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Dixon 966038601 Lawn Mower User Manual

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1. 2 7 64 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 consid
2. 21 Parking Brake 21 Fuel Tank 22 Seat Adjustment 22 OPERATION 23 23 Steering 23 Before Starlirtgr i sce 24 Starting the 24 Weak 222 2 2 28 Jumper 28 29 Operating On 30 MOWING Tips 31 Stopping 22 2 2 32 Manual Irangport 2 tate 33 Bypass 33 34 Maintenance Schedule 34 curi EET 36 Ignition 2222 2 2 37 Safety 222 2 2 9 37 Engine Cooling Air 38 Throttle Cable cesi ehe cas 38 Choke Cable 38 Air Filter 2 22 2222 39 Briggs amp Stratton 39 Kohler 40 Ruel tees 41 Fuel Pump Air 2 22 41 Tire 41 Parking 2 2222 99 42 m 42 Pump 43 Cutting
3. 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 e Read understand and follow all instructions on the machine and in the manual before starting e Do not put hands or feet near rotating parts under the machine Keep clear of the discharge opening at all times e Only allow responsible adults who are familiar with the instructions to operate the machine e 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 e Never carry passengers The machine is only 8011 512 intended for use by one person Read the operator s manual before starting the machine e Do not mow in reverse unless absolutely necessary Always look down and behind before and while backing e 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 e Do not operate machine without the entire grass catcher discharge guard or other safety devices in place and working e Slow down before t
4. 15 1 liters Spark plugs gap Champion XC12YC NGK BPR4ES 030 0 75 mm 030 0 75 mm Transmission O 60 Cutting Width Cutting Height Uncut Circle Number of Blades Blade Length Nose Rollers Sprung Seat Hinged Arm Rests Hour Meter Blade Engagement Deck Construction Productivity Weight Base Machine Length Base Machine Height Base Machine Width Overall Width Chute Up Overall Width Chute Down TECHNICAL DATA 966038601 966054301 966495301 966495401 2 132 48 155 1 4 3 8 11 3 1 4 3 8 11 3 18 46 cm 1674 41 cm Standard Standard Yes pos es 742 1 189 cm 7472 189 cm 47 119 cm 47 119 cm 46 118 cm 46 118 cm 557 133 51 130 6674 168 62 159 61 CONFORMITY CERTIFICATES USA requirements Labels are placed on the engine and or in the engine compartment stating that the machine will fulfill the requirements This is also applicable to special requirements for any of the states California emission rules etc Do not remove any of these labels Certificates can also be supplied with the machine at delivery or written in the Engine manual Take care of them as they are valuable documents CE requirements The Declaration of Conformity is included in the literature packet 62 WARRANTY DIXON ZTR COMMERCIAL RESIDENTIAL RAM 44 RAM 50 RAM 44 MAG RAM 50 MA
5. 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 8050 831 Clean regularly IMPORTANT INFORMATION Use protective glasses when cleaning and washing 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 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 Removal and installation of caster wheel Remove nut and caster bolt 8011 619 4 1 Caster yoke Pull the wheel out of the yoke and take care of 2 Caster bolt osi 3 Caster long spacer Install in reverse order Tighten caster bolt 4 Caster small spacers Hardware Caster wheels Check daily Inspect the entire machine for loose or missing hardware 47 MAINTENANCE Parking Brake Adjustment Jack up unit and support properly with jack stands Allow clearance to work at rear transaxles Before making any adjustmen
6. dryer etc Handle the fuel with Service care It is very flammable and can When ordering spare parts please specify the cause serious personal injury and purchase year model type and serial number property damage Drain the fuel into Always use genuine Dixon spare parts an approved container outdoors and An annual check up at an authorized service far away from open flame Never workshop is a good way to ensure that your machine use gasoline for cleaning Use performs its best the following season a degreaser and warm water instead 57 58 SCHEMATICS NOTE 1 UNOCCUPIED 2 BRAKE SWITCH IN OFF POSITION 3 MOTION CONTROL LEVERS OUT 4 PTO IN OFF POSITION SOLENOID m RED BLK RED BLK BRAKE SW TO EN ENGINE 20 AMP RIGHT MOTION WHT at y CONTROL LEVER bur el PUR T YEL RED WHT Cn YEL BLK BRN WHT GRN T LEFT MOTION N BLU CONTROL LEVER vgl PUR BLK gt BLK BRN _ BRN 5 BRN SEAT SW BLU PUR gx Ron PTO SW 7 5 AMP HOURMETER BLK BLK Le J ELECTRIC x ACCESSORY CLUTCH 7 OUTLET ENGINE BLK GROUND D KEY SWITCH POSITIONS POSITION 1 OFF at lo Lo es oo POSITION 2 RUN1 LJ POSITION 3 RUN2 AL Lo POSITION 4 START
7. become very hot during operation Allow engine and exhaust system to cool at least two 2 minutes before refueling 13 SAFETY General Maintenance 14 Never use the machine indoors or in spaces lacking proper ventilation The exhaust fumes contain carbon monoxide an odorless poisonous and lethal gas 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 you strike a foreign object stop and inspect the machine Repair if necessary before restarting Never make any adjustments or repairs with the engine running Check grass catcher components and the discharge guard frequently and replace with manufacturer s recommended parts when necessary 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 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 se
8. mtr reading stamp sign After the First 5 8 Hours 1 Change engine oil L Action Date mtr reading stamp sign 25 Hour Service 1 Check the engine air filter Sharpen Replace mower blades if required Check the tire pressures Check battery with cables Lubricate according to lubrication chart Check clean the engine s cooling air intake 25 om Clean the air cleaner s prefilter foam 1 0 ETE 65 SERVICE JOURNAL Action Date mtr reading stamp sign 50 Hour Service 1 Perform the 25 hour service 2 Clean replace the air cleaner s filter cartridge paper filter L shorter intervals for dusty operating conditions 3 Change engine oil L 4 Lubricate according to lubrication chart 5 Check adjust the parking brake 6 Change hydraulic pump and filter Action Date mtr reading stamp sign 100 Hour Service 1 Iv Perform the 25 hour service Perform the 50 hour service Change the engine oil filter Clean replace the spark plugs Replace the fuel filter Check V belts Check tighten caster wheel axle bolts every 200 hours Change the air filter s paper cartridge Change hydraulic pump oil and filter 200 hours L3 453 ES 66 SERVICE JOURNAL Action Date mtr reading stamp sign 300 Hour Service 1 NO oO om Perform the 25
9. 0 2 1 44 Blade 44 Adjusting the Mower 45 Leveling 45 Anti scalp rollers 46 22 2 2 47 Caster Wheels reet extet etre 47 Hardware 22 2 47 Parking Brake 48 Tracking ine 48 49 Lubrication 49 Front Wheel 50 Front Wheel 5 50 50 Engine 22 2 9 51 Engine Oil Levels 51 Changing the Engine 52 Transaxle Transmission Fluid Change 53 E 54 TROUBLE SHOOTING 55 STORAGE eritis tarea 57 Winter Storage 57 SENICE EE 57 SCHEMATIC 0 58 TECHNICAL 59 ACCOSSONIOS i 59 Torque 59 CONFORMITY 62 63 SERVICE
10. 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 Reverse Neutral Fast Warning Parking Brake CE conformity Warning Rotating blades Do not touch parts marking Only for keep away from the European market discharge deck Battery acid is corrosive explosive and flammable Do not stand here Noise emissions to the surroundings in accordance with the European Union s directive The machine s emission is stated in the chapter TECHNICAL DATA and on the decals Only machines for European Use protective glasses Use protective gloves market SYMBOLS AND DECALS Read Shut off engine and Keep a safe Use on slopes No passengers Operator s remove key before distance from no greater Manual performing any the machine than 10 maintenance or repair work Whole body Severing of fingers Do not open or Careful backing up Careful going exposure to and toes remove safety watch for other forward watch for thrown objects shields while people other people engine is running DANGER _ KEEP HANDS AND FEET AWAY Moving sharp blades under cover SAFETY Safety Instructions These instructions are for your safety Read them carefully
11. Ibs each Repeat steps on the opposite side Drain old oil filters of all free flowing oil prior to disposal Place used oil in appropriate containers 8019 510 and dispose of it in accordance with laws in your 1 Filter guard area 2 Transaxle filter Remove the top port plug see illustration from 3 Top port plug the left side and right side of the transaxles prior EZT filter change to filling with oil This will allow the transaxles to vent during oil fill Remove the cap from the transaxles expansion tank located on the vehicle frame at the bottom of each transaxles top port approximately 2 quarts per transaxle 4 quarts total Install the top port plug into each transaxle as the oil level reaches the port Install and torque the top port plugs to 180 in Ibs Continue to fill the transaxles through the expansion tank until the FULL COLD line is reached this will take approximately 23 additional ounces careful to not overtighten Proceed to the purge procedure 8019 012 1 Expansion tank 2 Tank cap 3 Transaxles EZT filter change 53 LUBRICATION Purging Due to the effects air has on efficiency in hydrostatic drive applications it is critical to purge the system These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate ma
12. deck by depressing the blade switch 2 Raise the mower deck by depressing the button on the lift lever and pulling backward 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 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 32 8050 151 1 8050 825 Raise the mower deck THROTTLE 8050 151 1 Move the throttle to the slow position OPERATION Manual Transport Bypass Linkages When pushing or pulling the mower engage the Z1 2800 Integrated Zero turn Transaxle bypass linkages The ZT 2800 bypass linkages are located on the rear of the frame below the rear engine guard 1 Raise the deck into the highest cutting position 2 Pullthe bypass linkages up and out of the keyhole slots Release the levers with the head outside the frame and held in the bypass position 3 Toreengage the 21 2800 to drive reverse the above procedure Load the machine into truck or trailer by driving up Bypass linkage 2 2800 engaged ramps in low gear DO NOT LIFT The machine is not in
13. 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 ei ei Check the tire pressures Check battery Sharpen Replace mower blades Clean the engine s cooling air intake 2 Clean the air cleaner s pre filter 2 foam Clean the air cleaner s filter cartridge 2 paper filter Check adjust the parking brake Inspect muffler spark arrester 34 MAINTENANCE Maintenance At Maintenance least interval once Daily Wkly each in hours Before After year 25 50 100 300 Check adjust throttle cable e 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 the air filter paper filter 2 Check the caster wheels every 200 hours Replace the air cleaner s pre filter foam Check adjust the mower deck e Check the engine valve clearance Perform the 300 hour service 9 Check hydraulic oil at reservoir Change hydraulic oil amp filter 200 hours Clean fins of oil cooler Kohler 1 First change after 5 8 hours When operating with heavy load or at high ambient temperatures
14. replace every 50 hours 2 In dus y conditions cleaning and replacement are required more often 3 Performed by authorized service workshop e Described in this manual Not described in this 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 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 e Keep battery and terminals clean e Keep battery bolts tight e 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 1 Lift seat and rotate forward 2 Disconnect BLACK battery cable first then the RED battery cable and remove the battery from the machine 3 Rinse the battery with plain water and dry 4 Clean terminals and battery cable ends with wire brush until shiny 5 Coat terminals with grease or petroleum jelly 6 Reinstall battery Replaci
15. slopes greater than 10 degrees Do not drive across slopes e The slowest speed possible should be used before starting up or down hills e Avoid stopping or changing speed on hills e f stopping is absolutely necessary pull drive levers into the neutral position and push to the outside of the unit and engage the parking brake e To restart movement release the parking brake IMPORTANT INFORMATION Control levers return to neutral when released This may cause the mower to suddenly stop e Pull the control levers back to the center of the mower and press forward to regain forward motion e all turns slowly 30 8050 781 8058 020 Released parking brake OPERATION Mowing Tips WARNING e Observe and flag rocks and other fixed objects to avoid collisions Clear the lawn of stones and other e Begin with a high cutting height and reduce it objects that can be thrown out by the until the desired mowing result is attained blades The average lawn should be cut to 27 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 e The mowing result will be best with a high engine speed the blades rotate rapidly and low spee
16. the best support and service Before the product is delivered the machine has for example been inspected and adjusted by your retailer See the certificate in the Service Journal in this operator s manual When you need spare parts or support in service questions warranty issues etc please consult the following professional This Operator s Manual belongs to the machine with Engine the manufacturing number Manufacturing Number The machine s manufacturing number can be found on the printed plate affixed to the right in the engine compartment Stated on the plate from the top are e he machine s type designation I D e The manufacturer s type number Model e 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 e The engine s model e The engine s type e Code Please have these available when ordering spare parts 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
17. the oil to run out into the container Reinstall the oil drain valve cap e Replace the oil filter if necessary e ill with new engine oil in accordance with Bains Checking the Oil Level The dipstick markings e Start the engine Run it for 3 5 minutes Stop and recheck the oil level 52 LUBRICATION Transaxle Transmission Fluid Change This transaxle is designed with an external filter for ease of maintenance To ensure constant fluid quality levels and longer life an oil filter change interval of every 200 hours is recommended The following procedure 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 11 12 Fill with 20W50 motor until oil just appears Reinstall the expansion tank cap by hand Be Remove the three filter guard screws and filter guard Clean any loose debris from around the perimeter of the filter See illustration 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 After the oil has drained wipe the filter base surface and apply a film of new oil to the gasket of the replacement filter Install the new filter by hand turning it three quarters to one full turn after the filter gasket contacts the filter base surface Reinstall the filter guard Torque screws to 65 in
18. to S B 5 Lo M G 5 TECHNICAL DATA Accessories Collection system 2 Torque Specifications Engine crankshaft bolt 50 ft lb 67 Nm Standard 1 4 fasteners Deck pulley bolts 150 ft lb 203 Nm Standard 5 16 fasteners Lug nuts 75 ft lb 100 Nm Standard s fasteners Blade bolt 90 ft lb 122 Nm Standard he fasteners Standard 1 2 fasteners 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 SAE Grade 5 SAE Grade 8 Flangelock Screw w Flangelock Nut uns Shank Size Diameter inches fine coarse thread Grade 5 Minimum commercial quality lower quality not recommended Metric Standard Hardware 9 ft lb 12 Nm 18 ft lb 25 Nm 33 ft lb 44 Nm 52 ft lb 70 Nm 80 ft lb 110 Nm pom pos pom pow 5 D x N 2 hd amp E E 9 E E N e e 59 TECHNICAL DATA 7 71 _ 96605301 966495301 968495401_ mme em oil See viscosity dia SAE 10W30 10W40 5W20 SAE 10W30 5W30 gram 5W30 API SF SJ API SF SJ Fuel Min 87 octane unleaded Max Min 86 octane unleaded Max ethanol 10 Max MTBE do ethanol 5 Max MTBE 1590 Fuel tank capacity 4 5 gallon 15 1 liters 4 5 gallons
19. unimproved wooded bush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable local or state laws if any If a spark arrester is used it should be maintained in effective working order by the operator CONTROLS This operator s manual describes the Dixon Zero Turn Rider The rider is fitted with a Kohler or Briggs amp Stratton four stroke overhead valve engine developing 24 26 horse power Transmission from the engine is made via two 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 13491501585 Mass Control Locations belt driven hydraulic pumps which in turn drive a hydraulic motor for each drive wheel Using the left and right steering controls the flow is regulated and thereby the direction and speed 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 Motion control levers Seat adjustment lever Cutting height adjuster Throttle control Cho
20. 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 Tee YK 8050 109 Remove battery hold down to replace battery MAINTENANCE Ignition System The engine is equipped with an electronic ignition system Only the spark plug requires maintenance For recommended spark plug see Technical Data 1 Remove the ignition cable boot and clean around the spark plug 2 Remove the spark plug with a spark plug socket wrench 3 Check the spark plug Replace the spark plug if fouled the electrodes are burned and if the insulation is cracked or damaged Clean the spark plug with a steel brush if it is to be reused 4 Measure the electrode gap with a gapping tool The gap should be 030 0 75 mm Adjust as necessary by bending the side electrode 5 Reinsert the spark plug turning by hand to avoid damaging the threads 6 After the spark plug is seated tighten it using a spark plug wrench so that the washer is compressed A used spark plug should be turned s of a turn from the seated position A new spark plug should be turned turn from the seated position 7 Replace the ignition cable Safety System The machine is equipped with a safety system that prevents starting or driving under the following conditions The engine can onl
21. 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 e Watch for holes ruts bumps rocks or other hidden objects Uneven terrain could overturn the machine Tall grass can hide obstacles e Choose a low ground speed so that you will not have to stop while on the slope e Do not mow on wet grass Tires may lose traction e Avoid starting stopping or turning on a slope If the tires lose traction disengage the blades and proceed slowly straight down the slope e Keep movement on the slopes slow and gradual Do not make sudden changes in speed or 9 Mow up down not side side direction which could cause machine to roll over e Use extra care while operating machine with grass catchers or other attachments they can affect the stability of the machine WARNING e Do not use on steep slopes e Do not try to stabilize the machine by putting foot on the ground e 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 Do not drive up or down hills with slopes greater than 10 degrees And do not drive across any slopes 11 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 tha
22. DIXOT Izr Operator Manual RAM 52ZT 966038601 RAM 48ZT 966495301 527 BF 966054301 RAM 48ZT BF 966495401 Please read the operator s manual carefully and make sure you understand the instructions before using the machine 2009 HTC All rights reserved Beatrice NE Printed in U S A 5 02 000 nee 5 Driving and Transport on Public Roads 5 io nom 5 Secum EET 5 GOGA SCM CS sar EE 6 SYMBOLS AND 7 tee 9 Safety 5 2 22 2 2 9 Personal Safety 11 Slope Operation nnet 11 Safe Handling of Gasoline 13 General 14 OLE DP 16 Customer 16 5 2 17 Motion Control Levers 18 lice nes rn 18 Cutting Height 19 Throttle trainer 19 CHOKES COD OL ss Correr tette teen 19 Ignition 20 Hour Meter iioii 20 et trt eet te 20 GU m n HM 2 Fuel Shut Off
23. FOR CONSEQUENTIAL DAMAGES UNDER ANY EXPRESS OR IMPLIED WARRANTY ARE EXCLUDED 63 SERVICE JOURNAL Action Date mtr reading stamp sign Delivery Service 1 2 3 12 13 14 Charge the battery Adjust the tire pressure of all wheels to 15 PSI 1 bar 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 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 OOOOOO OOOO Delivery service has been carried out No remaining notes Certified 64 SERVICE JOURNAL Action Date
24. G RAM ULTRA 50 RAM ULTRA 60 amp RAM ULTRA 72 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 1 COMMERCIAL WARRANTY use other than or in addition to mowing at owner s primary place of residence a One 100 parts and labor subject to the conditions and limitations described herein for a period of one year from date of purchase by the original owner b Attachments marketed through or approved by Dixon are warranted for one year parts and labor in commercial use applications c The RAM 44 RAM 50 RAM 44 MAG RAM 50 MAG RAM ULTRA 50 RAM ULTRA 60 and RAM ULTRA 72 are not subject to hour meter restrictions d Warranty applies to new mowers RESIDENTIAL WARRANTY used only at owner s primary place of residence a Two years 100 parts and labor subject to the conditions and limitations described herein for a period of two years from date of purchase by the original owner b Third year limited to 100 parts cost as shown in the current Dixon Parts Price List and subject to the conditions and limitations as described herein c Attachments marketed through or approved by Dixon are warranted for two years parts and labor in residential use applications d Warranty applies to new mo
25. anol 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 Fill to the bottom of the filler neck Do not overfill Wipe off any spilled oil or fuel Do not store spill or use gasoline near an open flame 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 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 22 8058 833 Fuel tank IMPORTANT INFORMATION Experience indicates that alcohol blended fuels called gasohol ethanol or methanol can attract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel system of an engine while in storage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer Drain the gas tank start the engine and let it run until the fuel lines and carburetor are empty Use fresh fuel the next season See Storage Instructions for additional information Never use engine or carburetor cleaners in the fuel tank or permanent damage may occur 8011 441 Seat adjustment OPERATION R
26. bearing grease IMPORTANT INFORMATION Use minimal lubrication and remove excess 8011 731 lubricant so that is does not come into contact with belts or belt pulley drive surfaces Deck Spindles Lower the cutting deck completely If a grease gun without a rubber hose is used the foot plate must be removed Lubricate with a grease gun one Zerk 2 3 strokes Use only good quality bearing grease 8011 732 Deck spindle Deck Outer Spindle Lubricate using a grease gun one zerk each side 2 3 strokes Use only good quality bearing grease 8061 025 Deck outer spindle with belt shield removed 50 LUBRICATION Engine Oil WARNING A Engine oil can be very hot if it is drained directly after stopping the engine Allow the engine to cool to a safe temperature before draining Engine Oil Filter e Drain the engine oil in accordance with the work description under the heading Engine Oil Change Engine Oil e Remove the oil filter If necessary use a filter remover e Wipe new clean engine oil onto the seal for the new filter e Mount the filter by hand with turn e Run the engine warm then check that there no leaks around the oil filter seal e Check the oil level in the engine fill if necessary The oil filter holds 0 1 qt 0 1 liters of oil 8011 734 Changing the oil filter IMPORTANT INFORMATION Used engine oil is a health hazard and must not be di
27. d 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 e 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 8050 819 mowing results Mowing pattern e 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 e Hose the mower deck underside with water after each use When cleaning the mower deck shall WARNING be raised into the transport position Make sure Never drive the rider on terrain that the mower is cooled and the engine is off slopes more than 10 degrees Mow e Use compressed air to clean top surface of the slopes up and down never side deck Avoid flooding water on top surface engine to side Avoid sudden directional and electrical components changes e When the mulching kit is used it is important that the mowing interval is frequent 31 OPERATION Stopping the Engine Allow the engine to idle a minute in order to attain normal operating temperature before stopping it if it has been worked hard Avoid idling the engine for longer periods as there is a risk of the spark plugs fouling 1 Disengage the mower
28. d be evenly adjusted 3 Set retaining pin into selected cutting height and 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 4 Push the release button on the cutting height lever and move lever to the pin release the button 5 Set the cutting height with the cutting height adjustment lever 8058 020 8058 019 Mower deck lifting lever 29 OPERATION 6 Engage the mower deck by pulling out the blade switch 7 Move throttle control to full throttle not choke 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 Operating On Hills Read Slope Operation in the Safety section WARNING Do not drive up or down hills with
29. d corrosion residues that can plug the carburetor and disrupt 2 Inspect the machine for worn or damaged parts engine function and tighten any nuts or screws that may have Fuel stabilizers are an acceptable option as regards become loose to the sticky residues that can occur during storage 3 Change the engine oil dispose of properly Add stabilizer to the fuel in the tank or in the storage 4 Empty the fuel tanks or add a fuel stabilizer Start container Always use the mixing ratios specified by the engine and allow it to run until the carburetor the manufacturer of the stabilizer Run the engine for is drained of fuel or the stabilizer has reached the at least 10 minutes after adding the stabilizer so that carburetor it reaches the carburetor Do not empty the fuel tank 5 Remove the spark plug and pour about a and the carburetor if you have added stabilizer tablespoon of engine oil into the cylinder Turn over the engine so that the oil is evenly distributed and then refit the spark plug WARNING 6 Lubricate all grease zerks joints and axles Never store an engine with fuel 7 Remove the battery Clean charge and store the in the tank indoors or in poorly battery in a cool place but protect it from direct ventilated spaces where fuel vapor cold can come in contact with open 8 Store the machine in a clean dry place and cover flames sparks or a pilot light such it for extra protection as in a boiler hot water tank clothes
30. e tire pressure for future reference 48 8050 092 1 Swivel washer gap 2 Retaining clip 3 Brake arm Brake arm LUBRICATION Lubrication Schedule 2 12 1 52 1 365 Every year Every Week Oil change Every day 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 Lubricate with grease gun aam Y Level check 25h 50h 100h 200h 300h 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 49 LUBRICATION Front Wheel Mount Lubricate with a grease gun one zerk for each wheel mount until the grease is forced out Use only good quality bearing grease Grease from well known brand names petrochemical companies usually maintains a good quality Front Wheel Bearings Lubricate with a grease gun one zerk for each set of wheel bearings until the grease is forced out Use only good quality
31. ea 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 inward As long as the control levers have not been moved forward or backwards mower will not move Slowly move both control levers forward slightly This will allow mower to start moving forward in a straight line Pull back on control levers to the neutral position and mower should stop moving Pull back slightly on control levers this will allow mower to start moving backwards Push forward on control levers to the neutral position and mower should stop moving To turn to the right While moving in a forward direction pull the right lever back towards the neutral position while maintaining the position of the left lever this will slow the rotation of the right wheel and cause the machine to turn in that direction To turn to the left While moving in a forward direction pull the left lever back towards the neutral position while maintaining the position of the right lever this will slow the rotation of the left wheel and cause the machine to turn in that direction To zero turn While moving in a forward direction first pull both control levers back until the mower stops or slows dramatically Then by alternating one lever slightly t
32. ead Safety Instructions section and following pages if you are unfamiliar with the machine Training Zero turn mowers are far more maneuverable than typical riding mowers due to their unique steering capabilities We suggest that this section be reviewed in its entirety prior to attempting to move the mower under its own power Additionally we suggest when first operating the mower use a reduced throttle speed and reduced ground speed by NOT moving control levers to the furthest forward or reverse positions during initial operation or until operator becomes comfortable with controls We also suggest first time users or new users to Zero Turn mowers to become familiar with the mower s movement on a hard surface Such as concrete or blacktop PRIOR to attempting to operate on turf Until operator becomes comfortable with mower controls and zero turning capability they may damage turf due to overly aggressive maneuvers IMPORTANT INFORMATION When control levers are in the reverse position they return to neutral when released This may cause the mower to suddenly stop Steering To move forward and backward The direction and speed of the mower s movements is effected by the movement of the control lever s on each side of mower The left control lever controls the left wheel The right control lever controls the right wheel First time users should push mower see Moving by Hand in the Operation section to an open flat ar
33. ee Engaging the Mower Deck In order to increase or decrease the engine speed the control is moved forward or back respectively Avoid idling the engine for long periods as there is a risk of fouling the spark plugs USE FULL THROTTLE WHEN MOWING for best mower performance and battery charging 8050 839 Choke Control The choke control is used for cold starts in order to provide the engine with a richer fuel mixture For cold starts the control should be pushed to the on position THROTTLE 8050 839 Choke control 19 CONTROLS Ignition Switch The ignition key is placed on the control panel and is used to start and stop the engine Hour Meter The hour meter displays the total operating time It will flash CHG OIL Change Oil at 50 hour intervals The flash duration is one hour before and one hour after the interval The CHG OIL icon will come on and shut off automatically The hour meter can not be manually reset Blade switch In order to engage the mower deck pull the knob out the mower blades are disengaged when the knob is depressed 20 THROTTLE 8050 839 8050 839 Hour meter 8050 839 Blade switch CONTROLS Fuses Fuses are located on the left hand side of the machine They are accessed by tilting t
34. engine and the exhaust system become very hot during operation Risk for burns if touched NN Allow engine and exhaust system to Nez cool at least two 2 minutes 8009 406 Loosen cover screws 3 Remove the foam filter precleaner Clean the foam filter with mild detergent and water Squeeze dry in a clean cloth Do not oil the foam sleeve 4 Tap the paper filter against a fixed surface to remove dust If the paper filter is still dirty it must C be replaced 5 Wipe clean the inside of air filter housing 6 Refitthe foam filter pre filter IMPORTANT INFORMATION s Do not use compressed air to clean the air 8019 014 filter Remove filter Do not wash the paper filter Do not oil the paper filter Mount the filter the air filter housing Replace the cover over the air filter housing and secure with screws IMPORTANT INFORMATION Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure 8019 015 Reinstall filter 39 MAINTENANCE Kohler Engine These engines are equipped with a replaceable high density paper air cleaner element Some engines are also equipped with an oiled foam precleaner surrounding the paper element Check the air cleaner daily or before starting the engine Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Al
35. erably 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 the 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 reco
36. es slowly unevenly or not at all Mower deck not engaging Transaxle leaks oil Uneven mowing results 56 Cause Clogged air intake or cooling fins 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 Poor contact of the battery terminal cable connections Charging lead is disconnected Parking brake on Bypass valve on pump open Drive belt for the transmission slack or has come off Air trapped in hydraulic system 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 Damaged seals housing or gaskets Air trapped in hydraulic system 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 STORAGE Winter Storage To ready the machine for storage At the end of the mowing season the machine should 1 Thoroughly clean the machine especially under be readied for storage or if it will not be in use for the mower deck Touch up damage to the paint longer than 30 days Fuel allowed to stand for long and spray a thin layer of oil on the underside of periods of time 30 days or more can leave sticky the mower deck to avoi
37. eve desired cut for the type of grass or conditions being mowed 8058 030 Lift link adjustment nut a e pee 8058 031 Deck front adjustment nuts 45 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 Anti scalp 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 The anti scalp rollers can be set in three positions e Upper position 1 to 27 38 to 64 mm grass 8050 830 e Middle position 2 to 4 64 to 102 mm grass e Lower position 4 to 6 102 to 128 mm grass The rollers should be approximately 6 5 mm from ground Do not adjust the rollers to support the deck IMPORTANT INFORMATION The anti scalp rollers must not be used for gauge wheels or the roller and deck may be damaged 46 MAINTENANCE Cleaning pom MET Regular cleaning and washing especially under the 4 mower deck will increase the machine s life span c lt lt Make it a habit to clean the machine directly after use after it is cooled
38. fic regulations before transporting the machine on any road e Do not tow this machine it may cause damage to the drive system e Do not tow any trailers etc with this mower They may jackknife or overturn causing damage to the mower and possibly serious injury to the operator e 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 Customer Responsibilities e Read and observe the safety rules e Follow a regular schedule in maintaining caring for and using your mower e Follow the instructions under Maintenance and Storage sections of this owner s manual A spark arrester for the muffler is available through your authorized Dixon dealer 16 8011 514 Regularly clean deck WARNING Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin causing serious injury If injured by escaping fluid see a doctor at once Serious infection or reaction can develop if proper medical treatment is not administered immediately IMPORTANT INFORMATION The parking brake is not sufficient to lock the machine in place during transport Ensure that the machine is well fastened to the transport vehicle Always reverse the machine onto the transport vehicle to avoid tipping it over WARNING This mower is equipped with an internal combustion engine and should not be used on or near any
39. 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 8058 020 Disengage the parking brake TROUBLESHOOTING Problem Engine will not start Starter does not turn the engine over Engine runs rough Engine seems weak Machine vibrates Cause 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 filter or fuel line Ignition system faulty 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 Faulty carburetor Choke control is pulled out with a warm engine Clogged fuel filter or jet Clogged ventilation valve on the fuel cap Fuel tank nearly empty Fouled spark plugs Rich fuel mixture or fuel air mixture Wrong fuel type Water in fuel Clogged air filter Clogged air filter Fouled spark plugs Carburetor incorrectly adjusted Air trapped in hydraulic system Blades are loose Blades are incorrectly balanced Engine is loose 55 TROUBLESHOOTING Problem Engine overheats Battery not charging The machine mov
40. forming maintenance on the battery The battery can explode and cause serious injury damage 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 A Avoid electrical sparking and its consequences by the following routines e Use protective goggles e Ensure that the fuel filler cap is mounted tightly and no flammable substances are stored in an open vessel e Never work with the starter circuit if there is spilled fuel e Disconnect the chassis cable from the battery first and reconnect it last e Donot make a bridge short circuit across the starter relay to run the starter 8009 728 Risk of sparking 15 SAFETY e Regularly clean deck and underside of deck avoid spraying engine and electrical components with water Transport e 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 e 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 e Do not operate this machine on public roadways e Check and abide by local traf
41. he seat forward They are 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 Fuel Shut Off Valve The fuel shut off valve is located at the right rear of the seat The valve is off when the handle tab is turned perpendicular to the fuel line 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 Do not rely solely on the parking brake to when transporting the mower Use straps to secure Fuses Released parking brake 8011 420 8058 020 21 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 Meth
42. 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 ET i a ETSI EJ EI Action Date mtr reading stamp sign At Least Once Each Year 1 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 10 Check the engine valve clearance EL TEE ES ET ESTIS 67 SERVICE JOURNAL Action Date mtr reading stamp sign SERVICE JOURNAL Action Date mtr reading stamp sign 69 SERVICE JOURNAL Action Date mtr reading stamp sign P N 115 294527R1 09 21 09
43. ingers 8011 719 Throttle Cable Check that the engine responds to throttle increases and that a good engine speed is attained at full throttle If doubts arise contact the service workshop If adjustments are necessary they can be made as follows for the lower cable 1 Loosen the clamping screw for the cable s outer casing and move the throttle to the full throttle position 2 Check that the throttle cable is mounted in the correct hole in the lower lever see illustration 3 Push the throttle cable s outer casing as far to the right as possible and tighten the clamping screw 8011 720 Adjusting the throttle cable Choke Cable If the engine produces black smoke or is difficult to start this can be because the choke cable is incorrectly adjusted upper cable If doubts arise contact the service workshop If adjustments are necessary they can be made as follows 1 Loosen the clamping screw for the cable s outer casing and push the choke control fully in 2 Check that the choke cable is mounted in the upper lever see illustration Push the choke cable s outer casing as far to the left as possible and tighten the clamping screw 8011 720 Adjusting the choke cable 38 MAINTENANCE Air Filter Briggs amp Stratton Engine 1 Loosen screws and remove air filter cover 2 Remove the filter cartridge by pulling upwards along the outside edge WARNING A The
44. intenance or any additional oil has been added to the system Resulting symptoms in hydrostatic systems may be 1 Noisy operation 2 Lack of power or drive after short term operation 3 High operation temperature and excessive expansion of oil 4 Shortened component life Before starting make sure the pump is at the proper oil level If not fill to the specifications outlined prior The following procedures are best performed with the vehicle drive wheels off the ground then repeated under normal operating conditions 1 Disengage the brake if activated 2 With the bypass valve open and the engine running at fast idle slowly move the steering control in both forward and reverse directions 5 or 6 times As air is purged from the unit the oil level will drop 3 With the bypass valve closed and the engine running slowly move the steering control in both forward and reverse directions 5 to 6 times Check the oil level and add oil as required after stopping the engine 4 t may be necessary to repeat Steps 2 and 3 until all the air is completely purged from the system When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds the transaxle is considered purged 5 After the vehicle has been used two times the level should be checked while the oil is cold and adjusted accordingly 54 WARNING Escaping hydraulic oil under pressure can have sufficient
45. ired and check condition 4 Reinstall the precleaner if equipped over the paper air cleaner element and install on the base Secure with the latch 5 Close and latch the door 40 IMPORTANT INFORMATION Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure 8058 028 1 Air cleaner access door 2 Air cleaner element 3 Latch 4 Precleaner on some models Air filter cleaning and replacement 8058 029 Unlatch and remove element MAINTENANCE Fuel Filter Replace the line mounted fuel filter every 100 hours once per season or more regularly if it is clogged 1 2 3 Replace the filter as follows Move the hose clamps away from the filter Use flat nosed pliers Pull the filter loose from the hose ends Push the new filter into the hose ends Position the filter with the FLOW arrow pointing up toward the fuel pump If necessary a soap solution can be applied to the filter ends to ease mounting Move the hose clamps back toward the filter Fuel Pump Air Filter Regularly check that the fuel pump s air filter is free from dirt Remove the screws and open the pump no hoses need be removed The filter can be cleaned with a brush if necessary Replace the filter on the console Tire Pressures All four tires shall have a pressure of 15 psi 103 kPa 1 bar 8011 468 Fuel filte
46. ke control Ignition switch oar 7 Hour meter 8 Blade switch 9 Fuses 10 Fuel shut off valve 11 Fuel tank cap 12 Parking brake 17 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 fit in the slots for moving the controls outward they can be adj
47. lutch 2 Idler spring 3 Clutch stop Pump belt removal 43 MAINTENANCE Cutting Blades In order 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 Damaged blades should be replaced when hitting obstacles that result in a breakdown Let the service workshop decide whether the blade can be repaired ground or must be replaced 8011 604 1 Balance the blades after sharpening Check the blades Check the blade mounts WARNING Blades are sharp Protect your hands with gloves and or wrap blades with a heavy cloth when handling Blade Replacement 1 Remove blade bolt by turning counterclockwise 2 Install new 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 90 ft Ibs 122 Nm IMPORTANT INFORMATION Special blade bolt is heat treated Replace with a Dixon bolt if required 1 Blade 2 Blade bolt special 3 Cutter housing Blade attachment Do not use lower grade hardware than specified 44 MAINTENANCE Adjusting the Mower Deck Leveling deck Adjust the deck while the mower i
48. mmendation 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 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
49. ng battery 1 Lift seat and rotate forward 2 Using two wrenches disconnect BLACK battery cable then RED battery cable 3 Position deck to lowest setting 4 Front underside of frame remove the nuts that secure the battery hold down 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 hold down and secure with nuts removed in Step 5 8 First connect RED battery cable to positive 4 battery terminal with hex bolt and hex nut 9 Connect BLACK grounding cable to negative battery terminal with remaining bolt and nut 10 Tighten securely 11 Lower seat 36 STANDARD STATE APPROXIMATE BATTERY CHARGING TIME TO FULL CHARGE AT 80 F 27 BATTERY OF Maximum Rate at 50 Amps 30 Amps 20 Amps 10 Amps CHARGE 12 6V 10096 FULL CHARGE 12 4V 7596 20 min 35 min 48 min 90 min 12 2V 5096 45 min 75 min 95 min 180 min 12 0V 2596 65 min 115 min 145 min 280 min 11 8V 0 85 150 195 370 Charging time depends on battery capacity condition age temperature and efficiency of charger 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
50. ngine it should aqui m be recharged See Battery in the Maintenance Pra ani 7 UL section Ada 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 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 28 OPERATION Running 1 Release the parking brake by moving the lever 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 first setting the parking brake will shut off the engine 2 Move the steering controls to the neutral position N IMPORTANT INFORMATION The mower deck s anti scalp rollers shoul
51. nk 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 about 10 seconds before retrying When the engine starts immediately release the ignition key back to the run position 26 Turn to the start position Return to run position 8011 419 1 8011 419 1 OPERATION Gradually pull choke control back when the engine has started THROTTLE 8050 817 1 Release choke 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 no choke 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 817 1 Set engine speed 27 OPERATION Weak Battery A WARNING Lead acid batteries generate explosive gases Keep sparks ii Se SSS SS flame and smoking materials away from batteries Always wear eye protection when around batteries If your battery is too weak to start the e
52. o the forward position and the other in the reverse position 23 OPERATION Before Starting e Read the sections Safety Instructions and Controls before starting the machine e Perform the daily maintenance before starting see Maintenance Schedule in the Maintenance section e Check that there is sufficient fuel in the fuel tank e Adjust the seat to the desired position The following conditions must be fulfilled before the engine can be started e The blade switch for engaging the mower blades must be depressed parking brake must be on Both steering controls must be in the locked outer neutral position 8050 825 Starting the Engine e Sit on the seat e 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 e Activate the parking brake by pushing the release button in and pulling the lever fully upwards 8058 020 Disengage the mower blades by depressing the blade switch 8050 839 Disengage mower blades 24 OPERATION Move the steering controls outward to the locked outer neutral position Move the throttle to the middle position If the engine is cold push the choke lever to ON 8050 817 1 Set the choke control 25 OPERATION Open the fuel valve for the fuel ta
53. r 8009 147 Fuel pump air filter 8011 564 Tire pressures 41 MAINTENANCE 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 A Faulty adjustment can result in reduced braking ability and can cause an accident 8058 020 IMPORTANT INFORMATION Released parking brake The machine must be standing still when applying the parking brake V belts Check every 100 hours of operation Check for severe cracking and large nicks NOTE The belt will show some small cracks in normal operation The belts are not adjustable Replace belts if they begin to slip from wear Deck Belt Removal 1 Park 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 Remove tension on the belt by moving the idler arm 6 Carefully slip belt up over the top of the cutter housing pulleys and remove belt Rolling belt over the pulleys may damage the belt 8011 622 Slackening the belt tensioner 42 MAINTENANCE Deck Belt Installation NOTE For ease in installing the deck belt refer to the rou
54. re operating or storing the machine Allow machine to cool before storage 8011 520 Never take passengers A 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 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 sure that you have first aid equipment close at hand when using the machine e Never use the machine when barefoot e Always wear protective shoes or boots preferably with steel toe caps e Always wear approved protective glasses or a full visor when assembling or driving e Always wear gloves when handling the blades e Never wear loose clothing that can get caught in moving parts e Use ear protectors to avoid damage to hearing Slope Operation Slopes are a major factor related to loss of control and m tip over accidents which can result in severe injury or Personal protective equipment death Operation on all slopes requires extra caution If
55. s on a level surface Make sure the tires are inflated to the correct pressure See Transmission under Technical Data If tires are under or over inflated 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 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 3 Move to the opposite side check that measurement is the same If adjustment is required with a 34 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 4 Turn any blade to align with the deck in front to rear manner If the rear blade tip does not measure s to Ye higher follow the front adjustment instructions that follow 5 With a 5 s 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 s 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 achi
56. so check for loose or damaged components Replace all bent or damaged air cleaner components Servicing Precleaner If so equipped wash and re oil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions Replace the precleaner annually or every 100 hours 1 Open the door on the blower housing to access the air cleaner element and precleaner 2 Unhook the latch and remove the air cleaner element assembly for servicing Make sure the base and the sealing areas are clean before reassembly 3 Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 4 Saturate the precleaner with new engine oil Squeeze out all excess oil Servicing Paper Element Check the paper element every 50 hours of operation more often under extremely dusty or dirty conditions Clean or replace the element as necessary Replace the air cleaner element annually or every 100 hours 1 Remove the precleaner if so equipped from the paper element 2 Gently tap the paper element to dislodge dirt Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a new one Handle the new element carefully do not use if the sealing surfaces are bent or damaged 3 Clean the air cleaner base as requ
57. sposed of on the ground or in nature it should always be disposed of at a workshop or appropriate disposal location Avoid skin contact wash with soap and water in case of spills Engine Oil Levels Check the oil level in the engine when the machine is standing level and the engine is stopped Remove the dipstick wipe it clean and then replace it The dipstick should be screwed into place Take the dipstick out again and read the oil level The oil level should lie between the markings on the dipstick If the level is approaching the ADD mark fill the oil to the FULL mark on the dipstick Never fill to above the FULL mark The oil is filled through the hole for the dipstick API class SF SG SH SJ or higher must be used Synthetic oil SAE 5W 30 or 10W 30 is recommended at all temperatures Mineral oil SAE 5W 30 10W 30 Remova he dissi be used between 18 C 0 F and 75 C 40 F At temperature above 5 C 40 F single grade SAE 30 must be used 51 LUBRICATION See the Technical Data section for oil amounts Changing the Engine Oil The engine oil should be changed for the first time after 5 8 hours of operation Thereafter it should be changed every 50 hours The oil drain valve is located on the left side of the unit below the oil filter Place the machine on flat surface e Place container under the engine where the oil drain valve exits e Remove the valve cap e Allow
58. t children will remain where you last saw them e 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 e Before and while backing look behind and down for small children e 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 e Never allow children to operate the machine e Use extra care when approaching blind corners shrubs trees or other objects that may block your view of a child 12 8011 509 Be extra cautious when driving on slopes 8011 517 Never allow children to operate the machine 8011 518 Keep children away from work area SAFETY WARNING The engine must not be started when the driver s floor plate or any protective plate for the mower deck s drive belt is removed Safe Handling of Gasoline To avoid personal injury or property damage use extreme care in handling gasoline Gasoline is extremely flammable and the vapors are explosive e Extinguish all cigarettes cigars pipes and other sources of ignition e Use only approved gasoline container e Never remove gas cap or add fuel with the engine running Allow engine to cool at leas
59. t two 2 minutes before refueling e Never fuel the machine indoors e 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 e Before you begin refueling minimize the risk of static electricity by touching a metal surface Never fill the fuel tank indoors e 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 WARNING e 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 There is risk for burns if touched nozzle e 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 e If fuel is spilled on clothing change clothing immediately e Never overfill fuel tank Replace gas cap and tighten securely e Do not start the engine near spilled fuel e Never use gasoline as cleaning agent e arise in fuel system engine must not be started until problem has been resolved e 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 The engine and the exhaust system
60. tended to be lifted by hand 8058 032 WARNING Make no adjustments without the engine stopped the ignition key removed the parking brake activated 8058 032 Bypass linkage 27 2800 locked in the bypass position 33 MAINTENANCE Maintenance Schedule The following is a list of maintenance procedures that must be performed on the machine For those points not described in this manual visit an authorized service workshop An annual service carried out by an authorized service workshop is recommended to maintain your machine in the best possible condition and to ensure safe operation Read Maintenance in the Safety section 1 First change after 5 8 hours When operating with a heavy load or at high ambient temperatures replace every 50 hours In dusty conditions cleaning and replacement are required more often For daily use the machine should be lubricated twice weekly Performed by authorized service workshop e Described in this manual Not described in this manual Maintenance Check the parking brake Check the engine s oil level every refueling Daily Before After Wkly At least once each year Maintenance interval in hours 25 50 100 300 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
61. ting decal on the top of the deck Wrap the deck belt around the electric clutch pulley that is located on the engine shaft 2 Route the belt forward 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 Replace belt shields on both mandrel housings and secure with fasteners Pump Belt Replacing pump belt Park the mower on a level surface Engage the parking brake Belt removal 1 3 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 pump pulleys Belt installation T 2 3 m Wrap the belt around the pulley 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 Reinstall the deck belt see Deck Belt Installation in this section of the manual 8011 764 1 Clutch pulley 2 Deck belt Belt routing deck belt 8054 002 1 Electric c
62. ts Set park brake Measure the distance between the rod swivel pin and the brake arm washer With the brake engaged there should be gap of e to 1 4 3 mm to 13 mm between the swivel pin and the brake arm washer If measurement is out of range adjust as follows Disengage park brake lever Remove retaining clip and remove brake arm by pulling horizontally from the EZT splined shaft Rotate brake arm on spline rearward to increase brake tension Rotate the brake arm one spline forward to decrease brake arm tension Reinstall the retaining clip and recheck gap between rod swivel pin and brake rod washer Repeat the procedure on the other EZT Tracking Adjustment If the mower is not tracking straight check the air pressure in both rear tires Recommended air pressure is 15 psi 1 bar If the unit will not track straight follow the steps below Tracking must be checked on a flat and level concrete or blacktop surface Mower is tracking to the right Increase the air pressure 2 3 psi 0 1 0 2 bar in the right rear tire or decrease the air pressure 2 3 psi in the left rear tire Mower is tracking to the left Increase the air pressure 2 3 psi 0 1 0 2 bar in the left rear tire or decrease the air pressure 2 3 psi in the right rear tire Recheck tracking and keep making adjustments with the tire pressure until the unit tracks straight DO NOT exceed maximum recommended tire pressure 24 psi 1 6 bar Record th
63. ttings of governors and avoid running the engine with overly high engine speeds If you run the engine too fast you risk damaging the machine components Be very careful when handling battery acid Acid on skin can cause serious corrosive burns If you spill battery acid on your skin rinse immediately with water Acid in the eyes can cause blindness contact a doctor immediately Be careful when servicing the battery Explosive gases form in the battery Never perform maintenance on the battery when smoking or near open flames or sparks The battery can explode and cause serious injury or damage 8011 515 Never drive the machine in an enclosed space A A 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 e Ensure that nuts and bolts especially the fastening bolts for the blade attachments are properly tightened torqued and that the equipment is in good condition e 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 e mulch blades should only be used in familiar areas when higher quality mowing is desired 6003 009 Do not smoke when per
64. urning e 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 8011518 complete stop before cleaning the machine Clear the area of objects before mowing removing the grass catcher or unclogging the discharge guard e Operate machine only in daylight or good artificial light Do not operate the machine while under the influence of alcohol or drugs 10 SAFETY Watch for traffic when operating near or crossing roadways Use extra care when loading or unloading the machine into a trailer or truck Always wear eye protection when operating machine Data indicates that operators age 60 years and above are involved in a large percentage of riding mower 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 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 befo
65. usted WARNING A The machine can turn very rapidly if one steering control is moved much further forward than the other 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 18 8061 020 8011 7912a 1 Forward 2 Neutral 3 Neutral slot Neutral lock 4 Reverse Motion control lever right side CONTROLS Cutting Height Adjuster The deck cutting height is obtained by pressing the button on the lift lever and pulling backward to lift the deck To lower the deck push button on the lift lever and push forward allowing the deck to lower to the correct cutting height The cutting height range is from 172 38mm to 4 102mm in 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 8050 838 The mower deck s cutting height adjuster 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 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 s
66. wers All Dixon warranty must be accomplished by authorized Dixon dealers and in accordance with Dixon warranty policy and allowances warranty claims must be submitted to Dixon for approval Warranty labor reimbursement to dealers based on published Dixon flat rate schedule Warranty does not apply to damage in transit or incidents of misuse negligence accidents or alteration The use of parts or components other than those supplied by Dixon VOIDS ALL WARRANT Y Battery warranty is limited to 1 year from mower manufacture date The following items are not covered by this warranty policy a Routine maintenance or adjustments to include any oils filters or other fluids used b Belts blades tires and cosmetic appearance paint seat fade etc c Pick up and delivery charges for transportation of mower to and from an authorized Dixon dealer s place of business d Engines These are covered under a separate warranty by each individual engine manufacturer Consult engine manual for warranty details e Any costs or expense of providing substitute equipment while repair work is being performed on a warranted mower THERE IS NO OTHER EXPRESS WARRANTY TO THE EXTENT PERMITTED BY LAW ALL IMPLIED 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
67. y be started when The mower deck is disengaged e steering controls are in the outer locked neutral position e driver is sitting in the driver s seat e 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 IMPORTANT INFORMATION Fitting the wrong spark plug type can damage the engine Inadequately tightened spark plug can cause overheating and damage the engine Tightening the spark plug too hard can damage the threads in the cylinder head 0 028 0 031 in 0 70 0 80 mm 8011 054 Measure the electrode gap 8058 026 1 Steering controls locked in neutral 37 MAINTENANCE Engine Cooling Air Intake Check that the engine s cooling air intake is free from leaves grass and dirt If the cooling air intake is clogged engine cooling deteriorates which can lead to engine damage The cooling air intakes rotates when the engine is running Mind your f

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