable and the vapors are explosive.
Extinguish all cigarettes, cigars, pipes, and other • sources of ignition.
Use only approved gasoline container.• Never remove gas cap or add fuel with the engine
running. Allow engine to cool at least two (2) minutes before refueling.
Never fuel the machine indoors.• Never store the machine or fuel container where
there is an open ame, spark, or pilot light such as on a water heater or other appliance.
Before beginning to refuel, minimize the risk of • static electricity by touching a metal surface.
Never ll containers inside a vehicle or on a truck • or trailer bed with plastic liner. Always place containers on the ground away from the vehicle when lling.
Remove gas-powered equipment from the truck • or trailer and refuel it on the ground. If this is not possible, refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle.
Keep the nozzle in contact with the rim of the fuel • tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.
If fuel is spilled on clothing, change clothing • immediately.
Never overll fuel tank. Replace gas cap and • tighten securely.
Do not start the engine near spilled fuel.• Never use gasoline as a cleaning agent.• If leaks arise in fuel system, engine must not be
started until problem has been resolved. Check the fuel level before each use and leave
space for the fuel to expand, as the heat from the engine and the sun may otherwise cause the fuel to expand and overow.
8011-516
Never fill the fuel tank indoors
WARNING!
The engine and the exhaust system become very hot during operation.
There is risk for burns if touched.
Allow engine and exhaust system to cool at least two (2) minutes before refueling.
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General Maintenance

Never operate machine in a closed area.• Keep all nuts and bolts tight to be sure the
equipment is in safe working condition. Never tamper with safety devices. Check their
proper operation regularly. Keep machine free of grass, leaves, or other
debris buildup. Clean oil or fuel spillage and remove any fuel-soaked debris. Allow machine to cool before storing.
If the machine strikes a foreign object, stop and • inspect the machine. Repair, if necessary, before restarting.
Never make any adjustments or repairs with the • engine running.
Check grass catcher components and the • discharge guard frequently and replace with manufacturer’s recommended parts, when necessary.
Mower blades are sharp. Wrap the blade or wear • gloves, and use extra caution when servicing them.
Check brake operation frequently. Adjust and • service as required.
Maintain or replace safety and instruction labels, • as necessary.
Do not modify safety equipment. Check regularly • to be sure it works properly. The machine must not be driven with defective or unmounted protective plates, protective cowlings, safety switches, or other protective devices.
Do not change the settings of governors and • avoid running the engine with overly high engine speeds. If the engine runs too fast, there is risk for damaging the machine components.
Be very careful when handling battery acid. Acid • on skin can cause serious corrosive burns. If battery acid is spilled on skin, rinse immediately with water.
Acid in the eyes can cause blindness, contact a • doctor immediately.
Be careful when servicing the battery. Explosive • gases form in the battery. Never perform maintenance on the battery when smoking or near open ames or sparks.
The battery can explode and cause serious injury • or damage.
Ensure that the equipment is in good condition • and that all nuts and bolts, especially those fastening the blade attachments, are properly tightened and torqued.
14
SAFETy
8011-515
Never drive the machine in an enclosed space
WARNING!
Use protective glasses for maintenance work.
WARNING!
The battery contains lead and lead compounds, chemicals that are considered to cause cancer, birth defects, and other reproductive system damage. Wash your hands after handling the battery.
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SAFETy
Sparking can occur when working with the battery and the heavy cables of the starter circuit. This can cause battery explosion, re or eye injury. Sparking in this circuit can not occur after the chassis cable (normally negative, black) is removed from the battery.
Use protective goggles.• Ensure that the fuel ller cap is mounted tightly
and no ammable substances are stored in an open vessel.
WARNING!
Avoid electrical sparking and its consequences by the following routines:
Never work with the starter circuit if there is spilled • fuel.
Disconnect the negative cable from the battery • rst and reconnect it last.
Do not make a bridge short circuit across the • starter relay to run the starter.
6003-009
Do not smoke when performing maintenance on the battery. The battery can explode and cause serious injury/damage.
Never use the machine indoors or in spaces • lacking proper ventilation. The exhaust fumes contain carbon monoxide, an odorless, poisonous, and lethal gas.
Stop to inspect the equipment if the machine runs • over or into anything. If necessary, make repairs before starting.
Never make adjustments with the engine running.• The machine is tested and approved only with the
equipment originally provided or recommended by the manufacturer. Only use approved repair parts for the machine.
The blades are sharp and can cause cuts and • gashes. Wrap the blades or use protective gloves when handling them.
Check the parking brake’s functionality regularly. • Adjust and service as necessary.
The mulch blades should only be used in familiar • areas when higher quality mowing is desired.
Reduce the risk of re by removing grass, leaves, • and other debris that may have accumulated on the machine.
Allow the machine to cool before putting it in • storage.
Regularly clean deck and underside of deck, • avoid spraying engine and electrical components with water.
8009-728
Risk of sparking
8011-514
Regularly clean deck
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SAFETy

Transport

The machine is heavy and can cause serious • crushing injuries. Be extra cautious when it is loaded on or unloaded from a vehicle or trailer.
Use an approved trailer to transport the machine. • Activate the parking brake, turn off the fuel supply, and fasten the machine with approved fastening devices, such as bands, chains, or straps, when transporting.
Do not operate this machine on public roadways.• Check and abide by local trafc regulations
before transporting the machine on any road. Do not tow this machine: it may cause damage to
the drive system. Load the unit onto truck or trailer by driving up
ramps of suitable strength using a slow speed. Do not lift! The machine is not intended to be lifted by hand.

Towing

If machine is equipped with a tow hitch, use extreme caution when towing. Never allow children or others in or on towed equipment..
Make wide turns to avoid jack-kning. Travel slowly and allow extra distance to stop. Do not tow on sloped ground. The weight of the towed equipment may cause loss of traction and loss of control.
Follow the manufacturer’s recommendation for weight limits for towed equipment. Do not tow near ditches, canals, and other hazards.

Spark Arrestor

A spark arrestor for the mufer is available through your authorized Dixon dealer.
WARNING!
Escaping hydraulic oil under pressure can have sufcient force to penetrate the skin, causing serious injury. If injured by escaping uid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately.
IMPORTANT INFORMATION
The parking brake is not sufcient to lock the machine in place during transport. Ensure that the machine is well fastened to the transport vehicle. Always reverse the machine onto the transport vehicle to avoid tipping it over.
WARNING!
This mower is equipped with an internal combustion engine and should not be used on or near any unimproved forested, bush covered or grassy lands unless the engine's system is equipped with a spark arrestor meeting applicable local or state laws (if any).
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Page 17

CONTROLS

This operator’s manual describes the Dixon Zero Turn Rider. The rider is tted with a Briggs & Stratton, four­stroke overhead valve engine developing 19-22 horse power.*

Control Locations

9
Transmission from the engine is made via two belt­driven hydraulic pumps. Using the left and right steering controls, the ow is regulated and thereby the direction and speed.
10
1
8
8050-845
26 35 47
Motion Control Levers1. Seat Adjustment Lever2. Lift Lever 3. Choke Control4. Throttle5.
*The power rating of the engines indicated is the average net power output (at specied rpm) of a typical production engine for the engine model measured to SAE standard J1349/ISO1585. Mass production engines may differ from this value. Actual power output for the engine installed in the nal machine will depend on the operating speed, environmental conditions and other variables.
Blade Switch6. Ignition Switch7. Bypass Linkage8. Fuel Tank9. Parking Brake10.
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CONTROLS

Motion Control Levers

The machine’s speed and direction are continuously variable using the two steering controls. The steering controls can be moved forward or backward about a neutral position. Furthermore, there is a neutral position, which is locked if the steering controls are moved outward.
When both controls are in the neutral position (N), the machine stands still.
By moving both controls an equal amount forward or backward, the machine moves in a straight line forward or backward respectively.
In order, for example, to turn right while moving forward, move the right control towards the neutral position. The rotation of the right wheel is reduced and the machine turns to the right.
Zero turn can be achieved by moving one control backward (behind the neutral position) and carefully moving the other steering control forward from its neutral position. The rotation direction when zero turning is determined by which steering control is moved backward behind the neutral position.
If the left steering control is pulled backward, the machine turns to the left. Use extra care when using this maneuver.
If the steering controls are in uneven positions when standing still or do not t in the slots for moving the controls outward, they can be adjusted
8050-833
Steering controls
WARNING!
The machine can turn very rapidly if one steering control is moved much further forward than the other.
18
8050-846
Forward1. Neutral2. Neutral slot, Neutral lock3. Reverse4.
Motion control lever pattern (right side)
Page 19
CONTROLS

Seat Adjustment Lever

The seat can be adjusted lengthways. Release levers are located at the lower front right, or on the right side—depending on model. When making adjustments, sit on the seat. Slide the lever and maneuver seat to appropriate placement and release lever.
IMPORTANT INFORMATION
Before pushing or towing tractor, transmission must be unlocked and park brake released. The tractor should never be pulled at more than 2 miles per hour (3.2 km/h) or for distances over ¼ mile (.402 km). Trailer the unit for distances over ¼ mile.

Bypass Linkage

Unlocking Transmission
When pushing or pulling the mower, engage the EZT (Integrated Zeroturn Transaxle) bypass linkages. The EZT bypass linkages are located on the rear of the frame, below the rear engine guard.
Raise the deck into the highest cutting 1. position.
Pull the EZT bypass linkages up and out of 2. the keyhole slots. Release the levers with the head outside the frame and held in the bypass position.
To reengage the EZT’s to drive, reverse the 3. above procedure.
8050-852
Seat adjustment
8058-032
Bypass linkage, EZT engaged
Bypass linkage, EZT locked in the bypass position
8058-033
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Page 20
CONTROLS

Fuel Tank

The machine has one fuel tank, just behind the seat. The tank capacity is 4.5 gallons (17 liters).
The engine will run on a minimum of 85-octane unleaded gasoline (no oil mix). Environmentally adapted alkylate gasoline can be used. See also Technical Data concerning ethanol fuel. Methanol fuel is not allowed.
When operating below 32°F (0°C) use fresh, clean winter grade gasoline to help insure good cold weather starting.
WARNING!
Gasoline is highly ammable. Observe caution and ll the tank outdoors. (See Safety)
8058-833
Fuel tank
WARNING!
Fill to the bottom of the ller neck. Do not overll. Wipe off any spilled oil or fuel. Do not store, spill or use gasoline near an open ame.
WARNING!
The engine and the exhaust system, become very hot during operation.
Risk for burns if touched.
Allow engine and exhaust system to cool at least two (2) minutes before refueling.
IMPORTANT INFORMATION
Experience indicates that alcohol blended fuels (called gasohol, ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. Drain the gas tank, start the engine and let it run until the fuel lines and carburetor are empty. Use fresh fuel the next season. See Storage Instructions for additional information. Never use engine or carburetor cleaners in the fuel tank or permanent damage may occur.
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Page 21
CONTROLS

Ignition Switch

The ignition key is placed on the driver’s panel and is used to start and stop the engine.
IMPORTANT INFORMATION
Do not run the starter for more than ve seconds each time. If the engine does not start, wait about 10 seconds before retrying.

Choke Control

The choke is used for cold starts to provide the engine with a richer fuel mixture. Pull the choke control knob up. On model 965883101 push the throttle control all the way forward to the choke position.
8050-847
Ignition Switch

Throttle Control

The throttle control regulates the engine speed and thereby the rate of rotation of the blades, assuming the blade switch is pulled out, see Engaging the Mower Deck.
In order to increase or decrease the engine speed, the control is moved.
Avoid idling the engine for long periods, as there is a risk of fouling the spark plug.
USE FULL THROTTLE WHEN MOWING, for best mower performance and battery charging.
8050-847
Choke control
8050-847
Throttle control
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CONTROLS

Blade Switch

In order to engage the mower deck, pull the knob out; the mower blades are disengaged when the knob is depressed.
IMPORTANT INFORMATION
The machine must stand absolutely still when applying the parking brake. Always set the parking brake before dismounting. Release the parking brake before moving the mower.

Parking Brake

The parking brake is found on the left of the machine. Push the release button and pull the lever backward to activate the brake—push forward to release it.
The park brake is designed to hold the mower from moving and is not intended for use in stopping the mower while it is in motion. The engine will stop if the park brake is engaged while the control levers are in the drive position.
IMPORTANT INFORMATION
In order to obtain an even cutting height it is important that the air pressure in all four tires is the same 15 psi (1 bar).
8050-847
Blade switch
8058-080
Released parking brake

Cutting Height Adjuster

To set the desired deck cutting height, press the release button and move the lever forward to the correct cutting height on the cutting plate. The cutting height range is from 1½" (38mm) to 4" (102mm) in ½" (13mm) increments. The heights are measured from the ground up to the blade tip with the engine not running.
IMPORTANT INFORMATION
Always use the high position to transport.
22
8058-019
Cut height lift lever
Page 23
CONTROLS

Fuses

Fuses are located on the left hand side of the machine. They are accessed by tilting the seat forward. They are at pin fuses of the same type used in automobiles.
There are two fuses with ratings and functions: 20 Amp Primary fuse
7.5 Amp Mower deck coupling

Fuel Shut Off Valve

The fuel shut off valve is located at the left rear of the seat. The valve is off when the handle tab is turned perpendicular to the fuel line.
8011-420
Fuses
Fuel shut off valve in the CLOSED position
8011-419
23
Page 24

OpERATION

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

Training

Zero turn mowers are far more maneuverable than typical riding mowers due to their unique steering capabilities.
We suggest that this section be reviewed in its entirety prior to attempting to move the mower under its own power. Additionally, we suggest when rst operating the mower, use a reduced throttle speed and reduced ground speed by NOT moving control levers to the furthest forward or reverse positions during initial operation, or until operator becomes comfortable with controls. We also suggest rst time users, or new users to Zero Turn mowers to become familiar with the mower’s movement on a hard surface, such as concrete or blacktop PRIOR to attempting to operate on turf. Until operator becomes comfortable with mower controls and zero turning capability, they may damage turf due to overly aggressive maneuvers.
IMPORTANT INFORMATION
When control levers are in the reverse position they return to neutral when released. This may cause the mower to suddenly stop.
inward. As long as the control levers have not been moved forward or backwards, mower will not move. Slowly move both control levers forward slightly. This will allow mower to start moving forward in a straight line. Pull back on control levers to the neutral position and mower should stop moving. Pull back slightly on control levers, this will allow mower to start moving backwards. Push forward on control levers to the neutral position and mower should stop moving.
To turn to the right
While moving in a forward direction, pull the right lever back towards the neutral position while maintaining the position of the left lever, this will slow the rotation of the right wheel and cause the machine to turn in that direction.
To turn to the left
While moving in a forward direction pull the left lever back towards the neutral position while maintaining the position of the right lever, this will slow the rotation of the left wheel and cause the machine to turn in that direction.
To zero turn
While moving in a forward direction, rst pull both control levers back until the mower stops or slows dramatically. Then by alternating one lever slightly to the forward position and the other in the reverse position.

Steering

To move forward and backward
The direction and speed of the mower’s movements is effected by the movement of the control lever(s) on each side of mower. The left control lever controls the left wheel. The right control lever controls the right wheel.
First time users should push mower (see Manual Transport in the Operation section) to an open, at area, without other people or vehicles/obstacles nearby. In order to move unit under its own power, the operator must be in the seat, start engine (see Before Starting in Operation section), adjust engine speed to idle, disengage parking brake, do not engage blades at this time, rotate control levers
24
Page 25
OpERATION

Before Starting

Read the sections Safety Instructions and • Controls before starting the machine.
Perform the daily maintenance before • starting (see Maintenance Schedule in the Maintenance section).
Check that there is sufcient fuel in the fuel • tank.
Adjust the seat to the desired position.
The following conditions must be fullled before the engine can be started:
The blade switch for engaging the mower • blades must be depressed.
The parking brake must be on.• Both steering controls must be in the locked
(outer) neutral position.

Starting the Engine

Sit on the seat. • Raise the mower deck by pushing the release
button on the top of the lifting lever. Pull the lifting lever backward to the locked (transport) position.
Activate the parking brake by pushing the release • button in and pulling the lever fully upwards.
8058-019
Cut height lift lever
Disengage the mower blades by depressing the blade switch.
8058-080
Released parking brake
8050-847
Blade switch
25
Page 26
OpERATION
Move the steering controls outward to the locked (outer) neutral position.
Move the throttle to the middle position.
8058-077
Place controls in neutral position
If the engine is cold, pull the choke control knob up. NOTE: On models without a separate choke control, push throttle control all the way forward to the choke position.
26
8050-849
Set the throttle
8050-850
Set the choke control
Page 27
OpERATION
Press in and turn the ignition key to the start position. When the engine starts, immediately release the
ignition key back to the run position.
IMPORTANT INFORMATION
Do not run the starter for more than 5 seconds each time. If the engine does not start, wait approximately 10 seconds before retrying.
Set the desired engine speed with the throttle. Allow the engine to run at a moderate speed, “half throttle”, for 3-5 minutes before loading it too heavily. USE FULL THROTTLE WHEN MOWING.
8050-781
Return to run position
WARNING!
Engine exhaust and certain vehicle components contain or emit chemicals considered to cause cancer, birth defects or other reproductive system damage. The engine exhaust contains carbon monoxide, which is a odorless, colorless, poisonous gas. Do not use the machine in enclosed spaces.
8050-849
Set the engine speed
27
Page 28
OpERATION

Weak Battery

WARNING!
Lead-acid batteries generate explosive gases. Keep sparks, ame and smoking materials away from batteries. Always wear eye protection when around batteries.
If your battery is too weak to start the engine, it should be recharged. (See Battery in the Maintenance section.)
If “jumper cables” are used for emergency starting, follow this procedure:
IMPORTANT INFORMATION
Your mower is equipped with a 12-volt negative grounded system. The other vehicle must also be a 12-volt negative grounded system. Do not use your mower to start other vehicles.
8011-642
Jumper cable connection

Jumper Cables

Connect each end of the RED cable to the 1. POSITIVE (+) terminal on each battery, taking care not to short against chassis.
Connect one end of the BLACK cable to the 2. NEGATIVE (-) terminal of the fully charged battery.
Connect the other end of the BLACK cable 3. to a good CHASSIS GROUND on the mower with the discharged battery, away from the fuel tank and battery.
To remove cables, reverse order
Remove BLACK cable rst from chassis and 1. then from the fully charged battery.
Remove RED cable last from both batteries.2.
28
Page 29

Running

Release the parking brake by moving the lever 1. downward. Your mower is equipped with an operator presence system. When the engine is running, any attempt by the operator to leave the seat without rst setting the parking brake will shut off the engine.
Move the steering controls to the neutral 2. position (N).
IMPORTANT INFORMATION
OpERATION
The mower deck’s anti-scalp rollers should be evenly adjusted.
Set retaining pin into selected cutting height and 3. secure the opposite side with a cotter hairpin.
WARNING!
Ensure that no one is near mower when engaging blade switch. Make sure the work area is free from objects that could be thrown by the rotating blades.
Push the release button on the cutting height lever 4. and move lever to the pin, release the button.
Set the cutting height with the cutting height 5. adjustment lever.
Engage the mower deck by pulling out the 6. blade switch.
8058-080
Released parking brake
8058-024
Secure selected cutting height
Mower deck lifting lever
8058-019
29
Page 30
OpERATION
Move throttle control to full throttle (not choke). 7. The machine’s speed and direction are continuously variable using the two steering controls. When both controls are in the neutral position, the machine stands still. By moving both controls an equal amount forward or backward, the machine moves in a straight line forward or backward respectively. In order, for example, to turn right while moving forward, move the right control towards the neutral position. The rotation of the right wheel is reduced and the machine turns to the right. Turning on the spot can be achieved by moving one control backward (behind the neutral position) and carefully moving the other steering control forward from its neutral position.
IMPORTANT INFORMATION
Control levers return to neutral when released. This may cause the mower to suddenly stop.
8050-849
Set blade engagement and throttle control

Operating On Hills

Read the Safety Instructions Driving on Slopes in the
Safety section.
WARNING!
Do not drive up or down hills with slopes greater than 10 degrees. Do not drive across slopes.
The slowest speed possible should be used • before starting up or down hills.
Avoid stopping or changing speed on hills.• If stopping is absolutely necessary, pull drive
levers into the neutral position and push to the outside of the unit and engage the parking brake.
To restart movement, release the parking • brake.
Pull the control levers back to the center of the • mower and press forward to regain forward motion.
Make all turns slowly.
8058-077
Place controls in neutral position and engage the parking brake.
30
Page 31
OpERATION

Mowing Tips

Observe and ag rocks and other xed • objects to avoid collisions.
Begin with a high cutting height and reduce it • until the desired mowing result is attained. The average lawn should be cut to 2½” (64 mm) during the cool season and over 3” (76 mm) during the hot months. For healthier and better looking lawns, mow often after moderate growth. For best cutting performance, grass over 6” (15 cm) in height should be mowed twice. Make the rst cut relatively high; the second to the desired height.
The mowing result will be best with a high • engine speed (the blades rotate rapidly) and low speed (the rider moves slowly). If the grass is not too long and dense, the driving speed can be increased without negatively affecting the mowing result.
The nest lawns are obtained by mowing • often. The lawn becomes more even and the grass clippings more evenly distributed over the mown area. The total time taken is not increased as a higher operating speed can be used without poor mowing results.
Avoid mowing wet lawns. The mowing result • is poorer because the wheels sink into the soft lawn, clumps build, and the grass clippings fasten under the cowling.
Hose the mower deck underside with water • after each use. When cleaning, the mower deck shall be raised into the transport position. Make sure the mower is cooled and the engine is off.
Use compressed air to clean top surface of • the deck. Avoid ooding water on top surface, engine and electrical components.
When the mulching kit is used, it is important • that the mowing interval is frequent.
WARNING!
Clear the lawn of stones and other objects that can be thrown out by the blades.
8050-819
Mowing pattern
WARNING!
Never drive the rider on terrain that slopes more than 10 degrees. Mow slopes up and down, never side to side. Avoid sudden directional changes.
31
Page 32
OpERATION

Stopping the Engine

Allow the engine to idle a minute in order to attain normal operating temperature before stopping it, if it has been worked hard. Avoid idling the engine for longer periods, as there is a risk of the spark plugs fouling.
Disengage the mower deck by depressing the 1. blade switch.
Raise the mower deck by depressing the button 2. and pulling backward to the transport position.
8011-668
Disengage the mower deck
When the machine is standing still, activate the 3. parking brake by pulling the lever upward.
Move the throttle to the minimum position (tortoise 4. symbol). Turn the ignition key to the stop position.
Move the steering controls outward.5. Remove key. Always remove key when leaving 6.
the mower to prevent unauthorized use.
IMPORTANT INFORMATION
Leaving the ignition switch in any other position than “OFF” will cause the battery to be discharged.
32
8058-019
Mower deck lifting lever
8058-080
Released parking brake
Page 33
OpERATION

Manual Transport

When pushing or pulling the mower, engage the EZT (Integrated Zeroturn Transaxle) bypass linkages. The EZT bypass linkages are located on the rear of the frame, below the rear engine guard.
Raise the deck into the highest cutting 1. position.
Pull the EZT bypass linkages up and out of 2. the keyhole slots. Release the levers with the head outside the frame and held in the bypass position.
To reengage the EZT’s to drive, reverse the 3. above procedure.
8058-032
Bypass linkage, EZT engaged
Bypass linkage, EZT locked in the bypass position
8058-033
33
Page 34

mAINTENANCE

Maintenance Schedule

The following is a list of maintenance procedures that must be performed on the machine. For those points not described in this manual, visit an authorized service workshop. An annual service carried out by
an authorized service workshop is recommended to maintain your machine in the best possible condition and to ensure safe operation.
Read Maintenance in the Safety section.
MAINTENANCE
Check the parking brake
Check the engine’s oil level (every refueling)
Check the safety system
Check for fuel and oil leakages
Check/clean the engine’s cooling air intake
Check the mower deck
Check for loose hardware (screws, nuts)
Clean under the mower deck
Start the engine and blades, listen for unusual sounds
Check for damage
Thoroughly clean around the engine
Clean around belts, belt pulleys
Check the tire pressures
Check battery connections
Sharpen3)/ Replace mower blades
Clean the engine’s cooling air intake
Clean the air cleaner’s pre-lter 2) (foam)
Clean the air cleaner’s lter cartridge 2) (paper lter)
Check/adjust the parking brake
Inspect mufer/spark arrestor
2)
Daily At
least once each
Before After 10 100 300
year
Maintenance interval
in hours
● ♦
● ♦ ♦ ♦ ♦ ♦ ♦
● ♦
1)
First change after 8-10 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
conditions, cleaning and replacement are required more often.
3)
Performed by authorized service workshop.
= Described in this manual
= Not described in this manual
= Refer to the engine manufacturer's manual
34
2)
In dusty
Page 35
mAINTENANCE
MAINTENANCE
Check/adjust throttle cable
Check the condition of belts, belt pulleys
Change the engine oil
Replace the engine oil lter
Clean/replace the spark plugs
Replace the fuel lter
Replace air lter 2) (paper lter)
Check the caster wheels (every 200 hours)
Replace the air cleaner’s pre-lter 2) (foam)
Dismantle and inspect starter 3) (every 500 hours)
Check/adjust the mower deck
Check the engine valve clearance
Perform the 300-hour service
1)
3)
3)
Daily At
least once each
Before After 10 100 300
year
Maintenance interval
in hours
■ ♦
♦ ♦
1)
First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
conditions, cleaning and replacement are required more often.
3)
Performed by authorized service workshop.
= Described in this manual
= Not described in this manual
= Refer to the engine manufacturer's manual
WARNING!
Before performing any service or adjustment checklist:
Engage the parking brake.
Place the Blade-switch in the disengaged position.
Turn the ignition switch to “OFF” position and remove the key.
Make sure the blades and all moving parts have completely stopped.
Disconnect the spark plug wire from all spark plugs and place the wire • where it cannot come in contact with the plug.
2)
In dusty
35
Page 36
mAINTENANCE

Battery

Your mower is equipped with a maintenance free battery and does not need servicing. However, periodic charging of the battery with an automotive type battery charger will extend its life.
Keep battery and terminals clean.• Keep battery bolts tight.• See charge for charging times.
Always use protective glasses when handling the battery.
Cleaning battery and terminals
Corrosion and dirt on the battery and terminals can cause the battery to “leak” power.
Lift seat and rotate forward.1. Disconnect BLACK battery cable rst, then 2.
the RED battery cable and remove the battery from the machine.
Rinse the battery with plain water and dry.3. Clean terminals and battery cable ends with 4.
wire brush until shiny. Coat terminals with grease or petroleum jelly5. Reinstall battery.6.
Replacing battery
Lift seat and rotate forward.1. Using two ½” wrenches disconnect BLACK 2.
battery cable then RED battery cable. Position deck to lowest setting.3. From underside of frame, remove the nuts that 4.
secure the battery hold-down. Carefully remove the battery from the mower.5. Install new battery with terminals in the same 6.
position as the old battery. Reinstall battery hold-down and secure with 7.
nuts removed in Step 5. First connect RED battery cable to positive (+) 8.
battery terminal with hex bolt and hex nut. Connect BLACK grounding cable to negative 9.
(-) battery terminal with remaining bolt and nut Tighten securely.10. Lower seat11.
STANDARD
BATTERY
12.6V 100%
12.4V 75% 20 min. 35 min. 48 min. 90 min.
12.2V 50% 45 min. 75 min. 95 min. 180 min.
12.0V 25% 65 min. 115 min. 145 min. 280 min.
11.8V 0% 85 min. 150 min. 195 min. 370 min.
STATE
OF
CHARGE
*Charging time depends on battery capacity,
condition, age, temperature and efciency of charger
APPROXIMATE BATTERY CHARGING TIME* TO FULL CHARGE AT 80OF / 27OC
Maximum Rate at:
50 Amps 30 Amps 20 Amps 10 Amps
- FULL CHARGE -
IMPORTANT INFORMATION
Do not attempt to open or remove caps or covers. Adding or checking level of electrolyte is not necessary.
Always use two wrenches for the terminal screws.
WARNING!
Do not short battery terminals by allowing a wrench or any other object to contact both terminals at the same time. Before connecting battery, remove metal bracelets, wristwatch bands, rings, etc.
Positive terminal must be connected rst to prevent sparks from accidental grounding.
36
8050-109
Remove battery hold-down to replace battery
Page 37
mAINTENANCE

Safety System

The machine is equipped with a safety system that prevents starting or driving under the following conditions.
The engine can only be started when:
The mower deck is disengaged.• The steering controls are in the outer, locked
neutral position. The driver is sitting in the driver’s seat.• The parking brake is on.
Make daily inspections to ensure that the safety system works by attempting to start the engine when one of the conditions is not met. Change the conditions and try again.
If the machine starts when one of these conditions is not met, turn the machine off and repair the safety system before using the machine again.
Make sure the engine stops when the parking brake is not engaged and the operator leaves the seated position.
Check that the engine stops if the mower blades are engaged and the driver temporarily moves off the drivers seat.
8058-078
Steering controls locked in neutral

Tire Pressures

All four tires should have a pressure of 15 psi / 103 kPa /1 bar.
8058-079
Check tire pressure
37
Page 38
mAINTENANCE

Parking Brake

WARNING!
The machine must be standing absolutely still when the park brake is engaged.
Visually check that no damage is found on the lever, linages, or switch belonging to the parking brake. Perform a stand still test and check that there is a braking action.
To adjust the parking brake, contact the Dixon service workshop.
WARNING!
Faulty adjustment can cause an accident.
8058-080
Released parking brake

Deck Belt

Check every 100 hours of operation. Check for severe cracking and large nicks.
NOTE: The belt will show some small cracks in normal operation.
The belts are not adjustable. Replace belts if they begin to slip from wear.
Deck Belt Removal
Park on a level surface. Apply parking brake.1. Lower the deck into the lowest cutting position.2. Remove bolts from belt shields and remove 3.
shields. Remove any dirt or grass that may have 4.
accumulated around the cutter housings and entire deck surface.
Carefully roll the belt over the top of the cutter 5. housing pulleys and off the mower.
Belt Shields
8058-081
Removing deck belt
38
Page 39
mAINTENANCE
Deck Belt Installation
NOTE: For ease in installing the deck belt, refer to the routing decal on the top of the deck.
Wrap the deck belt around the electric clutch 1. pulley that is located on the engine shaft.
Route the belt forward and up onto the deck.2. Place belt around spring loaded idler pulley.3. Wrap the belt around the stationary idler pulley 4.
and around the mandrel housings. Push inward on the idler arm and carefully route 5.
belt over stationary idler pulley. Once belt is properly routed, slowly release idler arm to tension belt.
Double check belt routing to make sure it 6. matches the decal afxed to the deck, and the belt does not have any twist. Correct as needed.
Replace belt shields on both mandrel housings 7. and secure with fasteners.

Pump Belt

Replacing EZT (E-Series Zeroturn Transaxle) belt
Park the mower on a level surface. Engage the parking brake.
1
2
8011-764
1. Clutch pulley
2. Deck belt
Belt routing, 54" deck belt
EZT Belt Removal
NOTE: To maintain efcient cooling and not damage the EZTs, be careful of the fan blades when servicing the belt.
Remove the deck belt (see Deck Belt Removal in this section of the manual).
Create slack in the belt by removing the spring • on the pump idler arm.
The belt should now be able to be removed • from the engine pulley and EZT pulleys.
EZT Belt Installation
Wrap the EZT belt around the EZT pulleys• Route the belt around the inside of the idler
pulley. Wrap the belt around the engine pulley.• Reattach the spring on the pump idler arm.• Install clutch onto engine shaft (pulley side
down), making sure key is installed. Align the clutch anti-rotation tab into slot on clutch. Secure clutch, install wire.
Reinstall the deck belt onto the electric clutch • (see Deck Belt Removal in this section of the manual).
39
Page 40
mAINTENANCE

Cutting Blades

To attain the best mowing effect, it is important that the blades are well sharpened and not damaged.
Bent or cracked blades or blades with large nicks should be replaced.
IMPORTANT INFORMATION
The sharpening of blades should be carried out by an authorized service workshop.
WARNING!
Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling.
Damaged blades should be replaced after hitting obstacles that result in a breakdown. A service workshop should decide whether the blade can be repaired/ground or must be replaced. Balance the blades after sharpening and check the blade mounts.

Blade replacement

Remove blade bolt by turning counter clockwise.1. Install new or resharpened blade with stamped 2.
“GRASS SIDE” facing towards ground/grass (down) or “THIS SIDE UP” facing deck and cutter housing.
Install and tighten blade bolt securely.3. Torque blade bolt to 90 ft/lbs (122 Nm).4.
IMPORTANT INFORMATION
The anti-scalp rollers must not be used for gauge wheels or the roller and deck may be damaged.

Anti-scalp Rollers

Anti-scalp rollers are properly adjusted when they are just slightly off of the ground when the deck is at the desired cutting height in the operating position. Anti­scalp rollers then keep the deck in the proper position to help prevent scalping in most terrain conditions.
IMPORTANT INFORMATION
Special blade bolt is heat treated.
Replace with a Dixon bolt if required.
Do not use lower grade hardware than specied.
3
1
2
8058-082
1. Blade
2. Blade bolt (special)
3. Cutter housing
Blade attachment
IMPORTANT INFORMATION
Adjust anti-scalp rollers with the mower on a at level surface.
The anti-scalp rollers can be set in three positions:
Upper position 1½ to 2½" (38 to 64 mm) grass• Middle position 2½" to 4" (64 to 102 mm) grass• Lower position 4" to 6" (102 to 128 mm) grass.
The rollers should be approximately ¼" (6.5 mm) from ground. Do not adjust the rollers to support the deck.
40
8050-830
Anti-scalp rollers
Page 41
mAINTENANCE

Adjusting the Mower Deck

Deck Leveling

Adjust the deck while the mower is on a level surface. Make sure the tires are inated to the correct pressure. See Transmission under Technical Data. If tires are under or over inated, the deck cannot be properly adjusted.
The deck should be adjusted slightly higher in the rear.
NOTE: To insure accuracy of leveling procedure, mower deck drive belt must be installed prior to leveling deck.
Wear heavy gloves. Turn each outer blade tip to 1. align with the deck or in a side-to-side manner.
Measure from the oor surface up to the bottom of 2. the blade tip on the discharge side of the mower deck. Retain this measurement.
Move to the opposite side, check that 3. measurement is the same. If adjustment is required—with a ¾" or adjustable wrench, turn the lift link adjustment nuts on either side counter clockwise to lower or clockwise to raise. Adjust until both side-to-side measurements are equal.
Turn any blade to align with the deck in front-4. to-rear manner. If the rear blade tip does not measure 1/8" to ½" higher, follow the front adjustment instructions that follow.
With a 5.
5
/8 or adjustable wrench, turn the nuts on the front suspension linkage. Clockwise raises the front of the mower, counter clockwise will lower the front. Adjust nuts until rear of mower deck is positioned level to 1/8" higher in the rear than the side-to-side measurement.
NOTE: This will place the mower deck in a base measurement position. Additional adjustment may be required to achieve desired cut for the type of grass or conditions being mowed.
8058-030
Lift link adjustment nut
8058-031
Deck front adjustment nuts
41
Page 42
mAINTENANCE

Caster Wheels

Check every 200 hours. Check that wheels rotates freely. If wheels do not rotate freely take the unit to your dealer for service.
Foam lled tires or solid tires will void the warranty.
IMPORTANT INFORMATION
2
1
DO NOT add any type of tire liner or foam ll material to the tires. Excessive loads created by foam lled tires will cause premature failures.
Only use O.E.M. specied tires.
Removal and installation of caster wheel
Remove nut and caster bolt. Pull the wheel out of the yoke and take care of the
spacers. Install in reverse order. Tighten caster bolt.

Hardware

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

Cleaning

Regular cleaning and washing, especially under the mower deck, will increase the machine’s life-span. Make it a habit to clean the machine directly after use (after it is cooled), before the dirt sticks.
Do not spray water on the top of the mower deck. Use compressed air to clean the top side of mower deck. Regularly clean deck and underside of the deck with normal water pressure. Do not use a high pressure washer or steam cleaner. Avoid spraying engine and electrical components with water
Do not rinse hot surfaces with cold water. Let unit cool before washing.
4
3
8058-083
1. Caster yoke
2. Caster bolt
3. Long spacer
4. Small spacers
Caster wheels
42
IMPORTANT INFORMATION
Use protective glasses when cleaning and washing.
Page 43
Lubrication Schedule

LUBRICATION

12/12 Every year
1/52 Every Week
1/365 Every day
Lubricate with grease gun
Oil change
Filter change
General
For engine lubrication, see the engine manufacturer's Owners Manual.
Remove the ignition key to prevent unintentional movements during lubrication.
When lubricating with an oil can, it must be lled with engine oil.
When lubricating with grease, unless otherwise stated, use a high grade molybdenum disulphide grease.
For daily use, the machine should be lubricated twice weekly.
8050-836
Lubricate with oil can
Level check
Wipe away excess grease after lubrication. It is important to avoid getting lubricant on the belts
or the drive surfaces on the belt pulleys. Should this happen, attempt to clean them with spirits. If the belt continues to slip after cleaning, it must be replaced. Gasoline or other petroleum products must not be used to clean belts.
43
Page 44
LUBRICATION

Wheel and Deck Zerks

Use only good quality bearing grease. Grease from well-known brand names (petrochemical
companies, etc.) usually maintains a good quality.

Front Wheel Mount

Lubricate with a grease gun until the grease is forced out.

Front Wheel Bearings

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

Deck Spindles

Lower the cutting deck completely. If a grease gun without rubber hose is used, the foot
plate must be removed. Lubricate with a grease gun, 2-3 strokes per spindle.
8050-009
Lubricating the front wheels
IMPORTANT INFORMATION
Use minimal lubrication and remove excess lubricant so that is does not come into contact with belts or belt pulley drive surfaces.
8058-058
Deck spindle
44
Page 45

TROUBLE SHOOTING

Problem Cause
Engine will not start Blade switch is engaged.
Steering controls are not locked in the neutral position
Parking brake is not activated
Battery is dead
Contamination in the carburetor or fuel line.
Fuel supply is closed or the shutoff valve for the fuel tank is in • the wrong position
Clogged fuel lter or fuel line
Ignition system faulty
Starter does not turn the engine over Battery is dead
Poor contact of the battery terminal cable connections
Blown fuse
Fault in the starter safety circuit. See Safety System in the Maintenance section
Engine runs rough Faulty carburetor
Choke control is pulled out with a warm engine
Clogged fuel lter or jet
Clogged ventilation valve on the fuel cap
Fuel tank nearly empty
Fouled spark plugs
Rich fuel mixture or fuel-air mixture.
Wrong fuel type
Water in fuel
Clogged air lter
Engine seems weak Clogged air lter
Fouled spark plugs
Carburetor incorrectly adjusted
Air trapped in hydraulic system
Machine vibrates Blades are loose
Blades are incorrectly balanced
Engine is loose
45
Page 46
TROUBLE SHOOTING
Problem Cause
Engine overheats Clogged air intake or cooling ns
Engine overloaded
Poor ventilation around engine
Defective engine speed regulator
Too little or no oil in the engine
Contamination in the carburetor or fuel line.
Fouled spark plugs
Battery not charging Poor contact of the battery terminal cable connections
Charging lead is disconnected
The machine moves slowly, unevenly, or not at all Parking brake on
Bypass valve on pump open
Drive belt for the transmission slack or has come off
Air trapped in hydraulic system
Mower deck not engaging Drive belt for the mower deck has come loose
Contact for the electromagnetic coupling has loosened
Blade switch is faulty or has come loose from cable • contact
Blown fuse
Transaxle leaks oil Damaged seals, housing, or gaskets
Air trapped in hydraulic system
Uneven mowing results Different air pressure in tires on the left and right sides.
Bent blades
Suspending for the mower deck is uneven
Blades are dull
Driving speed too high
Grass is too long
Grass collected under the mower deck
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Page 47
STORAGE

Winter Storage

At the end of the mowing season, the machine should be readied for storage (or if it will not be in use for longer than 30 days). Fuel allowed to stand for long periods of time (30 days or more) can leave sticky residues that can plug the carburetor and disrupt engine function.
Fuel stabilizers are an acceptable option as regards to the sticky residues that can occur during storage.
Add stabilizer to the fuel in the tank or in the storage container. Always use the mixing ratios specied by the manufacturer of the stabilizer. Run the engine for at least 10 minutes after adding the stabilizer so that it reaches the carburetor. Do not empty the fuel tank and the carburetor if you have added stabilizer
WARNING!
Never store an engine with fuel in the tank indoors or in poorly ventilated spaces where fuel vapor can come in contact with open ames, sparks, or a pilot light such as in a boiler, hot water tank, clothes drier, etc. Handle the fuel with care. It is very ammable and can cause serious personal injury and property damage. Drain the fuel into an approved container outdoors and far away from open ame. Never use gasoline for cleaning. Use a degreaser and warm water instead.
To ready the machine for storage, follow these steps:
Thoroughly clean the machine, especially under 1. the mower deck. Touch up damage to the paint and spray a thin layer of oil on the underside of the mower deck to avoid corrosion.
Inspect the machine for worn or damaged parts 2. and tighten any nuts or screws that may have become loose.
Change the engine oil; dispose of properly.3. Empty the fuel tanks or add a fuel stabilizer. Start 4.
the engine and allow it to run until the carburetor is drained of fuel or the stabilizer has reached the carburetor.
Remove the spark plug and pour about a 5. tablespoon of engine oil into the cylinder. Turn over the engine so that the oil is evenly distributed and then ret the spark plug.
Lubricate all grease zerks, joints, and axles.6. Remove the battery. Clean, charge, and store the 7.
battery in a cool place, but protect it from direct cold.
Store the machine in a clean, dry place and cover 8. it for extra protection.

Service

When ordering spare parts, please specify the purchase year, model, type, and serial number.
Always use genuine Dixon spare parts. An annual check-up at an authorized service
workshop is a good way to ensure that your machine performs its best the following season.
47
Page 48

SCHEmATIC

48
Page 49

TECHNICAL DATA

Torque Specications
Hex Head Cap Screws
The torque values shown should be used as a general guideline when specic torque values are not given.
U.S. Standard Hardware
Grade SAE Grade 5 SAE Grade 8 Flangelock Screw
w/Flangelock Nut
ft./lbs ft./lbs Nm ft./lbs Nm ft./lbs Nm
¼ 9 12 13 18
5
/16 18 24 28 38 24 33
3
/8 31 42 46 62 40 54
7
/16 50 68 75 108
½ 75 102 115 156
9
/16 110 150 165 224
5
/8 150 203 225 305
¾ 250 339 370 502
7
/8 378 513 591 801
Shank Size (Diameter in inches, ne or coarse thread)
11/8 782 1060 1410 1912
** Grade 5 - Minimum commercial quality (lower quality not recommended)
Metric Standard Hardware
Grade Grade 8.8 Grade 10.9 Grade 12.9
ft./lbs ft./lbs Nm ft./lbs Nm ft./lbs Nm
M4 1.5 2 2.2 3 2.7 3.6
M5 3 4 4.5 6 5.2 7
M6 5.2 7 7.5 10 8.2 11
M7 8.2 11 12 16 15 20
M8 13.5 18 18.8 25 21.8 29
M10 24 32 35.2 47 43.5 58
M12 43.5 58 62.2 83 75 100
M14 70.5 94 100 133 119 159
M16 108 144 147 196 176 235
M18 142 190 202 269 242 323
M20 195 260 275 366 330 440
Shank Size (Diameter in millimeters, ne or coarse thread)
M22 276 368 390 520 471 628
M24 353 470 498 664 596 794
M27 530 707 474 996 904 1205
49
Page 50
TECHNICAL DATA
966496201 / 966496301 966883101
Engine
Manufacturer Briggs & Stratton Briggs & Stratton
Type ELS ELS
Power 22 hp* 19.5 hp*
Lubrication Pressure with oil lter Pressure with oil lter
Oil capacity excluding lter 1.78 qt (1.68 liters) 1.78 qt (1.68 liters)
Oil capacity including lter 2 qt (1.89 liters) 2 qt (1.89 liters)
Engine oil, Synthetic Engine oil, Mineral Class
Fuel
Fuel tank capacity 4.5 gallon (17 liters) 4.5 gallon (17 liters)
Spark plugs/gap
Cooling Air cooling Air cooling
Air lter Standard Standard
Alternator 12V 16A 12V 16A
Starter Electric 12V Electric 12V
Transmission
Type Dual Hydro-Gear EZT Dual Hydro-Gear EZT
Speed and direction controls Dual levers, foam gripped Dual levers, foam gripped
Speed forward 0-6 mph / 0-9.7 km/h 0-6 mph / 0-9.7 km/h
SAE 10W30, 10W40, 5W20
5W30 API, SF-SG
Min 87 octane, unleaded (Max
methanol 10%, max MTBE 15%)
Champion RC12YC
.030" / 0.75 mm
SAE 10W30, 10W40, 5W20
5W30 API, SF-SG
Min 87 octane, unleaded (Max
methanol 10%, max MTBE 15%)
Champion RC12YC
.030" / 0.75 mm
Speed reverse 0-3.5 mph / 0-5.6 km/h 0-3.5 mph / 0-5.6 km/h
Brakes Mechanical parking brake Mechanical parking brake
Front caster tires, smooth tread 11 x 4-5, 4 ply 11 x 4-5, 4 ply
Rear tires, turf pneumatic 18 x 8.5-8 18 x 8.5-8
Tire pressure, front and rear 15 PSI / 103 kPa / 1 bar 15 PSI / 103 kPa / 1 bar
*The power rating of the engines indicated is the average net power output (at specied rpm) of a typical production engine for the engine model measured to SAE standard J1349/ISO1585. Mass production engines may differ from this value. Actual power output for the engine installed in the nal machine will depend on the operating speed, environmental conditions and other variables.
50
Page 51
TECHNICAL DATA
966496201 / 966496301 965883101
Equipment
Cutting width 42" 46"
Cutting height 1.5" - 4" / 2.5 cm - 10.6 cm 1.5" - 4" / 2.5 cm - 10.6 cm
Uncut circle 0 0
Number of blades 2 2
Blade length 145/8" / 37 cm 22¾ / 58 cm
Nose rollers No No
Sprung seat Standard Standard
Hinged armrests No No
Blade engagement Electric clutch Electric clutch
Deck construction Stamped Stamped
Productivity
Output 2.78 acres/hr / 11250 m2/hr 2.37 acres/hr / 9591 m2/hr
Overall dimensions
Weight 570 lbs / 258 kg 525 lbs / 238 kg
Base machine length 75" / 191 cm 75" / 191 cm
Base machine width 40" 102 cm 40" 102 cm
Base machine height 43¾" / 112 cm 41¾" / 106 cm
Overall width, chute up
Overall width, chute down 58 " / 147cm 56" / 142 cm
43" / 109 cm 48" / 122 cm
51
Page 52
TECHNICAL DATA
965883201
Engine
Manufacturer Briggs & Stratton
Type ELS
Power 22 hp*
Lubrication Pressure with oil lter
Oil capacity excluding lter 1.78 qt s(1.68 liters)
Oil capacity including lter 2 qts (1.89 liters)
Engine oil, Synthetic Engine oil, Mineral Class
Fuel
Fuel tank capacity 4.5 gallon (17 liters)
Spark plugs/gap
Cooling Air cooling
Air lter Standard
Alternator 12V 16A
Starter Electric 12V
Transmission
Type Dual Hydro-Gear EZT
Speed and direction controls Dual levers, foam gripped
Speed forward 0-9.5 mph / 0-15.3 km/h
SAE 10W30, 10W40, 5W20
5W30 API, SF-SG
Min 87 octane, unleaded (Max
methanol 10%, max MTBE 15%)
Champion RC12YC
.030" / 0.75 mm
Speed reverse 0-5 mph / 0-8 km/h
Brakes Mechanical parking brake
Front caster tires, smooth tread 11 x 4-5, 4 ply
Rear tires, turf pneumatic 18 x 9.5-8
Tire pressure, front and rear 15 PSI / 103 kPa / 1 bar
*The power rating of the engines indicated is the average net power output (at specied rpm) of a typical production engine for the engine model measured to SAE standard J1349/ISO1585. Mass production engines may differ from this value. Actual power output for the engine installed in the nal machine will depend on the operating speed, environmental conditions and other variables.
52
Page 53
TECHNICAL DATA
965883201
Equipment
Cutting width 54"
Cutting height 1.5" - 4" / 2.5 cm - 10.6 cm
Uncut circle 0
Number of blades 3
Blade length 18¼" / 46.4 cm
Nose rollers No
Sprung seat Standard
Hinged armrests No
Blade engagement Electric clutch
Deck construction Stamped
Productivity
Output 2.78 acres/hr / 11250 m2/hr
Overall dimensions
Weight
Base machine length 75" / 191 cm
Base machine width 40" 102 cm
Base machine height 41¾" / 106 cm
Overall width, chute up 57" / 145 cm
Overall width, chute down
538 lbs / 238 kg
67½" / 174 cm
53
Page 54

CONFORmITy CERTIFICATES

USA requirements
Labels are placed on the engine and/or in the engine compartment stating that the machine will fulll the requirements. This is also applicable to special requirements for any of the states, (California emission rules etc.). Do not remove any of these labels. Certicates can also be supplied with the machine at delivery or written in the Engine manual. Take care of them as they are valuable documents.
CE requirements
If required, vibration data corresponding to Directive 2002/44/EC is given in the Technical Data Section.
The Declaration of Conformity is included in the literature packet.
54
Page 55

WARRANTy

DIXON® ZTR® RESIDENTIAL
SpeedZTR™ and RAM 42 Residential Mowers
DIXON WARRANTS ITS ZTR MOWERS AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP FOR
THE PERIODS SET FORTH BELOW. THE SOLE REMEDY UNDER THIS WARRANTY IS REPLACEMENT
OR REPAIR OF PARTS INCLUDING LABOR COSTS.
THIS WARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMITATIONS:
RESIDENTIAL WARRANTY (used only at owner’s primary place of residence):1.
First two years - 100% parts and labor subject to the conditions and limitations described herein for a a. period of two years from date of purchase by the original owner.
Third year - limited to 100% parts cost as shown in the current Dixon Parts Price List and subject to the b. conditions and limitations as described herein.
Attachments marketed through or approved by Dixon are warranted for two years parts and labor in c. residential use applications.
NOT APPROVED FOR COMMERCIAL USE.2.
All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon warranty 3. policy and allowances. All warranty claims must be submitted to Dixon for approval.
Warranty applies to new mowers.4.
Warranty labor reimbursement to dealers based on published Dixon at rate schedule.5.
Warranty does not apply to damage in transit or incidents of misuse, negligence, accidents, or alteration. The 6. use of parts or components other than those supplied by Dixon VOIDS ALL WARRANTY.
Battery warranty is limited to 1 year from mower manufacture date.7.
The following items are not covered by this warranty policy:8.
Routine maintenance or adjustments to include any oils, lters or other uids used.a.
Belts, blades, tires and cosmetic appearance (paint, seat fade, etc.)b.
Pick up and delivery charges for transportation of mower to and from an authorized Dixon dealer’s place c. of business.
Engines. These are covered under a separate warranty by each individual engine manufacturer. Consult d. engine manual for warranty details.
Any costs or expense of providing substitute equipment while repair work is being performed on a e. warranted mower.
THERE IS NO OTHER EXPRESS WARRANTY. TO THE EXTENT PERMITTED BY LAW, ALL IMPLIED 9. WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED, OTHERWISE, ALL SUCH IMPLIED WARRANTIES ARE LIMITED TO THE SAME DURATION AND REMEDIES AS THE EXPRESS WARRANTY. ALL LIABILITIES FOR CONSEQUENTIAL DAMAGES UNDER ANY EXPRESS OR IMPLIED WARRANTY ARE EXCLUDED.
55
Page 56

SERVICE JOURNAL

Action
Delivery Service
1. Charge the battery.
2. Adjust the tire pressure of all wheels to 15 PSI (1 bar).
3. Mount the steering controls in the normal position.
4. Connect the contact box to the cable for the seat’s safety switch.
5. Check that the right amount of oil is in the engine.
6. Adjust the position of the steering controls.
7. Fill with fuel and open the fuel shut off valve.
8. Start the engine.
9. Check that there is drive to both wheels.
10. Check the mower deck adjustment.
11. Check:
Safety switch for the parking brake.
Safety switch for the mower deck.
Safety switch in the seat.
Date, mtr reading,
stamp, sign
Safety switch in the steering controls.
Parking brake functionality.
Driving forward.
Driving backward.
Engaging the blades.
12. Check engine high idle speed
13. Inform the customer about: Need and advantages of following the service schedule.
Need and advantages of leaving the machine for service.
Effects of service and maintaining a service journal on the machine’s resale value.
Application areas for mulching.
14. Fill in the sales papers, etc. Delivery service has
been carried out. No remaining notes. Certied:
56
Page 57
SERVICE JOURNAL
Action
Daily Service
1. Clean debris from mower.
2. Check engine oil level.
3. Check the tire pressures.
4. Check underside of deck.
5. Inspect deck pulleys.
6. Check/clean the engine’s cooling air intake.
7. Check safety system.
8. Check seat belt.
9. Check fuel system for leaks.
10. Inspect safety guards and shields.
11. Check brake adjustment.
Date, mtr reading,
stamp, sign
After 10 hours
1. Change the engine oil.
2. Change the oil lter.
3. Check hydraulic oil level.
4. Inspect hydraulic hoses.
5. Inspect hydraulic belt.
6. Inspect hydraulic lter.
7. Check neutral position.
8. Check safety system.
9. Check seat belt.
10. Check fuel system for leaks.
11. Inspect safety guards and shields.
12. Check brake adjustment.
57
Page 58
SERVICE JOURNAL
Action
100-Hour Service
1. Grease ttings (caster pivots and caster wheels)
2. Inspect dampeners
3. Inspect frame
4. Inspect throttle and choke cables
5. Inspect hardware
6. Check the tire pressures
7. Change the engine oil and lter
8. Change air lter
9. Inspect spark plug
10. Inspect fuel lter
11. Check engine RPM
12. Clean underside of deck
13. Check blade pitch
14. Grease blade spindles
Date, mtr reading,
stamp, sign
15. Inspect spindle bearings
16. Inspect deck belt and blades
17. Inspect idler arm bearings
18. Inspect deck idler pulleys
19. Check hydraulic oil level
20. Inspect hydraulic lter
21. Inspect hydraulic drive belt
22. Inspect hydraulic hoses
23. Check neutral position
24. Inspect battery connections
25. Check safety system
26. Check seat belt
27. Check fuel system for leaks
28. Inspect safety guards and shields
29. Check brake adjustment
58
Page 59
SERVICE JOURNAL
Action
300-Hour Service
1. Grease ttings (caster pivots and caster wheels)
2. Inspect dampeners
3. Inspect frame
4. Inspect throttle and choke cables
5. Inspect hardware
6. Check the tire pressures
7. Change the engine oil and lter
8. Change air lter
9. Inspect spark plug
10. Inspect fuel lter
11. Check engine RPM
12. Clean underside of deck
13. Check blade pitch
14. Grease blade spindles
Date, mtr reading,
stamp, sign
15. Inspect spindle bearings
16. Inspect deck belt and blades
17. Inspect idler arm bearings
18. Inspect deck idler pulleys
19. Check brake adjustment
20. Inspect safety guards and shields
21. Replace hydraulic drive belt
22. Inspect hydraulic hoses
23. Check neutral position
24. Inspect battery connections
25. Load test battery
26. Clean electrical connections
27. Inspect the clutch
28. Check safety system
29. Check seat belt
30. Check fuel system for leaks
59
Page 60
SERVICE JOURNAL
Action
At least once each year
1. Clean the engine’s cooling air intake.
2. Replace the air cleaner’s pre-lter (foam).
3. Replace the air lter’s paper cartridge.
4. Change the engine oil.
5. Replace the engine oil lter.
6. Check/adjust the cutting height.
7. Check/adjust the parking brake.
8. Clean/Change the spark plugs.
9. Replace the fuel lter.
10. Check the engine valve clearance.
Date, mtr reading,
stamp, sign
60
Page 61
SERVICE JOURNAL
Action
Date, mtr reading,
stamp, sign
61
Page 62
SERVICE JOURNAL
Action
Date, mtr reading,
stamp, sign
62
Page 63
Page 64
P/N 115 337627R1 11/16/09
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