Dixon 966503601, Operator'S Manual

Page 1: ...Operator Manual SZ4619 CA 966503601 Please read the operator s manual carefully and make sure you understand the instructions before using the machine ...

Page 2: ... information contained in these instructions Use only original parts for repairs The use of other parts voids the warranty Do not modify or install non standard equipment to the unit without consent from the manufacturer Modifications to the unit may cause unsafe operations or damage the unit When this product is worn out and no longer used it should be returned to the reseller or other party for ...

Page 3: ...ng 24 Steering 24 Before Starting 25 Starting the Engine 25 Weak Battery 28 Jumper Cables 28 Running 29 Operating On Hills 30 Mowing Tips 31 Stopping the Engine 32 Manual Transport 33 MAINTENANCE 34 Maintenance Schedule 34 Battery 36 Safety System 37 Tire Pressures 37 Parking Brake 38 Pump Belt 38 V belts 39 Deck Belt 39 Cutting Blades 40 Blade replacement 40 Anti scalp Rollers 40 Adjusting the Mo...

Page 4: ...nd 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 ...

Page 5: ...ng 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...

Page 6: ...ine s type designation I D The manufacturer s type number Model The machine s serial number Serial no Please have the type designation and serial number available when ordering spare parts The engine s manufacturing number is stamped on one of the valve covers The plate states The engine s model The engine s type Code Please have these available when ordering spare parts retailer See the certifica...

Page 7: ...es 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 market Use protective glasses Use protective glov...

Page 8: ...erforming 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 Moving sharp blades under cover symbols and decals 8 ...

Page 9: ... unless absolutely necessary Always look down and behind before and while backing Never direct discharged material toward anyone Avoid discharging material against a wall or obstruction Material may ricochet back toward the operator Stop the blades when crossing gravel surfaces Do not operate machine without the entire grass catcher discharge guard or other safety devices in place and working Slow...

Page 10: ...hts 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 before operating o...

Page 11: ...obstacles Choose a low ground speed so that you will not have to stop while on the slope Do not mow on wet grass Tires may lose traction Avoid starting stopping or turning on a slope If the tires lose traction disengage the blades and proceed slowly straight down the slope Keep movement on the slopes slow and gradual Do not make sudden changes in speed or direction which could cause machine to rol...

Page 12: ...esponsible adult other than the operator Be alert and turn machine off if a child enters the area Before and while backing look behind and down for small children Never carry children even with the blades shut off They may fall off and be seriously injured or interfere with safe machine operation Children who have been given rides in the past may suddenly appear in the mowing area for another ride...

Page 13: ...ground If this is not possible refuel such equipment with a portable container rather than from a gasoline dispenser nozzle Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Do not use a nozzle lock open device If fuel is spilled on clothing change clothing immediately Never overfill fuel tank Replace gas cap and tighten securely D...

Page 14: ...egularly to be sure it works properly The machine must not be driven with defective or unmounted protective plates protective cowlings safety switches or other protective devices Do not change the settings of governors and avoid running the engine with overly high engine speeds If the engine runs too fast there is risk for damaging the machine components Be very careful when handling battery acid ...

Page 15: ...ary make repairs before starting Never make adjustments with the engine running The machine is tested and approved only with the equipment originally provided or recommended by the manufacturer Only use approved repair parts for the machine The blades are sharp and can cause cuts and gashes Wrap the blades or use protective gloves when handling them Check the parking brake s functionality regularl...

Page 16: ...ys Check and abide by local traffic regulations before transporting the machine on any road Do not tow this machine it may cause damage to the drive system Load the unit onto truck or trailer by driving up ramps of suitable strength using a slow speed Do not lift The machine is not intended to be lifted by hand Towing If machine is equipped with a tow hitch use extreme caution when towing Never al...

Page 17: ... from the engine is made via two belt Motion Control Levers 1 Seat Adjustment Lever 2 Lift Lever 3 Blade Switch 4 Throttle choke 5 Ignition Switch 6 Bypass Linkage 7 Fuel Tank 8 Parking Brake 9 driven hydraulic pumps Using the left and right steering controls the flow is regulated and thereby the direction and speed Control Locations 8 9 2 6 3 5 4 7 1 8050 923 ...

Page 18: ...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 con...

Page 19: ...cated on the rear of the frame below the rear engine guard Raise the deck into the highest cutting 1 position Pull the EZT bypass linkages up and out of 2 the keyhole slots Release the levers with the head outside the frame and held in the bypass position To reengage the EZT s to drive reverse the 3 above procedure 8058 032 Bypass linkage EZT engaged 8058 033 Bypass linkage EZT locked in the bypas...

Page 20: ...he 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...

Page 21: ...ture Push the throttle control all the way forward to the choke position Throttle Control The throttle control regulates the engine speed and thereby the rate of rotation of the blades assuming the blade switch is pulled out see Engaging the Mower Deck In order to increase or decrease the engine speed the control is moved Avoid idling the engine for long periods as there is a risk of fouling the s...

Page 22: ...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 wh...

Page 23: ...ame type used in automobiles There are two fuses with ratings and functions 20 Amp Primary fuse 7 5 Amp Mower deck coupling Fuel Shut Off Valve The fuel shut off valve is located at the left rear of the seat The valve is off when the handle tab is turned perpendicular to the fuel line 8011 419 Fuel shut off valve in the CLOSED position 8011 420 Fuses ...

Page 24: ...er 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 IMPORTANT INFORMATION When control levers are in the reverse position they return to neutral when released This may cause the mower to suddenly stop inward As long as the control levers ha...

Page 25: ...tion The following conditions must be fulfilled before the engine can be started The blade switch for engaging the mower blades must be depressed The parking brake must be on Both steering controls must be in the locked outer neutral position Starting the Engine Sit on the seat Raise the mower deck by pushing the release button on the top of the lifting lever Pull the lifting lever backward to the...

Page 26: ...077 Place controls in neutral position 8050 900 Set the choke control Move the steering controls outward to the locked outer neutral position Move the throttle to the middle position Push throttle control all the way forward to the choke position ...

Page 27: ...ION Do not run the starter for more than 5 seconds each time If the engine does not start wait approximately 10 seconds before retrying 8050 781 Return to run position 8050 902 Set the engine speed Press in and turn the ignition key to the start position When the engine starts immediately release the ignition key back to the run position Set the desired engine speed with the throttle Allow the eng...

Page 28: ...taking care not to short against chassis Connect one end of the BLACK cable to the 2 NEGATIVE terminal of the fully charged battery Connect the other end of the BLACK cable 3 to a good CHASSIS GROUND on the mower with the discharged battery away from the fuel tank and battery To remove cables reverse order Remove BLACK cable first from chassis and 1 then from the fully charged battery Remove RED c...

Page 29: ...venly adjusted 8058 092 Released parking brake 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 Set retaining pin into selected cutting height and 3 secure the opposite side with a cotter hairpin Push the release button on the cutting height lever 4 and move lever to the pin release the butt...

Page 30: ... forward from its neutral position IMPORTANT INFORMATION Control levers return to neutral when released This may cause the mower to suddenly stop Operating On Hills Read the Safety Instructions Driving on Slopes in the Safety section The slowest speed possible should be used before starting up or down hills Avoid stopping or changing speed on hills If stopping is absolutely necessary pull drive le...

Page 31: ...lawn becomes more even and the grass clippings more evenly distributed over the mown area The total time taken is not increased as a higher operating speed can be used without poor mowing results Avoid mowing wet lawns The mowing result is poorer because the wheels sink into the soft lawn clumps build and the grass clippings fasten under the cowling Hose the mower deck underside with water after e...

Page 32: ...er position than OFF will cause the battery to be discharged 8011 668 Disengage the mower deck Raise the mower deck by depressing the button 2 and pulling backward to the transport position 8058 092 Released parking brake 8058 019 Mower deck lifting lever When the machine is standing still activate the 3 parking brake by pulling the lever upward Move the throttle to the minimum position tortoise 4...

Page 33: ...d Zeroturn Transaxle bypass linkages The EZT bypass linkages are located on the rear of the frame below the rear engine guard Raise the deck into the highest cutting 1 position Pull the EZT bypass linkages up and out of 2 the keyhole slots Release the levers with the head outside the frame and held in the bypass position To reengage the EZT s to drive reverse the 3 above procedure ...

Page 34: ...re screws nuts Clean under the mower deck Start the engine and blades listen for unusual sounds Check for damage Thoroughly clean around the engine Clean around belts belt pulleys Check the tire pressures Check battery connections Sharpen3 Replace mower blades Clean the engine s cooling air intake 2 Clean the air cleaner s pre filter 2 foam Clean the air cleaner s filter cartridge 2 paper filter C...

Page 35: ...move 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 Daily At least once each year Maintenance interval in hours Before After 10 100 300 Check adjust throttle cable Check the condition of belts belt pulleys Change the engine oil 1 Replace the en...

Page 36: ...ery with plain water and dry 3 Clean terminals and battery cable ends with 4 wire brush until shiny Coat terminals with grease or petroleum jelly 5 Reinstall battery 6 Replacing battery Lift seat and rotate forward 1 Using two wrenches disconnect BLACK 2 battery cable then RED battery cable Position deck to lowest setting 3 From underside of frame remove the nuts that 4 secure the battery hold dow...

Page 37: ...n 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 lea...

Page 38: ... efficient cooling and not damage the EZTs be careful of the fan blades when servicing the belt Remove the deck belt see Deck Belt Removal in this section of the manual Create slack in the belt by removing the spring on the pump idler arm The belt should now be able to be removed from the engine pulley and EZT pulleys EZT Belt Installation Wrap the EZT belt around the EZT pulleys Route the belt ar...

Page 39: ...llation NOTE For ease in installing the deck belt refer to the routing decal on the top of the deck Wrap the deck belt around the electric clutch 1 pulley that is located on the engine shaft Route the belt forward and up onto the deck 2 Place belt around spring loaded idler pulley 3 Wrap the belt around the stationary idler pulley 4 and around the mandrel housings Push inward on the idler arm and ...

Page 40: ...r resharpened blade with stamped 2 GRASS SIDE facing towards ground grass down or THIS SIDE UP facing deck and cutter housing Install and tighten blade bolt securely 3 Torque blade bolt to 90 ft lbs 122 Nm 4 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 ro...

Page 41: ...ement is the same If adjustment is required with a 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 8058 030 Lift link adjustment nut 8058 031 Deck front adjustment nuts Turn any blade to align with the deck in front 4 to rear manner If the rear blade tip does not measure 1 ...

Page 42: ... yoke and take care of the spacers Install in reverse order Tighten caster bolt Hardware Check daily Inspect the entire machine for loose or missing hardware Cleaning Regular cleaning and washing especially under the mower deck will increase the machine s life span Make it a habit to clean the machine directly after use after it is cooled before the dirt sticks Do not spray water on the top of the...

Page 43: ...y use the machine should be lubricated twice weekly 12 12 Every year 1 52 Every Week 1 365 Every day Lubricate with grease gun Oil change Filter change Lubricate with oil can Level check Wipe away excess grease after lubrication It is important to avoid getting lubricant on the belts or the drive surfaces on the belt pulleys Should this happen attempt to clean them with spirits If the belt continu...

Page 44: ...hemical companies etc usually maintains a good quality Front Wheel Mount Lubricate with a grease gun until the grease is forced out Front Wheel Bearings Lubricate 3 4 strokes with a grease gun on each set of wheel bearings Deck Spindles Lower the cutting deck completely Lubricate with a grease gun 2 3 strokes per spindle 8058 106 Deck spindle Transmission The transmission is maintenance free with ...

Page 45: ...oor contact of the battery terminal cable connections Blown fuse Fault in the starter safety circuit See Safety System in the Maintenance section Engine runs rough Faulty carburetor Choke control is pulled out with a warm engine Clogged fuel 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 ...

Page 46: ...g brake on Bypass valve on pump open Drive belt for the transmission slack or has come off Air trapped in hydraulic system Mower deck not engaging Drive belt for the mower deck has come loose Contact for the electromagnetic coupling has loosened Blade switch is faulty or has come loose from cable contact Blown fuse Transaxle leaks oil Damaged seals housing or gaskets Air trapped in hydraulic syste...

Page 47: ...y the fuel tanks or add a fuel stabilizer Start 4 the engine and allow it to run until the carburetor is drained of fuel or the stabilizer has reached the carburetor Remove the spark plug and pour about a 5 tablespoon of engine oil into the cylinder Turn over the engine so that the oil is evenly distributed and then refit the spark plug Lubricate all grease zerks joints and axles 6 Remove the batt...

Page 48: ...SCHEMATIC 48 ...

Page 49: ... 203 225 305 250 339 370 502 7 8 378 513 591 801 11 8 782 1060 1410 1912 Grade 5 Minimum commercial quality lower quality not recommended Metric Standard Hardware Grade Grade 8 8 Grade 10 9 Grade 12 9 ft lbs ft lbs Nm ft lbs Nm ft lbs Nm Shank Size Diameter in millimeters fine or coarse thread M4 1 5 2 2 2 3 2 7 3 6 M5 3 4 4 5 6 5 2 7 M6 5 2 7 7 5 10 8 2 11 M7 8 2 11 12 16 15 20 M8 13 5 18 18 8 25...

Page 50: ...ter Oil capacity excluding filter 1 34 qts 1 27 liters Oil capacity including filter 1 46 qts 1 38 liters Engine oil See viscosity diagram SAE 10W30 10W40 5W20 5W30 API SF SJ Fuel Min 87 octane unleaded Max ethanol 10 Max MTBE 15 Fuel tank capacity 4 gallons 15 1 liters Spark plugs gap Champion RC12YC 030 0 75 mm Cooling Air cooled Air filter Standard Alternator 12V Starter Electric Transmission T...

Page 51: ...ollers No Sprung Seat Standard Hinged Arm Rests Accessory Hour Meter Standard Blade Engagement Electromagnetic clutch Deck Construction Stamped Productivity 2 8 acres h 11290 m2 h Dimension Weight 525 lbs 238 kg Base Machine Length 75 191cm Base Machine Height 40 102cm Base Machine Width 41 106 cm Overall Width Chute Up 48 122 cm Overall Width Chute Down 56 142 cm ...

Page 52: ...or 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 If required vibration data corresponding to Directive 2002 44 EC is given in the Technical Data Section The Declaration of Conformity is included in the li...

Page 53: ...wers 4 Warranty labor reimbursement to dealers based on published Dixon flat rate schedule 5 Warranty does not apply to damage in transit or incidents of misuse negligence accidents or alteration The 6 use of parts or components other than those supplied by Dixon VOIDS ALL WARRANTY Battery warranty is limited to 1 year from mower manufacture date 7 The following items are not covered by this warra...

Page 54: ...rive to both wheels Check the mower deck adjustment Check Safety switch for the parking brake Safety switch for the mower deck Safety switch in the seat Safety switch in the steering controls Parking brake functionality Driving forward Driving backward Engaging the blades Check engine high idle speed Inform the customer about Need and advantages of following the service schedule Need and advantage...

Page 55: ... position Check safety system Check seat belt Check fuel system for leaks Inspect safety guards and shields Check brake adjustment Daily Service Clean debris from mower Check engine oil level Check the tire pressures Check underside of deck Inspect deck pulleys Check clean the engine s cooling air intake Check safety system Check seat belt Check fuel system for leaks Inspect safety guards and shie...

Page 56: ...k plug Inspect fuel filter Check engine RPM Clean underside of deck Check blade pitch Grease blade spindles Inspect spindle bearings Inspect deck belt and blades Inspect idler arm bearings Inspect deck idler pulleys Check hydraulic oil level Inspect hydraulic filter Inspect hydraulic drive belt Inspect hydraulic hoses Check neutral position Inspect battery connections Check safety system Check sea...

Page 57: ...Inspect fuel filter Check engine RPM Clean underside of deck Check blade pitch Grease blade spindles Inspect spindle bearings Inspect deck belt and blades Inspect idler arm bearings Inspect deck idler pulleys Check brake adjustment Inspect safety guards and shields Replace hydraulic drive belt Inspect hydraulic hoses Check neutral position Inspect battery connections Load test battery Clean electr...

Page 58: ...oling air intake Replace the air cleaner s pre filter foam Replace the air filter s paper cartridge Change the engine oil Replace the engine oil filter Check adjust the cutting height Check adjust the parking brake Clean Change the spark plugs Replace the fuel filter Check the engine valve clearance ...

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