Dixon DX148 BF/966664101 Operator`s manual

Operator Manual
DX148 / 966663901
DX152 CARB / 966664001
DX152 BF / 966664301
DX148 BF /966664101
DX152 / 966664201
DX161 / 966664501
DX161 / 966698901
Please read the operator’s manual carefully and make sure
you understand the instructions before using the machine.
Form Number 115 390327R2
11/8/10
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.
©2010 All rights reserved.
Orangeburg, SC. Printed in U.S.A.
Contents
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 Bolt......................................................22
Parking Brake....................................................23
Cutting Height Adjuster.....................................23
Seat Adjustment Lever......................................23
Hydro Release Levers.......................................24
Fuel Shut Off Valve............................................24
Fuses.................................................................24
Fuel Tank...........................................................25
OPERATION............................................................26
Training..............................................................26
Steering.............................................................26
Before Starting..................................................27
Starting the Engine............................................27
Jumper Cables.............................................30
Running.............................................................31
Operating on Hills.............................................32
Stopping the Engine..........................................33
Mowing Tips......................................................34
Moving Machine By Hand.................................35
MAINTENANCE.......................................................36
Maintenance Schedule.....................................36
Battery...............................................................38
Safety System....................................................39
Tire Pressures....................................................39
Parking Brake....................................................39
Deck Belt...........................................................40
Pump Belt..........................................................41
V-belts...............................................................42
Cutting Blades...................................................43
Adjusting the Mower Deck................................44
Leveling deck...............................................44
Anti-scalp rollers...............................................45
Caster Wheels...................................................46
Hardware...........................................................46
Cleaning............................................................46
LUBRICATION.........................................................47
Lubrication Schedule........................................47
Wheel and Deck Zerks......................................48
Front Wheel Mount.......................................48
Front Wheel Bearings...................................48
Deck Spindles..............................................48
Transaxle (Transmission) Fluid Change............49
TROUBLESHOOTING GUIDE.................................50
STORAGE...............................................................52
Winter Storage...................................................52
Service..............................................................52
WIRING DIAGRAMS...............................................53
TECHNICAL DATA..................................................54
Torque Specifications........................................60
CONFORMITY CERTIFICATES................................61
SERVICE JOURNAL................................................62
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
Towing
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’s
manual to the new owner.
The final chapter of this operator’s manual provides a
Service Journal. Ensure that service and repair work
are documented. A well-kept service journal reduces
service costs for the maintenance and affects the
machine’s resale value. Please contact your dealer for
more information. Take the operator’s manual along
when the machine is taken to your dealer for service.
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.
General
In this operator’s manual, left and right, backward and
forward are used in relation to the machine’s normal
driving direction.
Continuous dedication to improve our products
require that specifications and design are subject to
change without notice.
Driving and Transport on Public Roads
Check applicable road traffic regulations before
transporting on public roads. If the machine is
transported, you must always use approved fastening
equipment and ensure that the machine is well
anchored. DO NOT operate this machine on public
roadways.
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
This Operator’s 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:
1. The machine’s type designation (I.D.).
2. The manufacturer’s type number (Model).
3. 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:
4. The engine’s model.
5. The engine’s type.
6. Code
Please have these available when ordering spare
parts.
The wheel motors and hydrostatic pumps have a
barcode decal affixed at the rear.
6
retailer. See the certificate in the Service Journal in
this operator’s manual.
When you need spare parts or support in service
questions, warranty issues, etc., please consult
the following professional:
Engine
Transmission
symbols and decals
These symbols are found on the machine and in the
operator’s manual.
Study them carefully so that you know what they
mean.
IMPORTANT INFORMATION
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.
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
ReverseNeutral
Fast
Slow
Warning!
Parking Brake
CE conformity
marking. Only for
European market
Choke
Fuel
Do not stand here,
Use protective glasses
Noise emissions to the surroundings
in accordance with the European
Union’s directive. The machine’s
emission is stated in the chapter
TECHNICAL DATA and on the
decals.
Electromagnetic
Compatibility (EMC)
Compliance
Australia and
New Zealand only
Only for European market
Use protective gloves
7
symbols and decals
Read
Operator’s
Manual
Shut off engine and
remove key before
performing any
maintenance or repair work
Whole body
Severing of fingers
exposure to
and toes
thrown objects
Keep a safe
distance from
the machine
Do not open or remove safety
shields while
engine is running
Use on slopesNo passengers
no greater
than 10°
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
Protection frame (ROPS)
instructions
Do not touch parts
8
SAFETY
Safety Instructions
These instructions are for your safety. Read them carefully.
WARNING!
This symbol means that important safety instructions need to be emphasized. It concerns
your safety.
IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING
OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS
INJURY OR DEATH.
General Operation
• Read, understand, and follow all instructions on
the machine and in the manual before starting.
• 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.
• 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.
8011-512
Read the operator’s manual before starting the machine
8011-513
Clear the area of objects before mowing
9
SAFETY
•
•
•
•
•
•
•
•
•
10
Watch for traffic when operating near or crossing
roadways.
Use extra care when loading or unloading the
machine into a trailer or truck.
Always wear eye protection when operating
machine.
Data indicates that operators age 60 years and
above are involved in a large percentage of riding
mower-related injuries. These operators should
evaluate their ability to operate the riding mower
safely enough to protect themselves and others
from serious injury.
Follow the manufacturer’s recommendation for
wheel weights or counterweights.
Anyone who operates this machine must first read
and understand this 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.
8011-520
Never take passengers
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.
SAFETY
Personal Safety Equipment
WARNING!
When operating the machine, approved personal protective equipment (shown in
illustrations) should be used. Personal protective equipment cannot eliminate the risk of
injury but 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.
• 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.
8011-670a
Personal protective equipment
6003-004
Mow up and down, not side to side
WARNING!
Do not drive up or down hills with
slopes greater than 10 degrees. Do
not drive across any slopes.
11
SAFETY
Children
Tragic accidents can occur if the operator is not
alert to the presence of children. Children are often
attracted to the machine and the mowing activity.
Never assume 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.
8011-518
Keep children away from work area
8011-517
Never allow children to operate the machine
12
SAFETY
WARNING!
The engine must not be started when the driver’s floor plate or any protective plate for the
mower deck’s drive belt is removed.
Safe Handling of Gasoline
To avoid personal injury or property damage, use
extreme care in handling gasoline. Gasoline is
extremely flammable and the vapors are explosive.
• 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.
8011-516
Never fill the fuel tank indoors
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.
13
SAFETY
General Maintenance
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
14
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.
Ensure that the equipment is in good condition
and that all nuts and bolts, especially those
fastening the blade attachments, are properly
tightened and torqued.
8011-515
Never drive the machine in an enclosed space
WARNING!
Use protective glasses for
maintenance work.
WARNING!
The battery contains lead and lead
compounds, chemicals that are
considered to cause cancer, birth
defects, and other reproductive
system damage. Wash your hands
after handling the battery.
SAFETY
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.
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.
6003-009
Do not smoke when performing maintenance on the battery.
The battery can explode and cause serious injury/damage.
8009-728
Risk of sparking
15
SAFETY
•
•
•
•
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.
The underside of the deck can be cleaned with
water but avoid spraying the engine and electrical
components. To aid in drying, it is recommended
that the blades be engaged after washing the
underside of the deck.
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.
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.
16
8011-514
Regularly clean the deck
WARNING!
Escaping hydraulic oil under
pressure can have sufficient force
to penetrate the skin, causing
serious injury. If injured by escaping
fluid, see a doctor at once. Serious
infection or reaction can develop
if proper medical treatment is not
administered immediately.
IMPORTANT INFORMATION
The parking brake is not sufficient to lock the
machine in place during transport. Ensure that
the machine is well fastened to the transport
vehicle. Always reverse the machine onto the
transport vehicle to avoid tipping it over.
WARNING!
This mower is equipped with an
internal combustion engine and
should not be used on or near any
unimproved forested, bush covered
or grassy lands unless the engine's
system is equipped with a spark
arrestor meeting applicable local or
state laws (if any).
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’s manual describes the Dixon Zero Turn
Rider. The rider is fitted with either a Briggs & Statton
or Kawasaki four-stroke overhead valve engine.
Transmission from the engine is made via belt-driven
hydraulic pumps. Using the left and right steering
controls, the flow is regulated and thereby the
direction and speed.
Control Locations
3
4
5
2
6
1
6
14
13
7
8
9
10
12
11
8058-143
1.
2.
3.
4.
5.
18
Motion control levers
Tracking bolt
Parking brake
Fuel tank, right
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
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.
8058-042
Steering controls
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.
8050-601
Throttle control
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.
8050-601
Blade switch
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.
8050-601
20
Choke control
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.
8050-602
Ignition switch
Release the key to the RUN position when the engine
has started.
8050-603
Ignition switch - RUN position
For using “accessory”, turn the key counter clockwise.
8050-604
Ignition switch - accessory
21
CONTROLS
Hour Meter
The hour meter displays the total operating time.
It will flash CHG OIL (Change Oil) at 50 hour intervals.
The flash duration is one hour before and one hour
after the interval. The CHG OIL icon will come on
and shut off automatically. The hour meter cannot be
manually reset.
8050-601
Hour meter
Tracking Bolt
If the mower is not tracking straight, check the
air pressure in both rear tires. Recommended air
pressure for all tires is 15 psi (1 bar).
1. Tracking adjustment is made using the tracking
bolt. The tracking bolt acts as limiting device 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. Rotating the tracking bolt allows fine tuning
adjustments so the machine tracks straight with
the steering control levers in the full forward
position.
4. Rotate the bolt clockwise (as viewed from the
operation position) to increase the speed on
the lever. Rotate counterclockwise to decrease
speed.
22
8066-029
Tracking adjustment
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.
IMPORTANT INFORMATION
The machine must stand absolutely still when
applying the parking brake. Always set the
parking brake before dismounting. Release the
parking brake before moving the mower.
8066-029
Parking brake
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.
1
2
1. Deck lift pedal
2. Height pin
Cut height selection
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.
8058-139
Seat adjustment
23
CONTROLS
Hydro Release Levers
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.
2
1
1. IZT locked into the bypass position
2. Release lever, engaged
Right side, ZT linkage
8065-061
Fuel Shut Off Valve
The fuel shut off valve is located behind the seat.
The valve is off when the handle tab is turned
perpendicular to the fuel line.
8065-010
Fuel shut off valve in the CLOSED position.
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
8011-420
24
Fuses
CONTROLS
Fuel Tank
IMPORTANT INFORMATION
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.
Refer to the engine manufacturer's owner manual for
proper oil viscosity for cold weather.
8066-028
Right hand gasoline fuel tank
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.
IMPORTANT INFORMATION
Experience indicates that alcohol blended
fuels (called gasohol, ethanol or methanol)
can attract moisture which leads to separation
and formation of acids during storage. Acidic
gas can damage the fuel system of an engine
while in storage. To avoid engine problems,
the fuel system should be emptied before
storage of 30 days or longer. Drain the gas
tank, start the engine and let it run until the
fuel lines and carburetor are empty. Use fresh
fuel the next season. See Storage Instructions
for additional information. Never use engine
or carburetor cleaners in the fuel tank or
permanent damage may occur.
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.
26
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, the
mower turns to the direction of the reverse position
lever.
IMPORTANT INFORMATION
When control levers are in the reverse position
they return to neutral when released. This may
cause the mower to suddenly stop.
OPERATION
Before Starting
•
Read the sections Safety Instructions and
Controls before starting the machine.
• Perform the daily maintenance before starting
(see maintenance schedule in the Maintenance
section).
• Check that there is sufficient fuel in the fuel tank.
• Adjust the seat to the desired position.
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.
8066-029
Activate parking brake before starting
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.
8066-027
Set mower deck to the transport position
27
OPERATION
4. Disengage the mower blades by depressing the
blade switch.
8050-607
Press the control for disengaging the mower deck
5. Move the steering controls outward to the locked
(outer) neutral position.
8066-031
Place controls in neutral position
6. Move the throttle to the middle position.
8050-605
28
Set the throttle
OPERATION
7. Open the fuel tank valve.
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.
8065-013
Fuel valve in the OPEN position
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.
9. When the engine starts, immediately release the
ignition key back to the run 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.
8066-007
Turn to the START position
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.
29
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.
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
use the mower to start other vehicles.
If “jumper cables” are used for emergency starting,
follow this procedure:
Jumper Cables
• Connect each end of the RED cable to the
POSITIVE (+) terminal on each battery, taking
care not to short against chassis.
• Connect one end of the BLACK cable to the
NEGATIVE (-) terminal of the fully charged battery.
• 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
• Remove BLACK cable first from chassis and then
from the fully charged battery.
• Remove RED cable last from both batteries.
30
8011-642
Jumper cable connection
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).
8066-029
Parking brake released
3. Select the cutting height by setting the cutting
height pin into the desired hole. Release foot
pedal latch and lower deck to set cutting height.
4. Make sure the work area is free from objects that
could be thrown by the rotating blades.
WARNING!
Ensure that no one is near mower
when engaging blade switch.
8066-027
Cutting height selection
5. Move throttle control to full throttle (rabbit symbol).
6. Engage the mower deck by pulling out the blade
switch.
7. The machine’s speed and direction are
continuously variable using the two steering
controls. When both controls are in the neutral
position, the machine stands still.
By moving both controls an equal amount forward
or backward, the machine moves in a straight line
forward or backward respectively.
8050-601
Move the throttle to FULL, engage the mower deck
31
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.
•
•
•
IMPORTANT INFORMATION
Control levers return to neutral when released.
This may cause the mower to suddenly stop.
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.
8066-031
Place controls in neutral position
•
•
•
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.
8066-029
Release the parking brake to restart movement
32
OPERATION
Stopping the Engine
Move the throttle to the minimum position (tortoise
symbol). 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.
1. Disengage the mower deck by depressing the
blade switch.
8050-607
Disengage the mower deck and move throttle to minimum
2. Raise the mower deck by pressing the foot pedal
forward to the transport position.
3. When the machine is standing still, activate the
parking brake by pulling the lever upward.
4. Move the throttle to the minimum position (tortoise
symbol) Turn the ignition key to the stop position.
5. Move the steering controls outward.
8066-027
Raise deck to transport position
6. Remove key. To prevent unauthorized use, always
remove key when leaving the mower.
8066-031
Place controls in neutral position to stop
33
OPERATION
Mowing Tips
•
•
•
•
•
•
•
•
•
34
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.
8011-603b
Mowing pattern
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.
OPERATION
Moving Machine By Hand
WARNING!
2
No adjustments or maintenance
should be carried out unless:
•
the engine stopped
•
the ignition key removed
•
the parking brake activated
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.
Raise the deck to the highest (transport) position.
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.
To reengage the IZTs to drive, reverse the above
procedure.
1
1. IZT locked into the bypass position
2. Linkage lever, engaged
Right side, IZT linkage
8058-059
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.
Load the machine into truck or trailer by driving up
ramps in low gear. DO NOT LIFT! The machine is not
intended to be lifted by hand.
35
maintenance
Maintenance Schedule
The following is a list of maintenance procedures that
must be performed on the machine. For those points
not described in this manual, visit an authorized
service workshop. An annual service carried out by
an authorized service workshop is recommended to
maintain your machine in the best possible condition
and to ensure safe operation.
Read Maintenance in the Safety section.
Daily
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
Sharpen3)/ Replace mower blades
Clean the engine’s cooling air intake 2)
Clean the air cleaner’s pre-filter 2) (foam)
Clean the air cleaner’s filter cartridge 2) (paper filter)
Check/adjust the parking brake
Inspect muffler/spark arrestor
1)
Before
●
■
●
♦
After
■
●
●
●
♦
♦
♦
♦
●
At least
once
each
year
●
●
■
■
■
●
♦
Maintenance interval
in hours
50
250
500
●
●
●
♦
♦
♦
●
●
●
■
♦
♦
♦
●
●
●
■
■
■
●
♦
♦
♦
♦
●
●
●
■
●
♦
First change after 8-10 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
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
36
●
♦
2)
In dusty
maintenance
Daily
MAINTENANCE
Before
After
At least
once
each
year
Maintenance interval
in hours
50
250
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 air filter 2) (paper filter)
Check the caster wheels (every 200 hours)
Replace the air cleaner’s pre-filter 2) (foam)
Change the hydraulic oil (every 500 hours)
Replace the hydraulic oil filter (every 500 hours)
●
■
■
■
●
■
●
■
●
●
■
500
■
●
■
■
●
■
●
●
●
♦
●
♦
♦
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 5-8 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
conditions, cleaning and replacement are required more often. 3) Performed by authorized service workshop.
2)
In dusty
● = Described in this manual
♦ = Not described in this manual
■ = Refer to the engine manufacturer's manual
WARNING!
Before performing any service or adjustment checklist:
•
•
•
•
•
Engage the parking brake.
Place the Blade-switch in the disengaged position.
Turn the ignition switch to “OFF” position and remove the key.
Make sure the blades and all moving parts have completely stopped.
Disconnect the spark plug wire from all spark plugs and place the wire where it cannot come in contact with the plug.
37
maintenance
Battery
STANDARD
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.
BATTERY
STATE
APPROXIMATE BATTERY CHARGING TIME*
TO FULL CHARGE AT 80OF / 27OC
OF
CHARGE
Maximum Rate at:
50 Amps
30 Amps
20 Amps
10 Amps
12.6V
100%
- FULL CHARGE -
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
WARNING!
IMPORTANT INFORMATION
Always wear eye protection when
around batteries.
Do not attempt to open or remove caps or
covers. Adding or checking level of electrolyte
is not necessary.
Cleaning battery and terminals
Corrosion and dirt on the battery and terminals can
cause the battery to “leak” 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.
38
Always use two wrenches for the terminal
screws.
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
2
1. Terminal guard
2. Access doors
Battery cleaning and installation
1
8066-049
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:
1. The mower deck is disengaged.
2. The steering controls are in the outer, locked
neutral position.
3. 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.
8066-032
Conditions for starting
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.
Tire Pressures
Fill tire pressures to 15 psi / 103 kPa / 1 bar.
IMPORTANT INFORMATION
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.
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.
IMPORTANT INFORMATION
The machine must be standing still when
applying the parking brake.
8066-029
Parking brake
39
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 roll 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.
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 the
center spindle pulley.
2. With a ½" breaker bar, shift the idler arm counter
clockwise. When there is enough slack, slip the
belt onto the center spindle pulley.
3. Reinstall the belt guide removed in Step 5 above.
4. Double check belt routing to make sure it matches
the routing decal, and that the belt does not have
any twist. Correct if needed.
8065-040
Release the belt tension
8065-045
Remove belt guide
8065-047
Refer to belt routing decal
40
maintenance
5. Adjust belt tension by turning the eyebolt until
there is approximately 7/8" -1" of threads showing
outside the nut.
6. Belt tension should be set to 60-70 lbs.
7. Replace belt shields on both mandrel housings
and secure with fasteners.
8. Replace foot plate.
8065-054
Adjust belt tension
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.
8058-064
Remove fan covers
41
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
1. Repeat Steps 4 and 5 from the above instructions.
2. Slip the belt over the fans and route it between the
idler pulleys.
3. Place the belt over the right and left idler pulleys.
4. Place the belt on the engine pulley.
5. Use the breaker bar to hold the tension off the belt
while removing the implement used as a brace in
the plate.
6. Replace and secure clutch stop.
7. Reinstall the fan shields.
8. Reinstall the deck belt. (See Deck Belt Installation
in this section of the manual).
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.
42
3
1
2
1. Electric clutch
2. Idler arm release placement
3. Clutch stop
Pump belt removal
8058-060
maintenance
Cutting Blades
To attain the best mowing effect, it is important that
the blades are well sharpened and not damaged.
Bent or cracked blades or blades with large nicks
should be replaced.
Blades damaged from hitting obstacles that result
in a breakdown should be replaced. 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.
Blade Replacement
IMPORTANT INFORMATION
The sharpening of blades should be carried
out by an authorized service workshop.
WARNING!
3
Blades are sharp. Protect your hands
with gloves and/or wrap blades with
a heavy cloth when handling.
1. Remove blade bolt by turning counterclockwise.
2. Install new or re-sharpened 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 blade bolt to 45-55 ft-lbs (60-75 Nm).
2
1
1. Blade
2. Blade bolt (special)
3. Spindle housing
Blade attachment
IMPORTANT INFORMATION
Special blade bolt is heat treated.
Replace with a Dixon bolt if required.
Do not use lower grade hardware than
specified.
WARNING!
Before performing any service or adjustment checklist:
1. 2. 3. 4. 5. 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.
Disconnect the spark plug wire from all spark plugs and place the wire where it
cannot come in contact with the plug.
43
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, you cannot properly
adjust your deck.
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.
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.
• Disconnect the spark plug wire from
all spark plugs and place the wire
where it cannot come in contact with
the plug.
8058-151
Set blades to begin 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.
1
2
WARNING!
2
Blades are sharp. Protect your hands
with gloves and/or wrap blades with
a heavy cloth when handling.
44
1. Lift arm
2. Mounting bolts
Leveling the mower deck
8050-829
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.
IMPORTANT INFORMATION
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.
8058-054
Anti-scalp rollers
IMPORTANT INFORMATION
To avoid deck damage, the anti-scalp rollers
must not be adjusted to support the deck.
45
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.
8058-055
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.
46
Use protective glasses when
cleaning and washing.
LUBRICATION
Lubrication Schedule
8058-069
12/12 Every year
1/52 Every Week
1/365 Every day
Lubricate with grease gun
Level check
Oil change
Filter change
* Change hydraulic drive filters.
p See Engine Manufacturer's manual
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.
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.
47
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.
8058-057
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.
Lubricate with a grease gun, 2-3 strokes per spindle.
8058-058
Deck spindle
48
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 three ¼" 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.
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.
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.
2
3
1
1. Filter guard
2. Transaxle filter
3. Top port plug
IZT filter change
8019-010
49
troubleshooting guide
Problem
Cause
Engine will not start.
•
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.
Starter does not turn the engine over.
Engine runs rough.
Engine seems weak.
50
troubleshooting guide
Problem
Cause
Machine vibrates.
•
Blades are loose.
•
Blades are incorrectly balanced.
•
Blades are bent.
•Engine is loose.
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.
Battery not charging.
Machine moves slowly, unevenly, or not at all.
Mower deck not engaging.
•
Fouled spark plug.
•
Poor contact with battery terminal cable
connectors.
•
Charging lead is disconnected.
•
Fault in engine charging system.
•
Parking brake on.
•
Bypass valve on pump open.
•
Drive belt for the transmission gears slack or has
come off.
•
Air in hydraulic 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.
Uneven mowing results.
•
Damaged seals, housing, or gaskets.
•
Air trapped in hydraulic system.
•
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.
51
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.
52
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.
LEFT MOTION
CONTROL LEVER
RIGHT MOTION
CONTROL LEVER
YEL
YEL
BLU
SEAT
SW.
T-6
T-1
TIMER
T-2
YEL
YEL
BLK
WHT
BRN
BRAKE
SWITCH
GRN
ELECTRIC
CLUTCH
T-4
T-3
T-5
BRN/WHT BLK
BRN
BRN
YEL
SOLENOID
BLK
ENGINE
GROUND
BLK
PTO
SWITCH
WHT
GRN
BLU
BLK
GRN
BLK
7.5 AMP
PUR
PUR
BRN
PUR
GRN
WHT
GRY
TO
ENGINE
PIGTAIL
L
M
S
B
A
Y
BLK
YEL/RED
RED
20 AMP
ACCESSORY
OUTLET
RED/BLK
RED/BLK
BLK
G
HOURMETER
PUR
PUR
YEL
NOTES:
1. SEAT UNOCCUPIED
2. BRAKE SWITCH IN OFF POSITION
3. MOTION CONTROL LEVERS OUT
4. PTO IN OFF POSITION
WIRING DIAGRAM
53
TECHNICAL DATA
DX148 / 966663901
DX152 / 966664201
DX148 BF /966664101
DX152 BF / 966664301
Kawasaki 1)
Kawasaki 1)
FX-S
FX-S
Engine
Manufacturer
Type
Power
Lubrication
22 HP
2)
24 HP 2)
Pressure w/ Oil Filter
Pressure w/ Oil Filter
Min 87 octane unleaded (Max ethyl
alcohol 10%, Max MTBE 15%)
Min 87 octane unleaded (Max ethyl
alcohol 10%, Max MTBE 15%)
11 gallons / 41 liters
11 gallons / 41 liters
Air cooled
Air cooled
12v 15 amp @ 3600 rpm
12v 15 amp @ 3600 rpm
Electric
Electric
ZT-3400 Hydro Gear
ZT-3400 Hydro Gear
Dual levers, foam gripped
Dual levers, foam gripped
Speed forward
0-9 mph - 0-17.7 Km/h
0-9 mph - 0-17.7 Km/h
Speed reverse
0-5 mph - 0-9.7 Km/h
0-5 mph - 0-9.7 Km/h
Mechanical parking brake
Mechanical parking brake
13 x 6.5
13 x 6.5
23 x 8.50-12 4 ply
23 x 9.50-12
15 PSI / 103 kPa / 1 bar
15 PSI / 103 kPa / 1 bar
Fuel
Fuel capacity
Cooling
Alternator
Starter
Transmission
Transmission
Speed and direction controls
Brakes
Front caster tires, smooth tread
Rear tires, turf pneumatic
Tire pressures
1)
2)
See the Engine Manufacturer's manual for engine specifications.
The power rating of the engines indicated is the average net power
output (at specified rpm) of a typical production engine for the engine
model measured to SAE standard J1349/ISO1585. Mass production
engines may differ from this value. Actual power output for the engine
installed in the final machine will depend on the operating speed,
environmental conditions and other variables.
54
TECHNICAL DATA
DX148 / 966663901
DX152 / 966664201
DX148 BF /966664101
DX152 BF / 966664301
Cutting Width
48" (122 cm)
52" (132 cm)
Cutting Height
1½"-4½" (2.5-11.4 cm)
1½"-4½" (2.5-11.4 cm)
Uncut Circle
0
0
Number of Blades
3
3
16¼" / 41.3 cm
18" / 45.7 cm
No
No
Suspension
Suspension
Hinged Arm Rests
Yes
Yes
Hour Meter
Yes
Yes
Frame
Blade Length
Nose Roller
Seat
Blade Engagement
200 ft-lb
200 ft-lb
Deck Construction
11 gauge fabricated
11 gauge fabricated
3.3 acres/h / 13,355 m2/h
3.9 acres/h / 14,569 m2/h
Productivity
Dimension
Weight
860 lbs / 390 kg
880 lbs / 399 kg
Base Machine Length
75½" / 192 cm
75½" / 192 cm
Base Machine Height
50" / 127 cm
50" / 127 cm
Base Machine Width
49" / 125 cm
52" / 132 cm
Overall Width, Chute Up
53½" / 136 cm
62½" / 159 cm
65" / 165 cm
74" / 188 cm
Overall Width, Chute Down
55
TECHNICAL DATA
DX152 CARB / 966664001
DX161 / 966664501
Kawasaki 1)
Briggs & Stratton 1)
FX-S
Cyclonic
Engine
Manufacturer
Type
Power
Lubrication
22 HP
2)
28 HP 2)
Pressure w/ Oil Filter
Pressure w/ Oil Filter
Min 87 octane unleaded (Max ethyl
alcohol 10%, Max MTBE 15%)
Min 87 octane unleaded (Max ethyl
alcohol 10%, Max MTBE 15%)
11 gallons / 41 liters
11 gallons / 41 liters
Air cooled
Air cooled
12v 15 amp @ 3600 rpm
12v 15 amp @ 3600 rpm
Electric
Electric
ZT-3400 Hydro Gear
ZT-3400 Hydro Gear
Dual levers, foam gripped
Dual levers, foam gripped
Speed forward
0-9 mph - 0-17.7 Km/h
0-9 mph - 0-17.7 Km/h
Speed reverse
0-5 mph - 0-9.7 Km/h
0-5 mph - 0-9.7 Km/h
Mechanical parking brake
Mechanical parking brake
13 x 6.5
13 x 6.5
23 x 8.50-12
23 x 10.50-12
15 PSI / 103 kPa / 1 bar
15 PSI / 103 kPa / 1 bar
Fuel
Fuel capacity
Cooling
Alternator
Starter
Transmission
Transmission
Speed and direction controls
Brakes
Front caster tires, smooth tread
Rear tires, turf pneumatic
Tire pressures
1)
2)
See the Engine Manufacturer's manual for engine specifications.
The power rating of the engines indicated is the average net power
output (at specified rpm) of a typical production engine for the engine
model measured to SAE standard J1349/ISO1585. Mass production
engines may differ from this value. Actual power output for the engine
installed in the final machine will depend on the operating speed,
environmental conditions and other variables.
56
TECHNICAL DATA
DX152 CARB / 966664001
DX161 / 966664501
Cutting Width
52" (132 cm)
61" (155 cm)
Cutting Height
1½"-4½" (2.5-11.4 cm)
1½"-4½" (2.5-11.4 cm)
Uncut Circle
0
0
Number of Blades
3
3
18" / 45.7 cm
21" / 53.3 cm
No
No
Suspension
Suspension
Hinged Arm Rests
Yes
Yes
Hour Meter
Yes
Yes
Frame
Blade Length
Nose Roller
Seat
Blade Engagement
200 ft-lb
200 ft-lb
Deck Construction
11 gauge fabricated
11 gauge fabricated
3.9 acres/h / 14,569 m2/h
3.9 acres/h / 14,569 m2/h
Productivity
Dimension
Weight
880 lbs / 399 kg
910 lbs / 413 kg
Base Machine Length
75½" / 192 cm
75½" / 192 cm
Base Machine Height
50" / 127 cm
50" / 127 cm
Base Machine Width
52" / 132 cm
52" / 132 cm
Overall Width, Chute Up
62½" / 159 cm
62½" / 159 cm
74" / 188 cm
74" / 188 cm
Overall Width, Chute Down
57
TECHNICAL DATA
DX161 / 966664501
Engine
Manufacturer
Type
Power
Lubrication
Fuel
Fuel capacity
Cooling
Alternator
Starter
Kawasaki 1)
FX-S
26 HP 2)
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
Transmission
Transmission
Speed and direction controls
ZT-3400 Hydro Gear
Dual levers, foam gripped
Speed forward
0-9 mph - 0-17.7 Km/h
Speed reverse
0-5 mph - 0-9.7 Km/h
Brakes
Front caster tires, smooth tread
Rear tires, turf pneumatic
Tire pressures
1)
2)
Mechanical parking brake
13 x 6.5
23 x 10.50-12
15 PSI / 103 kPa / 1 bar
See the Engine Manufacturer's manual for engine specifications.
The power rating of the engines indicated is the average net power
output (at specified rpm) of a typical production engine for the engine
model measured to SAE standard J1349/ISO1585. Mass production
engines may differ from this value. Actual power output for the engine
installed in the final machine will depend on the operating speed,
environmental conditions and other variables.
58
TECHNICAL DATA
DX161 / 966664501
Frame
Cutting Width
61" (155 cm)
Cutting Height
1½"-4½" (2.5-11.4 cm)
Uncut Circle
0
Number of Blades
3
Blade Length
Nose Roller
Seat
21" / 53.3 cm
No
Suspension
Hinged Arm Rests
Yes
Hour Meter
Yes
Blade Engagement
200 ft-lb
Deck Construction
11 gauge fabricated
Productivity
3.9 acres/h / 14,569 m2/h
Dimension
Weight
910 lbs / 413 kg
Base Machine Length
75½" / 192 cm
Base Machine Height
50" / 127 cm
Base Machine Width
52" / 132 cm
Overall Width, Chute Up
62½" / 159 cm
Overall Width, Chute Down
74" / 188 cm
59
TECHNICAL DATA
Torque Specifications
Hex Head Cap Screws
The torque values shown should be used as a general guideline when specific torque values are not given.
U.S. Standard Hardware
Shank Size (Diameter in inches, fine or coarse thread)
Grade
SAE Grade 5
SAE Grade 8
Flangelock Screw
w/Flangelock Nut
Size
ft./lbs
Nm
ft./lbs
Nm
ft./lbs
Nm
¼
9
12
13
18
/16
18
24
28
38
24
33
/8
31
42
46
62
40
54
/16
50
68
75
108
½
75
102
115
156
/16
110
150
165
224
/8
150
203
225
305
¾
250
339
370
502
/8
378
513
591
801
1 /8
782
1060
1410
1912
5
3
7
9
5
7
1
** Grade 5 - Minimum commercial quality (lower quality not recommended)
Metric Standard Hardware
Shank Size (Diameter in millimeters, fine or coarse thread)
Grade
60
Grade 8.8
Grade 10.9
Grade 12.9
Size
ft./lbs
Nm
ft./lbs
Nm
ft./lbs
Nm
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
21.8
29
M10
24
32
35.2
47
43.5
58
M12
43.5
58
62.2
83
75
100
M14
70.5
94
100
133
119
159
M16
108
144
147
196
176
235
M18
142
190
202
269
242
323
M20
195
260
275
366
330
440
M22
276
368
390
520
471
628
M24
353
470
498
664
596
794
M27
530
707
474
996
904
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.
61
SERVICE JOURNAL
Action
Date, mtr reading,
stamp, sign
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
q
q
q
q
q
q
q
q
q
q
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
q
q
q
q
q
q
q
q
q
q
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
62
q
q
q
q
Delivery service has
been carried out
No remaining notes
Certified:
SERVICE JOURNAL
Action
Date, mtr reading,
stamp, sign
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
q
q
q
q
q
q
q
q
q
q
q
q
Daily Service
Clean debris from mower
Check engine oil level
Check the tire pressures
Check underside of deck
Inspect deck pulleys
Check/clean the engine’s cooling air intake
Check safety system
Check seat belt
Check fuel system for leaks
Inspect safety guards and shields
Check brake adjustment
q
q
q
q
q
q
q
q
q
q
q
63
SERVICE JOURNAL
Action
Date, mtr reading,
stamp, sign
25-Hour Service
Check the fuel pump’s air filter
Sharpen/Replace mower blades if required
Check the tire pressures
Check battery with cables
Lubricate according to lubrication chart
Check/clean the engine’s cooling air intake
Clean the air cleaner’s pre-filter (foam)
q
q
q
q
q
q
q
50-Hour Service
Perform the 25-hour service.
Clean/replace the air cleaner’s filter cartridge (paper filter
(shorter intervals for dusty operating conditions).
Change engine oil.
Lubricate according to lubrication chart.
Check/adjust the parking brake.
64
q
q
q
q
q
SERVICE JOURNAL
Action
Date, mtr reading,
stamp, sign
100-Hour Service
Perform the 25-hour service
Perform the 50-hour service
Change the engine oil filter
Clean/replace the spark plugs
Replace the fuel filter
Check V-belts
Check tighten caster wheel axle bolts (every 200 hours)
Change the air filter’s paper cartridge
Change hydraulic pump oil and filter (200 hours)
q
q
q
q
q
q
q
q
q
300-Hour Service
Perform the 25-hour service.
Perform the 50-hour service.
Perform the 100-hour service.
Check/adjust the mower deck.
Clean the combustion chamber and grind the valve seats.
Check the engine valve clearance.
Replace the air cleaner’s pre-filter (foam).
q
q
q
q
q
q
q
65
SERVICE JOURNAL
Action
Date, mtr reading,
stamp, sign
At Least Once Each Year
Clean the engine’s cooling air intake (25 hours).
Replace the air cleaner’s pre-filter (foam) (300 hours).
Replace the air filter’s paper cartridge.
Change the engine oil (50 hours).
Replace the engine oil filter (100 hours).
Check/adjust the cutting height.
Check/adjust the parking brake (50 hours).
Clean/Change the spark plugs (100 hours).
Change the fuel filter (100 hours).
Check the engine valve clearance.
66
q
q
q
q
q
q
q
q
q
q
SERVICE JOURNAL
Action
Date, mtr reading,
stamp, sign
67
Operator / Parts Manual
Collection System
48" / 966693201
52" / 966693202
61" / 966693203
Form Number 115 395527 Rev B
2012-07-31
CONGRATULATIONS on the purchase of a new
collection system. It has been designed, engineered
and manufactured to give you the best possible
dependability and performance.
Should you experience any problem you cannot
easily remedy, please contact your nearest authorized
service center/ department. They have competent,
well-trained technicians and the proper tools for
service and repairs.
Please read and retain this manual. The instructions
will enable you to assemble and maintain your
collection system properly. Always observe the
SAFETY RULES.
CAUTION
•
•
•
•
•
DO NOT operate mower with grass
catcher partially installed.
Disengage blades and stop engine
before leaving mower seat to
empty containers, unclogging
chutes, etc.
Close cover before starting.
Disengage mower blades when
crossing driveways or gravel
surfaces and other areas where
thrown objects could be a hazard.
DO NOT attempt to vacuum cans
or other potentially hazardous
projectiles.
KNOW YOUR BLOWER SYSTEM
READ THIS OPERATION MANUAL AND SAFETY
RULES BEFORE ASSEMBLING OR OPERATING
YOUR BLOWER SYSTEM. Compare the illustrations
with the carton contents to familiarize yourself
with the parts before starting the assembly. Study
the operating instructions and safety precautions
thoroughly to insure proper functioning of your Grass
Catcher and to prevent injury to yourself and others.
Save this manual for future reference.
The operation of any mower can result
in foreign objects thrown into the eyes,
which can result in severe eye damage.
ALWAYS wear safety glasses or eye
shields before starting your mower and
while mowing. Standard safety glasses
are recommended or a wide vision
safety mask for over spectacles.
©2012 HTC. All Rights Reserved.
Swainsboro, GA. Printed in U.S.A.
CONTENTS
SAFETY RULES..........................................................4
ASSEMBLY.................................................................6
REPAIR PARTS.........................................................10
BLOWER ASSEMBLY.......................................10
HOOD AND MOUNTS.......................................12
DRIVE AND WEIGHTS.....................................14
TOOLS REQUIRED
Wrench 5/16" (2)
Wrench 1¼" (1)
Wrench ¾" (1)
Wrench 9/16" (2)
Wrench ½" (1)
Socket ½"
Socket 11/8"
Screwdriver, standard (1)
Torque wrench (150 ft/lbs)
Ratchet with ½" drive, 6" extension
NOTE: When the terms RH (right hand) or LH (left
hand) are used, it refers to when the operator is
seated on the mower.
CONTAINER CONTENTS
•
•
•
•
Blower Assembly
Bagger Assembly
Belts
Mounting Brackets
• Containers
• Shields
• Bag of Hardware
CAUTION
BEFORE ASSEMBLING GRASS
CATCHER TO MOWER:
• Set parking brake.
• Place motion control levers in
NEUTRAL position.
• Turn ignition key OFF and remove
key.
• Make sure the blades and all
moving parts have completely
stopped.
• Disconnect spark plug and place
wire where it cannot come in
contact with plug.
SAFETY RULES
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS
DANGER !
THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING OBJECTS.
FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR
DEATH.
GENERAL OPERATION
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
4
Read, understand and follow all instructions in the
manual and on the machine before starting.
Only allow responsible adults who are familiar with
the instructions to operate the machine.
Clear the area of objects such as rocks, stones,
toys, wire etc., that could be picked up and
thrown by the blades.
Be sure the area is clear of all people and pets
before mowing. Stop the machine if anyone enters
the area.
Never carry passengers or children, even with
blades off.
Do not mow in reverse unless absolutely
necessary. Always look down and behind before
and while backing.
Be aware of the mower discharge direction and
do not direct it towards anyone. Do not operate
the mower without either the entire grass catcher
or the guard in place.
Slow down before turning.
Never leave the machine unattended when the
engine is running. Always turn off the blades, set
the parking brake, stop the engine and remove
the key before leaving the machine.
Turn off blades when not mowing.
Stop engine before removing grass catcher or
unclogging chute.
Mow only in daylight or good artificial light.
Do not operate the machine while under the
influence of alcohol or drugs.
If front weights are included in the collection
system, DO NOT operate mower with the grass
catcher unless the weights are installed.
Watch out for traffic when operating near or
crossing roadways.
Use extra care when loading and unloading the
machine onto a trailer or truck.
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.
•
Keep machine free of grass, leaves or other
debris buildup that can touch hot exhaust/engine
parts and burn. Do not allow the mower deck
to plow leaves or other debris that can cause
buildup to occur. Clean any oil or fuel spills before
operating or storing the machine. Allow machine
to cool before storage.
SLOPE OPERATION
Slopes are a major factor related to loss-of-control and
tip-over accidents, which can result in severe injury or
death. All slopes require extra caution. If you cannot
back up the slope or if you feel uneasy on it, do not
mow it.
DO
• Mow up and down slopes (10° Max.), not across.
• Remove obstacles such as rocks, tree limbs, etc.
• Watch for holes, ruts, or bumps. Uneven terrain
could overturn the machine. Tall grass can hide
obstacles.
• Use slow speed. Choose a low speed so that you
will not have to stop while on the slope.
• Use extra care with grass catchers or other
attachments. These can change the stability of
the machine.
• Keep all movement on the slopes slow and
gradual. Do not make sudden changes in speed
or direction.
• Avoid starting or stopping on a slope. If tires
lose traction, disengage the blades and proceed
slowly straight down the slope.
DO NOT
• Do not turn on slopes unless necessary, and then,
turn slowly and gradually downhill, if possible.
• Do not mow near drop-off, ditches, or
embankments. The mower could suddenly turn
over if a wheel is over the edge of a cliff or ditch,
or if an edge caves in.
• Do not mow on wet grass. Reduced traction
could cause sliding.
• Do not try to stabilize the machine by putting your
foot on the ground.
SAFETY RULES
SAFE OPERATION PRACTICES FOR RIDE-ON MOWERS
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 where you last
saw them.
• NEVER allow children to operate the machine.
• Keep children out of the mowing area and under
the watchful care of another responsible adult.
• Be alert and turn off the machine if children enter
the area.
• Before and when backing, look behind and down
for small children.
• Never carry children. They may fall off and be
seriously injured or interfere with safe machine
operation.
• Use extra care when approaching blind corners,
shrubs, trees, or other objects that may obscure
vision.
•
•
•
•
•
•
Keep machine free of grass, leaves, or other
debris buildup. Clean oil or fuel spills. Allow
machine to cool before storing.
Stop and inspect the equipment if you strike an
object. Repair, if necessary, before restarting.
Never make adjustments or repairs with the
engine running.
Grass catcher components are subject to wear,
damage, and deterioration, which could expose
moving parts or allow objects to be thrown.
Frequently check components and replace
with manufacturer’s recommended parts, when
necessary.
Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves, and use extra caution
when servicing them.
Check brake operation frequently. Adjust and
service as shown in the Operator’s Manual.
SERVICE
•
•
•
•
•
The operation of any mower can result in foreign
objects being thrown into the eyes, which can
result in severe eye damage. Always wear safety
glasses or eye shields while operating your
mower or performing any adjustments or repairs.
We recommend a wide vision safety mask over
spectacles or standard safety glasses.
Use extra care in handling gasoline and other
fuels. They are flammable and vapors are
explosive.
- Use only an approved container.
- Never remove gas cap or add fuel with the
engine running.
- Allow engine to cool before refueling.
- Do not smoke.
- Never refuel the machine indoors.
- Never store the machine or fuel container
inside where there is an open flame, such as
a water heater.
Never run a machine inside a closed area.
Keep nuts and bolts, especially blade attachment
bolts, tight and keep equipment in good
condition.
Never tamper with safety devices. Check their
proper operation regularly.
CAUTION
In order to prevent accidental starting
when setting up, transporting,
adjusting or making repairs, always
disconnect spark plug wire and place
wire where it cannot contact spark
plug.
WARNING!
Battery posts, terminals and related
accessories contain lead and lead
compounds, chemicals know to the
State of California to cause cancer
and birth defects or other reproductive
harm. Wash hands after handling.
WARNING!
DO NOT tow any trailers, etc. with this
mower. They may jackknife or over
turn causing damage to the mower and
possibly serious injury to the operator.
5
ASSEMBLY
1
INSTALLING DRIVE PULLEY
AND DECK STOP TUBES
1. Using two 9/16" wrenches, remove the hardware
and discharge chute from the deck.
2. Lower deck to the lowest cutting position.
3. With a ½" wrench, remove the hardware of the
right hand (discharge side) belt cover and remove
the shield from the deck.
5. Remove the top nut and the deck belt pulley.
Install new stacked drive pulley onto the deck
spindle assembly, seating the pulley securely onto
the spindle notches. Using a 11/8" and the ratchet
with extension, fasten the pulley to the spindle
using the original nut. Torque nut to 150 ft/lbs.
Retain the original pulley for reuse when not using
the collection system.
6. Reinstall the deck belt.
Stacked drive
pulley
Belt
cover
Deck belt
pulley
Bolts for removal of
discharge chute
4. Relieve the tension from the deck belt and remove
it from the center deck pulley.
(See Operator’s Manual if necessary)
7. Locate the deck stop behind the rear lift link on
each side of the deck.
8. Set deck stop tube on the deck stop on each
side.
Deck Stop Tube
Deck Stop
Lift Link
6
ASSEMBLY
2
MOUNTING BLOWER ASSEMBLY
1. Position the discharge tabs on the deck into the
blower mount bracket slots and set blower onto
the deck.
2. The blower should sit flush against the outside of
the deck.
3. Secure the mount bracket to the deck with the pin
and hairpin cotter supplied with the kit.
5. Attach the belt shields from the collection kit onto
the deck and blower housing.
6. Replace the blower belt cover removed in Step 1.
Belt covers
Discharge tab
Mount Bracket slots
Pin
3
4
INSTALLING DRIVE BELT
1. Remove the blower belt cover to access the
pulleys.
2. Move the tension release lever to the forward
(disengaged) position.
3. Place the belt over the top pulley of the new
stacked deck pulley and refer to the illustration to
complete the installation of the drive belt. The belt
should have a twist in both sides coming off the
outer pulley.
4. Move the tension release arm to the rear and
engage it into the latch.
Tension Release Arm
Idler Pulleys
INSTALLING MIDDLE CHUTE
1. Place middle chute over the top end of the blower
assembly and latch the chute to the blower
assembly.
Middle chute
Chute latch
Outer Pulley
Twist in Belt
7
ASSEMBLY
5
BAGGER ASSEMBLY
1. Attach hitch tube to support bracket with 3/8-16 x 2
shoulder bolts and secure with flange nuts.
Support bracket
4. Place the hood / hitch assembly onto the hitch
tube.
5. Open the hood and secure the (2) springs to
the bolts on the hood assembly and the hitch
assembly.
Attach springs to
hitch and hood
Set hood/latch assembly
onto hitch tube
Hitch tube
2. Place the support bracket against the frame rear
guard. Using the outer right hole and inner left
hole, secure with 5/16 x 1 bolts and 5/16 nyloc nuts.
3. Attach support tube to frame hitch with ½ x 2¼
bolt and ½ nyloc nut.
Attach hitch tube
to frame
8
6. Attach right and left straps to the hood/latch
assembly with 3/8-16 x 1 bolts and flange nuts.
Attach straps to
hinge assembly
ASSEMBLY
9. Secure inner end of straps to unit fuel tank mounts
with 3/8-16 x 1 thread forming bolts and flange
nuts, as shown.
Fuel tank mount
6
INSTALLING WEIGHT
1. Bolt cast weight and two weight brackets together
using 2¾" bolts and nuts.
2. Slide both weight brackets over the front tube on
the frame, positioning the assembly in the center
of the frame.
3. Secure with 3¾" bolts and nuts.
Front tube
Cast weight
2¾ Bolt
3¾ Bolt
Weight bracket
10. With the hood open, secure the (3) bags in place.
The back of the bags will hook over the mounting
tabs on the hitch assembly.
11. Close the hood, and lock the draw latch over the
draw latch keeper on the hitch assembly.
Draw
Latch
Bag
Draw latch
keeper
Mount
tabs
9
TIPS FOR IMPROVED BAGGING
GENERAL RECOMMENDATIONS
•
Always observe safety rules when performing any
maintenance.
• Before each use check for loose fasteners.
• Clean unit thoroughly after each use.
BLADE CARE
• For best results mower blades must be kept
sharp. Replace bent or damaged blades.
• See instructions in the mower operator’s manual.
•
•
•
•
•
•
•
•
16
Follow the mower operation instructions in the
Operator Manual.
When using the grass catcher on a lawn where
grass and leaf bagging equipment has not been
used previously, thatch and debris that has
accumulated for long periods of time is picked
up. The amount collected and the total time of
operation may be greater than will be experienced
with regular use of the grass catcher.
Always run throttle at full speed when bagging.
Select a speed low enough to give good mower
cutting performance, good quality cut and good
bagging performance.
NOTE: It may be necessary to overlap width of
cut to suit your conditions.
If grass is extremely tall, it should be mowed
twice. The first cut should be at one of the highest
settings, the second time to desired height.
Use the left hand side of mower for trimming.
Frequently clean the hood debris screen.
(Located inside the rear of the hood). A clogged
screen results in poor ventilation and may cause
plugging.
Avoid cutting wet grass or in the morning while
the dew is still heavy. Grass clippings collected
under these conditions tend to be sticky and
adhere to the walls of the flow path causing
clogging.
If the grass catcher fails to pick up cut grass
or leaves, it is an indication that clogging has
occurred in the system or that the grass catcher
containers are full.
a. Disengage blades, place motion control levers
in neutral position.
- Unlatch and raise cover.
- Slide out containers and dispose of
clippings.
- Replace containers, close cover, and
latch.
b. Unlatch chutes and check for clogging.
- Remove all debris in chute.
- Reassemble and latch chutes.
STORAGE
When grass catcher is to be stored for a period of
time, clean it thoroughly, remove all dirt, grass, leaves,
etc. Store in a clean, dry place.
CAUTION
Do not leave grass in bagger
containers. Empty containers after
each use and before storing. Failure
to do so may result in spontaneous
combustion which could develop into
a fire.
CAUTION
Grass catcher components are subject
to wear, damage and deterioration,
which could expose moving parts or
allow objects to be thrown. Frequently
check components and replace with
manufacturer’s recommended parts,
when necessary.