Dixon DX254 / 966651201, Operator'S Manual

Page 1: ...272 966651501 DX260 966721501 DX254 BF 966651202 DX260 BF 966651302 DX272 BF 966651502 Operator Manual Please read the operator s manual carefully and make sure you understand the instructions before using the machine Form Number 115 382427R2 03 23 11 ...

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 r...

Page 3: ...ATION 26 Training 26 Steering 26 Roll Bar and Safety Belt 27 Before Starting 27 Starting the Engine 28 Jumper Cables 30 Running 31 Operating on Hills 32 Stopping the Engine 33 Mowing Tips 34 Moving Machine By Hand 35 MAINTENANCE 36 Battery 38 Safety System 39 Tire Pressures 39 Parking Brake 39 Deck Belt 40 Pump Belt 41 V belts 41 Cutting Blades 42 Adjusting the Mower Deck 43 Leveling Deck 43 Anti ...

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: ...g 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: ...ufacturing number can be found on the printed plate affixed to the right side in the engine compartment Stated on the plate from the top are The machine s type designation I D The manufacturer s type number Model The machine s serial number Serial no Please have the type designation and serial number available when ordering spare parts The engine s manufacturing number is stamped either on one of ...

Page 7: ...tated in the chapter TECHNICAL DATA and on the decals Only machines for European market Use protective gloves 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 Used in this publication to notify the ...

Page 8: ...nce 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 Warning Rotating blades keep away from the discharge deck Do not touch parts Battery acid is corrosive explosive and flammable ...

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: ...er relay to run the starter Never use the machine indoors or in spaces lacking proper ventilation The exhaust fumes contain carbon monoxide an odorless poisonous and lethal gas Stop to inspect the equipment if the machine runs over or into anything If necessary make repairs before starting Never make adjustments with the engine running The machine is tested and approved only with the equipment ori...

Page 16: ...a cautious when it is loaded on or unloaded from a vehicle or trailer Use an approved trailer to transport the machine Activate the parking brake turn off the fuel supply and fasten the machine with approved fastening devices such as bands chains or straps when transporting Do not operate this machine on public roadways Check and abide by local traffic regulations before transporting the machine o...

Page 17: ...educe speed when turning crossing slopes and on rough slick or muddy surfaces Stay off slopes too steep for safe operation Watch where you are going especially at row ends on roads and around trees Do not permit others to ride Operate the mower smoothly no jerky turns starts or stops When mower is stopped set brakes securely and use park brake If any part of ROPS is damaged the entire ROPS must be...

Page 18: ...driven hydraulic transaxles Using the left and right steering controls the flow is regulated and thereby the direction and speed Control Locations 1 2 3 4 5 6 8 9 10 12 7 1 Motion control levers 2 Tracking bolt left side 3 Parking brake 4 Fuel tank left 5 Pump release valves 6 Hour meter 7 Ignition switch 8 Choke control 9 Throttle control 10 Blade switch 11 Deck lift 12 Deck release 11 ...

Page 19: ... 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...

Page 20: ... nut 4 Test operate unit by driving it at full throttle and the full forward position on both motion control levers Gradually turn in the right hand tracking bolt until the unit noticeably starts drifting right 5 Drive forward at full throttle with both motion control levers in the full forward position Gradually turn in the left tracking until unit tracks straight Hour Meter The hour meter displa...

Page 21: ... Push in and turn the key clockwise to start the engine 8050 601 Blade switch 8050 602 Ignition switch Parking Brake The parking brake is found on the left of the machine Pull the lever backward to activate the brake and forward to release it IMPORTANT INFORMATION The machine must stand absolutely still when applying the parking brake Always set the parking brake before dismounting Release the par...

Page 22: ...CONTROLS 22 8050 781 Ignition switch RUN position Release the key to the RUN position when the engine has started For using accessory turn the key clockwise 8050 848 Ignition switch accessory ...

Page 23: ...ed in automobiles There are three fuses with ratings and functions 1 20 A Primary fuse 2 7 5 A Mower deck coupling 3 10 A Accessories 8065 043 Fuses Cutting Height Pedals The cutting height pedals release the deck lift to allow setting the desired deck height Apply pressure to the lift pedal and rotate foot to also apply pressure to the release pedal unlocking the deck lift For transport push the ...

Page 24: ...el Shut Off Valve The fuel shut off valve is located at the right rear of the seat The valve has three positions right tank left tank and OFF 8065 099 Gas model fuel shut off valve in the CLOSED position Hydro Bypass Transaxle bypass must be engaged when pushing or pulling the mower The bypass valves are located on the inner front sides of the transaxles See Moving Machine By Hand in the Operation...

Page 25: ...g operation Risk for burns if touched Allow engine and exhaust system to cool before refueling WARNING Fill to bottom of filler neck Do not overfill Wipe off any spilled oil or fuel Do not store spill or use gasoline near an open flame 8065 007 Gasoline fuel tanks IMPORTANT INFORMATION It is recommended that fuel be added to both tanks on initial start up Read the safety instructions before refuel...

Page 26: ...rting in the Operation section Adjust the engine speed to idle disengage the parking brake but do not engage the blades at this time Rotate control levers inward As long as the control levers have not been moved forward or backwards the mower will not move Slowly move both control levers forward slightly This will allow mower to start moving forward in a straight line Pull the control levers back ...

Page 27: ...ower blades must be depressed 2 The parking brake must be on Roll Bar and Safety Belt Operate the unit with the roll bar in the raised and locked position and use the seat belt There is no rollover protection when the roll bar is down If it is necessary to lower roll bar do not wear the seat belt Raise the roll bar as soon as clearance permits 8065 011 Roll bar in upright position WARNING The seat...

Page 28: ...fully forward 3 Activate the parking brake 4 Disengage the mower blades by depressing the blade switch 5 Move the steering controls outward to the locked outer neutral position 8050 601 Press the control for disengaging the mower deck 8065 096 Place controls in neutral position 8065 017 Set mower deck to the transport position ...

Page 29: ...the engine is cold the choke control should be pulled fully up 8050 605 Set the throttle and choke 8 Open the fuel tank valve for the selected tank 9 Press in and turn the ignition key to the start position IMPORTANT INFORMATION Do not run the starter for more than 5 seconds each time If the engine does not start wait about 10 seconds before retrying WARNING Engine exhaust and certain vehicle comp...

Page 30: ... the discharged battery away from the fuel tank and battery To remove cables reverse order Remove BLACK cable first from chassis and then from the fully charged battery Remove RED cable last from both batteries 8011 642 Jumper cable connection IMPORTANT INFORMATION The mower is equipped with a 12 volt negative grounded system The other vehicle must also be a 12 volt negative grounded system Do not...

Page 31: ...e engine 2 Move the steering controls to the neutral position N 3 The cutting height can be set from 1 5 2 5 cm 14 cm by setting the cutting height pin into the desired hole Release deck height control by pushing forward on the pedal 4 Set pin at desired cutting height Pin is removed by rotating 180O Push pedal again to lower deck to selected setting 8065 006 Release the parking brake 8065 017 Cut...

Page 32: ... regain forward motion Make all turns slowly IMPORTANT INFORMATION Control levers return to neutral when released This may cause the mower to suddenly stop WARNING Do not drive up or down hills with slopes greater than 10 degrees Do not drive across slopes 5 Make sure the work area is free from objects that could be thrown by the rotating blades 6 Move throttle control to full throttle 7 Engage th...

Page 33: ...y depressing the blade switch 8050 607 Disengage the mower deck and move throttle to minimum Raise the mower deck by pressing the foot pedal forward to the transport position When the machine is standing still activate the parking brake by pulling the lever upward Turn the ignition key to the stop position Move the steering controls outward Remove ignition key To prevent unauthorized use always re...

Page 34: ... The lawn becomes more even and the grass clippings more evenly distributed over the mown area The total time taken is not increased as a higher operating speed can be used without poor mowing results Avoid mowing wet lawns The mowing result is poorer because the wheels sink into the soft lawn clumps build and the grass clippings fasten under the cowling Hose the mower deck underside with water af...

Page 35: ...unit The bypass valves are located on the front inner sides of the transaxles Set the deck to the lowest position when accessing the pump valves To disengage each pump turn the slot on the pump valve 45O clockwise from the DRIVE position to the BYPASS position WARNING No adjustments or maintenance should be carried out unless the engine stopped the ignition key removed the parking brake activated ...

Page 36: ...ng brake Check the engine s oil level every refueling Check the safety system Check for fuel and oil leakages Check clean the engine s cooling air intake Check the mower deck Check for loose hardware screws nuts Clean under the mower deck Start the engine and blades listen for unusual sounds Check for damage Thoroughly clean around the engine Clean around belts belt pulleys Check the tire pressure...

Page 37: ...ing 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 50 250 500 Check adjust throttle cable Check the condition of belts belt pulleys Change the engine oil 1 Replace the engine oil filter Clean replace the spark plugs...

Page 38: ...ARGE 12 4V 75 20 min 35 min 48 min 90 min 12 2V 50 45 min 75 min 95 min 180 min 12 0V 25 65 min 115 min 145 min 280 min 11 8V 0 85 min 150 min 195 min 370 min Charging time depends on battery capacity condition age temperature and efficiency of charger Battery Removal Corrosion and dirt on the battery and terminals can cause the battery to lose power 1 Lift the seat and rotate fully forward until ...

Page 39: ... blades are engaged and the driver temporarily moves off the driver s seat IMPORTANT INFORMATION To be able to drive the driver must sit in the seat and release the parking brake before the steering controls can be moved into the neutral position otherwise the engine will stop 8065 021 Conditions for starting Tire Pressures Fill tire pressures to 15 psi 103 kPa 1 bar IMPORTANT INFORMATION DO NOT a...

Page 40: ... 4 Carefully roll the belt over the top of the cutter housing pulleys 5 Remove the belt guide hardware with a wrench and set belt guide aside 6 Remove the belt from around the electric clutch on the engine shaft 8065 046 Remove belt guide Deck Belt Installation NOTE For ease in installing the deck belt refer to the routing decal on the cutting deck 1 Place the belt around all the pulleys except th...

Page 41: ...pening in the idler arm shift the arm to create slack in the belt While holding the idler back with the breaker bar wrap the belt around the right pump pulley 5 Replace and secure clutch stop 6 Reinstall the deck belt See Deck Belt Installation in this section of the manual 8068 092 1 Electric clutch 2 Idler release placement 3 Clutch stop Pump belt removal V belts Check every 100 hours of operati...

Page 42: ...rpening 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 or resharpened blade with stamped GRASS SIDE facing towards ground grass down or THIS SIDE UP facing deck and spindle housing 3 Install and tighten blade bolt securely 4 Torque blad...

Page 43: ...site side check that measurement is the same If adjustment is required use the nuts to adjust the right and left side eyebolts up or down until both side to side measurements are equal Record measurement 3 Turn both outer blades to align with the deck in front to rear manner Reposition rear mounting eyebolts up or down until rear blade tips are positioned 1 8 to 3 8 higher in the rear than the fro...

Page 44: ...200 hours Check that wheels rotate freely Removal and Installation Remove nut and caster bolt Pull the wheel out of the fork Install in reverse order Tighten caster bolt Torque to 45 ft lbs 61 Nm then back nut off turn NOTE Tire should rotate freely but axle spacers should not If wheels do not rotate freely take the unit to the dealer for service The anti scalp rollers can be set in three position...

Page 45: ...or approval before conducting maintenance of a Hydro Gear product unless the servicing dealer is a current Authorized Hydro Gear Service Center Regular external maintenance of the ZT 5400 Powertrain should include the following 1 Check oil level in expansion tanks When the engine is cold the tanks should be at the FULL COLD level 2 Inspect the vehicle drive belt idler pulley s and idler spring s I...

Page 46: ...ith grease unless otherwise stated use high grade molybdenum disulphide grease For daily use the machine should 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 clean them with spirits If the belt continues to slip after cleaning it must be replaced Ga...

Page 47: ...xpose zerk Lubricate with a grease gun until the grease is forced out around the top washer Front Wheel Bearings Lubricate 3 4 strokes with a grease gun on each set of wheel bearings 8065 032 Lubricating front wheels 8058 131 Deck spindle Deck Spindle Lower the cutting deck completely If a grease gun without rubber hose is used the foot plate must be removed Lubricate with a grease gun 2 3 strokes...

Page 48: ...n your area 8 Remove the top fill vent port plug from the left side and right side of the transaxles prior to filling with oil This will allow the transaxles to vent during oil fill 9 Remove the cap from the transaxles expansion tank located on the vehicle frame 10 Fill with 20W50 motor oil until oil just appears at the bottom of each transaxles top port approximately 2 quarts per transaxle 4 quar...

Page 49: ... oil level will drop 3 With the bypass linkage closed and the engine running slowly move the directional control in both forward and reverse directions 5 to 6 times Check the oil level and add oil as required after stopping the engine It may be necessary to repeat Steps 2 and 3 until all the air is completely purged from the system When the hydraulic drive operates at normal noise levels and moves...

Page 50: ...the engine over Dead battery Poor contacts on the battery terminal cable connections Fuse blown Ignition system faulty Fault in the starter safety circuit See Safety System in the Maintenance section Engine runs rough Faulty carburetor Choke control is pulled out with warm engine Clogged fuel filter or jet Clogged ventilation valve on the fuel cap Fuel tank nearly empty Fouled spark plug Spark plu...

Page 51: ...on gears slack or has come off Air in hydraulic system Mower deck not engaging Drive belt for the mower deck has come loose Contact for the electromagnetic coupling has loosened Blade switch is faulty or has come loose from the cable contact Fuse has blown Hydraulic drive leaks oil Damaged seals housing or gaskets Air trapped in hydraulic system Uneven mowing results Unequal tire pressure on the l...

Page 52: ... tanks or add a fuel stabilizer Start the engine and allow it to run until the carburetor is drained of fuel or the stabilizer has reached the carburetor 5 Remove the spark plug and pour about a tablespoon of engine oil into the cylinder Turn over the engine so that the oil is evenly distributed and then refit the spark plug 6 Lubricate all grease zerks joints and axles 7 Remove the battery Clean ...

Page 53: ...TIMER SCHEMATIC WIRING DIAGRAM 53 ...

Page 54: ...d direction controls Dual levers foam gripped Dual levers foam gripped Speed forward 0 11 mph 0 17 7 Km h 0 11 mph 0 17 7 Km h Speed reverse 0 6 mph 0 9 7 Km h 0 6 mph 0 9 7 Km h Brakes Internal Cog Internal Cog Front caster tires smooth tread 13 x 6 5 4 ply 13 x 6 5 4 ply Rear tires turf pneumatic 23 x 10 5 12 4 ply 24 x 12 12 4 ply Tire pressures 15 PSI 103 kPa 1 bar 15 PSI 103 kPa 1 bar 1 See t...

Page 55: ... Seat Suspension Suspension Hinged Arm Rests Yes Yes Hour Meter Yes Yes Blade Engagement 150 ft lb Ogura 150 ft lb Ogura Deck Construction 7 gauge 7 gauge Productivity 5 acres h 20 234 m2 h 6 acres h 24 480 m2 h Dimension Weight 1260 lbs 572 kg 1320 lbs 599 kg Base Machine Length 82 210 cm 82 210 cm Base Machine Height 47 121 cm 47 121 cm Base Machine Width 52 132 cm 55 140 cm Overall Width Chute ...

Page 56: ...ls Dual levers foam gripped Dual levers foam gripped Speed forward 0 11 mph 0 17 7 Km h 0 11 mph 0 17 7 Km h Speed reverse 0 6 mph 0 9 7 Km h 0 6 mph 0 9 7 Km h Brakes Internal Cog Internal Cog Front caster tires smooth tread 13 x 6 5 4 ply 13 x 6 5 4 ply Rear tires turf pneumatic 24 x 12 12 4 ply 24 x 12 12 4 ply Tire pressures 15 PSI 103 kPa 1 bar 15 PSI 103 kPa 1 bar 1 See the Engine Manufactur...

Page 57: ...ension Hinged Arm Rests Yes Yes Hour Meter Yes Yes Blade Engagement 150 ft lb Ogura 150 ft lb Ogura Deck Construction 7 gauge 11 gauge Productivity 6 acres h 24480 m2 h 7 2 acres h 29137 m2 h Dimension Weight 1320 lbs 599 kg 1400 lbs 635 kg Base Machine Length 82 210 cm 86 218 cm Base Machine Height 47 121 cm 47 121 cm Base Machine Width 55 140 cm 57 145 cm Overall Width Chute Up 61 156 cm 73 187 ...

Page 58: ... 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 Size 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 2...

Page 59: ...t 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 ...

Page 60: ...stment 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 and adjustment 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 advant...

Page 61: ...Change the engine oil Change the oil filter Inspect hydraulic hoses Inspect hydraulic belt Inspect hydraulic filter Check neutral position Check safety system Check seat belt Check ROPS Check fuel system for leaks Inspect safety guards and shields Check brake adjustment ...

Page 62: ...s 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 ROPS Check fuel system for leaks Inspect safety guards and shields Check brake adjustment ...

Page 63: ...is 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 ROPS Check fuel system for leaks Inspect safety guards and shields Check brake adjustment ...

Page 64: ...ct spark 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 Inspect hydraulic filter Inspect hydraulic drive belt Inspect hydraulic hoses Check neutral position Inspect battery connections Check safety system Check seat belt Check ROPS C...

Page 65: ...PM 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 Change hydraulic oil 400 hours Change hydraulic filter Replace hydraulic drive belt Inspect hydraulic hoses Check neutral position Inspect battery connections Load test battery Clean electrical connections Inspect the clutch ...

Page 66: ...lace 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 Inspect spark plug Check the engine valve clearance Change hydraulic oil Change hydraulic filter ...

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