Dixon 27 KOH/968999588 Operator'S Manual Download

Page: 3 / 88

CONTENTS

Contents

..................................................................3

Introduction

..............................................................5

Congratulations

.....................................................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 Instructions

..................................................9

General

Operation

.................................................9

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

Operation

..................................................11

Children

...............................................................12

Maintenance

........................................................13

Transport

.............................................................16

Customer

responsibilities

....................................17

Controls

..................................................................18

Control

Locations

................................................18

Steering

Controls

.............................................19

Hour

Meter

......................................................20

Parking

Brake

..................................................20

Blade

Switch

....................................................20

Ignition

Switch

.................................................21

Fuses

...............................................................21

Refueling

.........................................................22

Fuel Shut Off Valve ..........................................23

Seat Adjustment Knobs ..................................23

Choke

Control

.................................................23

Throttle

Control

................................................24

Lifting Level for Deck .......................................24

Operation

................................................................26

Training

................................................................26

Roll

Bar

................................................................26

Before

Starting

....................................................26

Starting the Engine ..............................................26
To start an engine with a weak battery ................31
Running

...............................................................32

Operating on hills ................................................33
Mowing

Tips

........................................................34

Stopping the Engine ............................................35
Moving by Hand ..................................................36

Maintenance

............................................................ 37

Maintenance

Schedule

........................................ 37

Battery

................................................................. 39

Ignition

System

.................................................... 40

Checking the Safety System ............................... 40

Checking the Engine’s Cooling Air Intake ............ 41

Checking and Adjusting the Throttle Cable.......... 41

Checking and Adjusting the Choke Cable ........... 41

Replacing the Air Filter ........................................ 42

Replacing the Fuel Filter ...................................... 46

Checking the Fuel Pump’s Air Filter..................... 46

Checking

Tire

Pressures

..................................... 46

Checking the Parking Brake ................................ 47

Checking the V-belts ............................................ 47

Deck

belt

.............................................................. 47

Checking the Blades ............................................ 50

Adjusting the Mower Deck ................................... 52

Cleaning and Washing ......................................... 54

Caster

Wheels

..................................................... 54

Hardware

............................................................. 54

Lubrication

.............................................................. 55

Lubrication

Schedule

........................................... 55

General

................................................................ 55

Lubricating the Cables ......................................... 56

Lubricating with Lubrication Schedule ................. 56

Trouble Shooting Guide

......................................... 63

Storage

.................................................................... 66

Winter

Storage

..................................................... 66

Service

................................................................. 66

Wiring diagram

....................................................... 67

Technical Data

........................................................ 68

Accessories

......................................................... 74

Torque

Specifi cations .......................................... 74

Conformity Certifi cates

.......................................... 77

USA

requirements

............................................... 77

Service Journal

....................................................... 78

Delivery

Service

................................................... 78

After the First 5-8 Hours ...................................... 79

25-Hour

Service

................................................... 80

50-Hour

Service

................................................... 81

100-Hour

Service

................................................. 82

300-Hour

Service

................................................. 83

At Least Once Each Year .................................... 84

Warranty

.................................................................. 86

English

Summary of Contents for 27 KOH/968999588

Page 1: ...make sure you understand the instructions before using the machine GRIZZLY 52 27 KOH 968999588 GRIZZLY 60 27 KOH 968999590 GRIZZLY 60 30 KOH 968999591 GRIZZLY 72 30 KOH 968999592 GRIZZLY 60 27 KOH 968...

Page 2: ......

Page 3: ...e 37 Maintenance Schedule 37 Battery 39 Ignition System 40 Checking the Safety System 40 Checking the Engine s Cooling Air Intake 41 Checking and Adjusting the Throttle Cable 41 Checking and Adjusting...

Page 4: ...d 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 Stat...

Page 5: ...ad 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 th...

Page 6: ...umber 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 man...

Page 7: ...ial for misuse or misassembly WARNING Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx xx xxxxxxxx xxxx xxxxxx IMPORTANT INFORMATION Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxxxxx xx xxxxxxxx xxxx...

Page 8: ...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 w...

Page 9: ...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 lo...

Page 10: ...dways 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 i...

Page 11: ...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 Wa...

Page 12: ...Never assume that children will remain where you last saw them Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator Be alert and turn machine of...

Page 13: ...ce containers on the ground away from your vehicle when filling Remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment wi...

Page 14: ...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 a...

Page 15: ...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 Use protective go...

Page 16: ...d 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 pu...

Page 17: ...not use ROPS as a lifting attaching or anchoring point Do not use ROPS for wrecking or towing Do not exceed Max GVW 2822 lbs 1283 kg Read machine operator s manual before each use Securely fasten you...

Page 18: ...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 Zero Turn Rider Control Locations 1 Motion con...

Page 19: ...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 neu tr...

Page 20: ...before dismounting Release the parking brake before moving the mower Hour meter 2 Hour Meter The hour meter displays the total operating time It will flash CHG OIL Change Oil at 50 hour intervals The...

Page 21: ...e located in a holder at the right hand side of the battery compartment They are flat pin fuses of the same type used in automobiles There are three fuses as well as socket for one spare fuse Fuse rat...

Page 22: ...and exhaust system to cool at least two 2 minutes 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 ope...

Page 23: ...e 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 o...

Page 24: ...transport position or one of the 17 different cutting height positions The cutting height is set by placing a peg in the hole for the desired cutting height and the peg is then locked on the inside h...

Page 25: ...lts act as limiting devices for the motion control levers when in the full forward position 2 Start by loosening jam nut on right tracking bolt Back the tracking bolt out until flush with nut 3 Loosen...

Page 26: ...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 contro...

Page 27: ...ng the mower blades must be depressed The parking brake must be on Both steering controls must be in the locked outer neutral position Starting the Engine 1 Sit on the seat 2 Raise the mower deck by p...

Page 28: ...6 Set the throttle OPERATION Depress the control for disengaging the mower deck 4 Disengage the mower blades by depressing the blade switch 8050 151 5 Move the steering controls outward to the locked...

Page 29: ...Set the choke control 7 If the engine is cold the choke control should be pushed to its extents 8050 148 8 Open the fuel valve for the selected fuel tank Open the fuel valve 8011 506 9 Press in and tu...

Page 30: ...when the engine has started 12 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...

Page 31: ...k 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 To attach jumper cables Connect each end of t...

Page 32: ...ly 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 s...

Page 33: ...to the outside of the unit and engage the parking brake To restart movement release the parking brake Pull the control levers back to the center of the mower and press forward to regain forward motio...

Page 34: ...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...

Page 35: ...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 depressing the blade switch 2 Raise the mower deck by depressin...

Page 36: ...gnition key removed the parking brake activated Vent screw on the hydraulic pump 8011 507 OPERATION English 36 In order for the machine to be moved with the engine turned off the vent screws on both h...

Page 37: ...vice workshop z Described in this manual Not described in this manual Maintenance Before After Daily Weekly At least once each year Maintenance interval in hours 25 50 100 300 Check the parking brake...

Page 38: ...l filter 200 hours Clean fins of oil cooler Kohler z z z z z z z z z z z MAINTENANCE z z z z z z z z z z z z z z 1 First change after 5 8 hours When operating with a heavy load or at high ambient temp...

Page 39: ...wrenches disconnect BLACK battery cable then RED battery cable 4 Remove the knobs and remove battery hold downs 5 Carefully remove the battery from the mower 6 Install new battery with terminals in t...

Page 40: ...can cause overheating and damage the engine Tightening the spark plugs too hard can damage the threads in the cylinder head 8011 054 Measure the electrode gap Checking the Safety System The machine is...

Page 41: ...on 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...

Page 42: ...e 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 l...

Page 43: ...is performed 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...

Page 44: ...least two 2 minutes Cleaning replacing the air filter is carried out as follows IMPORTANT INFORMATION Do not use compressed air to clean the air filter Do not wash the paper filter Do not oil the pap...

Page 45: ...the end of the housing and push it in to the end IMPORTANT INFORMATION The end cover must be installed with the rubber valve pointing downwards otherwise the rubber valve will not function 7 Turn the...

Page 46: ...pointing up toward the fuel pump If necessary a soap solution can be applied to the filter ends to ease mounting 4 Move the hose clamps back toward the filter Checking the Fuel Pump s Air Filter Regul...

Page 47: ...ip from wear Deck belt To replace deck belt Deck belt removal Park on a level surface Apply park brake Lower the deck into the lowest cutting position Using a ratchet with a 9 16 socket on the spring...

Page 48: ...decal on the top of deck for belt routing information After installation is complete check the belt for twists 8011 580 Belt routing deck belt 1 2 3 4 5 6 7 8011 622 Slackening the belt tensioner Dec...

Page 49: ...of the way Using a drive ratchet inserted into the square hole in the pump idler arm relieve the tension on the pump belt and remove belt To reinstall belt Swing pump idler pulley toward engine to rou...

Page 50: ...hen handling Bent or cracked blades or blades with large nicks should be replaced Damaged blades should be replaced when hitting obstacles that result in a breakdown Let the service workshop decide wh...

Page 51: ...ith star on cutter housing Install new or re sharpened blade with stamped GRASS SIDE facing towards ground grass down or THIS SIDE UP facing deck and cutter housing Install and tighten blade bolt secu...

Page 52: ...See Technical Data 3 Rotate blades to align front to back 4 Set the cutting height to 4 5 Measure front blade tip should be 4 from ground if not turn locknut on top of front eyebolt till measurement i...

Page 53: ...or gauge wheels or the roller and deck may be damaged CZ 9 Anti scalp roller The anti scalp rollers can be set in three positions Upper position 1 to 3 38 to 76 mm grass Middle position 3 to 4 76 to 1...

Page 54: ...nd washing Foam filled tires or solid tires will void the warranty Removal and installation of caster wheel Remove nut and caster bolt Pull the wheel out of the fork and take care of the sleeve Instal...

Page 55: ...ld be lubricated twice weekly 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...

Page 56: ...Bushings and Linkage Lubricate the bearing of the shafts and linkage for brake system and steering with oil spray or oil can 1 Hydraulic System Oil Level The hydraulic oil and filter must be replaced...

Page 57: ...of the engine clean the area around the oil fill cap dipstick before removing it 2 Remove the oil drain plug and the oil fill cap dipstick Be sure to allow ample time for complete drainage 3 Reinstall...

Page 58: ...remove the dipstick wipe oil off Reinsert the dipstick into the tube and rest the cap on the tube Do not thread the cap onto the tube 4 Pull the dipstick out and check the oil level The oil level shou...

Page 59: ...hange intervals longer than recommended can cause engine damage IMPORTANT INFORMATION Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended interv...

Page 60: ...hemical companies etc usually maintains a good quality 6 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 m...

Page 61: ...ing Control Shafts Tip the driver s seat Lubricate with a grease gun one zerk for each steering control shaft until the grease is forced out Use only good quality molybdenum disulphide grease Grease f...

Page 62: ...e oil filter If necessary use a filter remover 3 Wipe new clean engine oil onto the seal for the new filter 4 Mount the filter by hand with turn 5 Run the engine warm then check that there are no leak...

Page 63: ...ts 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 Fault...

Page 64: ...ion incorrect Air trapped in hydraulic system Battery not charging Poor contact with battery terminal cable connectors The machine moves slowly unevenly or not at all Parking brake on Bypass valve on...

Page 65: ...nd right sides Bent blades The suspension for the mower deck is uneven The chain fixture has come loose The blades are blunt Driving speed too high The grass is too long Grass collected under the mowe...

Page 66: ...rs and 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 und...

Page 67: ...English 67 WIRING DIAGRAM...

Page 68: ...n 43 liters Spark plugs gap Champion RX12YC Champion RX12YC 030 0 75 mm 030 0 75 mm Cooling Air cooling Air cooling Air filter Standard Standard Alternator 12V 16A 12V 16A Starter Electric 12V Electri...

Page 69: ...ctric clutch Electric clutch Deck construction 11 gauge w 10 gauge skirts 11 gauge w 10 gauge skirts Productivity Productivity 4 1 acres h 16605m2 h 5 1 acres h 20655m2 h Overall dimensions Weight 114...

Page 70: ...n 43 liters Spark plugs gap Champion RX12YC Champion RX12YC 030 0 75 mm 030 0 75 mm Cooling Air cooling Air cooling Air filter Standard Standard Alternator 12V 16A 12V 16A Starter Electric 12V Electri...

Page 71: ...nt Electric clutch Electric clutch Deck construction 11 gauge w 10 gauge skirts 11 gauge w 10 gauge skirts Productivity Productivity 6 acres h 24300m2 h 5 1 acres h 20655m2 h Overall dimensions Weight...

Page 72: ...rs Spark plugs gap Champion RX12YC Champion RX12YC 030 0 75 mm 030 0 75 mm Cooling Air cooling Air cooling Air filter Standard Standard Alternator 12V 16A 12V 16A Starter Electric 12V Electric 12V Tra...

Page 73: ...ngagement Electric clutch Electric clutch Deck construction 11 gauge w 10 gauge skirts 11 gauge w 10 gauge skirts Productivity Productivity 6 acres h 24300m2 h 5 1 acres h 20655m2 h Overall dimensions...

Page 74: ...15 Fuel tank capacity 11 4 gallon 43 liters Spark plugs gap Champion RX12YC 030 0 75 mm Cooling Air cooling Air filter Standard Alternator 12V 16A Starter Electric 12V Transmission Transmission Dual...

Page 75: ...Michigan Seat Standard Hinged armrests Yes Hour meter Standard Blade engagement Electric clutch Deck construction 11 gauge w 10 gauge skirts Productivity Productivity 5 1 acres h 20655m2 h Overall di...

Page 76: ...fasteners 80 ft lb 110 Nm When this product is worn out and no longer used it should be returned to the reseller or other party for recycling In order to implement improvements specifications and desi...

Page 77: ...pecial 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...

Page 78: ...Check the mower deck adjustment 11 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 b...

Page 79: ...English 79 SERVICE JOURNAL After the First 5 8 Hours 1 Change engine oil...

Page 80: ...ervice 1 Check the fuel pump s air filter 2 Sharpen Replace mower blades if required 3 Check the tire pressures 4 Check battery with cables 5 Lubricate according to lubrication chart 6 Check clean the...

Page 81: ...ign 50 Hour Service 1 Perform the 25 hour service 2 Clean replace the air cleaner s filter cartridge paper filter shorter intervals for dusty operating conditions 3 Change engine oil 4 Lubricate accor...

Page 82: ...orm the 50 hour service 3 Change the engine oil filter 4 Clean replace the spark plugs 5 Replace the fuel filter 6 Clean the cooling fins on the engine and transmission 7 Check V belts 8 Check tighten...

Page 83: ...th the customer as to which additional work is to be carried out 2 Perform the 25 hour service 3 Perform the 50 hour service 4 Perform the 100 hour service 5 Check adjust the mower deck 6 Clean the co...

Page 84: ...the air filter s paper cartridge 4 Change the engine oil 50 hours 5 Replace the engine oil filter 100 hours 6 Check adjust the cutting height 7 Check adjust the parking brake 50 hours 8 Clean Change...

Page 85: ...English 85 SERVICE JOURNAL Action Date mtr reading stamp sign...

Page 86: ...d by authorized Dixon dealers and in accordance with Dixon warranty policy and allow ances All warranty claims must be submitted to Dixon for approval 4 Warranty labor reimbursement to dealers based o...

Page 87: ......

Page 88: ...Part No 539 131266R01 09 25 07...

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Dixon 27 KOH/968999588, Operator'S Manual

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