Dixon KODIAK 52 Specifications

Set-Up Instructions
for CE Kodiak Models
Setup
c. Using 1/2C x 3 1/4 cap screws thru the
rear hole on the left and right side.
d. Install the 1/2C centerlock nuts finger
tight.
4. Torque all 1/2” hardware to 80 ft./lbs. (110 N•m).
5. Install and tighten knobs against the side
post.
Uncrate machine.
ROPS Assembly
(Roll Over Protection System)
ROPS Assembly Components
1
1 - Top Loop
1 - Left Side Post
1 - Right Side Post
1 - Hardware Bag
2 - 1/2” Latch Pins w/lanyard
6 - 1/2C x 3 1/4” Cap screws
6 - 1/2C Centerlock Nuts
2 - Knobs
(all hardware Grade 5).
2
3
4
5
1. Remove roll bar and parts bag from the box.
2. Install roll bar side posts.
a. Locate the LEFT and RIGHT side posts.
b. Slide the left side post into the left side
receiver on the frame, do the same on
the right side.
c. Using 1/2C x 3 1/4 cap screws, two per
post, align the holes in the side post with
the frame receiver.
d. Install the 1/2C centerlock nuts finger tight
to the side post bolts.
3. Install roll bar top loop.
a. Align the holes of the top loop with the left
and right side posts.
b. Slide the latch pins thru the front hole on
the left and right side to connect the top
loop to the side posts and secure with the
hairpin.
6
7
5
4
1. Latch Pin
2. Top Loop
3. Knob
4 1/2C x 3 1/4 Cap Screws
5. 1/2C Centerlock Nuts
6. Right Side Post
7. Left Side Post
PART NO. 539 130506 REV. IR (01/25/07)
1
Tires
Mount rear drive wheels using the lug nuts installed
on the hubs.
1
Check the tire pressure in all four tires. All tires
should be 15 psi.
Control Arms
Remove top bolt in control arm and loosen bottom bolt, rotate the control levers to the upright
position. Align the levers so they are even in the
neutral position. Reinstall hardware and tighten.
FIG - 1
2
Seat Install
1. Motion Control Lever
2. Control Arm
FIG - 1
1. Remove seat assembly from the crate.
2. Remove the four 5/16C nyloc nuts or 5/16C
studded knobs from the bottom of the seat.
Retain for use later.
3. Align the seat bottom with the holes in the seat
frame. Place seat on top of the seat frame
and secure with the four nuts or knobs removed in step 2.
4. Connect the wire harness from the seat to the
frame harness.
2
1
Engine Oil
Check engine oil with dip stick. Add if needed per
the engine manufactures specifications. See engine manual for oil type and filling specifications.
FIG - 2
1. Operating Range
2. “F” Full Mark
FIG - 2
Loosen the discharge chute slightly and lower into
position. Chute should be snug but still pivot freely.
2
1
Install armrests to seat. Hardware and armrests
are in the plastic bag.
3
Discharge Chute
If discharge chute is not assembled to the cutting
deck follow the instructions below.
1. Hook the spring end over the discharge chute
and align the I.D. of the spring with the holes
in the chute.
2. Align the chute and spring with the tabs on the
cutting deck. Rotate the spring end counterclockwise so it rests on top of the cutting deck.
3. Slide the clevis pin with a 5/16 washer thru
the holes of the chute, deck and spring.
4. Secure clevis pin with 5/16 washer and cotter
pin.
5. If assembled properly the chute should be
spring loaded in the down position. FIG - 3
4
5
1. Discharge Chute
2. 5/16 Washer
3. Clevis Pin
4. 1/2 X 3/4 Cotter Pin
5. Spring
FIG - 3
2
Adjusting the Mower Deck
WARNING!
Before performing any service or adjustment check list:
1. Engage the parking brake.
2. Place the blade-switch in the disengaged position.
3. Turn ignition switch to “OFF” position and remove the key.
4. Make sure the blades and all moving parts have completely stopped.
5. Disconnect the spark plug wire from all spark plugs and place the wire where it
cannot come in contact with the plug.
Deck Leveling
WARNING!
1. Position the mower on a level, hard surface
2. Check the pressure in all four tires. See
“Technical Data” section in the Operator’s
manual.
3. Set deck cutting height at 4".
4. Rotate blades to align front to back.
5. Measure front blade tip,should be 4” from
ground, if not turn locknut on top of front
eyebolt till measurement is achieved. Check
blade tip at front on opposite front blade.
Adjust locknut on front eyebolt as necessary.
6. Check rear blade measurement, should be 4
1/4” from ground, if not turn locknut on top of
rear eyelbolt to achieve measurement.
Repeat procedure on opposite side.
8. If deck leveling cannot be achieved call
Technical Support at toll free number 1-866729-5123.
Blades are sharp. Protect your
hands with gloves and/or wrap
blades with a heavy cloth when
handling.
3
2
1
4
1. Front Eyeblot
2. Front Locknut
3. Rear Locknut
4. Rear Eyebolt
Leveling mower deck
3
8011-601-1
Tracking
1. Tracking adjustment is accomplished using
the tracking bolts. The tracking bolts act as
limiting device for the motion control levers
when in the full-forward position.
2. Start by loosening jam nut on right tracking
bolt. Back the tracking bolt out until flush with
nut.
3. Loosen tracking bolts and back out until flush
with nut.
4. Move unit to an open unobstructed area
such as an empty parking lot or open field for
tracking adjustment.
5. Test operate unit by driving it at full throttle
and full forward position on both motion
control levers. Gradually turn in the tracking
bolt on the right hand side until the unit
noticeably starts drifting right.
6. Stop the unit and tighten right jam nut in this
position.
7. Restart the unit and drive forward at full
throttle with both motion control levers in full
forward position. Gradually turn in the
tracking bolt (left side) until unit tracks
straight.
8. Stop the unit and tighten left jam nut in this
position.
4.5
5.0
Tracking bolt
4
5.5
6.0
Operator’s Manual
KODIAK 52, 20 HONDA / 968999635
KODIAK 60, 25 KOH / 968999636
Please read the operator’s manual carefully and make sure you
understand the instructions before using the machine.
OPERATOR’S MANUAL
KODIAK SERIES
Contents
Introduction .............................................................3
General ................................................................3
Driving and Transport on Public Roads ...............3
Towing .................................................................3
Operating .............................................................3
Manufacturing Number ........................................4
Symbols and Decals ...............................................5
Safety Instructions..................................................7
General Use.........................................................7
Safety Equipment.................................................9
Driving on Slopes.................................................9
Children..............................................................10
Maintenance ......................................................11
Transport............................................................14
Roll over Protection System ROPS ...................15
Customer Responsibilities .................................15
Controls .................................................................16
Control Locations ..............................................16
Motion Control Levers........................................17
Hour Meter .........................................................18
Tracking Knob....................................................18
Park Brake .........................................................18
Blade switch.......................................................19
Ignition Switch....................................................19
Fuses .................................................................19
Seat Locking Device ..........................................20
Refueling............................................................20
Fuel Shut Off Valve............................................21
Seat Adjustment Lever.......................................21
Choke Control ....................................................21
Throttle Control ..................................................22
Lifting Lever for the Mower Deck .......................22
Pump release valves..........................................23
Accessories........................................................23
Operation ...............................................................24
Training ..............................................................24
Roll bar and safety belt ......................................25
Before Starting ...................................................25
Starting the Engine ............................................25
To start an engine with a weak battery ..............29
Running..............................................................30
Operating on Hills ..............................................31
Mowing Tips.......................................................32
Stopping the Engine...........................................33
Moving by Hand .................................................34
Maintenance ......................................................... 35
Maintenance Schedule...................................... 35
Battery............................................................... 37
Ignition System.................................................. 38
Checking the Safety System ............................. 39
Checking the Engine's Cooling Air Intake ......... 40
Replacing the Air Filter...................................... 41
Replacing the Fuel Filter ................................... 43
Checking the Fuel Pump’s Air Filter.................. 43
Checking Tire Pressures................................... 44
Checking the Park Brake .................................. 44
Checking the V-belts ......................................... 44
Checking the Blades ......................................... 45
Adjusting the Mower Deck ................................ 47
Cleaning and Washing ...................................... 49
Caster Wheels................................................... 49
Hardware........................................................... 49
Lubrication............................................................ 50
General ............................................................. 50
Lubricating the Cables ...................................... 51
Shaft Bushings and Linkage ............................. 51
Lubrication Schedule......................................... 51
Trouble Shooting Guide ...................................... 61
Storage .................................................................. 63
Winter Storage .................................................. 63
Service .............................................................. 63
Wiring diagrams ................................................... 64
Technical Data ...................................................... 65
Accessories....................................................... 67
Torque Specifications........................................ 67
Conformity Certificates........................................ 68
Service Journal .................................................... 69
Delivery Service ................................................ 69
After the First 8 Hours ....................................... 70
25-Hour Service ................................................ 71
50-Hour Service ................................................ 72
100-Hour Service .............................................. 73
300-Hour Service .............................................. 74
At Least Once Each Year.................................. 75
English-1
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.
English-2
INTRODUCTION
Introduction
Congratulations
Thank you for purchasing a Dixon ride-on mower. This machine is built for superior efficiency to rapidly mow
primarily large areas. A control panel 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, etc.) 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.
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.
Towing
Do not tow this machine, it may cause damage to the drive system.
Do not tow any trailers, etc. with this mower. They may jackknife or overturn causing damage to the mower
and possibly serious injury to the operator.
Operating
This machine is constructed only for mowing grass on lawns and other free and even ground without
obstacles such as stones, tree stumps, etc. The machine can also be used for other tasks when equipped
with special accessories provided by the manufacturer. Operating instructions are provided with delivery.
All other types of use 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 judgement, 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.
English-3
INTRODUCTION
Unauthorized modifications to the design of the machine may absolve the manufacturer from liability for
any resulting personal injury or property damage.
Good Service
Dixon’s products are sold all over the world and only in specialized retail stores with complete service. This
ensures that you as a customer receive only the best support and service. Before the product is delivered,
the machine has, for example, been inspected and adjusted by your retailer, see the certificate in the
Service Journal in this operator’s manual.
When you need spare parts or support in service questions, warranty issues, etc., please consult
the following professional:
This Operator’s Manual belongs to the
machine with manufacturing number:
Engine
Transmission
Manufacturing Number
The machine’s manufacturing number can be found on the printed plate affixed to the left in the engine
compartment. Stated on the plate, from the top are:
•
The machine’s type designation (I.D.).
•
The manufacturer's type number (Model).
•
The machine’s serial number (Serial no.)
Please state the type designation and serial number when ordering spare parts.
The engine’s manufacturing number is stated on a barcode decal. This is placed on the left side of the
crankcase, in front of the starter. The plate states:
•
The engine’s serial number (E/NO).
•
The engine’s type designation (Code).
Please state these when ordering spare parts.
The hydraulic pump’s manufacturing number is stated on a barcode decal affixed to the left side of the
pump housing. The plate states:
•
The pump’s type designation.
•
The pump’s serial number.
The hydraulic motor’s manufacturing number is stated on a round metal plate. This is placed on the gable
inside the motor. The plate states:
•
The hydraulic motor’s type designation and design version.
•
The hydraulic motor’s serial number.
English-4
SYMBOLS AND DECALS
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.
WARNING!
Xxxxxxx xxxx xxxxxxxx xxx x
Xxxxx xxxxxx xx.
xx xxxxxxxx xxxxx xxx xx.
Used in this publication to notify the reader of a risk of personal injury or death, particularly if the reader
should neglect to follow instructions given in the manual.
IMPORTANT INFORMATION
Xxxxxxx xxxx xxxxxxxx xxx xxx
xxxx xxxxxx xx.
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.
Reverse
Neutra
Fast
Slow
Choke
Fuel
P
Warning!
Park brake
CE conformity
marking. Only for
European market
Battery acid is corrosive, explosive,
and flammable
Warning! Rotating
blades, keep away from
the discharge deck
Do not stand here
Do not touch rotating
parts
Noise emissions to the surroundings
in accordance with the European
Union’s directive. The machine’s
emission is stated in the chapter
TECHNICAL DATA and on the decals.
Only machines for European market
Use protective glasses
Use protective gloves
English-5
SYMBOLS AND DECALS
Read
Operator´s
Manual.
Whole body
exposure to
thrown
objects.
Shut off engine
& remove key
before
performing any
maintenance or
repair work.
Severing of
fingers &
toes.
Keep a safe
distance from
the machine.
Do not open
or remove
safety shields
while engine
is running.
Use on
slopes no
greater
than 10°.
No
passengers
Careful
backing up,
watch for other
people.
Careful going
forward, watch
for other people.
Moving sharp blades
under cover
ROPS warning decal
English-6
SAFETY INSTRUCTIONS
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 park brake, stop
engine, and remove keys before
dismounting.
8011-512
Read the operator’s manual before starting the
machine
8011-513
Clear the area of objects before mowing
8011-520
Never take passengers
English-7
SAFETY INSTRUCTIONS
•
Disengage blades when not mowing.
Shut off engine and wait for all parts to
come to a complete stop before cleaning
the machine, removing the grass
catcher, or unclogging the discharge
guard.
•
Operate machine only in daylight or good
artificial light.
•
Do not operate the machine while under
the influence of alcohol or drugs.
•
Watch for traffic when operating near or
crossing roadways.
•
Use extra care when loading or
unloading the machine into a trailer or
truck.
•
Always wear eye protection when
operating machine.
•
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 Operation
Manual. Local laws may regulate the age
of the user.
•
Keep machine free of grass, leaves or
other debris build-up which can touch hot
exhaust / engine part and burn. Do not
allow the mower deck to plow leaves or
other debris which can cause build-up to
occur. Clean any oil or fuel spillage
before operating or storing the machine.
Allow machine to cool before storage.
English-8
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 a odorless, colorless,
poisonous gas. Do not use the
machine in enclosed spaces.
SAFETY INSTRUCTIONS
Personal Safety Equipment
WARNING!
When using the machine, approved personal protective equipment (shown in
illustrations) shall be used. Personal protective equipment cannot eliminate
the risk of injury but it will reduce the degree of injury if an accident does
happen. Ask your retailer for help in choosing the right equipment.
•
Make sure that you have first aid equipment
close at hand when using the machine.
•
Never use the machine when barefoot.
Always wear protective shoes or boots,
preferably with steel toecaps.
•
Always wear approved protective glasses
or a full visor when assembling or driving.
•
Always wear gloves when handling the
blades.
•
Never wear loose clothing that can get
caught in moving parts.
•
Use ear protectors to avoid damage to
hearing.
8011-670
Personal protective equipment
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.
6003-004
Mow up and down, not side-to-side
WARNING!
Do not drive up or down hills
with slopes greater than 10
degrees. And do not drive
across any slopes.
Keep all movement on the slopes slow
and gradual. Do not make sudden
changes in speed or direction, which
could cause the machine to roll over.
English-9
SAFETY INSTRUCTIONS
•
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 your 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.
Children
8011-519
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.
•
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 your view of a child.
Be extra cautious when driving on slopes
8011-517
Never allow children to operate the machine
8011-518
Keep children away from the work area
English-10
SAFETY INSTRUCTIONS
Maintenance
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 at least
two (2) minutes 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
appliances.
•
Before you begin refueling, 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 your
vehicle when filling.
•
Remove gas-powered equipment from the
truck or tailer and refuel it on the ground. If this
is not possible, then 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 lockopen 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 the fuel system, the engine
must not be started until the problem has been
resolved.
8011-516
Never fill the fuel tank indoors
WARNING!
The engine and the exhaust
system, become very hot during
operation.
Risk for burns if touched.
Allow engine and exhaust
system to cool at least two (2)
minutes before refueling
English-11
SAFETY INSTRUCTIONS
•
Check the fuel level before each use and
leave space for the fuel to expand,
because the heat from the engine and
the sun may otherwise cause the fuel to
expand and overflow.
General Maintenance
•
Never operate machine in a closed area.
•
Keep all nuts and bolts tight to be sure the
equipment is in safe working condition.
•
Never tamper with safety devices. Check
their proper operation regularly.
•
Keep machine free of grass, leaves, or other
debris build-up. Clean oil or fuel spillage and
remove any fuel-soaked debris. Allow
machine to cool before storing.
•
If you strike a foreign object, stop and
inspect the machine. Repair, if necessary,
before restarting.
•
Never make any adjustments or repairs with
the engine running.
•
Check grass catcher components 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 you run the engine too
fast, you risk damaging the machine
components.
Be very careful when handling battery acid.
Acid on skin can cause serious corrosive
burns. If you spill battery acid on your skin,
rinse immediately with water.
English-12
8011-515
Never drive the machine in an enclosed space
Always use protective glasses
when handling the battery.
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 INSTRUCTIONS
•
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 when
smoking or near open flames or sparks.
The battery can explode and cause serious
injury/damage.
•
Ensure that nuts and bolts, especially the
fastening bolts for the blade attachments,
are properly tightened, torqued and that the
equipment is in good condition.
•
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 you run the engine too
fast, you risk damaging the machine
components.
•
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.
6003-009
Do not smoke when performing maintenance on the
battery. The battery can explode and cause serious
injury/damage
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 is
stored in an open vessel.
•
Never work with the starter circuit if there
is spilled fuel.
•
Disconnect the chassis 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.
8009-728
Risk of sparking
English-13
SAFETY INSTRUCTIONS
•
Stop and inspect the equipment if you run
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 park brake’s functionality
regularly. Adjust and service as necessary.
•
The mulch blades should only be used in
familiar areas when higher quality mowing is
desired.
•
Reduce the risk of fire by removing grass,
leaves, and other debris that may have
accumulated on the machine. Allow the
machine to cool before putting it in storage.
•
Regularly clean deck and underside of deck,
avoid spraying engine and electrical
components with water.
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 park 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.
•
Do not tow any trailers, etc. with this
mower. They may jackknife or overturn
causing damage to the mower and
possibly serious injury to the operator.
English-14
8011-644
Avoid spraying engine and electrical components
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 park 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.
SAFETY INSTRUCTIONS
Rollover Protection System ROPS
The ROPS increases the basic weight of the unit by 42 lbs/19 kg. The ROPS on the US units are standard,
on the European units the ROPS is an accessory.
WARNING!
The structures capability may be impaired by structural damage if overturned, or
alteration occurs. If any of these conditions take place, the total structure MUST
be replaced.
•
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 your seat belt if the unit has a ROPS.
•
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 - no jerky turns, starts or stops.
•
When mower is stopped, set brakes securely and use park brake.
•
If any part of ROPS is damaged, the entire ROPS must be 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.
Customer Responsibilities
•
Read and observe the safety rules.
•
Follow a regular schedule in maintaining,
caring for and using your mower.
•
Follow the instructions under
"Maintenance” and "Storage” sections of
this owner’s manual.
WARNING!
This mower is equipped with an internal combustion engine and should not be
used on or near any unimproved forest-covered, bush-covered or grass-covered
land unless the engine’s exhaust system is equipped with a spark arrester
meeting applicable local or state laws (if any). If a spark arrester is used, it should
be maintained in effective working order by the operator.
A spark arrester for the muffler is available through your authorized Dixon dealer.
English-15
CONTROLS
Controls
This operator’s manual describes the Dixon
Zero Turn Rider. The rider is fitted with a
Honda or Kohler four-stroke V-Twin engine
developing 19-25 horse power.
Transmission from the engine is made via two
belt-driven hydraulic pumps, which in turn
drive a hydraulic motor for each drive wheel.
Using the left and right steering controls, the
flow is regulated and thereby the direction
and speed.
8050-139
Zero Turn Rider
1
1
13
10
5
6
11 12
7
2 4 9
8
8050-766
Locations of the controls
Controls
Page
Page
1.
Motion control, left and right
17
8.
Fuel tank cap
20
2.
Hour meter
18
9.
Fuel shut off valve
21
3.
Park brake
18
10.
Seat adjustment lever
21
4.
Blade-switch
19
11.
Choke control
21
5.
Ignition switch
19
12.
Throttle control
22
6.
Fuses
19
13.
Lifting lever, mower deck
22
7.
Seat locking device
20
English-16
CONTROLS
1. 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.
8011-788-1
Steering controls
In order, 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.
WARNING!
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.
The machine can turn very
rapidly if one steering control
is moved much further forward
than the other.
If the steering controls are in uneven
positions when standing still they can be
adjusted using the adjustment screws for the
steering lever, not the link system, for the
controls.
1
2
3
4
8011-791
1
2
3
4
Forward
Neutral
Neutral slot, Neutral lock
Reverse
Motion control lever pattern (right side)
English-17
CONTROLS
2. 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 can not be
manually reset.
8050-140
Hour meter
3. Park Brake
The park brake is found on the left of the
machine. Pull the lever backward to activate
the brake and forward to release it.
8050-138
Park brake released
English-18
CONTROLS
4. Blade switch
In order to engage the mower deck, pull the
knob out; the mower blades are disengaged
when the knob is depressed.
8050-142
Blade Switch
5. Ignition Switch
The ignition key is placed in the ignition
switch on the driver’s panel and is used to
start and stop the engine.
IMPORTANT INFORMATION
Do not run the starter for more than five
seconds each time. If the engine does not
start, wait about 10 seconds before retrying.
8050-141
Ignition key and hour meter
6. Fuses
The fuses are located in a holder to the left of
the hydraulic tank. They are flat pin fuses of
the same type used in automobiles.
There are three fuses, as well as socket for
one spare fuse.
Fuse ratings and functions:
•
20 A, Primary fuse.
•
7.5 A, Mower deck coupling.
•
7.5.A, Accessory outlet.
•
Socket for spare fuse.
8011-443
Fuses
English-19
CONTROLS
7. Seat Locking Device
Under the rear part of the seat is a locking
device that locks the seat into its folded
position. The seat has hinges at the front
edge and can be folded forward when the
locking device is pushed.
8011-440
The seat’s locking device
8. Refueling
The machine has two fuel tanks, one on each
side just behind the seat. The tanks take
5.7 gallons (22 liters) each.
The engine will run on a minimum of 87-octane
unleaded gasoline (no oil mix). Environmentally
adapted alkylate gasoline can be used beneficially.
See also Technical Data concerning methanol and
ethanol fuels.
WARNING!
Gasoline is highly flammable.
Observe caution and fill the
tank outdoors
(see the safety rules).
WARNING!
The engine and the exhaust
system, become very hot
during operation.
Risk for burns if touched.
allow engine and exhaust
system to cool at least two (2)
minutes.
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.
When operating in temperatures below 32 °F.
(0 °C.), use fresh, clean winter grade gasoline
to help insure good cold weather starting.
English-20
8011-524
Fuel tanks
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.
CONTROLS
9. Fuel Shut Off Valve
The fuel shut off valve is located at the right
rear of the seat. The valve has three
positions; right tank, left tank and center is the
off position.
8011-506
Fuel valve
10. 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), after which the seat
can be moved backward or forward.
8011-441
Lengthways adjustment
11. Choke Control
The choke control is used for cold starts in
order to provide the engine with a richer fuel
mixture.
For cold starts the control should be pulled
out.
8050-143
Choke control
English-21
CONTROLS
12. Throttle Control
The throttle control regulates the engine
speed and thereby the rate of rotation of the
blades, assuming the blade switch is pulled
out, see Engaging the Mower Deck.
In order to increase or decrease the engine
speed, the control is moved downward or
upward 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.
8050-144
Throttle control
13. Lifting Lever for the Mower Deck
The lifting lever is used to place the mower
deck in the transport position or one of the
14 different cutting height positions.
The cutting height is set by placing a peg in
the hole for the desired cutting height and the
peg is then locked on the inside (hidden in the
illustration) with the supplied pin.
1.
Pull the lever backward to the locked
position to engage the transport position.
The deck is then raised.
2.
Depress the lock handle, counter hold,
and move the lifting lever forward toward
the peg to engage the set cutting height.
The deck is then lowered.
3.
The lifting lever can also be used to
temporarily adjust the cutting height,
such as when passing a minor bump in
the lawn.
IMPORTANT INFORMATION
In order to obtain an even cutting height it
is important that the air pressure in all
four tires is the same 15 psi (1 bar).
English-22
8011-525-1
The mower deck’s lifting lever
CONTROLS
Pump release valves
IMPORTANT INFORMATION
Only rotate valve 1/4 - 1/2 turn to release
system.
Tighten the valve moderately.
Do not overtighten the valve when
closing. That can damage the valve seat.
Pump release valves are located at the
pumps. They are used to release the system
so the machine may be moved by hand when
not running. Tilt seat forward to gain access
to the pumps. Use a 5/8” wrench to open
valve.
8011-507
Pump release valve
Accessories
For mulching, there is a BioClip attachment
available. This is mounted underneath the
mower deck and consists of control plates
and BioClip blades.
8011-566
BioClip attachment
English-23
OPERATION
Operation
Read “Safety Instructions” section and following pages, if you are unfamiliar with the machine.
Training
Zero turn mowers are far more maneuverable than typical riding mowers due to their unique steering
capabilities.
We recommend that this section be reviewed in it’s entirety prior to attempting to move the mower under its
own power. Additionally, we suggest when first operating mower, use a reduced throttle speed and reduced
ground speed by NOT moving control levers to the furthest forward or reverse positions during initial
operation, or until operator becomes comfortable with controls. We also suggest first time users, or new
users to ZeroTurn mowers to become familiar with the mowers movement on a hard surface, such as
concrete or blacktop PRIOR to attempting to operate on turf. Until operator becomes comfortable with
mower controls and zero turning capability, they may damage turf due to over aggressive maneuvers.
To move forward and backward
The direction and speed of the mowers movements is effected by the movement of the control lever(s) on
each side of mower. The left control lever controls the left wheel motor. The right control lever controls the
right wheel motor.
IMPORTANT INFORMATION
When control levers are in the reverse
position they return to neutral when
released. This may cause the mower to
suddenly stop.
First time users should push mower (see “Moving by Hand” in the “Operation” section) to an open, flat area,
without other people or vehicles/obstacles near by. In order to move unit under its own power, the operator
must be in the seat, start engine (see “Before Starting” in “Operation” section), adjust engine speed to idle,
disengage park brake, do not engage blades at this time, rotate control levers inward. As long as the
control levers have not been moved forward or backwards, mower will not move. Slowly move both control
levers forward slightly, this will allow mower to start moving forward in a straight line. Pull back on control
levers to the neutral position and mower should stop moving. Pull back slightly on control levers, this will
allow mower to start moving backwards. Push forward on control levers to the neutral position and mower
should stop moving.
To turn to the right
While moving in a forward direction, pull the right lever back towards the neutral position while maintaining
the position of the left lever, this will slow the rotation of the right wheel and cause the machine to turn in
that direction.
To turn to the left
While moving in a forward direction pull the left lever back towards the neutral position while maintaining
the position of the right lever, this will slow the rotation of the left wheel and cause the machine to turn in
that direction.
To zero turn
While moving in a forward direction, first pull both control levers back until the mower stops or slows
dramatically. Then by alternating one lever slightly to the forward position and the other in the reverse
position.
English-24
OPERATION
Roll bar and safety belt
WARNING!
Operate the unit with the roll bar in the raised
and locked position and use the seat belt.
There is no rollover protection when the roll
bar is down. If it is necessary to lower roll bar,
do not wear the seat belt. Raise the roll bar
as soon as clearance permits.
The seat belt must be used
when the roll bar is in upright
position.
Roll bar
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 tanks.
•
Adjust the seat to the desired position.
8011-464
Roll bar in upright position
The following conditions must be fulfilled
before the engine can be started:
•
the driver must be seated on the seat,
•
the blade switch for engaging the mower
blades must be depressed,
•
the park brake must be on,
•
both steering controls must be in the
locked (outer) neutral position.
Starting the Engine
1.
Sit on the seat.
2.
Raise the mower deck by pulling the
lifting lever backward to the locked
position (transport position).
3.
Activate the park brake.
8011-527-1
Start conditions
8011-552
Raise the mower deck
English-25
OPERATION
4.
Disengage the mower blades by
depressing the blade switch.
8050-131
Depress the control for disengaging the mower deck
5.
Move the steering controls outward to
the locked (outer) neutral position.
8011-526
Steering controls in the outward, locked
neutral position
6.
Move the throttle to the middle position.
8050133
Set the throttle
English-26
OPERATION
7.
If the engine is cold, the choke control
shall be pulled out to its extents.
8050-134
Set the choke control
8.
Open the fuel valve for the selected fuel
tank.
8011-506
Open the fuel valve
9.
Press in and turn the ignition key to the
start position.
STOP
8050-135
Turn to the start position
English-27
OPERATION
10. When the engine starts, immediately
release the ignition key back to the run
position.
STOP
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.
key-run
Return to run position
11. Slowly slide the choke control to the off
position when the engine has started.
8050-134
Gradually slide the choke control
12. Set the desired engine speed with the
throttle.
Allow the engine to run at a moderate
speed, “half throttle”, for 3-5 minutes
before loading it too heavily.
USE FULL THROTTLE WHEN
MOWING.
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 a odorless, colorless,
poisonous gas. Do not use the
machine in enclosed spaces.
English-28
8050-133
Set the engine speed
OPERATION
To start an engine with a 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.
If your battery is too weak to start the engine,
it should be recharged. (See “Battery” in the
the “Maintenance” section).
If “jumper cables” are used for emergency
starting, follow this procedure:
IMPORTANT INFORMATION
Your 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 your mower
battery to start other vehicles.
To attach 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.
8011-642
Jumper cables connection
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.
English-29
OPERATION
Running
1.
Release the park brake by moving the
lever forward.
Your 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
park brake will shut off the engine.
2.
Move the steering controls to the neutral
position (N).
8050-138
Released park brake
3.
Select the cutting height by placing the
peg in one of the holes. Lock the peg on
the inside with the pin.
4.
Press in the stop handle, counter hold,
and carefully move the lifting lever
forward from the transport position
toward the peg.
IMPORTANT INFORMATION
The mower deck’s anti-scalp rollers shall
be evenly adjusted.
8011-561-1
Cutting height selection
WARNING!
Ensure that no one is near the
machine when engaging the
blade switch.
5.
Engage the mower deck by pulling out
the blade switch.
6.
Move throttle control to full throttle
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.
English-30
8050-131
Engaging the mower deck
OPERATION
In order, 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.
Turning on the spot can be achieved by
moving one control backward (behind
the neutral position) and carefully moving
the other steering control forward from its
neutral position.
Operating on hills
Read “Slope Operation” in the “Safety
Instructions”.
WARNING!
Do not drive up or down
hills with slopes greater
than 10 degrees. And do not
drive across any slopes.
•
The slowest speed possible should be
used before starting up or down hills.
•
Avoid stopping or changing speed on
hills.
•
If stopping is absolutely necessary, pull
drive levers into the neutral position and
push to the outside of the unit and
engage the park brake.
IMPORTANT INFORMATION
Control levers return to neutral when
released. This may cause the mower to
suddenly stop.
•
To restart movement, release the park
brake.
•
Pull the control levers back to the center
of the mower and press forward to regain
forward motion.
•
Make all turns slowly.
8011-640-1
Stopping conditions
5080-138
Released park brake
English-31
OPERATION
Mowing Tips
•
•
Observe and flag rocks and other fixed
objects to avoid collisions.
WARNING!
Begin with a high cutting height and
reduce it until the desired mowing result
is attained.
Clear the area of objects such
as rocks, toys, wire, etc.,
which could be picked up and
thrown by the blades.
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, the
mower deck shall be raised into the
transport position. Make sure the mower
is cooled and the engine is off.
•
Use compressed air to clean top surface
of the deck. Avoid flooding water on top
surface of the deck.
•
When the mulching kit is used, it is
important that the mowing interval is
frequent.
English-32
8011-603
Mowing patterns
WARNING!
Never drive the rider on terrain
that slopes more than 10°.
Mow slopes up and down,
never side-to-side. Avoid
sudden directional changes.
OPERATION
Stopping the Engine
Allow the engine to idle a minute in order to
attain normal operating temperature before
stopping it, if it has been worked hard. Avoid
idling the engine for longer periods, as there
is a risk of the spark plugs fouling.
1.
Disengage the mower deck by
depressing the blade switch.
8050-131
Disengage the mower deck
2.
Raise the mower deck by pulling the
lifting lever backward to the transport
position.
3.
When the machine is standing still,
activate the park brake by pulling the
lever backward.
4.
Move the throttle to the minimum position
(tortoise symbol). Turn the ignition key to
the stop position. Never use choke to
stop engine.
5.
Move the steering controls outward.
6.
Remove key. Always remove key when
leaving the mower to prevent
unauthorized use.
8011-552
Raise the mower deck with the lifting lever
IMPORTANT INFORMATION
Leaving the ignition switch in any other
position than "OFF" will cause the battery
to be discharged.
English-33
OPERATION
Moving by Hand
In order for the machine to be moved with the
engine turned off, the vent screws on both
hydraulic pumps must be opened one quarter
to one half turn.
WARNING!
No adjustments or
maintenance to carried out
unless:
- the engine is stopped,
- the ignition key has been
removed,
- the park brake is on.
English-34
8011-507
Vent screw on the hydraulic pump
MAINTENANCE
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 Instructions” section.
z = Described in this manual
 = Not described in this manual
Daily
Maintenance
Page Before After
Check the park brake
44
z
Check the engine’s oil level (every refueling)
55
z
Check the hydraulic system’s oil level
53
z
Check the safety system
39
z
-

Check for fuel and oil leakages
Weekly
Check/clean the engine’s cooling air intake
40
z
Check the mower deck
45
z
Check hardware (screws, nuts, etc.)
49
z
Clean under the mower deck
49
z
Start the engine and blades, listen for unusual
sounds
-

Check for damage
-

Thoroughly clean around the engine
-

Thoroughly clean around the hydraulic system
-

Clean around belts, belt pulleys, etc.
-

At
least
once
each
year
Maintenance interval
in hours
25
50
Check the tire pressures
44
z
Check battery
37
z
Sharpen/Replace mower blades
45
z
Check the fuel pump’s air filter 2)
43
z
Clean the engine’s cooling air intake 2)
40
z
z
Clean air filter dust cap
40
z
z
Check/adjust the park brake
-


Inspect muffler/Spark arrester
-


100
300
English-35
MAINTENANCE
Daily
Maintenance
Weekly
Page Before After
At
least
once
each
year
Maintenance interval
in hours
25
50
100
Check the condition of belts, belt pulleys, etc.
44
z
z
Change the engine oil 1)
57
z
z
Replace the engine oil filter (every 200 hours)
62
z
z
Clean/replace the spark plugs
38
z
z
Replace the fuel filter
43
z
z
Replace the air filter (main cartridge) 2)
(every 200 hours)
40
z
z
Check the caster wheels (every 200 hours)
49
Clean the cooling fins 2)
300
z
-
Clean fins of oil cooler (Kohler)


z
z
Replace the air cleaner’s pre-filter 2) (foam filter)
40
z
z
Check/adjust the mower deck
47
z
z
-


Change the hydraulic oil (every 300 hours)

Dismantle and inspect starter 4) (every 500 h)
Replace the hydraulic oil filter (every 300 hours)
-


Check the engine valve clearance 4)
-


Perform the 300-hour service 4)
82


Lubricate according to Lubrication Schedule
52
z
z
z
z
z
z
z
1)
First change after 8 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours. 2) In dusty conditions, cleaning
and replacement are required more often. 3) For daily use, the machine should be lubricated twice weekly. 4) Performed by authorized service workshop.
z = Described in this manual
 = Not described in this manual
WARNING!
No adjustments or maintenance to be carried out unless:
• The engine is stopped.
• The ignition key has been removed.
• The park brake is on.
English-36
MAINTENANCE
Battery
Your 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.
Always use protective glasses
when handling the battery.
•
Keep battery and terminals clean.
IMPORTANT INFORMATION
•
Keep battery bolts tight.
•
Recharge at 6-10 amperes for 1 hour
Do not attempt to open or remove caps
or covers. Adding or checking level of
electrolyte is not necessary.
To clean battery and terminals
Always use two wrenches for the
terminal screws
Corrosion and dirt on the battery and
terminals can cause the battery to “leak”
power.
1.
Lift seat and rotate forward.
2.
Remove the red terminal guard.
3.
Disconnect BLACK battery cable first,
then the RED battery cable and remove
the battery from the machine.
4.
Rinse the battery with plain water and
dry.
5.
Clean terminals and battery cable ends
with wire brush until shiny.
6.
Coat terminals with grease or petroleum
jelly
7.
Reinstall battery.
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.
Replacing battery
1.
Lift Seat and rotate forward.
2.
Remove the terminal guard.
3.
Using two 1/2" wrenches disconnect
BLACK battery cable then RED battery
cable.
4.
Unscrew the knob and remove battery
hold down.
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 hold down.
8.
First connect RED battery cable to
positive (+) battery terminal with hex bolt
and hex nut.
8011-445
Battery installation
English-37
MAINTENANCE
9.
Connect BLACK grounding cable to
negative (-) battery terminal with
remaining hex bolt and hex nut.
10. Fit the terminal guard.
11. Lower seat.
Ignition System
The engine is equipped with an electronic
ignition system. Only the spark plugs require
maintenance.
For recommended spark plugs, see Technical
Data.
IMPORTANT INFORMATION
1.
Remove the ignition cable boot and
clean around the spark plug.
Fitting the wrong spark plug type can
damage the engine.
2.
Remove the spark plug with a spark plug
socket wrench.
3.
Check the spark plug. Replace the spark
plug if fouled, the electrodes are burned
and if the insulation is cracked or
damaged. Clean the spark plug with a
steel brush if it is to be reused.
4.
Measure the electrode gap with a
gapping tool. The gap should be .030"
(0.75 mm). Adjust as necessary by
bending the side electrode.
5.
Reinsert the spark plug, turning by hand
to avoid damaging the threads.
6.
After the spark plug is seated, tighten it
using a spark plug wrench so that the
washer is compressed. A used spark
plug should be turned 1/8 of a turn from
the seated position. A new spark plug
should be turned 1/4 a turn from the
seated position.
7.
Replace the ignition cable.
English-38
Inadequately tightened spark plugs can
cause overheating and damage the
engine. Tightening the spark plugs too
hard can damage the threads in the
cylinder head.
8011-054
Measure the electrode gap
MAINTENANCE
Checking the Safety System
The 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 driver is sitting in the driver’s seat.
4.
The park 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 stands up.
8050-527
Conditions for starting
IMPORTANT INFORMATION
In order to drive the unit, the driver must
sit in the seat and release the park brake
before the steering controls can be
moved into the neutral position,
otherwise the engine will stop.
English-39
MAINTENANCE
Checking the Engine's Cooling Air Intake
Check that the engine’s cooling air intake is
free from leaves, grass, and dirt.
If the cooling air intake is clogged, engine
cooling deteriorates, which can lead to
engine damage.
Replacing the Air Filter (Kohler)
Heavy duty air filter
If the engine seems weak or runs unevenly,
the air filter may be clogged. If the engine is
run with a dirty air filter, the spark plugs can
become fouled, disrupting operation.
It is important to replace the air filter regularly
(see the heading Maintenance Schedule for
the proper service interval).
8011-625
Check and clean the cooling air intake
Dust cap
Check the dust cap every day by pressing the
rubber valve with two fingers to let out the
dirt.
Clean the dust cap by removing the end
cover of the the air cleaner and clean the
inside.
IMPORTANT INFORMATION
The end cover must be installed with the
rubber valve pointing downwards,
otherwise the rubber valve will not
function.
8011-447
Pressing the rubber valve
WARNING!
To clean or replace the air filter:
1.
Unhook the two retaining clips and
remove the end cover.
2.
Remove the main filter (outer filter) by
pulling it out by hand.
3.
Check the inner filter. If it appears dirty, it
should be replaced. Remove the inner
filter, if necessary, by pulling it out by
hand.
4.
Clean inside of the filter housing. Wipe
dry only.
5.
Install the inner filter with the open end
first. Ensure that it enters its recess at
the end of the housing by pushing it in to
the stop.
The engine and the exhaust
system, become very hot
during operation. Risk for
burns if touched. Allow engine
and exhaust system to cool at
least two (2) minutes.
8011-448
Removing the end cover
English-40
MAINTENANCE
6.
Install the main filter with the open end
first. Ensure that it enters its recess at
the end of the housing by pushing it in to
the stop.
IMPORTANT INFORMATION
The end cover must be installed with the
rubber valve pointing downwards,
otherwise the rubber valve will not
function.
8011-449
Installing the main filter
7.
Replace the end cap and turn the end
cover so the rubber valve is pointing
downwards. Secure the retaining clips.
Air filter indicator (optional)
Change the main filter when the yellow piston
is hanging at the top of the cylinder. To reset
the indicator, push on the button (arrow) at
the cylinder. A number of pushes may be
required. If it indicates soon after a main filter
replacement, change the inner filter.
8011-450
Installing the inner filter
Replacing the Air Filter (Honda)
Standard air filter
If the engine seems weak or runs unevenly,
the air filter may be clogged. If run with a dirty
air filter, the spark plugs can become fouled,
disrupting operation.
It is important to replace the air filter regularly
(see the heading Maintenance Schedule for
the proper service interval).
To clean or replace the air filter:
8011-467
Air filter indicator
WARNING!
The engine and the exhaust
system, become very hot
during operation. Risk for
burns if touched. Allow engine
and exhaust system to cool at
least two (2) minutes.
1.
Loosen the fastener and the two top
inner screws. Remove the air cleaner
cover.
2.
Remove the paper filter.
8057-101
Remove the filter cover
English-41
MAINTENANCE
3.
Remove the foam rubber pre-filter and
clean or replace as necessary. To clean,
wash with warm water using a mild
detergent. Squeeze out excess water
and allow to air dry. After drying, dip the
filter in clean engine oil and squeeze out
excess.
4.
Tap the paper filter against a fixed
surface to remove dust. If the paper filter
is still dirty, it must be replaced.
8057-728
IMPORTANT INFORMATION
Remove the paper filter
Do not used compressed air to clean the
air filter.
Do not wash the paper filter.
Do not oil the paper filter.
5.
Refit the air filter as follows:
Place the foam prefilter into the air
cleaner compartment. Replace the
gaskets.
Mount the paper filter in the air filter
housing and tighten the screws and
wing nuts.
8057-182
Remove dust
3
1
2
8057-103
1. Paper filter
2. Gaskets
3. Pre-filter
Reassemble air filter as shown
English-42
MAINTENANCE
Replacing the Fuel Filter
Replace the line-mounted fuel filter every
100 hours (once per season) or more often if
it becomes clogged.
Replace the filter as follows:
1.
Move the hose clamps away from the
filter. Use flat-nosed pliers.
2.
Pull the filter loose from the hose ends.
3.
Push the new filter into the hose ends.
Position the filter with the “FLOW” arrow
pointing up toward the fuel pump. If
necessary, a soap solution can be
applied to the filter ends to ease
mounting.
4.
8009-146
Fuel filter
Move the hose clamps back toward the
filter.
8011-468
Fuel filter Kohler
Checking the Fuel Pump’s Air Filter
Regularly check that the fuel pump’s air filter
is free from dirt.
On Kohler engine removal of the pump
screws is not needed due to the filter facing
outward.
Remove the screws and open the pump, no
hoses need be removed.
The filter can be cleaned with a brush if
necessary.
Replace the filter on the console.
8009-147
The fuel pump’s air filter
English-43
MAINTENANCE
Checking Tire Pressures
All four tires should have a pressure of 15 psi
/ 103 kPa /1 bar.
8011-564
Checking the Park Brake
Tire pressures
Visually check that no damage is found on
the lever, links, or switch belonging to the
park brake. Perform a test drive and check
that there is sufficient braking action.
To adjust the park brake, contact the Dixon
service workshop.
WARNING!
Faulty adjustment can cause
an accident.
8050-138
Park brake in the released position
Checking the V-belts
Deck belt
Check every 100 hours of operation. Check
for severe cracking and large nicks.
NOTE: The belt will show some small cracks
in normal operation.
To replace belt, lower the deck to its lowest
position. Remove the foot plate and belt
shields.
Use a ratchet with a 9/16” socket on the
spring idler bolt to relieve the tension on the
belt. Slide the belt off the pulley and remove
the belt.
8011-622
Slackening the belt tensioner
Reverse the procedure for installation. See
the decal on the top of deck for belt routing
information.
After installation is complete check the belt
for twists.
8011-764
Belt routing, deck belt
English-44
MAINTENANCE
Pump belt
Check belt every 100 hours for excessive
wear.
To replace belt. Relieve tension on the deck
belt and remove deck belt from clutch. See
“Deck belt” on page 44. Loosen bolt on the
clutch tie down and rotate out of the way.
Using a 1/2” drive ratchet inserted into the
square hole in the pump idler arm, relieve the
tension on the pump belt and remove belt.
To reinstall belt. Swing pump idler pulley out
toward engine to route belt around it. Then
route belt around the pulley for the left pump
first (right hand pulley in the illustration).
8011-623
Slackening the belt tension
Reinstall idler spring and use the ratchet to
rotate idler so the belt may be installed all the
way around the last pulley.
Checking the Blades
In order to attain the best mowing performance, it is
important that blades are well sharpened and not
damaged.
8011-624
Belt routing, hydraulic pumps
WARNING!
Blades are sharp. Protect your
hands with gloves and/or wrap
blades with a heavy cloth when
handling.
Bent or cracked blades or blades with large nicks
should be replaced.
Check the blade mounts.
8011-604
Check the blades
IMPORTANT INFORMATION
The sharpening of blades should be carried
out by an authorized service workshop.
After hitting obstacles that result in a breakdown,
damaged blades should be replaced. The service
workshop should decide whether the blade can be
repaired/ground or must be discarded.
English-45
MAINTENANCE
Blade replacement:
3
1
WARNING!
Blades are sharp. Protect your
hands with gloves and/or wrap
blades with a heavy cloth when
handling.
2
5
4
•
Remove blade bolt by turning
counterclockwise.
IMPORTANT INFORMATION
To ensure proper assembly, center hole in
blade must align with star on cutter
housing.
•
Install new or re-sharpened blade with
stamped “GRASS SIDE” facing towards
ground/grass (down) or “THIS SIDE UP”
facing deck and cutter housing.
•
Install and tighten blade bolt securely.
Torque blade bolt to 90 ft/lbs (122 Nm).
IMPORTANT INFORMATION
Special blade bolt is heat treated.
Replace with a Dixon bolt if required.
Do not use lower grade hardware than
specified.
English-46
8050-132
1. Blade
2. Center hole
3. Cutter housing
4. Blade bolt
5. Trash guard
Blade attachment
MAINTENANCE
Adjusting the Mower Deck
WARNING!
Before performing any service or adjustment checklist:
1. Engage the park brake.
2. Place the blade-switch in the disengaged position.
3. Turn ignition switch to “OFF” position and remove the key.
4. Make sure the blades and all moving parts have completely stopped.
5. Disconnect the spark plug wire from all spark plugs and place the wire where it
cannot come in contact with the plug.
Leveling
1.
Position the mower on a level, preferably
concrete, surface.
2.
Check the pressure in all four tires. See
“Technical Data” section.
3.
Rotate blades to align front to back.
4.
Set cutting height to 4".
5.
Measure front blade tip, should be 4"
from ground, if not turn locknut on top of
front eyebolt till measurement is
achieved. Check blade tip at front on
opposite front blade. Adjust locknut on
front eyebolt as necessary.
6.
Check rear blade measurement, should
be 4 1/4" from ground, if not turn locknut
on top of rear eyebolt to achieve
measurement. Repeat procedure on
opposite side.
7.
If deck leveling cannot be achieved call
Technical Support at toll free number
877-288-6673.
WARNING!
Blades are sharp. Protect your
hands with gloves and/or wrap
blades with a heavy cloth when
handling.
3
2
1
4
1. Front eyebolt
2. Front locknut
3. Rear locknut
4. Rear eyebolt
8011-601-1
Leveling the mower deck
Adjusting Cutting Height
1.
Raise and secure the deck height lever
to the transport position (6").
2.
Position blade tip so it is straight forward.
3.
Measure from the cutting edge of the
blades to a flat level surface. The
distance should be 6" (150 mm).
4.
Drop and secure the lever at (for
example) the 2" cutting height. Measure
as above. The distance should be 2"
(50 mm).
English-47
MAINTENANCE
To adjust anti-scalp rollers
Anti-scalp rollers are properly adjusted when
they are just slightly off of the ground when
the deck is at the desired cutting height in the
operating position. Anti-scalp 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.
CZ-9
Anti-scalp roller
The anti-scalp rollers can be set in three positions.
•
Upper position 1.5" to 3" (38 to 76 mm) grass.
•
Middle position 3" to 4.5" (76 to 114 mm)
grass.
•
Lower position 4.5" to 6" (114 to 152 mm)
grass.
The rollers should be approximately 1/4" (6.5 mm)
from ground.
IMPORTANT INFORMATION
The anti-scalp rollers must not be used for
gauge wheels or the roller and deck may
be damaged.
Engine oil cooler
Kohler engine only.
1.
Clean the outside of fins with a brush.
2.
Remove the two screws holding the
cooler unit to the blower housing.
3.
Tilt the cooler downward.
4.
Clean the inside of the cooler with a
brush or with compressed air.
5.
Reinstall the oil cooler to the blower
housing.
8011-472
Engine oil cooler
English-48
MAINTENANCE
Cleaning and Washing
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 deck, avoiding spraying
engine and electrical components with water.
8050-092
Cleaning
Use protective glasses when
cleaning and washing.
Caster Wheels
Check every 200 hours. Lift front of unit off of
ground so caster wheels can rotate freely.
Tighten caster bolt (34) then back off a half
turn. Check that wheel rotates freely. If wheel
does not rotate freely back the caster bolt off
in quarter turn increments until wheel rotates
freely.
1
2
IMPORTANT INFORMATION
DO NOT add any type of tire liner or foam
fill material to the tires. Excessive loads
created by foam filled tires will cause
premature failures.
3
8011-619
Caster wheels
Only use O.E.M. specified tires.
Foam filled tires or solid tires will void the warranty.
Removal and installation of caster wheel
1.
Remove nut (1) and caster bolt (2).
2.
Pull wheel out of fork and remove sleeve (3).
3.
Place sleeve in new wheel and rim assembly.
Install in reverse order. Tighten caster bolt
according to instructions above.
Hardware
Check daily. Inspect the entire machine for loose or
missing hardware.
English-49
LUBRICATION
Lubrication
Lubrication Schedule
KODIAK
8011-765
12/12 Every year
1/52 Every week
Lubricate with grease gun
Oil change
Lubricate with oil can
Level check
1/365 Every day
Filter change
General
Remove the ignition key to prevent unintentional movements during lubrication.
When lubricating with an oil can, it must be filled with engine oil.
When lubricating with grease, unless otherwise stated, use a high grade molybdenum disulfide 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.
English-50
LUBRICATION
Lubricating the Cables
If possible, grease both ends of the cables and move the controls to end stop positions when lubricating.
Refit the rubber covers on the cables after lubrication. Cables with sheaths will bind if they are not
lubricated regularly. If a cable binds, it can disrupt operation.
If a cable binds, remove the cable and hang it vertically. Lubricate it with light engine oil until the oil begins
to escape from the bottom.
Tip: Fill a small plastic bag with oil and tape it so that it seals against the sheath and allow the cable to hang
vertically from the bag overnight. If you do not succeed in lubricating the cable, it must be replaced.
Shaft Bushings and Linkage
Lubricate the bearings of the shafts and
linkage for the brake system and steering
with oil spray or oil can.
Lubricating in Accordance with the
Lubrication Schedule
8011-565
1. Hydraulic System, Oil Level
The hydraulic oil and filter should be replaced
every 300 hours, and at least once a year.
Contact an authorized service workshop.
Check the oil level in the hydraulic tank daily.
The level shall be about 3/4"-1"
(19 - 25 mm) below the top of the tank.
Check connections, hoses, and tubes for
damage or leaks. Replace or repair if
doubtful.
Changing Oil and Filters
Oil and filter changes should be carried out
by an authorized service workshop due to the
risk of impurities enter the system.
Checking the hydraulic oil
WARNING!
If a leak is suspected, use a
piece of cardboard or wood,
NOT your hands, to check for
leaks. 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.
2. Driver’s Seat
Tip the seat.
Lubricate the hinges at the front of the seat
using an oil can.
Lubricate the seat slide adjustment and lever
mechanism with the oil can.
8011-571
Lubricating the lengthways adjuster under the seat
English-51
LUBRICATION
3. Engine Oil Kohler Engine
Changing the Engine Oil
Change oil after every 100 hours of operation
(more frequently under severe conditions).
Refill with service class SG, SH, SJ or higher
oil as specified in the Viscosity Grades table
on page 54.
Change the oil while the engine is still warm.
The oil will flow more freely and carry away
more impurities. Make sure the engine is
level when filling, checking or changing the
oil.
WARNING!
The engine and the exhaust
system, become very hot
during operation. Risk for burns
if touched. Allow engine and
exhaust system to cool at least
two (2) minutes.
Change the oil as follows:
1.
To keep dirt, debris, etc., out of the
engine, clean the area around the oil fill
cap/dipstick before removing it.
2.
Remove the oil drain plug and the oil fill
cap/dipstick. Be sure to allow ample time
for complete drainage.
3.
Reinstall the drain plug. Make sure it is
tightened to 10 ft.lb. (13.6 Nm) torque.
4.
Fill the crankcase, with new oil of the
proper type, to the “FULL” mark on the
dipstick. Refer to Oil Type, page 54.
Always check the level with the dipstick
before adding more oil.
5.
Reinstall the oil fill cap/dipstick and
tighten securely.
IMPORTANT INFORMATION
To prevent extensive engine wear or
damage, always maintain the proper oil
level in the crankcase. Never operate the
engine with the oil level below the “ADD”
mark or over the “FULL” mark on the
dipstick.
6.
Start the engine. Run it for a few seconds
and recheck the oil level.
English-52
IMPORTANT INFORMATION
Used engine oil is a health hazard and
must not be disposed of on the ground or
in nature; it should always be disposed
of at a workshop or appropriate disposal
location.
Avoid skin contact; wash with soap and
water in case of spills.
LUBRICATION
Checking the Oil Level
The importance of checking and maintaining
the proper oil level in the crankcase cannot
be overemphasized.
Check oil before each use as follows:
1.
Make sure the engine is stopped, level,
and is cool so the oil has had time to
drain into the oil pan.
2.
To keep dirt, debris, etc., out of the
engine, clean the area around the
dipstick before removing it.
3.
Unthread and remove the dipstick; wipe
oil off. Reinsert the dipstick into the tube
and rest the cap on the tube. Do not
thread the cap onto the tube.
4.
Pull the dipstick out and check the oil
level. The oil level should be up to, but
not over, the “FULL” mark on the
dipstick.
8011-471
Oil dipstick
5.
If the level is low, add oil of the proper
type, up to the “FULL” mark on the
dipstick. Refer to Oil Type, page 54.
Always check the level with the dipstick
before adding more oil.
IMPORTANT INFORMATION
To prevent extensive engine wear or
damage, always maintain the proper oil
level in the crankcase. Never operate the
engine with the oil level below the “ADD”
mark or over the “FULL” mark on the
dipstick.
8009-464
Level marking
English-53
LUBRICATION
Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important. So is
checking oil daily and changing oil regularly.
Failure to use the correct oil, or using dirty oil,
causes premature engine wear and failure.
Oil Type
Use high quality detergent oil of API
(American Petroleum Institute) service class
SG, SH, SJ or higher. Select the viscosity
based on the air temperature at the time of
operation.
Recommended SAE viscosity grades
10W-30
**
*
5W-20, 5W-30
Kohler “Command”
IMPORTANT INFORMATION
Using other than service class SG, SH, SJ
or higher oil or extending oil change
intervals longer than recommended can
cause engine damage.
0
F -20
C -30
-20
20
-10
32 40
0
80
60
10
20
30
100
40
Temperature range expected before next oil change
* Use of synthetic oil having 5W-20 or 5W-30 rating is
acceptable, up to 40o F(+4o C).
** Synthetic oils will provide better starting in extreme
cold below -10o F (-23o C).
IMPORTANT INFORMATION
Synthetic oils meeting the listed
classifications may be used with oil
changes performed at the recommended
intervals. However to allow piston rings to
properly seat, a new or rebuilt engine
should be operated for at least 50 hours
using standard petroleum based oil before
switching to synthetic oil.
A logo or symbol on oil containers identifies
the API service class and SAE viscosity
grade.
English-54
8011-766
Viscosity grades table
LUBRICATION
3. Engine Oil
Changing the Engine Oil
The engine oil must be changed for the first
time after 8 hours of operation. Thereafter, it
should be changed every 100 hours.
IMPORTANT INFORMATION
WARNING!
The engine and the exhaust
system, become very hot
during operation. Risk for
burns if touched. Allow engine
and exhaust system to cool at
least two (2) minutes.
1.
Place the machine on a flat surface.
2.
Place a container under the engine oil
drain plug.
3.
Remove the dipstick and open the oil
drain plug.
4.
Allow the oil to run out into the container.
5.
Then close the oil drain plug.
6.
Replace the oil filter if necessary.
7.
Fill with new engine oil in accordance
with Checking the Oil Level.
8.
Start the engine. Run it for a few
seconds. Stop and recheck the oil level.
Used engine oil is a health hazard and
must not be disposed of on the ground or
in nature; it should always be disposed
of at a workshop or appropriate disposal
location.
Avoid skin contact; wash with soap and
water in case of spills.
8011-455
Oil drain plug
Checking the Oil Level
Check the oil level in the engine when the
machine is standing level and the engine is
stopped.
Remove the dipstick, wipe it clean, and then
replace it.
The dipstick should not be screwed into
place.
Take the dipstick out again and read the oil
level.
8011-569
Remove the dipstick
English-55
LUBRICATION
The oil level should lie between the markings
on the dipstick. If the level is approaching the
“ADD” mark, fill the oil to the “FULL” mark on
the dipstick.
Never fill above the “FULL” mark.
The oil is filled through the hole for the
dipstick.
8009-159
The dipstick markings
Use engine oil SAE 30 or SAE 10W-30 or,
alternately, 10W/40, class SC–SJ
(over +32 °F/0 °C).
Over +68 °F/+20 °C SAE 40 can be used.
Use engine oil SAE 5W-20, class SC–SJ
(under +32 °F/0 °C).
The engine holds 1.6 qt/1.5 liters of oil
excluding the filter (including filter 1.8 qt/1.7
liters).
8009-140
Engine oils
4. Throttle and Choke Cables, Lever
Bearings
Lubricate the cable ends by the carburetor
with a oil can. Move the controls to the end
points and lubricate again.
The throttle cable is also lubricated by the
control when the control console is removed.
On Kohler engine the cables are placed
under the air filter housing.
5. Front Wheel Mount
Lubricate with a grease gun, one zerk for
each wheel mount, until the grease is forced
out.
Use only good quality molybdenum disulfide
grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
English-56
LUBRICATION
6. Front Wheel Bearings
Lubricate with a grease gun, one zerk for
each set of wheel bearings, until the grease is
forced out.
Use only good quality molybdenum disulfide
grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
8011-573
Lubricating the front wheels
7. Deck belt pulleys
Lubricate with a grease gun two strokes.
8011-461
Deck belt pulleys
8. Mower Deck Height Adjuster
Lubricate using a grease gun, one zerk,
until the grease squeezes out.
Lubricate the lever latch run in the lever.
Use only good quality molybdenum disulfide
grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
8011-456-1
Lubricating the cutting height adjuster
English-57
LUBRICATION
9. Belt Adjuster, Mower Deck
Remove the foot plate (two screws) and
lubricate with a grease gun, one zerk, until
grease is forced out.
Use only good quality molybdenum disulfide
grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
IMPORTANT INFORMATION
8011-576
Use minimal lubrication and remove excess
lubricant so that it does not come into
contact with belts or belt pulley drive
surfaces.
The belt adjuster grease zerk
10. Steering Control Shafts
Tip the driver’s seat.
Lubricate with a grease gun, one zerk for
each steering control shaft, until the grease is
forced out.
Use only good quality molybdenum disulfide
grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
8011-578
Lubricating the steering control shafts
11. Mower Deck Struts
Lubricate with a grease gun, one zerk for
each strut, until the grease is forced out.
Use only good quality molybdenum disulfide
grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
8011-577-1
Lubricating struts
English-58
LUBRICATION
12. Brake Arms
Remove one rear wheel at a time (four
screws).
Lubricate with a grease gun, one zerk for
each brake arm, until the grease is forced
out.
Use only good quality molybdenum disulfide
grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
8011-579
Lubricating brake arms
IMPORTANT INFORMATION
Use minimal lubrication and remove excess
lubricant so that is does not come into
contact with the brake band.
13. Belt Adjuster, Hydraulic Pumps
Lubricate using a grease gun, one zerk, until
the grease squeezes out.
Use only good quality molybdenum disulfide
grease.
Grease from well-known brand names
(petrochemical companies, etc.) usually
maintains a good quality.
IMPORTANT INFORMATION
Use minimal lubrication and remove excess
lubricant so that is does not come into
contact with belts or belt pulley drive
surfaces.
8011-575
Lubricating the belt adjuster
English-59
LUBRICATION
14. Changing the Oil Filter
1.
Drain the engine oil in accordance with
the work description under the heading
Engine Oil/Change Engine Oil.
2.
Remove the oil filter. If necessary, use a
filter remover.
3.
Wipe new, clean engine oil onto the seal
for the new filter.
4.
Mount the filter by hand with + 3/4 turn.
5.
Run the engine warm, then check that
there are no leaks around the oil filter
seal.
6.
8057-734
Changing the oil filter Honda
Check the oil level in the engine, fill to
proper level if necessary. The oil filter
holds 0.2 qt (0.2 liters) of oil.
8057-745
Changing the oil filter Kohler
English-60
TROUBLE SHOOTING GUIDE
Trouble Shooting Guide
Problem
Cause
The engine will not start.
•
The blade switch is engaged.
•
The steering controls are not locked in the
neutral position.
•
The driver is not sitting in the driver’s seat.
•
The park brake is not activated.
•
The battery is dead.
•
Contamination in the carburetor or fuel line.
•
The fuel supply is closed or the tap
for the fuel tanks is in the wrong position.
•
Clogged fuel filter or fuel line.
•
Dead battery.
•
Poor contacts on the battery terminal
cable connections.
•
Fuse blown.
•
Ignition system faulty.
•
Fault in the starter safety circuit.
See Checking the Safety System in the
Maintenance section.
•
Faulty carburetor.
•
The choke control is pulled out with a warm
engine.
•
Defective valves.
•
Defective piston, cylinder, piston ring, or
cylinder head seal.
•
The cylinder head bolts are loose.
•
Clogged fuel filter or jet.
•
Clogged ventilation valve on the fuel cap.
•
Fuel tank nearly empty.
•
Defective spark plugs.
•
The spark plugs are loose.
•
Defective ignition cable.
•
Defective spark plug electrode.
•
Defective spark plug connection.
•
Rich fuel mixture or fuel-air mixture.
•
Wrong fuel type.
•
Water in the fuel.
•
Clogged air filter.
The starter does not turn the engine over.
The engine runs rough.
English-61
TROUBLE SHOOTING GUIDE
Problem
Cause
The engine seems weak.
•
Clogged air filter.
•
Defective spark plugs.
•
Carburetor incorrectly adjusted.
•
Clogged air intake or cooling fins.
•
Engine overloaded.
•
Poor ventilation around engine.
•
Defective engine speed regulator.
•
Soot in the combustion chamber.
•
Too little or no oil in the engine.
•
Defective spark plugs.
•
Pre-ignition incorrect.
Battery not charging.
•
Poor contact with battery terminal cable
connectors.
The machine moves slowly, unevenly,
or not at all.
•
Park brake on.
•
Bypass valve on pump open.
•
Drive belt for the pump slack or has come off.
•
Defective hydraulic system.
•
Air in the 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.
•
Different air pressure in the tires on the left and
light sides.
•
Bent blades.
•
The chains for suspending the mower deck are
uneven.
•
The chain fixture has come loose.
•
The blades are blunt.
•
Driving speed too high.
•
The grass is too long.
•
Grass collected under the mower deck.
•
The blades are loose.
•
The blades are incorrectly balanced.
•
The engine is loose.
The engine overheats.
Mower deck not engaging.
Uneven mowing results.
The machine vibrates.
English-62
STORAGE
Storage
To ready the machine for storage, follow these
steps:
Winter Storage
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 used oil
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 plugs and pour about a
tablespoon of engine oil into each cylinder.
Turn over the engine so that the oil is evenly
distributed and then refit the spark plugs.
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.
At the end of the mowing season (or if it will not be
in use for longer than 30 days), the machine
should be readied for storage. 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 sticky residues 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 it reaches the carburetor.
Do not empty the fuel tank and the carburetor if
you have added stabilizer.
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 careless
use can cause serious personal
injury and property damage.
Drain the fuel into an approved
container outdoors and far
away from open flame. Never
use gasoline for cleaning. Use
a degreaser and warm water
instead.
Service
When ordering spare parts, please specify the
purchase year, model, type, and serial number.
Always use genuine Dixon spare parts.
An annual checkup at an authorized service
workshop is a good way to ensure that your
machine performs its best the following season.
English-63
WIRING DIAGRAMS
Wiring diagram
6. Seat unoccupied
11. Brake switch OFF pos.
8. Blade switch in OFF position
14-15. Motion control levers OUT
1. Battery
2. Accessory outlet
3. Key switch
4. To engine pigtail
5. Hour meter
6. Seat switch
7. Run relay
8. PTO switch
9. Brake relay
10. Electric clutch
11. Brake switch
12. Start relay
13. Starter solenoid
14. Left motion control lever
15. Right motion control lever
BLK = Black
BLU = Blue
BRN = Brown
GRN = Green
GRY = Grey
LT.BLU = Light Blue
ORG = Orange
PUR = Purple
RED = Red
WHT = White
YEL = Yellow
NO = Normally Open
NC = Normally Closed
COM = Common
8011-650
English-64
TECHNICAL DATA
968999635
968999636
Engine
Manufacturer
Honda
Kohler
Type
GXV620
CV730
Power
20 hp / 14.9kW
25 hp / 18.4kW
Lubrication
Pressure with oil filter
Pressure with oil filter
Oil capacity excl filter
1.9 qts.(1.8 liters)
1.6 qts (1.7 liters)
Oil capacity incl filter
2.2 qts. (2.1 liters)
1.9 qts (1.8 liters)
Engine oil
(See viscosity diagram)
SAE 10W30, 5W30, SAE 30,
API SF, SG
SAE 10W30, 5W40, 5W30
API SG, SH, SJ
Fuel
Min 86 octane unleaded (Max ethanol
10%, Max MTBE 15%)
Min 87 octane unleaded (Max ethanol
10%, Max MTBE 15%)
Fuel tank capacity
11.4 gallons / 43 liters
11.4 gallons / 43 liters
Spark plugs / gap
NGK BPR5ES
.030" / 0.75 mm
Champion Platinum 3071
.030" / 0.75 mm
Cooling
Air-cooled
Air-cooled
Air filter
Standard
Heavy duty canister
Alternator
12 V 15 A
12 V 15 A
Starter
Electric
Electric
Transmission
Dual pumps, Wheel drive motors
Dual pumps, Wheel drive motors
Speed and direction controls
Dual levers, foam gripped
Dual levers, foam gripped
Speed forward
0-9.5 mph / 15.3 km/h
0-9.5 mph / 15.3 km/h
Speed reverse
0-5 mph / 0-8 km/h
0-5 mph / 0-8 km/h
Brakes
Hydrostatic/brake linings
Hydrostatic/brake linings
Front caster tires, Smooth tread
13 x 5-6, 4 ply
13 x 5-6, 4 ply
Rear tires, Turf pneumatic
23 x 9.50-12
23 x 10.50-12
Tire pressure, front and rear
15 PSI / 103 kPa / 1 bar
15 PSI / 103 kPa / 1 bar
Hydraulic reservoir + system
3 qt / 2.8 liter
3 qt / 2.8 liter
Hydraulic oil
Full synthetic 15W-50
Full synthetic 15W-50
Transmission
English-65
TECHNICAL DATA
968999635
968999636
Equipment
Cutting width
52" / 132 cm
60" / 152 cm
Cutting height
1.5" to 5" (38-127 mm)
1.5" to 5" (38-127 mm)
Uncut circle
0" / 0 cm
0" / 0 cm
Number of blades
3
3
Blade length
52" (132 cm)
60" (152 cm)
Anti-scalp rollers
Yes
Yes
Frame construction
Steel uni-frame
Steel uni-frame
Ball bearing wheels
Yes
Yes
Seat
High-density closed cell foam padded
back and arm rests water-repellent
fabric. Operator suspension system.
High-density closed cell foam padded
back and arm rests water-repellent
fabric. Operator suspension system.
Hinged armrests
Yes
Yes
Hour meter
Digital with service intervals
Digital with service intervals
Blade engagement
200 ft/lb Warner
Mag-stop Electromagnetic clutch
200 ft/lb Warner
Mag-stop Electromagnetic clutch
3.8 acres/h/15405 m2/h
3.8 acres/h/15405 m2/h
Weight
960 lbs (435 kg)
990 lbs (449 kg)
Machine length
79" (201 cm)
81" (206 cm)
Machine width
48
52
Machine height (ROPS up)
70.5" (179 cm)
70.5" (179 cm)
Machine height (ROPS down)
57" (145 cm)
57" (145 cm)
Hand/Arm - A(8)
2.44 m/s2
2.20 m/s2
Whole Body - A(8)
0.23 m/s2
0.14 m/s2
Hand/Arm - ahv,eq
2.82 m/s2
2.54 m/s2
Whole Body - ahv,eq
0.27 m/s2
0.16 m/s2
Productivity
Productivity
Overall Base Dimensions
Vibration
Daily Exposure
Equivalent Vibration
English-66
TECHNICAL DATA
Accessories
BioClip attachment (Mulch kit)
Front baffle kit
Roll Over Protection System. ROPS with seat belt. Accessory only for EC models. Standard on US models.
Collection system
Torque Specifications
•
Engine crankshaft bolt
50 ft/lb (67 Nm)
•
Deck pulley bolts
45 ft/lb (61 Nm)
•
Hydraulic tube nuts
30 ft/lb (41 Nm)
•
Wheel motor hub nut
90 ft/lb (122 Nm)
•
Lug nuts
75 ft/lb (100 Nm)
•
Blade bolt
90 ft/lb (122 Nm)
•
Standard ¼" fasteners
9 ft/lb (12 Nm)
•
Standard
5/16"
fasteners
3
18 ft/lb (25 Nm)
•
Standard /8" fasteners
33 ft/lb (44 Nm)
•
Standard 7/16" fasteners
52 ft/lb (70 Nm)
•
Standard ½" fasteners
80 ft/lb (110 Nm)
When this product is worn out and no longer used, it shall be returned to the reseller or other party for
recycling.
In order 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 operation or damage the unit.
English-67
CONFORMITY CERTIFICATESE
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, (Californian 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.
USA requirements
Vibration Data corresponding to Directive 2002/44/EC is given in the Technical Data section.
The Declaration of Conformity is included in the literature packet.
English-68
SERVICE JOURNAL
Service Journal
Action
Date, mtr reading, stamp, sign
Delivery Service
1. Charge the battery.
2. Mount the rear wheels.
3. Adjust the tire pressure of all wheels to 15 PSI (1 bar).
4. Mount the steering controls in the normal position.
5. Connect the seat fold-up stop.
6. Connect the cable to the safety switch under the seat.
7. Mount the arm rests on the seat’s back support.
8. Check that the right amount of oil is in the engine.
9. Check that the right amount of oil is in the hydraulic tank.
10. Adjust the position of the steering controls.
11. Fill with fuel and open the fuel valve.
12. Check that the machine has no transport damage.
13. Start the engine.
14. Check that there is drive to both wheels.
15. Bleed the hydraulic system if necessary.
16. Check the mower deck adjustment.
17. Check:
The safety switch for the park brake.
The safety switch for the mower deck.
The safety switch in the seat.
The safety switch in the steering controls.
Park brake functionality.
Driving forward.
Driving backward.
Engaging the blades.
18. Check the idle speed.
19. Check the engine high idle speed.
English-69
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
20. Inform the customer about:
Delivery service has been carried
out.
The need and advantages of following the service schedule.
The need and advantages of leaving the machine
for service every 300 hours.
The effects of service and maintaining a service journal on
the machine’s resale value.
Application areas for BioClip.
21. Fill in the sales papers, etc.
After the First 8 Hours
1. Change engine oil.
English-70
No remaining notes.
Certified:
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
25-Hour Service
1. Check the fuel pump’s air filter.
2. Check the hydraulic system’s oil level.
3. Check the tire pressures.
4. Lubricate the belt adjuster, mower deck.
5. Lubricate the belt adjuster, hydraulic pumps.
6. Check/clean the engine’s cooling air intake.
7. Clean air filter dust cap.
English-71
SERVICE JOURNAL
Action
50-Hour Service
1. Perform the 25-hour service.
2. Lubricate the front wheel bearings.
3. Lubricate the steering control shafts.
4. Lubricate the mower deck struts.
5. Lubricate the cutting height adjuster.
6. Check/adjust the park brake.
English-72
Date, mtr reading, stamp, sign
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
100-Hour Service
1.
Perform the 25-hour service.
2.
Perform the 50-hour service.
3.
Change engine oil.
4.
Check whether the hydraulic oil needs changing
(every 300 hours).
5.
Check whether the engine oil filter needs changing
(every 200 hours).
6.
Clean/replace the spark plugs.
7.
Replace the fuel filter.
8.
Clean the cooling fins on the engine and transmission.
9.
Check V-belts.
10. Check tighten caster wheel axle bolts (every 200 hours).
11. Clean and check the need to change the air filter’s
paper cartridge (every 200 hours).
12. Clean fins of oil cooler (Kohler).
13. Replace main air filter cartridge (200h).
English-73
SERVICE JOURNAL
Action
300-Hour Service
1.
Inspect the machine. Come to agreement with the customer
as to which additional work is to be carried out.
2.
Perform the 25-hour service.
3.
Perform the 50-hour service.
4.
Perform the 100-hour service.
5.
Change the oil and filter in the hydraulic system.
6.
Clean the combustion chamber and grind the valve seats.
7.
Check the play in the engine valves.
8.
Dismantle and inspect starter (500 h).
English-74
Date, mtr reading, stamp, sign
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
At Least Once
Each Year
1.
Clean the engine’s cooling air intake (25 hours).
2.
Replace the air cleaner’s pre-filter (Oil-foam) (300 hours).
3.
Replace the air filter’s main cartridge (200 hours).
4.
Change the engine oil (100 hours).
5.
Replace the engine oil filter (200 hours).
6.
Change the oil and filter in the hydraulic system (300 hours).
7.
Check/adjust the cutting height.
8.
Check/adjust the park brake (50 hours).
9.
Clean/Change the spark plugs (100 hours).
10. Change the fuel filter (100 hours).
11. Clean the cooling fins (100 hours).
12. Check the play in the engine valves (300 hours).
13. Perform the 300-hour service at an authorized service
workshop.
14. Clean fins of oil cooler (Kohler).
English-75
SERVICE JOURNAL
Action
English-76
Date, mtr reading, stamp, sign
539 130504
01/07