Dixon DX161/966698901 Specifications

Operator Manual

Form Number 115 619927 Rev A 2013-07-15

DX161 / 966698901

Please read the operator manual carefully and make sure you understand the instructions before using the machine.

Gasoline containing up to 10% ethanol (E10) is acceptable for use in this machine. The use of any gasoline exceeding 10% ethanol (E10) will void the product warranty.

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

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

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

Do not modify or install non-standard equipment to the unit without consent from the manufacturer.

Modifications to the unit may cause unsafe operations or damage the unit.

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

©2013 All rights reserved.

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

IntRODUCtIOn ......................................................5

Driving and transport on Public Roads .............5

towing ................................................................5

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

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

Manufacturing number .................................6

SYMBOLS AnD DeCALS .........................................7

SAFetY ....................................................................9

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

Personal Safety equipment ..............................11

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

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

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

transport ..........................................................16

towing ..............................................................16

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

Rollover Protection system (ROPS) ..................17

COntROLS ............................................................18

Control Locations .............................................18

Motion Control Levers ......................................19

throttle Control .................................................20

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

Choke ...............................................................20

Ignition Switch ..................................................21

Hour Meter .......................................................22

tracking ............................................................22

Parking Brake ...................................................23

Cutting Height Adjuster ....................................23

Seat Adjustment Lever .....................................23

Bypass Linkages ..............................................24

Fuel Shut Off Valve ...........................................24

Fuses ................................................................24

Fuel tank ..........................................................25

OPeRAtIOn ...........................................................26

training .............................................................26

Steering ............................................................26

Before Starting .................................................27

Starting the engine ...........................................28

Jumper Cables Use ....................................31

COntentS

Running ............................................................32

Operating on Hills ............................................33

Stopping the engine .........................................34

Mowing tips .....................................................35

Moving Machine By Hand ................................36

MAIntenAnCe ......................................................37

Maintenance Schedule ....................................37

Battery ..............................................................39

Safety System ...................................................40

tire Pressures ...................................................40

Parking Brake ...................................................40

Deck Belt ..........................................................41

Pump Belt .........................................................42

V-belts ..............................................................43

Cutting Blades ..................................................44

Adjusting the Mower Deck ...............................45

Leveling deck ..............................................45

Anti-scalp rollers...............................................46

Caster Wheels ..................................................47

Hardware ..........................................................47

Cleaning ...........................................................47

LUBRICAtIOn ........................................................48

Lubrication Schedule .......................................48

Wheel and Deck Zerks .....................................49

Front Wheel Mount ......................................49

Front Wheel Bearings ..................................49

Deck Spindles .............................................49

transaxle (transmission) Fluid Change ...........50

transmission Purging ..................................51

tROUBLeSHOOtInG GUIDe ................................52

StORAGe ..............................................................54

Winter Storage ..................................................54

Service .............................................................54

WIRInG DIAGRAMS ..............................................55

teCHnICAL DAtA .................................................56

COnFORMItY CeRtIFICAteS ...............................59

SeRVICe JOURnAL ...............................................60

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 that is 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) by all who operate this machine is important for the safety of the operator and others.

It can also considerably increase the life span of the machine and increase its resale value.

If you sell your machine, be sure to give the operator manual to the new owner.

the final chapter of this operator 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 manual along when the machine is taken to your dealer for service.

General

In this operator 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 recommendation for weight limits for towed equipment. Do not tow near ditches, canals, and other hazards.

Operating

this machine is constructed only for mowing grass on lawns and even ground without obstacles such as stones or tree stumps. 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 judgment, careful use in accordance with these instructions and common sense.

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

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

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

5

INTRODUCTION

Good Service

Dixon’s products are sold only in specialized retail stores with complete service. this ensures that you as a customer receive only the best support and service.

Before the product is delivered, the machine has, for example, been inspected and adjusted by your retailer. See the certificate in the Service Journal in this operator manual.

When you need spare parts or support in service questions, warranty issues, etc., please consult the following professional: this Operator Manual belongs to the machine with the manufacturing number:

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

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

• the manufacturer’s type number (Model).

• the machine’s serial number (Serial no.)

Please have the type designation and serial number available when ordering spare parts.

the engine’s manufacturing number is stamped on one of the valve covers.

the plate states:

• the engine’s model.

• the engine’s type.

• Code

Please have these available when ordering spare parts.

the wheel motors and hydrostatic pumps have a barcode decal affixed at the rear.

engine

6 transmission

symbOls aND DeCals these symbols are found on the machine and in the operator manual.

Study them carefully so that you know what they mean.

WARNING!

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

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

IMPORTANT INFORMATION

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

Used in this publication to notify the reader of a risk of material damage, particularly if the reader should neglect to follow instructions given in the manual.

Used also when there is a potential for misuse or misassembly.

R N

Reverse neutral Fast Slow Choke Fuel

Warning!

Parking Brake Ce conformity marking

Only for european market

Do not stand here

Use protective glasses noise emissions to the surroundings

Australia and new Zealand only

Use protective gloves electromagnetic

Compatibility (eMC)

Compliance

Australia and new Zealand only

7

symbOls aND DeCals

Read Operator Manual

Shut off engine and remove key before performing any maintenance or repair work

Keep a safe distance from the machine

Use on slopes no greater than 10° no passengers

Whole body exposure to thrown objects

Severing of fingers and toes

Do not open or remove safety shields while engine is running

Careful backing up, watch for other people

Careful going forward, watch for other people

Battery acid is corrosive, explosive and flammable

Moving sharp blades under cover

Warning! Rotating blades, keep away from the discharge deck

8

Do not touch parts

Protection frame (ROPS) instructions

saFeTy

Safety Instructions

these instructions are for your safety. Read them carefully.

WARNING!

THIS CUTTING MACHINE IS CAPABLE

OF AMPUTATING HANDS AND FEET

AND THROWING OBJECTS. FAILURE

TO OBSERVE THE FOLLOWING SAFETY

INSTRUCTIONS COULD RESULT IN

SERIOUS INJURY OR DEATH.

WARNING!

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

General Operation

• Read, understand, and follow all instructions on the machine and in the manual before starting.

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

• Do not put hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times.

• Only allow responsible adults, who are familiar with the instructions, to operate the machine.

• Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blades.

• Be sure the area is clear of bystanders before operating. Stop machine if anyone enters the area.

• never carry passengers. the machine is only intended for use by one person.

• Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing.

• never direct discharged material toward anyone.

Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blades when crossing gravel surfaces.

• Do not operate machine without the entire grass catcher, discharge guard, or other safety devices in place and working

• Slow down before turning.

• never leave a running machine unattended.

Always turn off blades, set parking brake, stop engine, and remove keys before dismounting.

Read the operator manual before starting the machine

8011-512

Clear the area of objects before mowing

8011-513

9

saFeTy

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

• Operate machine only in daylight or good artificial light.

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

• Watch for traffic when operating near or crossing roadways.

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

• Always wear eye protection when operating machine.

• Wear proper Personal Protective equipment

(PPe) while operating this machine, including (at a minimum) sturdy footwear, eye protection, and hearing protection. Do not mow in shorts and/or footwear with open toes.

• Data indicates that operators age 60 years and above are involved in a large percentage of riding mower-related injuries. these operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.

• Follow the manufacturer’s recommendation for wheel weights or counterweights.

• Anyone who operates this machine must first read and understand this Operator 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 or storing the machine.

• Allow machine to cool before storage.

Never take passengers

WARNING!

8011-520

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

10

saFeTy

Personal Safety Equipment

WARNING!

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

• Always have first aid equipment close at hand when using the machine.

• never operate the machine when barefoot.

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

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

• Always wear gloves when handling the blades.

• Always use ear protectors to avoid damage to hearing.

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

Slope Operation

Slopes are a major factor related to loss of control and tip-over accidents, which can result in severe injury or death. Operation on all slopes requires extra caution.

If you cannot back up the slope or if you feel uneasy on it, do not mow it.

• Mow up and down slopes (10 degrees maximum), not across.

• Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. tall grass can hide obstacles.

• Choose a low ground speed so that you will not have to stop while on the slope.

• Do not mow on wet grass. tires may lose traction.

• Avoid starting, stopping, or turning on a slope. If the tires lose traction, disengage the blades and proceed slowly straight down the slope.

• Keep movement on the slopes slow and gradual.

Do not make sudden changes in speed or direction, which could cause machine to roll over.

• Use extra care while operating machine with grass catchers or other attachments; they can affect the stability of the machine.

Personal protective equipment

Mow up and down, not side to side

8011-670a

WARNING!

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

6003-004

11

saFeTy

• Do not use on steep slopes.

• Do not try to stabilize the machine by putting a foot on the ground.

• Do not mow near drop-offs, ditches, or embankments. the machine could suddenly roll over if a wheel is over the edge or if the edge caves in.

WARNING!

CHILDREN CAN BE INJURED BY THIS

EQUIPMENT. The American Academy of Pediatrics recommends that children be a minimum of 16 years of age before operating a riding lawn mower. Keep children out of the mowing area and in the watchful care of a responsible adult other than the operator.

Be extra cautious when driving on slopes

Children tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity.

Never assume that children will remain out of the path of danger.

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

• Be alert and turn machine off if a child enters the area.

• Before and while backing, look behind and down for small children.

• never carry children, even with the blades shut off. they may fall off and be seriously injured or interfere with safe machine operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine.

• never allow children to operate the machine.

• Use extra care when approaching blind corners, shrubs, trees, or other objects that may block the view of a child.

Never allow children to operate the machine

8011-519

8011-517

8011-518

Keep children away from work area

12

saFeTy

Safe Handling of Gasoline

WARNING!

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

There is risk for burns if touched.

Allow engine and exhaust system to cool before refueling.

to avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

• extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only approved gasoline container.

• never remove gas cap or add fuel with the engine running. Allow engine to cool before refueling.

• never fuel the machine indoors.

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

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

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

• Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

• If fuel is spilled on clothing, change clothing immediately.

• never overfill fuel tank. Replace gas cap and tighten securely.

• Do not start the engine near spilled fuel.

• never use gasoline as a cleaning agent.

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

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

Never fill the fuel tank indoors

WARNING!

8011-516

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

13

saFeTy

General Maintenance

• never operate machine in a closed area.

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

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

• Keep machine free of grass, leaves, or other debris buildup. Clean oil or fuel spillage and remove any fuel-soaked debris. Allow machine to cool before storing.

• If the machine strikes a foreign object, stop and inspect the machine. Repair, if necessary, before restarting.

• never make any adjustments or repairs with the engine running.

• Check grass catcher components and the discharge guard frequently and replace with manufacturer’s recommended parts, when necessary.

• Mower blades are sharp. Wrap the blade or wear gloves, and use extra caution when servicing them.

• Check brake operation frequently. Adjust and service as required.

• Maintain or replace safety and instruction labels, as necessary.

• Do not modify safety equipment. Check regularly to be sure it works properly. the machine must not be driven with defective or unmounted protective plates, protective cowlings, safety switches, or other protective devices.

• Do not change the settings of governors and avoid running the engine with overly high engine speeds. If the engine runs too fast, there is risk for damaging the machine components.

• Be very careful when handling battery acid. Acid on skin can cause serious corrosive burns. If battery acid is spilled on skin, rinse immediately with water.

• Acid in the eyes can cause blindness, contact a doctor immediately.

• Be careful when servicing the battery. explosive gases form in the battery. never perform maintenance on the battery near open flames or sparks or while smoking.

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

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

14

Never drive the machine in an enclosed space

CAUTION!

Use protective glasses for maintenance work.

8011-515

WARNING!

The battery contains lead and lead compounds, chemicals that are considered to cause cancer, birth defects, and other reproductive system damage. Wash your hands after handling the battery.

saFeTy

Sparking can occur when working with the battery and the heavy cables of the starter circuit. this can cause battery explosion, fire or eye injury. Sparking in this circuit can not occur after the chassis cable

(normally negative, black) is removed from the battery.

WARNING!

Avoid electrical sparking and its consequences by the following routines:

• Use protective goggles.

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

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

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

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

6003-009

Do not smoke when performing maintenance on the battery.

The battery can explode and cause serious injury/damage.

• never use the machine indoors or in spaces lacking proper ventilation. the exhaust fumes contain carbon monoxide, an odorless, poisonous, and lethal gas.

• Stop to inspect the equipment if the machine runs over or into anything. If necessary, make repairs before starting.

• never make adjustments with the engine running.

• the machine is tested and approved only with the equipment originally provided or recommended by the manufacturer. Only use approved repair parts for the machine.

• the blades are sharp and can cause cuts and gashes. Wrap the blades or use protective gloves when handling them.

• Check the parking brake functions regularly.

Adjust or service as necessary.

• Mulch blades should only be used in familiar areas when higher quality mowing is desired.

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

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

• Regularly clean the upper side of the deck with compressed air after the surfaces have cooled.

Risk of sparking

8009-728

Regularly clean deck

0000-000

15

saFeTy

Transport

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

• Use an approved trailer to transport the machine.

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

• Do not operate this machine on public roadways.

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

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

• Load the unit onto truck or trailer by driving up ramps of suitable strength using a slow speed.

DO nOt LIFt! the machine is not intended to be lifted by hand.

WARNING!

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


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.

Towing

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

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

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

Spark Arrestor

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

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.

WARNING!

This mower is equipped with an internal combustion engine and should not be used on or near any unimproved forested, bush covered or grassy lands unless the engine's system is equipped with a spark arrester meeting applicable local or state laws (if any). If a spark arrestor is used, it should be maintained in effective working order by the operator.

16

CONTROls

Rollover Protection system (ROPS)

the ROPS increases the basic weight of the unit by

70 lbs / 32 kg. the ROPS is an accessory.

• Do 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 the seat belt when using the unit with the ROPS in the upright position.

• When operating with the ROPS in the folded position, the seat belt should not be worn.

• Where possible, avoid operating the unit near ditches, embankments and holes.

• Reduce 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 without 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 replaced.

• Check all bolts including seat belt for correct torque before each use.

• Check ROPS structure for damage before each use.

• ROPS bar is nOt intended for use in sub zero temperatures.

WARNING!

The rollover protection system's capabilities may be impaired by damage if the mower is overturned or if alteration to the ROPS occurs. If these conditions take place, the total structure MUST be replaced.

17

CONTROls this operator manual describes the Dixon Zero turn

Rider. the rider is fitted with a four-stroke overhead valve engine.

transmission from the engine is made via belt-driven

Control Locations

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

3

4

5

2

6

1

18

6

14

7

13

8

9

10

11

12

1. Motion control levers

2. tracking bolt

3. Parking brake

4. Fuel tank, right

5. Protection frame (ROPS)

6. Hydro release levers

(below frame)

7. Hour meter

8. Ignition switch

9. Choke

10. Blade switch

11. throttle control

12. Seat adjustment lever

13. Height adjustment

14. Deck lift pedal

8058-143

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.

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

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

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

Steering controls

8058-042

WARNING!

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

1. Forward

2. neutral

3. neutral slot, neutral lock

4. Reverse

Motion control lever pattern (right side)

8065-053

19

CONTROls

Throttle Control

the throttle control regulates the engine speed and the rate of rotation of the blades.

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.

Blade Switch

to engage the mower deck, pull the blade switch knob out. the mower blades are disengaged when the knob is pressed down fully.

Throttle control

Choke

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

For cold starts the control should be pulled out to its extent. Push choke in after engine starts.

Blade switch

Choke control

20

8050-601

8050-601

8050-601

CONTROls

Ignition Switch

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

Press in and turn the key clockwise to start the engine.

Release the key to the RUn position when the engine has started.

Ignition switch

8050-602

For models equipped with headlights, turn the key clockwise to ACCeSSORY for headlight use.

Ignition switch - RUN position

8050-603

Ignition switch - accessory

8050-604

21

CONTROls

Hour Meter

the hour meter displays the total operating time with the blade activated, eliminating hours being added if the key was accidentally left on.

to view the operating hours, turn the key to the On position and engage the blade switch. the clutch will engage and the hours should be shown on the meter.

the display on the hour meter will turn on the oil can icon after every fifty hours of use and will stay on for two hours or until the meter is manually reset. to manually reset the timer, turn the ignition key to the

RUn position and then engage and disengage the blade switch five times at one second intervals.

Hour meter

Tracking

If the mower is not tracking straight, check the air pressure in both rear tires. Recommended air pressure for the rear tires is 15 psi (1 bar).

1. tracking adjustments are made using the tracking bolts. the tracking bolts act as limiting devices for the motion control levers when in the full-forward position.

2. For preliminary tracking adjustment, move unit to an open, unobstructed area such as an empty parking lot or open field.

3. Back the tracking bolts out until flush with 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 tracking bolt on the right hand side 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 bolt until unit tracks straight.

Tracking adjustment

8050-601

8066-052

22

CONTROls

Parking Brake

the parking brake is found on the left of the machine.

Pull the lever backward to activate the brake and push forward to release it.


The machine must be not be moving when engaging the parking brake. Always set the parking brake before dismounting. Release the parking brake before moving the mower.

Cutting Height Adjuster

the desired cutting height is set with the height pin. the cutting height pedal releases the deck lift to place the deck at the selected height.

For transport, push the deck lift pedal fully forward until the deck lift latches in the transport (highest) position.

Parking brake

1

2

8066-052

8066-027

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), so the seat can be moved backward or forward.

1. Deck lift pedal

2. Height pin

Cut height selection


Seat should not be adjusted while unit is in motion.

Seat adjustment

8058-139

23

CONTROls

Bypass Linkages

the levers are located on each side of the rear of the unit below the rear engine plate. the bypass linkage is used when manually pushing or pulling the unit.

See Moving Machine By Hand in the Operation section.

WARNING!

Bypass linkages are located close to the muffler. To prevent burns, the engine should be shut off and allowed to cool before the bypass linkage levers are handled.

1

1. IZt locked into the bypass position

2. Release lever, engaged

Right side, ZT linkage

2

Fuel 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.

8065-061

Fuses

Fuses are located on the left hand side of the machine. they are accessed by tilting the seat forward. Fuses are flat pin fuses type as used in automobiles.

there are two fuses with ratings and functions of:

1. 20 A, Primary fuse

2. 7.5 A, Mower deck coupling

Fuel shut off valve in the CLOSED position.

8065-099

8011-420

Fuses

24

CONTROls

Fuel Tank


It is recommended that fuel be added to both tanks on initial start up.

Read the safety instructions before refueling. the combined capacity for the two tanks is 11 gallons (41 liters).

Regularly check the gas cap gasket for damage and keep the cap properly tightened.

the engine will run on a minimum of 87-octane unleaded gasoline (no oil mix). environmentally adapted alkylate gasoline can be used. See technical

Data concerning ethanol fuel. Methanol fuel is not allowed. Do not use e85 alcohol based fuel. Damage to the engine and components may occur.

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

Right hand gasoline fuel tank

8066-028

WARNING!

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

WARNING!

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

Risk for burns if touched.

Allow engine and exhaust system to cool before refueling.


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.

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.

25

OPeRaTION

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

Training

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

this section should be reviewed in its entirety prior to attempting to move the mower under its own power.

When first operating the mower or until becoming comfortable with controls, use a reduced throttle speed and reduced ground speed. DO nOt move control levers to the furthest forward or reverse positions during initial operation.

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

Steering

To move forward and backward the direction and speed of the mower’s movements 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

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

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

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

To turn to the right

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

To turn to the left

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

To zero turn

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

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


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

26

OPeRaTION

Before Starting

1. Read the sections Safety Instructions and

Controls before starting the machine.

2. Perform the daily maintenance before starting

(see Maintenance Schedule in the Maintenance section).

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

4. Adjust the seat to the desired position.

5. Select the cutting height by setting the cutting height pin into the desired hole and securing with the hairpin.

Seat adjustment

8058-139 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.

Cutting height selection

8066-027

27

OPeRaTION

Starting the Engine

1. Sit on the seat.

2. Raise the mower deck to the transport position by locking the lift pedal fully forward.

3. Activate the parking brake by pulling the lever fully upwards.

Set mower deck to the transport position

8066-027

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

Activate parking brake before starting

8066-052

Press the control for disengaging the mower deck

8050-607

28

OPeRaTION

5. Move the steering controls outward to the locked

(outer) neutral position.

WARNING!

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

Place controls in neutral position

6. Move the throttle to the middle position.

8066-054

7. Open the fuel tank valve for the selected tank.

Set the throttle

8050-605

Fuel valve in the OPEN position

8065-103

29

OPeRaTION

8. Press in and turn the ignition key to the start position.

For cold starts, the choke control should be pulled out to its extent. Push the choke in after engine starts.


Do not run the starter for more than 5 seconds each time. If the engine does not start, wait about 10 seconds before retrying.

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

10. 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.

Turn to the START position

8066-007

30

OPeRaTION

Weak Battery

WARNING!

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


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 use the mower to start other vehicles.

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

Jumper Cables Use

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

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

5. Remove ReD cable last from both batteries.

Jumper cable connection

8011-642

31

OPeRaTION

Running

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

2. Move the steering controls to the neutral position

(n).

3. Release foot pedal latch and lower deck to set cutting height.

Parking brake released

8066-052

WARNING!

Ensure that no one is near mower when engaging blade switch.

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

5. Move throttle control to full throttle (rabbit symbol).

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

Cutting height selection

8066-027

Move the throttle to FULL, engage the mower deck

8050-601

32

OPeRaTION

Operating on Hills

Read the Safety Instructions Driving on Slopes in the

Safety section.

WARNING!

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

• the slowest speed possible should be used before starting up or down hills.

• Avoid stopping or changing speed on hills.

• If stopping is absolutely necessary, pull drive levers into the neutral position and push to the outside of the unit and engage the parking brake.

• to restart movement, release the parking brake.

• Pull the control levers back to the center of the mower and press forward to regain forward motion.

• Make all turns slowly.


8066-054

Release the parking brake to restart movement

8066-052

33

OPeRaTION

Stopping the Engine

1. Move the throttle to the minimum position (tortoise symbol).

8050-607

Disengage the mower deck and move throttle to minimum

2. Move the steering controls outward into the neutral position.

3. Disengage the mower deck by depressing the blade switch.

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

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

If the engine has been worked hard, allow it to idle at least 60 seconds to attain a normal operating temperature before stopping. to prevent fouling the spark plugs, avoid idling the engine for longer periods.


6. turn the ignition key to the OFF position and remove key. Always remove key when leaving the mower to prevent unauthorized use.

8066-054


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

34

OPeRaTION

Mowing Tips

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

• Begin with a high cutting height and reduce it until the desired mowing result is attained. the average lawn should be cut to 2½" (64 mm) during the cool season and over 3" (76 mm) during the hot months. For healthier and better looking lawns, mow often after moderate growth.

• For best cutting performance, grass over 6" (15 cm) in height should be mowed twice. Make the first cut relatively high; the second to the desired height.

• the mowing result will be best with a high engine speed (the blades rotate rapidly) and low speed

(the rider moves slowly). If the grass is not too long and dense, the driving speed can be increased without negatively affecting the mowing result.

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

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

• Hose the mower deck underside with water after each use. When cleaning, raise the mower deck to the transport position. Make sure the mower is cooled and the engine is off. to aid the deck in drying after cleaning, restart the engine and engage the blades for about 1-2 minutes.

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

• When the mulching kit is used, it is important that the mowing interval is frequent and that the deck is cleaned more often.

WARNING!

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

Mowing pattern

8011-603b

WARNING!

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

Avoid sudden directional changes.

35

OPeRaTION

Moving Machine By Hand

WARNING!

No adjustments or maintenance should be carried out unless:

• the engine stopped

• the ignition key removed

• the parking brake activated

1

When pushing or pulling the mower, engage the IZt

(Integrated Zeroturn transaxle) bypass linkages. the linkages are located on each side of the rear of the unit below the engine plate.

1. Raise the deck to the highest (transport) position.

2. engage the parking brake.

3. Pull the bypass linkages up and out of the keyhole slots. Release the lever with the head outside the bracket and held into the bypass setting.

4. to reengage the IZts to drive, reverse the above procedure.

Load the machine into truck or trailer by driving slowly up the ramps. DO nOt LIFt! the machine is not intended to be lifted by hand.

1. IZt locked into the bypass position

2. Linkage lever, engaged

Right side, IZT linkage

WARNING!

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

2

8058-059

36

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

MAINTENANCE

Check the parking brake

Check the engine’s oil level (every refueling)

Check the safety system

Check for fuel and oil leakages

Check/clean the engine’s cooling air intake

Check the mower deck

Check for loose hardware (screws, nuts)

Clean under the mower deck

Start the engine and blades, listen for unusual sounds

Check for damage thoroughly clean around the engine

Clean around belts, belt pulleys

Check the tire pressures

Check battery connections

Sharpen 3) / Replace mower blades

Clean the engine’s cooling air intake 2)

Clean the air cleaner’s foam pre-filter 2)

Clean the air cleaner’s paper filter cartridge 2)

Check/adjust the parking brake

Inspect muffler/spark arrestor 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.

Daily

After

At least once each year

Maintenance interval in hours

50 250 500 Before

●

♦

●

■

♦

♦

♦

♦

●

●

●

■

●

●

●

■

■

■

●

♦

●

♦

♦

♦

●

●

●

■

●

♦

●

♦

♦

♦

●

●

●

■

■

■

●

♦

●

●

●

■

♦

●

♦

♦

●

♦

1) First change after 8-10 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.

2) In dusty conditions, cleaning and replacement are required more often.

3) Performed by authorized service workshop.

●

= Described in this manual

♦

= not described in this manual

■

= Refer to the engine manufacturer's manual

37

maINTeNaNCe

MAINTENANCE

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

Replace the fuel filter

Replace paper air filter 2)

Check the caster wheels (every 200 hours)

Replace the air cleaner’s foam pre-filter 2)

Change the hydraulic oil (every 500 hours)

Replace the hydraulic oil filter (every 500 hours)

Dismantle and inspect starter 3) (every 500 hours)

Check/adjust the mower deck

Check the engine valve clearance 3)

Perform the 500-hour service 3)

1) First change after 8-10 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.

2) In dusty conditions, cleaning and replacement are required more often.

3) Performed by authorized service workshop.

●

= Described in this manual

♦

= not described in this manual

■

= Refer to the engine manufacturer's manual

Daily

Before After

At least once each year

●

■

●

■

●

●

■

■

●

■

Maintenance interval in hours

50 500 250

■

●

■

■

■

●

■

●

●

♦

♦

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.

♦

●

●

●

♦

♦

38

maINTeNaNCe

Battery

the 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.

• Keep battery and terminals clean.

• Keep battery bolts tight.

• See chart for charging times.

CAUTION!

Always wear eye protection when around batteries.

StAnDARD

BAtteRY

12.6V

12.4V

12.2V

12.0V

11.8V

StAte

OF

CHARGe

100%

75%

50%

25%

0%

APPROXIMAte BAtteRY CHARGInG tIMe* tO FULL CHARGe At 80 O F / 27 O C

50 Amps

Maximum Rate at:

30 Amps 20 Amps 10 Amps

- FULL CHARGe -

20 min.

45 min.

65 min.

85 min.

35 min.

75 min.

115 min.

150 min.

48 min.

95 min.

145 min.

195 min.

*Charging time depends on battery capacity, condition, age, temperature and efficiency of charger

90 min.

180 min.

280 min.

370 min.


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.

Cleaning battery and terminals

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

1. Open the terminal access doors.

2. 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.

Replacing battery

1. Lift seat and rotate forward.

2. Open terminal access doors

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

4. Using a 7 /

16

wrench, remove the bolts on either side of the terminal guard and lift off guard.

5. Carefully remove the battery from the mower.

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

7. Reinstall battery terminal guard.

8. First connect ReD battery cable to positive (+) battery terminal with hex bolt and hex nut.

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

10. Close access doors.

11. Lower seat.

WARNING!

Do not short battery terminals by allowing a wrench or any other object to contact both terminals at the same time.

Before connecting battery, remove metal bracelets, wristwatch bands, rings, etc.

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

2

1. terminal guard

2. Access doors

Battery cleaning and installation

2

1

8066-049

39

maINTeNaNCe

Safety System

this machine is equipped with a safety system that prevents starting or driving under the following conditions.

the engine can only be started when:

• the mower deck is disengaged.

• the steering controls are in the outer, locked neutral position.

• the parking brake is on.

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

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

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

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

Conditions for starting

Tire Pressures

Fill tire pressures to 15 psi / 103 kPa / 1 bar.


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

Only use O.E.M. specified tires.

8066-032

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.

WARNING!

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

40


The machine must be standing still when applying the parking brake.

Parking brake

8066-052

maINTeNaNCe

Deck Belt

Deck Belt Removal

Park on a level surface. Apply park brake. Lower the deck into the lowest cutting position.

1. Remove foot plate and belt shields.

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

3. With a ½" breaker bar and using the square opening in the idler arm, shift the arm counter clockwise to relieve the tension on the belt.

4. Carefully slip the belt over the top of the cutter housing pulleys.

5. Remove the belt guide hardware with a ½" wrench and set belt guide aside.

6. Remove the belt from around the electric clutch on the engine shaft.

Release the belt tension

8065-040

Deck Belt Installation nOte: For ease in installing the deck belt, refer to the routing decal on the cutting deck.

7. Place the belt around all the pulleys except the center spindle pulley.

8. With a ½" breaker bar, shift the idler arm counter clockwise. When there is enough slack, slip the belt onto the center spindle pulley.

9. Reinstall the belt guide removed in Step 5 above.

10. Double check belt routing to make sure it matches the routing decal affixed to the deck, and that the belt does not have any twist. Correct if needed.

Remove belt guide

8065-045

Refer to belt routing decal

8065-047

41

maINTeNaNCe

11. Adjust belt tension by turning the eyebolt until there is approximately 7 /

8

" -1" of threads showing outside the nut.

12. Belt tension should be set to 60-70 lbs.

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

14. Replace foot plate.

Pump Belt

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

Replacing Pump Belt

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

Belt Removal

From the top side of the deck:

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

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

Adjust belt tension

Remove fan covers

42

8065-054

8058-064

maINTeNaNCe

From the underside of the deck:

3. Remove clutch stop to access the belt.

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

5. With the idler arm in the slack position, slip a screwdriver, clevis pin or similar into the 3 /

8

" hole in the plate that sits between the two fan covers. this will keep the idler in the extended position and allow removal of the breaker bar.

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

Belt Installation

7. Repeat Steps 4 and 5 from the above instructions.

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

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

10. Place the belt on the engine pulley.

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

12. Replace and secure clutch stop.

13. Reinstall the fan shields.

14. Reinstall the deck belt. (See Deck Belt

Installation in this section of the manual).

3

1

1. electric clutch

2. Idler arm release placement

3. Clutch stop

Pump belt removal

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.

2

8058-060

43

maINTeNaNCe

Cutting Blades

to attain the best mowing effect, it is important that the blades are well sharpened and not damaged.

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

Let the service workshop should decide whether the blade can be repaired/ground or must be replaced.

Balance the blades after sharpening.

Check the blade mounts.

WARNING!

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

The sharpening of blades should be carried out by an authorized service workshop.

WARNING!

Before performing any service or adjustment checklist:

• Engage the parking brake.

• Place the Blade switch in the disengaged position.

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

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

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. Seat the blade opening firmly onto the spindle housing.

4. tighten blade bolt securely.

5. torque blade bolt to 90 ft/lbs (122 nm).

2

3

1


Special blade bolt is heat treated.

Replace with a Dixon bolt if required.

Do not use lower grade hardware than specified.

1. Blade

2. Blade bolt (special)

3. Spindle housing

Blade attachment

44

maINTeNaNCe

Adjusting the Mower Deck

Leveling deck

Adjust the deck while the mower is on a level surface. Make sure the tires are inflated to the correct pressure. See Technical Data under Transmission.

If tires are under or over inflated, the deck cannot be properly adjusted.

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

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

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

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

3. turn both outer blades to align with the deck in front-to-rear manner. Reposition rear mounting bolts up or down until rear of mower deck is positioned level to 1 /

8

" higher in the rear than the side-to-side measurement.

4. Confirm measurements once again. Blade tips should be level in a side-to-side manner. In the rear, blade tips should be level to 1 /

8

" higher than side-to-side measurement. In the front, blade tips should be level to 1 /

8

" lower than side-to-side measurement.

nOte: this will place the mower deck in a standard measurement position. Additional adjustment may be required to achieve desired cut for the type of grass or conditions being mowed.

Set blades to begin measurement

2

1. Lift arm

2. Mounting bolts

Leveling the mower deck

1

2

8058-151

8050-829

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. Antiscalp rollers then keep the deck in the proper position to help prevent scalping in most terrain conditions.


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

Anti-scalp rollers can be set in three positions:

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

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

• Lower position 4½" to 6" (114 to 152 mm) grass.

the rollers should be approximately ¼" (6.5 mm) from ground. Do not adjust the rollers to support the deck.

Anti-scalp rollers


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

8058-054

46

maINTeNaNCe

Caster Wheels

Check every 200 hours. Check that wheels rotate freely.

Removal and Installation

1. Remove nut and caster bolt.

2. Pull the wheel out of the fork.

3. Install in reverse order.

4. tighten caster bolt. If wheels do not rotate freely, take the unit to the dealer for service.

Hardware

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

Caster wheel

Cleaning

Regular cleaning and washing, especially under the mower deck, will increase the machine’s life-span.

Make it a habit to clean the machine directly after use

(after it is cooled), before the dirt sticks.

Do not spray water on the top of the mower deck. Use compressed air to clean the top side of mower deck.

Regularly clean deck and underside of the deck with normal water pressure. Do not use a high pressure washer or steam cleaner. Avoid spraying engine and electrical components with water.

Do not rinse hot surfaces with cold water. Let unit cool before washing.

Use protective glasses when cleaning and washing.

8058-055

47

Lubrication Schedule

lUbRICaTION

8058-069

12/12 every year

1/52 every Week

1/365 every day

*

Change hydraulic drive filters.

p See engine Manufacturer's manual

Lubricate with grease gun

Oil change

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 high grade molybdenum disulphide grease.

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

Filter change

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 continues to slip after cleaning, it must be replaced.

Gasoline or other petroleum products must not be used to clean belts.

48

lUbRICaTION

Wheel and Deck Zerks

Use only good quality bearing grease.

Grease from well-known brand names (petrochemical companies, etc.) usually maintains a good quality.

Front Wheel Mount

Lubricate with a grease gun until the grease is forced out from the caster tube.

Front Wheel Bearings

Lubricate 3-4 strokes with a grease gun on each set of wheel bearings.

Lubricating front wheels

Deck Spindles

Lower the cutting deck completely.

If a grease gun without rubber hose is used, the foot plate must be removed to access the center spindle.

Lubricate with a grease gun, 2-3 strokes per spindle.

Outer deck spindle

8058-057

8058-058

Center deck spindle

8065-200

49

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. Remove the filter guard screws and filter guard.

Clean any loose debris from around the perimeter of the filter. See illustration.

2. Place an oil drain pan (12" or more diameter and

8 qt. capacity is optimal) beneath the oil filter.

Remove the oil filter from the transaxle.

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

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

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

5. Reinstall the filter guard. torque screws to

65 in/lbs. each.

6. Repeat steps on the opposite side.

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

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

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

10. Fill with 20W50 motor oil until oil just appears at the bottom of each transaxles’ top port

(approximately 2 quarts per transaxle, 4 quarts total). Install the top port lug into each transaxle as the oil level reaches the port.

NOTE: If synthetic oil is used, each transaxle must be thoroughly drained of the mineral-based oil and a new filter installed before refilling the transaxle with synthetic oil.

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

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

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

14. Proceed to the purge procedure.

3

1. Filter guard

2. transaxle filter

3. top port plug

IZT filter change

2

1

8019-010

50

lUbRICaTION

Transmission 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 maintenance or any additional oil has been added to the system.

Resulting symptoms in hydrostatic systems may be:

• noisy operation.

• Lack of power or drive after short term operation.

• High operation temperature and excessive expansion of oil.

• Shortened component life.

Before starting, make sure the oil tank is at the proper oil level. If not, fill to the specifications outlined above.

the following procedures are best performed with the vehicle drive wheels off the ground, then repeated under normal operating conditions.

See Moving Machine By Hand in the Operation section for bypass linkage adjustments.

1. Disengage the brake if activated.

2. With the bypass linkage open and the engine running at fast idle, slowly move the directional 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 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.

4. 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 smoothly forward and reverse at normal speeds, the hydraulic drive is considered purged.

5. After the vehicle has been used two times, the oil level should be checked while the oil is cold and adjusted accordingly.

51

Problem engine will not start engine runs rough engine seems weak

TROUblesHOOTING GUIDe

Cause

Starter does not turn the engine over

• 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

• Clogged fuel filter or fuel line

• Faulty ignition system

• 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

• 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 plug is loose

• Rich fuel mixture or fuel-air mixture

• Wrong fuel type

• Water in the fuel

• Clogged air filter

• Clogged air filter

• Fouled spark plugs

• Carburetor incorrectly adjusted

52

TROUblesHOOTING GUIDe

Cause Problem

Machine vibrates engine overheats

• Clogged air intake or cooling fins

• engine overloaded

• Poor ventilation around engine

• Defective engine speed regulator

• too little or no oil in the engine

• Fouled spark plug

Battery not charging

Machine moves slowly, unevenly, or not at all

• Parking brake on

• Bypass valve on pump open

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

• Air in hydraulic system

Mower deck not engaging

• Poor contact with battery terminal cable connectors

• Charging lead is disconnected

• Fault in engine charging system

• Drive belt for the mower deck has come loose

• Contact for the electromagnetic coupling has loosened

• the blade switch is faulty or has come loose, from the cable contact

• the fuse has blown

Hydraulic drive leaks oil

• Damaged seals, housing, or gaskets

• Air trapped in hydraulic system

Uneven mowing results

• Blades are loose

• Blades are incorrectly balanced

• Blades are bent

• engine is loose

• Unequal tire pressure on the left and right sides

• Blades are bent

• Suspension for the mower deck is uneven

• Blades are dull

• Driving speed too high

• the grass is too long

• Grass collected under the mower deck

53

sTORaGe

Winter Storage

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

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

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

WARNING!

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

Never use gasoline for cleaning. Use a degreaser and warm water.

to ready the machine for storage, follow these steps:

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

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

3. Change the engine oil; dispose of properly.

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

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

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

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

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

Service

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

Always use genuine Dixon spare parts.

An annual check-up at an authorized service workshop is a good way to ensure that the machine performs its best the following season.

54

sCHemaTICs DIaGRam

55

Engine

Manufacturer

Type

Power

Lubrication

Fuel

Fuel capacity

Cooling

Alternator

Starter

Transmission

Transmission

Speed and direction controls

Speed forward

Speed reverse

Brakes

Front caster tires, smooth tread

Rear tires, turf pneumatic

Tire pressures

1) The power rating as declared by the engine manufacturer is the average gross power output at the specified RPM of a typical production engine for the engine model measured using SAE Standards for engine gross power.

Refer to the engine manufacturer engine specifications.

TECHNICAL DATA

DX161 / 966698901

Kawasaki

FX730

23.5 HP 1)

Pressure w/ Oil Filter

Min 87 octane unleaded (Max ethyl alcohol 10%, Max MTBE 15%)

11 gallons / 41 liters

Air cooled

12v 15 amp @ 3600 rpm

Electric

ZT-3400 Hydro Gear

Dual levers, foam gripped

0-10 mph - 0-16.1 Km/h

0-5 mph - 0-8 Km/h

Mechanical parking brake

13 x 6.5

23 x 10.50-12

15 PSI / 103 kPa / 1 bar

56

Frame

Cutting Width

Cutting Height

Uncut Circle number of Blades

Blade Length nose Roller

Seat

Hinged Arm Rests

Hour Meter

Blade engagement

Deck Construction

Productivity

Dimension

Weight

Base Machine Length

Base Machine Height

Base Machine Width

Overall Width, Chute Up

Overall Width, Chute Down

TeCHNICal DaTa

DX161 / 966698901

61" (155 cm)

1½"-5" (2.5-12.7 cm)

0

3

21" / 53.3 cm no

Premium Commercial eVC

Yes

Digital

200 ft-lb

11 gauge fabricated

4.9 acres/h / 19,823 m 2 /h

955 lbs / 433 kg

76" / 193 cm

51" / 129 cm

49" / 124 cm

63" / 160 cm

76" / 193 cm

57

58

TeCHNICal DaTa

TORQUE SPECIFICATIONS engine crankshaft bolt 50 ft/lb (67 nm)

Deck pulley bolts 150 ft/lb (201 nm)

Standard 5 /

16

" fasteners 18 ft/lb

Standard 3 /

8


Blade bolt 90 ft/lb (122 nm)

Standard ¼" fasteners 9 ft/lb (12 nm)

Standard 7 /

16


Standard ½" fasteners 80 ft/lb

HEX HEAD CAP SCREWS the torque values shown should be used as a general guideline when specific torque values are not given.

Grade SAe Grade 5

U.S. Standard Hardware

SAe Grade 8

Size ft./lbs nm ft./lbs nm

Flangelock Screw w/Flangelock nut ft./lbs nm

¼ 9 12 13 18

(25 nm)

(44 nm)

(70 nm)

(110 nm)

24

40

33

54

9 / 16

5 / 8

¾

7 / 8

1 1 / 8

5 / 16

3 / 8

7 / 16

½

110

150

250

378

782

18

31

50

75

150

203

339

513

1060

24

42

68

102

165

225

370

591

1410

28

46

75

115

224

305

502

801

1912

38

62

108

156

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

Grade Grade 8.8

Metric Standard Hardware

Grade 10.9

Size

M4 ft./lbs

1.5

nm

2 ft./lbs

2.2

nm

3

M10

M12

M14

M16

M5

M6

M7

M8

M18

M20

M22

M24

M27

24

43.5

70.5

108

3

5.2

8.2

13.5

142

195

276

353

530

32

58

94

144

11

18

4

7

190

260

368

470

707

35.2

62.2

100

147

4.5

7.5

12

18.8

202

275

390

498

474

47

83

133

196

6

10

16

25

269

366

520

664

996

119

176

242

330

471

596

904

Grade 12.9

ft./lbs

2.7

nm

3.6

5.2

8.2

7

11

15

21.8

43.5

75

20

29

58

100

159

235

323

440

628

794

1205

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.

59

seRVICe JOURNal

Action

Delivery Service

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 the effects of service and maintaining a service journal on the machine’s resale value

Application areas for Mulching

Fill in the sales papers, etc Delivery service has been carried out no remaining notes

Certified:

60

Date, mtr reading, stamp, sign q q q q q q q q q q q q q q q q q q q q q q q q

Action

After the first 10 hours

Change the engine oil

Change the oil filter

Check hydraulic oil level

Inspect hydraulic hoses

Inspect hydraulic belt

Inspect hydraulic filter

Check neutral position

Check safety system

Check seat belt

Check fuel system for leaks

Inspect safety guards and shields

Check brake adjustment seRVICe JOURNal

Daily Service

Clean debris from mower

Check engine oil level


Check underside of deck

Inspect deck pulleys


Check safety system

Check seat belt

Check fuel system for leaks

Inspect safety guards and shields

Check brake adjustment

Date, mtr reading, stamp, sign q q q q q q q q q q q q q q q q q q q q q q q

61

62 seRVICe JOURNal

Action

25-Hour Service

Check the fuel pump’s air filter

Sharpen/Replace mower blades if required


Check battery with cables

Lubricate according to lubrication chart


Clean the air cleaner’s foam pre-filter

Date, mtr reading, stamp, sign q q q q q q q

50-Hour Service

Perform the 25-hour service.

Clean/replace the air cleaner’s paper filter cartridge

(shorter intervals for dusty operating conditions).

Change engine oil.

Lubricate according to lubrication chart.

Check/adjust the parking brake.

q q q q q

seRVICe JOURNal

Action

100-Hour Service

Perform the 25-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)

Date, mtr reading, stamp, sign q q q q q q q q q

300-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 foam pre-filter q q q q q q q

63

64 seRVICe JOURNal

Action

At Least Once Each Year

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

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

Check the engine valve clearance

Date, mtr reading, stamp, sign q q q q q q q q q q

Action seRVICe JOURNal

Date, mtr reading, stamp, sign

65

66

Action seRVICe JOURNal

Date, mtr reading, stamp, sign

Dixon DX161/966698901 Specifications

Operator Manual

Congratulations

General

Driving and Transport on Public Roads

Towing

Operating

Good Service

Safety Instructions

Personal Safety Equipment

Slope Operation

Safe Handling of Gasoline

General Maintenance

Transport

Towing

Spark Arrestor

Rollover Protection system (ROPS)

Control Locations

Motion Control Levers

Throttle Control

Blade Switch

Choke

Ignition Switch

Hour Meter

Tracking

Parking Brake

Cutting Height Adjuster

Seat Adjustment Lever

Bypass Linkages

Fuel Shut Off Valve

Fuses

Fuel Tank

Training

Steering

Before Starting

Starting the Engine

Weak Battery

Running

Operating on Hills

Stopping the Engine

Mowing Tips

Moving Machine By Hand

Maintenance Schedule

♦

♦

Battery

Safety System

Tire Pressures

Parking Brake

Deck Belt

Pump Belt

V-belts

Cutting Blades

Adjusting the Mower Deck

Anti-scalp rollers

Caster Wheels

Hardware

Cleaning

Lubrication Schedule

Wheel and Deck Zerks

Transaxle (Transmission) Fluid Change

Winter Storage

Service

Delivery Service

After the first 10 hours

Daily Service

25-Hour Service

50-Hour Service

100-Hour Service

300-Hour Service

At Least Once Each Year

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