Dixon 966690603, Ultra 52 Operator's Manual

Operator Manual

Form Number 115 521627 Rev A 2012-08-15

Ultra 52 / 966690603

Please read the operator’s manual carefully and make sure you

understand the instructions before using the machine.

Gasoline containing up to 10% ethanol (E10) is acceptable for

use in this machine. The use of any gasoline exceeding 10%

ethanol (E10) will void the product warranty.

To implement improvements, specifications and designs can be altered without prior
notification.

Note that no legal demands can be placed based on the information contained in these
instructions.

Use only original parts for repairs. The use of other parts voids the warranty.

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

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

©2012 All rights reserved.

Orangeburg, SC. Printed in U.S.A.

CONTENTS

INTRODUCTION ............................................................... 5

General .......................................................................5

Driving and Transport on Public Roads ......................5

Towing ........................................................................ 5

Operating ....................................................................5

Good Service ..............................................................6

Manufacturing Number ........................................... 6

SYMBOLS AND DECALS ................................................. 7

SAFETY ............................................................................ 9

Safety Instructions ...................................................... 9

Personal Safety Equipment ...................................... 11

Slope Operation ........................................................ 11

Safe Handling of Gasoline ........................................13

General Maintenance ...............................................14

Transport...................................................................16

Towing ...................................................................... 16

Spark Arrestor ........................................................... 16

CONTROLS .................................................................... 17

Control Locations ...................................................... 17

Steering Control Levers ............................................18

Parking Brake ........................................................... 19

Throttle Control .........................................................19

Ignition Switch ........................................................... 19

Choke Control ........................................................... 20

Blade Switch .............................................................20

Fuses ........................................................................20

Hour Meter ................................................................ 21

Cutting Height Adjuster ............................................. 21

Fuel Shut Off Valve ................................................... 22

Tracking ....................................................................22

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

Moving Machine by Hand ......................................... 33

MAINTENANCE ..............................................................34

Maintenance Schedule ............................................. 34

Battery ......................................................................36

Safety System ........................................................... 37

Tire Pressures ..........................................................37

Parking Brake ........................................................... 37

V-belts ....................................................................... 38

Deck Belt ..............................................................38

Pump Belt ................................................................. 39

V-belts ....................................................................... 39

Cutting Blades ..........................................................40

Blade Replacement ..............................................40

Adjusting the Mower Deck ........................................41

Leveling ................................................................41

Anti-Scalp Rollers ................................................. 42

Caster Wheels .......................................................... 43

Cleaning .................................................................... 43

Hardware .................................................................. 43

LUBRICATION ................................................................44

Front Wheel Mount ................................................... 45

Front Wheel Bearings ...............................................45

Deck Spindles ....................................................... 45

Engine Lubrication ....................................................45

Transaxle Fluid Change ............................................ 46

TROUBLESHOOTING ....................................................47

Winter Storage .......................................................... 49

STORAGE ....................................................................... 49

SCHEMATICS ................................................................. 50

TECHNICAL DATA .......................................................... 51

Torque Specifications ............................................... 51

CONFORMITY CERTIFICATES .....................................54

SERVICE JOURNAL ....................................................... 55

WARNING!

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

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

WARNING!

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

WARNING!

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

INTRODUCTION

Congratulations

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

This manual is a valuable document. Read the
contents carefully before using or servicing the
machine. The following of instructions (use, service,
maintenance, 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 final 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 specifications and design are subject to
change without notice.

Driving and Transport on Public Roads

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

Towing

If machine is equipped with a tow hitch, use extreme
caution when towing. Never allow children or others in
or on towed equipment.

Make wide turns to avoid jack-knifing. Travel slowly
and allow extra distance to stop. Do not tow on sloped
ground. The weight of the towed equipment may
cause loss of traction and loss of control.

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

Operating

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

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

The machine must only be operated, maintained,
and repaired by persons familiar with the
machine’s special characteristics and who are also
knowledgeable about the safety instructions. Use only
approved repair parts to maintain this machine.

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

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

5

INTRODUCTION

Good Service

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

retailer. See the certificate in the Service Journal in
this operator’s manual.

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

This Operator’s Manual belongs to the machine with
the manufacturing number:

Manufacturing Number

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

• The machine’s type designation (I.D.).

• The manufacturer’s type number (Model).

• The machine’s serial number (Serial no.)
Please have the type designation and serial number

available when ordering spare parts.
The engine’s manufacturing number is stamped on

one of the valve covers.
The plate states:

• The engine’s model.

• The engine’s type.

• Code
Please have these available when ordering spare

parts.
The wheel motors and hydrostatic pumps have a

barcode decal affixed at the rear.

Engine Transmission

6

SYMBOLS AND DECALS

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

Study them carefully so that you know what they
mean.

WARNING!

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

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

IMPORTANT INFORMATION

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

Used in this publication to notify the reader of a risk
of material damage, particularly if the reader should
neglect to follow instructions given in the manual.
Used also when there is a potential for misuse or
misassembly.

R N

Reverse Neutral Fast Slow Choke Fuel

Warning! Parking Brake CE conformity marking.

Only for European market

Use protective glasses

Noise emissions to the

surroundings
Australia and

New Zealand only

Use protective gloves

Do not stand here

Electromagnetic

Compatibility (EMC)

Compliance

Australia and

New Zealand only

7

Read Operator’s

Manual

SYMBOLS AND DECALS

Shut off engine and

remove key before

performing any

maintenance

or repair work

Keep a safe

distance from the

machine

Use on slopes no

greater than 10° No passengers

Whole body exposure

to thrown objects

Moving sharp blades under cover

Severing of fingers

and toes

Do not open or

remove safety shields

while engine is running

Battery acid is corrosive, explosive and flammable

Careful backing up,

watch for other people

Warning! Rotating blades,

keep away from the

discharge deck

Careful going forward,

watch for other people

8

Do not touch parts

SAFETY

Safety Instructions

These instructions are for your safety. Read them
carefully.

WARNING!

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.

• It is recommended that someone be aware that
you are mowing and can provide help in case of
injury or accident.

• 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.

WARNING!

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

8011-512

Read the operator’s manual before starting the machine

8011-513

Clear the area of objects before mowing

9

SAFETY

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

• Operate machine only in daylight or good artificial
light.

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

• Watch for traffic when operating near or crossing
roadways.

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

• Always wear eye protection when operating
machine.

• Wear proper Personal Protective Equipment
(PPE) while operating this machine, including (at
a minimum) sturdy footwear, eye protection, and
hearing protection. Do not mow in shorts and/or
footwear with open toes.

• 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 first read
and understand this Operation Manual. Local laws
may regulate the age of the user.

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

• Allow machine to cool before storage.

8011-520

Never take passengers

WARNING!

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

10

SAFETY

Personal Safety Equipment

WARNING!

When using the machine, approved
personal protective equipment (shown
in illustrations) shall be used. Personal
protective equipment cannot eliminate
the risk of injury but it will reduce the
degree of injury if an accident does
happen. Ask your retailer for help in
choosing the right equipment.

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

• Never use the machine when barefoot.

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

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

• Always wear gloves when handling the blades.

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

• Use ear protectors to avoid damage to hearing.

8011-670a

Personal protective equipment

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.

6003-004

Mow up and down, not side to side

WARNING!

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

11

SAFETY

• 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.

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.

WARNING!

CHILDREN CAN BE INJURED BY THIS
EQUIPMENT. The American Academy
of Pediatrics recommends that children
be a minimum of 16 years of age before
operating a riding lawn mower.

8011-519

Be extra cautious when driving on slopes

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

• 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

12

8011-517

Never allow children to operate the machine

SAFETY

Safe Handling of Gasoline

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
to a safe temperature before refueling.

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 to a safe
temperature before refueling.

• Never fuel the machine indoors.

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

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

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

• Remove gas-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 overfill fuel tank. Replace gas cap and
tighten securely.

• Do not start the engine near spilled fuel.

• Never use gasoline as a cleaning agent.

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

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

8011-516

Never fill the fuel tank indoors

WARNING!

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

13

SAFETY

General Maintenance

• Never operate machine in a closed area.

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

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

• Keep machine free of grass, leaves, or other
debris buildup. Clean oil or fuel spillage and
remove any fuel-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 flames or sparks.

• The battery can explode and cause serious injury
or damage.

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

14

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.

SAFETY

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

WARNING!

Avoid electrical sparking and its
consequences by the following routines:

• Use protective goggles.

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

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

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

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

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

• Allow the machine to cool before putting it in
storage.

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

8009-728

Risk of sparking

8011-514

Regularly clean deck

15

SAFETY

Transport

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

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

• Do not operate this machine on public roadways.

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

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

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

• When loading or unloading this machine, do not
exceed the maximum recommended operation
angle of 10O.

IMPORTANT INFORMATION

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

WARNING!

Use extreme caution when loading the
machine into a truck or trailer using
ramps. There is the possibility of serious
injury or death if the machine falls off the
ramps.

WARNING!

Escaping hydraulic oil under pressure
can have sufficient force to penetrate the
skin, causing serious injury. If injured
by escaping fluid, see a doctor at once.
Serious infection or reaction can develop
if proper medical treatment is not
administered immediately.

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-knifing. Travel slowly
and allow extra distance to stop. Do not tow on sloped
ground. The weight of the towed equipment may
cause loss of traction and loss of control.

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

Spark Arrestor

A spark arrestor for the muffler is available through
your authorized Dixon dealer.

16

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).

CONTROLS

This operator’s manual describes the Dixon Zero Turn
Rider. The rider is fitted with a four-stroke overhead
valve engine.

Transmission from the engine is made via belt-driven

Control Locations

9 8

7

hydraulic pumps. Using the left and right steering
controls, the flow is regulated and thereby the
direction and speed.

2

1

6

5

11

1. Motion control levers

2. Parking brake

3. Throttle control

4. Blade switch

10

4

3

5. Ignition switch

6. Choke control

7. Fuses

8. Fuel tank cap

9. Fuel shut off valve

10. Deck lift

11. Hour meter

8050-080

17

CONTROLS

Steering Control Levers

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

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

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

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

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

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

8055-221

Steering controls

WARNING!

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

18

8061-038

1. Forward

2. Neutral

3. Neutral slot, Neutral lock

4. Reverse

Motion control lever, right side

CONTROLS

Parking Brake

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

IMPORTANT INFORMATION

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

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.

To increase or decrease the engine speed, the control
is moved forward or back respectively.

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

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

8066-052

Parking brake not activated

Ignition Switch

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

IMPORTANT INFORMATION

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

8050-081

Throttle control

8050-081

Ignition switch

19

CONTROLS

Choke Control

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

For cold starts the control should be pulled up.

WARNING!

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

Blade Switch

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

8050-081

Choke control

Fuses

Fuses are located on the left hand side of the
machine. Access the fuses by tilting the seat
forward. The flat 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

20

8050-081

Blade switch

8050-082

Fuses

CONTROLS

Seat Adjustment Lever

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

Hour Meter

The hour meter displays the total operating time with
the blade activated.

The display on the hour meter will turn on the oil can
icon after every fifty hours of use and will stay on
for two hours or until the meter is manually reset. To
manually reset the timer, turn the ignition key to the
run position and then engage and disengage the
blade switch five times at one second intervals.

8058-221

Lengthways adjustment

IMPORTANT INFORMATION

To obtain an even cutting height, it is
important that the air pressure is 15 psi in all
tires.

Cutting Height Adjuster

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

8050-081

Hour meter

8066-027

The mower deck’s lifting pedal

21

CONTROLS

Fuel Shut Off Valve

The fuel shut off valve is located in the fuel line under
the seat. Tilt seat forward for access. The fuel valve is
ON when the valve is parallel to the fuel line. Rotate
the valve ¼ turn clockwise to turn fuel OFF.

IMPORTANT INFORMATION

To obtain an even cutting height, it is
important that the air pressure is 15 psi in all
tires.

Tracking

If the mower is not tracking straight, check the
air pressure in both rear tires. Recommended air
pressure is 15 psi. (1 bar) Tracking must be checked
on a flat and level concrete or blacktop surface. If the
unit still does not track straight contact your Dixon
workshop for adjustments.

8050-010

Fuel shut off valve in the OPEN position.

WARNING!

No adjustments or maintenance to be
carried out unless:

• the engine stopped

• the ignition key removed

• the parking brake activated

22

CONTROLS

Fuel Tank

Read the safety instructions before refueling. The
machine has one fuel tank, just behind the seat. The
tank capacity is 5 gallons (19 liters).

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

The engine will run on a minimum of 85-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. Do not use E85 alcohol based fuel.
Damage to engine and components may occur.

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

8050-091

Fuel tank

WARNING!

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

WARNING!

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

Risk for burns if touched.

Allow engine and exhaust system to cool
before refueling.

WARNING!

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

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.

23

OPERATION

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

Training

Due to unique steering capabilities, zero turn mowers
are far more maneuverable than typical riding
mowers.

This section should be reviewed in its entirety prior to
attempting to move the mower under its own power.
When first operating the mower or until becoming
comfortable with controls, use a reduced throttle
speed and reduced ground speed. DO NOT move
control levers to the furthest forward or reverse
positions during initial operation.

First time users should become familiar with the
mower’s movement on a hard surface, such as
concrete or blacktop PRIOR to attempting to operate
on turf. Until the operator becomes comfortable with
the mower controls and zero turning capability, overly
aggressive maneuvers may damage turf.

Steering

To move forward and backward

The direction and speed of the mower’s movements
are 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 the mower (see Moving
Machine By Hand in the Operation section) to an
open, flat area without other people, vehicles or
obstacles nearby. To move the unit under its own
power, the operator must sit in the seat and start
the engine (see Before Starting in the Operation
section). Adjust the engine speed to idle, disengage
the parking brake but do not engage the blades at
this time. Rotate control levers inward. As long as
the control levers have not been moved forward or
backwards, the mower will not move.

Slowly move both control levers forward slightly. This
will allow mower to start moving forward in a straight
line. Pull the control levers back to the neutral position
and the mower should stop moving.

Pull back slightly on control levers, allowing the
mower to move backwards. Push the control levers
forward to the neutral position and mower should stop
moving.

To turn to the right

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

To turn to the left

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

To zero turn

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

Then by alternating one lever slightly to the forward
position and the other in the reverse position,
complete the turn.

24

OPERATION

Before Starting

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

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

3. Check that there is sufficient fuel in the fuel tank.

4. Make sure that the parkng brake is engaged.

5. Adjust the seat to the desired position.

6. Place the steering controls in the neutral position.

8066-052

Activate parking brake

7. Raise the mower deck to the highest (transport)
level by setting the pedal fully forward.

8. Set the height selection pin at the desired cutting
height and secure with the hairpin.

The following conditions must be fulfilled 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.

8066-053

Place controls in neutral position

Set the pin to the desired mowing height

25

OPERATION

Starting the Engine

1. Sit on the seat.

2. Raise the mower deck by setting the deck pedal
fully forward.

3. Activate the parking brake.

4. Disengage the mower blades by pressing the
blade switch downwards.

Set the pin to the desired mowing height

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

26

8050-081

Disengage the mower blades

8066-053

Place controls in neutral position

OPERATION

6. Move the throttle to the middle position.

7. If the engine is cold, the choke control should be
pulled up.

8050-177

Set the throttle

8. Open the fuel tank valve.

8050-177

Set the throttle

8050-010

Open the fuel valve

27

OPERATION

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

10. When the engine starts, immediately release the
ignition key back to the run position. Push the
choke control in gradually when the engine has
started.

8050-780

Turn to START 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.

11. Set the engine speed with the throttle. Allow the
engine to run at a moderate speed, approximately
mid throttle, for 3-5 minutes before loading it too
heavily. USE FULL THROTTLE WHEN MOWING
(no choke).

8050-781

Release ignition to the RUN position

28

8050-178

Set the engine speed

OPERATION

Weak Battery

WARNING!

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

IMPORTANT INFORMATION

Your mower is equipped with a 12-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.

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

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

Jumper cables

1. Connect each end of the RED cable to the
POSITIVE (+) terminal on each battery, taking
care not to short against chassis.

2. Connect one end of the BLACK cable to the
NEGATIVE (-) terminal of the fully charged battery.

3. Connect the other end of the BLACK cable to a
good CHASSIS GROUND on the mower with the
discharged battery, away from the fuel tank and
battery.

To remove cables, reverse order

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

2. Remove RED cable last from both batteries.

8011-642

Jumper cable connection

29

OPERATION

Running

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

2. Move the steering controls inwards, out of the
neutral position (N).

3. Release deck height control with the cutting
height adjustment pedal.

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

5. Move throttle control to full throttle.

8066-052

Released parking brake

WARNING!

Make sure 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.

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

8066-027

Deck lifting pedal

30

8050-178

Set blade engagement and throttle control

OPERATION

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.

IMPORTANT INFORMATION

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

8066-053

Place controls in neutral position

• 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.

8066-052

Released parking brake

31

OPERATION

Mowing Tips

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

• Begin with a high cutting height and reduce it until
the desired mowing result is attained.
The average lawn should be cut to 2½" (64 mm)
during the cool season and over 3" (76 mm)
during the hot months. For healthier and better
looking lawns, mow often after moderate growth.
For best cutting performance, grass over 6" (15
cm) in height should be mowed twice. Make the
first cut relatively high, the second to the desired
height.

• The mowing result will be best with a high engine
speed (the blades rotate rapidly) and low speed
(the rider moves slowly). If the grass is not
too long and dense, the driving speed can be
increased without negatively affecting the mowing
result.

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

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

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

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

• When the mulching kit is used, it is important that
the mowing interval is frequent.

WARNING!

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

8011-603

Mowing pattern

WARNING!

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

32

OPERATION

Stopping the Engine

Allow the engine to idle a minute 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.

1. Disengage the mower deck by pressing the blade
switch in.

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

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

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

8050-081

Set blade engagement and throttle control

5. Move the steering controls outward.

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

IMPORTANT INFORMATION

Leaving the ignition switch in any other
position than OFF will cause the battery to be
discharged.

8066-027

Mower deck’s lifting pedal

8066-053

Place controls in neutral position

33

Moving Machine by Hand

OPERATION

WARNING!

No adjustments or maintenance should
be carried out unless:

• the engine stopped

• the ignition key removed

• the parking brake activated

When pushing or pulling the mower, engage the IZT
(Integrated Zeroturn Transaxle) bypass linkages. The
linkages are located on each side of the rear of the
unit below the rear engine plate.

Raise the deck to the highest (transport) position.
Pull the bypass linkages up and out of the keyhole

slots. Release the lever with the head outside the
bracket and held into the bypass setting.

To reengage the IZTs to drive, reverse the above
procedure.

2

1

8058-059

1. IZT locked into the bypass position

2. Linkage lever, engaged

Right side, IZT linkage

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 foam pre-filter

Clean the air cleaner’s paper filter cartridge

Check/adjust the parking brake

Inspect muffler/spark arrestor

2)

2)

2)

Daily At least

once
each

Before After 50 250 500

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.

2)

In dusty conditions, cleaning and replacement are required more

often.

3)

Performed by authorized service workshop.

● = Described in this manual

♦ = Not described in this manual

■ = Refer to the engine manufacturer's manual

35

MAINTENANCE

MAINTENANCE

Check/adjust throttle cable

Check the condition of belts, belt pulleys

Change the engine oil

Replace the engine oil filter

Clean/replace the spark plugs

Replace the fuel filter

Replace paper air filter

Check the caster wheels (every 200 hours)

Replace the air cleaner’s foam pre-filter

Check the hydraulic oil in the oil tank

Change the hydraulic oil (every 500 hours)

Replace the hydraulic oil filter (every 500 hours)

Dismantle and inspect starter 3) (every 500 hours)

Check/adjust the mower deck

Check the engine valve clearance

Perform the 500-hour service

1)

2)

2)

3)

3)

Daily At least

once
each

Before After 50 250 500

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.

2)

In dusty conditions, cleaning and replacement are required more

often.

3)

Performed by authorized service workshop.

● = Described in this manual

♦ = Not described in this manual

■ = Refer to the engine manufacturer's manual

WARNING!

Before performing any service or
adjustment checklist:

• Engage the parking brake.

• Place the Blade-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.

36

MAINTENANCE

Battery

Your mower is equipped with a maintenance free
battery that 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 the chart for charging times

Cleaning battery and terminals

Corrosion and dirt on the battery and terminals can
cause the battery to lose power.

1. Open the terminal access doors.

2. Remove the red terminal guard.

3. Disconnect BLACK battery cable first, then the
RED battery cable and remove the battery from
the machine.

4. Rinse the battery with plain water and dry.

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

6. Coat terminals with grease or petroleum jelly

7. Reinstall battery.

IMPORTANT INFORMATION

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

Always use protective glasses when
handling the battery.

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.

STAT E

OF

CHARGE

*Charging time depends on battery capacity,

condition, age, temperature and efficiency 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 -

WARNING!

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

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

Always use two wrenches for the terminal
screws.

Replacing battery

1. Lift seat and rotate forward.

2. Open terminal access doors

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

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

5. Carefully remove the battery from the mower.

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

7. Reinstall battery terminal guard.

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

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

10. Close access doors.

11. Lower seat.

2

1

2

8066-049

1. Terminal guard

2. Access doors

Battery cleaning and installation

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:

1. The mower deck is disengaged.

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

3. The driver is sitting in the driver’s seat.

4. The parking brake is on.

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

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

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

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

8050-913

Start conditions

IMPORTANT INFORMATION

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

Tire Pressures

All tires should be at 15 psi / 103 kPa / 1 bar.

Parking Brake

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

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

WARNING!

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

8066-052

Check for proper operation of parking brake

38

MAINTENANCE

V-belts

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

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

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

Deck Belt

1. Park on a level surface. Apply parking brake.

2. Lower the deck into the lowest cutting position.

3. Remove bolts from belt shields and remove
shields.

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

5. Carefully roll the belt over the top of the cutter
housing pulleys and remove belt.

Deck Belt Installation

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

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

2. Route the belt forward between the ZT-3400
transaxles and up onto the deck.

3. Place belt around spring loaded idler pulley.

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

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

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

7. Adjust tension with deck eyebolt.

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

8050-842

Remove belt shields

8050-843

Belt routing, deck belt

39

MAINTENANCE

Pump Belt

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

Replacing Pump Belt

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

Belt Removal

From the top side of the deck:

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

2. Tilt seat forward to access fan covers. Remove
both fan covers.

From the underside of the mower:

3. Remove clutch stop to access the belt.

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

5. With the idler arm in the slack position, slip a
screwdriver, clevis pin or similar into the 3/8" hole
in the plate that sits between the two fan covers.
This will keep the idler in the extended position
and allow removal of the breaker bar.

6. Remove belt from the engine and pump pulleys
over the top of the fans.

8058-064

Remove fan covers

Belt Installation

If the pump is not locked in the extended position,
repeat Steps 4 and 5 from the above instructions.

1. Slip the belt over the fans and route it between the
idler pulleys.

2. Place the belt over the right and left idler pulleys.

3. Place the belt on the engine pulley.

4. Use the breaker bar to hold the tension off the belt
while removing the implement used as a brace in
the plate.

5. Replace and secure clutch stop.

6. Reinstall the fan shields.

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

V-belts

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

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

3

1

2

8058-060

1. Electric clutch

2. Idler arm release placement

3. Clutch stop

Pump belt removal

40

MAINTENANCE

Cutting Blades

For the best mowing results, it is important that blades
are well sharpened and not damaged.

Replace blades that have been bent or cracked when
hitting obstacles.

Let the service workshop decide whether a blade
with large nicks can be repaired/ground or must be
replaced. Balance the blades after sharpening.

Check the blade mounts.

Blade Replacement

WARNING!

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

1

3

1. Remove blade bolt by turning counterclockwise.

IMPORTANT INFORMATION

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

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

3. Install and tighten blade bolt securely.

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

IMPORTANT INFORMATION

Special blade bolt is heat treated.

Replace with a Dixon bolt if required.

2

8050-844

1. Blade

2. Blade bolt (special)

3. Cutter housing

Blade attachment

Do not use lower grade hardware than
specified.

41

Adjusting the Mower Deck

WARNING!

1. Before performing any service or adjustment checklist:

2. Engage the parking brake.

3. Place the Blade switch in the disengaged position.

4. Turn ignition switch to OFF position and remove the key.

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

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

MAINTENANCE

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

Leveling

Adjust the deck while the mower is on a level
surface. Make sure the tires are inflated to the correct
pressure. See Technical Data under Transmission.
If tires are under or over inflated, the deck cannot be
properly adjusted.

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

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

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

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

3. Turn both outer blades to align with the deck in
front-to-rear manner. Reposition rear mounting
bolts up or down 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 standard
measurement position. Depending on the type of
grass being mowed or environmental conditions,
additional adjustments may be required to achieve the
desired cut.

WARNING!

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

1

2

3

8050-083

1. Front lift arm

2. Rear lift arm

3. Slotted deck hanger plates

Leveling the mower deck

42

MAINTENANCE

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

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

Anti-scalp rollers can be set in three positions:

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

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

• Lower position 4½" to 6" (114 to 152 mm) grass.
The rollers should be approximately ¼" (6.5 mm) from

ground. Do not adjust the rollers to support the deck.

8058-054

Anti-scalp rollers

IMPORTANT INFORMATION

To avoid deck damage, the anti-scalp rollers
must not be adjusted to support the deck.

43

MAINTENANCE

Caster Wheels

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

Foam filled tires or solid tires will void the warranty.

Removal and installation of caster wheel

1. Remove nut (1) and caster bolt (2).

2. Pull the wheel out of the fork and take care of the
sleeve (3).

3. Reinstall in reverse order. Tighten caster bolt.

IMPORTANT INFORMATION

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

Only use O.E.M. specified tires.

2

1

3

8011-619-1

Caster wheels

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.

Use protective glasses when
cleaning and washing.

Hardware

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

44

LUBRICATION

12/12 Every year

1/52 Every Week

1/365 Every day

Lubricate with grease gun

Oil change

*Change transaxles (transmission) filters.

General

Remove the ignition key to prevent unintentional
movements during lubrication.

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

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

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

8011-672-6

Level check

Filter change

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.

45

LUBRICATION

Wheels and Deck Spindles

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, one zerk for each wheel
mount, until the grease is forced out.

Front Wheel Bearings

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

IMPORTANT INFORMATION

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

Deck Spindles

Lower the cutting deck completely.
If you use grease gun without rubber hose, the foot

plate must be removed.
Lubricate with a grease gun, one zerk, 2-3 strokes on

all three spindles.

Engine Lubrication

Refer to the engine manufacturer's manual for
maintenance and service instructions.

8050-009

Lubricating the wheel bearings

8050-709

Deck spindle

46

LUBRICATION

Transaxle Fluid Change
(Transmission)

This transaxle is designed with an external filter for
ease of maintenance. To ensure constant fluid quality
levels and longer life, an oil filter change interval of
every 200 hours is recommended.

The following procedure is performed with the
transaxles installed in the mower and the mower on
level ground. Apply the pump release valve for each
transaxle and set the parking brake.

1. Remove the three ¼" filter guard screws and filter
guard. Clean any loose debris from around the
perimeter of the filter.

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

10. Fill with 20W50 motor oil until oil just appears
at the bottom of each transaxles’ top port
(approximately 2 quarts per transaxle, 4 quarts
total). Install the top port lug into each transaxle
as the oil level reaches the port.

11. Install and torque the top port plugs to 180 in./lbs.

12. Continue to fill the transaxles through the
expansion tank until the FULL COLD line is
reached (this will take approximately 23 additional
ounces).

13. Reinstall the expansion tank cap by hand. Be
careful to not overtighten.

2. Place an oil drain pan (12" or more diameter and
8 qt. capacity is optimal) beneath the oil filter.
Remove the oil filter from the transaxle.

3. After the oil has drained, wipe the filter base
surface and apply a film of new oil to the gasket of
the replacement filter.

4. Install the new filter by hand, turning it three­quarters to one full turn after the filter gasket
contacts the filter base surface.

5. Reinstall the filter guard. Torque screws to
65 in/lbs. each.

6. Repeat steps on the opposite side.

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

8. Remove the top port plug (see illustration) from
the left side and right side of the transaxles prior
to filling with oil. This will allow the transaxles to
vent during oil fill.

9. Remove the cap from the transaxles’ expansion
tank located on the vehicle frame.

2

3

1

8019-010

1. Filter guard

2. Transaxle filter

3. Top port plug

ZT-3400 filter change

47

TROUBLESHOOTING

Problem Cause

The engine will not start. • Blade lever is engaged.

• Steering controls are not locked in neutral
position.

• Driver is not sitting in driver’s seat.

• Parking brake is not activated.

• Battery is dead.

• Contamination in carburetor or fuel line.

• Fuel supply is closed or tap for fuel tank is in
wrong position.

• Clogged fuel filter or fuel line.

The starter does not turn the engine over. • Dead battery.

• Poor contacts on the battery terminal cable
connections.

• Fuse blown.

• Ignition system faulty.

• Fault in the starter safety circuit. See Checking the
Safety System in the Maintenance section.

The engine runs rough. • Faulty carburetor.

• Choke control used with warm engine.

• Defective valves.

• Defective piston, cylinder, piston ring, or
cylinder head seal.

• Cylinder head bolts are loose.

• Clogged fuel filter or jet.

• Clogged ventilation valve on fuel cap.

• Fuel tank nearly empty.

• Fouled spark plug.

• Spark plug is loose.

• Defective ignition cable.

• Defective spark plug electrode.

• Defective spark plug connection.

• Rich fuel mixture or fuel-air mixture.

• Wrong fuel type.

• Water in fuel.

• Clogged air filter.

48

TROUBLESHOOTING

Problem Cause

The engine seems weak. • Clogged air filter.

• Fouled spark plugs.

• Carburetor incorrectly adjusted.

The engine overheats. • Clogged air intake or cooling fins.

• Engine overloaded.

• Poor ventilation around engine.

• Defective engine speed regulator.

• Soot in the combustion chamber.

• Too little or no oil in the engine.

• Fouled spark plug.

Battery not charging. • Poor contact with battery terminal cable

connectors.

The machine moves slowly, unevenly, or not at all. • Parking brake on.

• Hydraulic pump bypass linkage engaged.

• Drive belt for the transmission gears slack or has
come off.

• Defective hydraulic system.

• Air 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 the
cable contact.

• Fuse has blown.

Uneven mowing results. • Different air pressure in the tires on left and right

sides.

• Bent blades.

• Suspension for the mower deck is uneven.

• Blades are dull.

• Driving speed too high.

• Grass is too long.

• Grass collected under the mower deck.

The machine vibrates. • Blades are loose.

• Blades are incorrectly balanced.

• Engine is loose.

49

STORAGE

Winter Storage

The machine should be readied for storage at the
end of the mowing season or if it will not be in use for
longer than 30 days. Fuel allowed to stand for long
periods of time (30 days or more) can leave sticky
residues that can plug the carburetor and disrupt
engine function.

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

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

WARNING!

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

To ready the machine for storage, follow these steps:

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

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

3. Change the engine oil; dispose of properly.

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

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

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

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

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

Service

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

Always use genuine Dixon spare parts.
An annual checkup at an authorized service workshop

is a good way to ensure that the machine performs its
best the following season.

50

SCHEMATIC

8053-002

51

TECHNICAL DATA

966690603

Engine

Manufacturer Kohler

Type Courage Pro

Power 25 hp

Lubrication Pressure with oil filter

Fuel Min 87 octane unleaded (Max

ethanol 10%, Max MTBE 15%)

Fuel tank capacity 5 gallons / 19 liters

Cooling Air cooled

Air filter Standard

Alternator 12V / 16A

Starter Electric 12V

Transmission

Transmission ZT3400 Hydro Gear

Speed and direction controls Dual levers, foam gripped

Speed forward 0-10 mph / 0-16.1 km/h

Speed reverse 0-5 mph / 0-5 km/h

Brakes Mechanical parking brake

Front caster tires, smooth tread 13 x 6.5-6, 4 ply

Rear tires, turf pneumatic 23 x 9.5-12

Tire pressure 15 PSI / 103 kPa / 1 bar

1,2)

1)

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

2)

Refer to the engine manufacturer's owner's
manual for engine specifications.

52

TECHNICAL DATA

966690603

Equipment

Cutting width 52" / 132 cm

Cutting height 1½ - 5" / 3.8 - 13 cm

Number of blades 3

Blade length 18" / 46 cm

Nose Rollers Yes

Sprung seat Standard

Hinged armrests Yes

Hour Meter Standard

Blade engagement Electromagnetic clutch

Deck construction 11 gauge w/10 gauge skirts

Productivity

Output 4.2 acres/h / 16,347 m2/h

Overall dimensions

Weight 740 lbs / 336 kg

Base machine length 75½" / 191 cm

Base machine width 49" / 124 cm

Base machine height 42" / 109 cm

Overall width, chute up 54" / 137 cm

Overall width, chute down 67" / 170 cm

53

TECHNICAL DATA

Torque Specifications

Engine crankshaft bolt 50 ft/lb (67 Nm)
Deck pulley bolts 75 ft/lb (100 Nm)
Lug nuts 75 ft/lb (100 Nm)
Blade bolt 55 ft/lb (75 Nm)
Standard ¼" fasteners 9 ft/lb (12 Nm)

HEX HEAD CAP SCREWS

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

U.S. Standard Hardware

Grade

Size 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, fine or coarse thread)

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

11/8 782 1060 1410 1912

SAE Grade 5 SAE Grade 8 Flangelock Screw

Metric Standard Hardware

Grade

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

Size 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

M22 276 368 390 520 471 628

M24 353 470 498 664 596 794

M27 530 707 474 996 904 1205

Grade 8.8 Grade 10.9 Grade 12.9

Standard 5/16" fasteners 18 ft/lb (25 Nm)
Standard 3/8" fasteners 33 ft/lb (44 Nm)
Standard 7/16" fasteners 52 ft/lb (70 Nm)
Standard ½" fasteners 80 ft/lb (110 Nm)

w/Flangelock Nut

54

CONFORMITY CERTIFICATES

USA requirements

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

55

SERVICE JOURNAL

Action

Delivery Service

Charge battery.

Adjust tire pressure of all wheels according to Technical Data.

Mount the steering controls in the normal position.

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

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

Adjust the position of the steering controls.

Fill with fuel and open the fuel shut off valve.

Start the engine.

Check that there is drive to both wheels.

Check the mower deck adjustment.

Check:

The safety switch for the parking brake.

The safety switch for the mower deck.

The safety switch in the seat.

Date, mtr reading, stamp, sign

The safety switch in the steering controls.

Parking brake functionality.

Driving forward.

Driving backward.

Engaging the blades.

Check the idle speed

Check the engine high idle speed

Inform the customer about:

The need and advantages of following the service schedule.

The need and advantages of leaving the machine for service

every 300 hours.

The effects of service and maintaining a service journal on the

machine’s resale value.

Application areas for Mulching.

Fill in the sales papers

Delivery service has been carried out.

No remaining notes.

Certified:

56

SERVICE JOURNAL

Action

After the First 10 Hours

Change engine oil.

Date, mtr reading, stamp, sign

25-Hour Service

Check the fuel pump’s air filter.

Check the hydraulic system’s oil level.

Check the tire pressures.

Lubricate the belt adjuster, mower deck.

Lubricate the belt adjuster, hydraulic pumps.

Check/clean the engine’s cooling air intake.

Clean air filter dust cap.

57

SERVICE JOURNAL

Action

50-Hour Service

Perform the 25-hour service.

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

(shorter intervals for dusty operating conditions).

Change engine oil.

Lubricate according to lubrication chart.

Check/adjust the parking brake.

Date, mtr reading, stamp, sign

100-Hour Service

Perform the 25-hour service.

Perform the 50-hour service.

Change the engine oil filter.

Clean/replace the spark plugs.

Replace the fuel filter.

Clean the cooling fins on the engine and transmission.

Check V-belts.

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

Change the air filter’s paper cartridge.

58

SERVICE JOURNAL

Action

300-Hour Service

Perform the 25-hour service.

Perform the 50-hour service.

Perform the 100-hour service.

Check/adjust the mower deck.

Clean the combustion chamber and grind the valve seats.

Check the engine valve clearance.

Replace the air cleaner’s prefilter (foam).

Date, mtr reading, stamp, sign

At Least Once Each Year

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

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

Replace the air filter’s paper cartridge.

Change the engine oil (50 hours).

Replace the engine oil filter (100 hours).

Check/adjust the cutting height.

Check/adjust the parking brake (50 hours).

Clean/change the spark plugs (100 hours).

Change the fuel filter (100 hours).

Clean the cooling fins (100 hours).

Check the engine valve clearance.

59