Dixon XS5025 User's Manual

Operator’s Manual
Ram Xs5025 / 968999722
Ram Xs6025 / 968999723
Ram Xs7227 / 968999724
Ram Xs5025BF / 968999725
Ram Xs6025BF / 968999726
Please read the operator’s manual carefully and make sure you
understand the instructions before using the machine.
English
©2007 HTC. All rights reserved.
Beatrice, NE. Printed in U.S.A.
CONTENTS
INTRODUCTION............................................................... 5
General ....................................................................... 5
Driving and Transport on Public Roads ...................... 5
Towing......................................................................... 5
Operating .................................................................... 5
Good Service .............................................................. 6
SYMBOLS AND DECALS ................................................. 7
SAFETY ............................................................................ 9
Safety Instructions ...................................................... 9
General Operation ...................................................... 9
Personal Safety Equipment ...................................... 11
Slope Operation ........................................................ 11
Safe Handling of Gasoline ........................................ 13
General Maintenance ............................................... 14
Transport .................................................................. 16
Roll over Protection system (ROPS) ........................ 17
CONTROLS .................................................................... 18
Control Locations ...................................................... 18
Steering Control Levers ............................................ 19
Parking Brake ........................................................... 20
Throttle Control ......................................................... 20
Blade Switch ............................................................. 20
Ignition Switch........................................................... 21
Choke Control ........................................................... 21
Fuses ........................................................................ 21
Fuel Tank .................................................................. 22
Fuel Shut Off Valve ................................................... 23
Cutting Height Adjuster ............................................. 23
Hour Meter ................................................................ 24
OPERATION ................................................................... 25
Training ..................................................................... 25
Steering .................................................................... 25
To move forward and backward ...................... 25
To turn to the right ........................................... 25
To turn to the left ............................................. 25
To zero turn ..................................................... 25
Before Starting .......................................................... 26
Starting the Engine ................................................... 26
Starting the engine with a weak battery .................... 28
To attach jumper cables .................................. 28
Running .................................................................... 29
Operating on hills ...................................................... 30
Mowing Tips ............................................................. 31
Stopping the Engine ................................................. 32
Moving by Hand ........................................................ 33
Pump release valves ...................................... 33
MAINTENANCE .............................................................. 34
Maintenance Schedule ............................................. 34
Battery ...................................................................... 36
Ignition System ......................................................... 37
Safety System........................................................... 37
Engine Cooling Air Intake ......................................... 38
Throttle Cable ........................................................... 38
Choke Cable ............................................................ 38
Air Filter Maintenance ............................................... 39
Replacing Air Filter.......................................... 39
Fuel Filter .................................................................. 40
Tire Pressures .......................................................... 41
Parking Brake ........................................................... 41
V-belts ....................................................................... 41
Deck belt ................................................................... 42
Pump belt.................................................................. 43
Cutting Blades .......................................................... 43
Blade replacement .......................................... 44
Adjusting the Mower Deck ........................................ 45
Leveling deck .................................................. 45
Anti-scalp rollers ............................................. 46
Cleaning and Washing .............................................. 47
Caster Wheels .......................................................... 47
Hardware .................................................................. 47
LUBRICATION ................................................................ 48
Lubricating the Cables .............................................. 49
Front Wheel Mount ................................................... 49
Front Wheel Bearings ............................................... 49
Deck spindle ............................................................. 49
Deck outer spindle .................................................... 50
Engine Oil ................................................................. 50
Engine Oil Filter .............................................. 50
Changing the Engine Oil ................................. 51
Engine Oil Levels ............................................ 51
Hydraulic Pump ....................................................... 52
Fluid Change .................................................. 52
Purging Procedures ........................................ 52
TROUBLESHOOTING .................................................... 53
STORAGE....................................................................... 55
Storage ..................................................................... 55
Winter Storage ................................................ 55
Service ...................................................................... 55
SCHEMATICS ................................................................. 56
TECHNICAL DATA .......................................................... 57
Accessories .............................................................. 61
Torque Specifications................................................ 61
CONFORMITY CERTIFICATES ..................................... 62
Conformity Certificates ............................................. 62
SERVICE JOURNAL....................................................... 63
After the First 5-8 Hours ........................................... 64
25-Hour Service ........................................................ 65
50-Hour Service ........................................................ 66
100-Hour Service ...................................................... 67
300-Hour Service ...................................................... 68
At Least Once Each Year.......................................... 69
English-3
WARNING!
Failure to follow cautious operating practices can result in serious injury to the
operator or other persons. The owner must understand these instructions, and must
allow only trained persons who understand these instructions to operate the mower.
Each person operating the mower must be of sound mind and body and must not be
under the influence of any mind altering substance.
WARNING!
Engine exhaust, some of its constituents, and certain vehicle components contain
or emit chemicals known to the State of California to cause cancer and birth defects
or other reproductive harm.
WARNING!
Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
English-4
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) 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 with this mower. They may jackknife or overturn causing damage to the mower and
possible serious injury to the operator.
Operating
This machine is constructed only for mowing grass on lawns 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 for the accessories are provided with delivery. All other types of uses
are incorrect. The manufacturer’s directions concerning operation, maintenance, and repairs must be carefully
followed.
Lawn mowers and all power equipment, can be potentially dangerous if used improperly. Safety requires good
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.
Unauthorized modifications to the design of the machine may absolve the manufacturer from liability for any
resulting personal injury or property damage.
English-5
INTRODUCTION
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
the 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 have the type designation and serial number available when ordering spare parts.
The engine’s manufacturing number is stamped on one of the valve covers.
The plate states:
• The engine’s model.
• The engine’s type.
• Code
Please have these available when ordering spare parts.
The wheel motors and hydrostatic pumps have a barcode decal affixed at the rear.
English-6
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!
Xxxx xxxxxx xxxxx xxxx
xxxxxxxxx xxxxxx xxxxxxxxx.
xx xxxxxxxx xxxx xxxxxx.
Used in this publication to notify the reader of a risk of personal injury or death, particularly if the reader should
neglect to follow instructions given in the manual.
IMPORTANT INFORMATION
Xxxx xxxxxx xxxxx xxxx xxxxxxxxx
xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx
xxxxxx.
Used in this publication to notify the reader of a risk of material damage, particularly if the reader should neglect
to follow instructions given in the manual. Used also when there is a potential for misuse or misassembly.
R N
Reverse
Neutral
Fast
Slow
Choke
Fuel
P
Warning!
Parking Brake
CE conformity
marking. Only for
European market
Battery acid is corrosive, explosive and flammable
Use protective glasses
Warning! Rotating blades,
keep away from the
discharge deck
Do not touch parts
Do not stand here
Use protective gloves
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
English-7
SYMBOLS AND DECALS
Read
Operator’s
Manual
Shut off engine and
remove key before
performing any
maintenance or repair work
Keep a safe
distance from
the machine
Use on slopes
no greater
than 10°
No passengers
Whole body
exposure to
thrown objects
Severing of fingers
and toes
Do not open or
remove safety
shields while
engine is running
Careful backing up,
watch for other
people
Careful going
forward, watch for
other people
Moving sharp blades under cover
English-8
SAFETY
Safety Instructions
These instructions are for your safety. Read them carefully.
WARNING!
This symbol means that important safety instructions need to be emphasized.
It concerns your safety.
IMPORTANT: THIS CUTTING MACHINE IS CAPABLE OF AMPUTATING HANDS AND FEET AND THROWING
OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN
SERIOUS INJURY OR DEATH.
General Operation
•
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•
•
•
•
•
•
•
•
•
Read, understand, and follow all instructions
on the machine and in the manual before
starting.
Do not put hands or feet near rotating parts
or under the machine. Keep clear of the
discharge opening at all times.
Only allow responsible adults, who are
familiar with the instructions, to operate the
machine.
Clear the area of objects such as rocks, toys,
wire, etc., which could be picked up and
thrown by the blades.
Be sure the area is clear of bystanders
before operating. Stop machine if anyone
enters the area.
Never carry passengers. The machine is only
intended for use by one person.
Do not mow in reverse unless absolutely
necessary. Always look down and behind
before and while backing.
Never direct discharged material toward
anyone. Avoid discharging material against
a wall or obstruction. Material may ricochet
back toward the operator. Stop the blades
when crossing gravel surfaces.
Do not operate machine without the entire
grass catcher, discharge guard, or other
safety devices in place and working
Slow down before turning.
Never leave a running machine unattended.
Always turn off blades, set parking brake,
stop engine, and remove keys before
dismounting.
Disengage blades when not mowing. Shut
off engine and wait for all parts to come to a
complete stop before cleaning the machine,
removing the grass catcher, or unclogging
the discharge guard.
8011-512
Read the operator’s manual before starting the machine
8011-513
Clear the area of objects before mowing
English-9
SAFETY
•
•
•
•
•
•
•
•
•
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 buildup which can touch hot exhaust
/ engine part and burn. Do not allow the
mower deck to plow leaves or other debris
which can cause buildup to occur. Clean any
oil or fuel spillage before operating or storing
the machine. Allow machine to cool before
storage.
English-10
8011-520
Never take passengers
WARNING!
Engine exhaust and certain
vehicle components contain
or emit chemicals considered
to cause cancer, birth defects,
or other reproductive system
damage. The engine exhaust
contains carbon monoxide,
which is a odorless, colorless,
poisonous gas. Do not use the
machine in enclosed spaces.
SAFETY
Personal Safety Equipment
WARNING!
When using the machine, approved personal protective equipment (shown in
illustrations) shall be used. Personal protective equipment cannot eliminate the
risk of injury but it will reduce the degree of injury if an accident does happen.
Ask your retailer for help in choosing the right equipment.
•
•
•
•
•
•
•
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 toe caps.
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.
8011-670a
Slope Operation
Slopes are a major factor related to loss of control and
tip-over accidents, which can result in severe injury or
death. Operation on all slopes requires extra caution. If
you cannot back up the slope or if you feel uneasy on
it, do not mow it.
• Mow up and down slopes (10 degrees
maximum), not across.
• Watch for holes, ruts, bumps, rocks, or
other hidden objects. Uneven terrain could
overturn the machine. Tall grass can hide
obstacles.
• Choose a low ground speed so that you will
not have to stop while on the slope.
• Do not mow on wet grass. Tires may lose
traction.
• Avoid starting, stopping, or turning on a
slope. If the tires lose traction, disengage the
blades and proceed slowly straight down the
slope.
• Keep 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.
• Use extra care while operating machine with
grass catchers or other attachments; they
can affect the stability of the machine.
Personal protective equipment
6003-004
Mow up and down, not side to side
WARNING!
Do not drive up or down hills
with slopes greater than 10
degrees. And do not drive across
any slopes.
English-11
SAFETY
•
•
•
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
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.
8011-509
Be extra cautious when driving on slopes
8011-517
Never allow children to operate the machine
8011-518
Keep children away from work area
English-12
SAFETY
WARNING!
The engine must not be started when the driver’s floor plate or any protective
plate for the mower deck’s drive belt is removed.
Safe Handling of Gasoline
To avoid personal injury or property damage, use
extreme care in handling gasoline. Gasoline is
extremely flammable and the vapors are explosive.
• Extinguish all cigarettes, cigars, pipes, and
other sources of ignition.
• Use only approved gasoline container.
• Never remove gas cap or add fuel with the
engine running. Allow engine to cool 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
appliance.
• 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
the vehicle when filling.
• Remove gas-powered equipment from the
truck or trailer and refuel it on the ground. If
this is not possible, refuel such equipment
with a portable container, rather than from a
gasoline dispenser nozzle.
• Keep the nozzle in contact with the rim of the
fuel tank or container opening at all times
until fueling is complete. Do not use a nozzle
lock-open device.
• If fuel is spilled on clothing, change clothing
immediately.
• Never overfill fuel tank. Replace gas cap and
tighten securely.
• Do not start the engine near spilled fuel.
• Never use gasoline as a cleaning agent.
• If leaks arise in fuel system, engine must not
be started until problem has been resolved.
• Check the fuel level before each use and
leave space for the fuel to expand, as the
heat from the engine and the sun may
otherwise cause the fuel to expand and
overflow.
8011-516
Never fill the fuel tank indoors
WARNING!
The engine and the exhaust
system become very hot during
operation.
There is risk for burns if
touched.
Allow engine and exhaust
system to cool at least two (2)
minutes before refueling.
English-13
SAFETY
General Maintenance
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•
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•
•
•
•
•
•
•
•
•
•
Never operate machine in a closed area.
Keep all nuts and bolts tight to be sure the
equipment is in safe working condition.
Never tamper with safety devices. Check
their proper operation regularly.
Keep machine free of grass, leaves, or other
debris buildup. Clean oil or fuel spillage
and remove any fuel-soaked debris. Allow
machine to cool before storing.
If 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.
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.
English-14
8011-515
Never drive the machine in an enclosed space
Use protective glasses for
maintenance work.
WARNING!
The battery contains lead and
lead compounds, chemicals
that are considered to cause
cancer, birth defects, and other
reproductive system damage.
Wash your hands after handling
the battery.
SAFETY
•
•
•
•
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 are
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.
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.
8009-728
Risk of sparking
English-15
SAFETY
•
•
•
•
•
The blades are sharp and can cause
cuts and gashes. Wrap the blades or use
protective gloves when handling them.
Check the parking brake’s functionality
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.
8011-514
Transport
•
•
•
•
•
•
•
The machine is heavy and can cause serious
crushing injuries. Be extra cautious when it
is loaded on or unloaded from a vehicle or
trailer.
Use an approved trailer to transport the
machine. Activate the parking brake, turn off
the fuel supply, and fasten the machine with
approved fastening devices, such as bands,
chains, or straps, when transporting.
Do not operate this machine on public
roadways.
Check and abide by local traffic regulations
before transporting the machine on any road.
Do not tow this machine, it may cause
damage to the drive system.
Do not tow with this mower. They may
jackknife or overturn causing damage to the
mower and possibly serious injury to the
operator.
Load the unit onto truck or trailer by driving
up ramps of suitable strength using a slow
speed. Do not lift! The machine is not
intended to be lifted by hand.
English-16
Regularly clean deck
WARNING!
Escaping hydraulic oil under
pressure can have sufficient
force to penetrate the skin,
causing serious injury. If injured
by escaping fluid, see a doctor
at once. Serious infection or
reaction can develop if proper
medical treatment is not
administered immediately.
IMPORTANT INFORMATION
The parking brake is not sufficient
to lock the machine in place during
transport. Ensure that the machine is
well fastened to the transport vehicle.
Always reverse the machine onto the
transport vehicle to avoid tipping it over.
SAFETY
Roll over Protection system (ROPS)
The ROPS increases the basic weight of the unit by 42
lbs/19 kg. The ROPS is an accessory.
• Do not use ROPS as a lifting, attaching or
anchoring point.
• Do not use ROPS for wrecking or towing.
• Do not exceed Max GVW: 2822 lbs/1283 kg.
• Read machine operator´s manual before
each use.
• Securely fasten 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.
WARNING!
The rollover protection
system's capabilities may
be impaired by damage if
the mower is overturned
or if alteration to the ROPS
occurs. If these conditions
take place, the total structure
MUST be replaced.
WARNING!
This mower is equipped
with an internal combustion
engine and should not
be used on or near any
unimproved forested, bush
covered or grassy lands
unless the engine's system
is equipped with a spark
arrester meeting applicable
local or state laws (if any).
If a spark arrester is used,
it should be maintained in
effective working order by
the operator.
English-17
CONTROLS
This operator’s manual describes the Dixon Zero
Turn Rider. The rider is fitted with a Kohler fourstroke overhead valve engine developing 25-27 horse
power*.
Transmission from the engine is made via a belt-driven
hydraulic pumps. Using the left and right steering
controls, the flow is regulated and thereby the direction
and speed.
Control Locations
9
8
7
2
1
10
OFF
CHOKE
ON
THROTTLE
11
BLADES
6
12
3
1.
2.
3.
4.
5.
6.
5
Motion control levers
Parking brake
Throttle control
Blade switch
Ignition switch
Choke control
*As rated by the engine manufacturer.
English-18
4
7.
8.
9.
10.
11.
12.
Fuses
Fuel tank cap
Fuel shut off valve
Deck lift
Seat adjustment lever
Hour meter
CONTROLS
1. Steering 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.
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.
Zero turn can be achieved by moving one control
backward (behind the neutral position) and carefully
moving the other steering control forward from its
neutral position. The rotation direction when zero
turning is determined by which steering control is
moved backward behind the neutral position. If the left
steering control is pulled backward, the machine turns
to the left. Use extra care when using this maneuver.
If the steering controls are in uneven positions when
standing still or do not fit in the slots for moving the
controls outward, they can be adjusted.
8011-789
Steering controls
WARNING!
The machine can turn very
rapidly if one steering control
is moved much further forward
than the other.
1
2
3
4
8011-7912
1. Forward
2. Neutral
3. Neutral slot, Neutral lock
4. Reverse
Motion control lever, right side
English-19
CONTROLS
2. Parking Brake
IMPORTANT INFORMATION
The machine must stand absolutely still
when applying the parking brake. Always
set the parking brake before dismounting.
Release the parking brake before moving
the mower.
The parking brake is found on the left of the machine.
Pull the lever backward to activate the brake and
forward to release it.
8061-019
Parking brake not activated
3. 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 forward or back respectively.
Avoid idling the engine for long periods, as there is a
risk of fouling the spark plugs.
USE FULL THROTTLE WHEN MOWING, for best
mower performance and battery charging.
BLADES
THROTTLE
ON
CHOKE
OFF
8061-017
Throttle control
4. Blade Switch
In order to engage the mower deck, pull the knob out;
the mower blades are disengaged when the knob is
depressed.
BLADES
THROTTLE
ON
CHOKE
OFF
8061-017
Blade switch
English-20
CONTROLS
5. Ignition Switch
The ignition key is placed on the control panel and is
used to start and stop the engine.
BLADES
THROTTLE
ON
CHOKE
OFF
8061-017
Ignition switch
6. 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 pushed to the ON
position.
BLADES
THROTTLE
ON
CHOKE
OFF
8061-017
Choke control
7. Fuses
Fuses are located on the left hand side of the machine.
They are accessed by tilting the seat forward. They are
flat pin fuses of the same type used in automobiles.
There are two fuses with ratings and functions:
• 20 A, Primary fuse.
• 7.5 A, Mower deck coupling.
8011-420
Fuses
English-21
CONTROLS
8. Fuel Tank
Read the safety instructions before refueling. The
machine has one fuel tank, just behind the seat. The
tank capacity is 5.7 gallons (22 liters).
Make sure the fuel cap is properly tightened and the
cap gasket is not damaged.
The engine will run on a minimum of 85-octane
unleaded gasoline (no oil mix). Environmentally
adapted alkylate gasoline can be used. See also
Technical Data concerning ethanol fuel. Methanol fuel
is not allowed. Do not use E85 alcohol based fuel.
Damage to engine and components may occur.
WARNING!
8011-625
Fuel tank
Gasoline is highly flammable.
Observe caution and fill the
tank outdoors (see the safety
instruction).
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 before refueling
WARNING!
Fill to bottom of filler neck. Do
not overfill. Wipe off any spilled
oil or fuel. Do not store, spill
or use gasoline near an open
flame.
When operating in temperatures below 32° F. (0° C.),
use fresh, clean winter grade gasoline to help insure
good cold weather starting.
English-22
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 left rear of the
seat. The valve is off when the handle tab is turned
perpendicular to the fuel line.
8011-419
Fuel shut off valve in the CLOSED position
10. Cutting Height Adjuster
The deck cutting height is obtained by pressing the
foot pedal forward to lift the deck. To lower the deck,
apply pressure to the top side of the foot pedal and
allow it to pivot while the lift arm rotates to the rear of
the unit. To stop in the desired cutting position, rotate
the foot pedal down into the notch in the height plate.
The cutting height range is from 1½" (38mm) to 4½"
(114mm) in ¼ (6mm) increments. The heights are
measured from the ground up to the blade tip with the
engine not running.
The mower deck’s lifting lever
8050-117
IMPORTANT INFORMATION
In order to obtain an even cutting height,
it is important that the air pressure in the
front tires is 15 psi and the rear tires is 10
psi.
IMPORTANT INFORMATION
Always use the high position to transport.
English-23
CONTROLS
11. 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
12. Hour Meter
The hour meter displays the total operating time.
It will flash CHG OIL (Change Oil) at 50 hour intervals.
The flash duration is one hour before and one hour
after the interval. The CHG OIL icon will come on
and shut off automatically. The hour meter cannot be
manually reset.
BLADES
THROTTLE
ON
CHOKE
OFF
8011-441
Hour meter
English-24
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 suggest that this section be reviewed in its entirety
prior to attempting to move the mower under its own
power. Additionally, we suggest when first operating
the 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 Zero Turn mowers to become familiar with
the mower’s 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 overly aggressive maneuvers.
IMPORTANT INFORMATION
When control levers are in the reverse
position they return to neutral when
released. This may cause the mower to
suddenly stop.
Steering
To move forward and backward
The direction and speed of the mower’s movements
is effected by the movement of the control lever(s)
on each side of mower. The left control lever controls
the left wheel. The right control lever controls the right
wheel.
First time users should push mower (see “Moving by
Hand” in the Operation section) to an open, flat area,
without other people or vehicles/obstacles nearby. 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 parking 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-25
OPERATION
Before Starting
•
Read the sections Safety Instructions and
Controls before starting the machine.
• Perform the daily maintenance before
starting (see Maintenance Schedule in the
Maintenance section).
• Check that there is sufficient fuel in the fuel
tank.
• Adjust the seat to the desired position.
The following conditions must be fulfilled before the
engine can be started:
• The driver must be seated on the seat.
• The blade switch for engaging the mower
blades must be depressed.
• The parking brake must be on.
• Both steering controls must be in the locked
(outer) neutral position.
8050-117
The mower deck’s lifting lever
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 parking brake.
8061-019
Parking brake not activated
Disengage the mower blades by pressing the blade
switch downwards.
BLADES
THROTTLE
ON
CHOKE
OFF
8011-441
Hour meter
English-26
OPERATION
Move the steering controls outward to the locked
(outer) neutral position.
8061-012
Place controls in neutral position
Move the throttle to the middle position.
WARNING!
Engine exhaust and certain
vehicle components contain
or emit chemicals considered
to cause cancer, birth defects
or other reproductive system
damage. The engine exhaust
contains carbon monoxide,
which is a odorless, colorless,
poisonous gas. Do not use the
machine in enclosed spaces.
BLADES
THROTTLE
ON
CHOKE
OFF
8061-001
Set the throttle
If the engine is cold, the choke lever should be pushed
to the ON position.
BLADES
THROTTLE
ON
CHOKE
OFF
8061-004
Set the choke control
English-27
OPERATION
Starting the 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.
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
to start other vehicles.
If your battery is too weak to start the engine, it should
be recharged. (See “Battery” in the Maintenance
Section.)
If “jumper cables” are used for emergency starting,
follow this procedure:
8011-642
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.
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-28
Jumper cable connection
OPERATION
Running
1. Release the parking brake by moving the
lever downward.
NOTE: The mower is equipped with an
operator presence system. When the engine
is running, any attempt by the operator to
leave the seat without first setting the parking
brake will shut off the engine.
2. Move the steering controls to the neutral
position (N).
8061-019
Released parking brake
3. Select the cutting height with the cutting
height adjustment pedal.
4. Make sure the work area is free from objects
that could be thrown by the rotating blades.
5. Engage the mower deck by pulling out the
blade switch.
WARNING!
Ensure that no one is near
mower when engaging blade
switch.
8050-117
The mower deck’s lifting lever
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.
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 (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.
BLADES
THROTTLE
ON
CHOKE
OFF
8061-017
Set blade engagement and throttle control
English-29
OPERATION
Operating on hills
Read the Safety Instructions “Driving on Slopes” in the
“Safety Instructions”.
WARNING!
Do not drive up or down hills with
slopes greater than 10 degrees.
Do not drive across slopes.
•
•
•
The slowest speed possible should be used
before starting up or down hills.
Avoid stopping or changing speed on hills.
If stopping is absolutely necessary, pull drive
levers into the neutral position and push
to the outside of the unit and engage the
parking brake.
IMPORTANT INFORMATION
Control levers return to neutral when
released. This may cause the mower to
suddenly stop.
•
•
•
To restart movement, release the parking
brake.
Pull the control levers back to the center
of the mower and press forward to regain
forward motion.
Make all turns slowly.
8061-020
Place controls in neutral position to stop
8061-019
Released parking brake
English-30
OPERATION
Mowing Tips
•
•
•
•
•
•
•
•
Observe and flag rocks and other fixed
objects to avoid collisions.
Begin with a high cutting height and reduce it
until the desired mowing result is attained.
The average lawn should be cut to 2½"
(64 mm) during the cool season and over
3" (76 mm) during the hot months. For
healthier and better looking lawns, mow
often after moderate growth. For best cutting
performance, grass over 6" (15 cm) in height
should be mowed twice. Make the first cut
relatively high, the second to the desired
height.
The mowing result will be best with a high
engine speed (the blades rotate rapidly) and
low speed (the rider moves slowly). If the
grass is not too long and dense, the driving
speed can be increased without negatively
affecting the mowing result.
The finest lawns are obtained by mowing
often. The lawn becomes more even and the
grass clippings more evenly distributed over
the mown area. The total time taken is not
increased as a higher operating speed can
be used without poor mowing results.
Avoid mowing wet lawns. The mowing result
is poorer because the wheels sink into
the soft lawn, clumps build, and the grass
clippings fasten under the cowling.
Hose the mower deck underside with water
after each use. When cleaning, 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, engine and electrical components.
When the mulching kit is used, it is important
that the mowing interval is frequent.
WARNING!
Clear the lawn of stones and
other objects that can be thrown
out by the blades.
8011-603
Mowing pattern
WARNING!
Never drive the rider on terrain
that slopes more than 10 degrees.
Mow slopes up and down, never
side to side. Avoid sudden
directional changes.
English-31
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.
• Disengage the mower deck by depressing
the blade switch.
BLADES
THROTTLE
ON
CHOKE
OFF
8061-017
Disengage the mower deck and move throttle to minimum
•
•
•
Raise the mower deck by pressing the foot
pedal forward to the transport position.
When the machine is standing still, activate
the parking brake by pulling the lever
upward.
Move the throttle to the minimum position
(tortoise symbol). Turn the ignition key to the
stop position.
The mower deck’s lifting lever
•
•
8050-117
Move the steering controls outward.
Remove key. Always remove key when
leaving the mower to prevent unauthorized
use.
IMPORTANT INFORMATION
Leaving the ignition switch in any other
position than “OFF” will cause the battery
to be discharged and the hour meter to
accumulate hours.
English-32
8061-020
Place controls in neutral position to stop
OPERATION
Moving by Hand
IMPORTANT INFORMATION
Tighten the valve moderately.
Do not overtighten the valve when closing.
That can damage the valve seat.
Pump release valves
Pump release valves are located at the front and rear
of the pump. 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 pump.
The rear bypass valve sits directly opposite the front
valve, below the seat support. It is not visible in the
illustration.
Use a 17 mm open end wrench or socket and ratchet.
Turn the outer locknut 2-3 turns. Using an 8mm
wrench or socket, turn the inner nut one turn.
Reverse the procedure to reset the pump.
English-33
8011-507
Pump release valve
English-33
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.
1)
First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
3)
2)
In dusty conditions, cleaning and
4)
replacement are required more often. For daily use, the machine should be lubricated twice weekly. Performed by authorized service workshop.
z = Described in this manual
 = Not described in this manual
Daily
Maintenance
Weekly
Before After
Check the parking brake
z
Check the engine’s oil level (every refueling)
z
Check the safety system
z

Check for fuel and oil leakages
Check/clean the engine’s cooling air intake
z
Check the mower deck
Check for loose hardware (screws, nuts)
z
z
Clean under the mower deck
z
Start the engine and blades, listen for unusual sounds

Check for damage

Thoroughly clean around the engine

Clean around belts, belt pulleys

At Maintenance interval
least in hours
once
each
year 25
50 100 300
Check the tire pressures
z
Check battery
z
z
z
z
z
z
Sharpen/Replace mower blades
Clean the engine’s cooling air intake
2)
Clean the air cleaner’s pre-filter 2) (foam)
z
Check/adjust the parking brake
z


Inspect muffler/Spark arrester


Clean the air cleaner’s filter cartridge
English-34
2)
(paper filter)
MAINTENANCE
Daily
Maintenance
Weekly
Before After
At Maintenance interval
least in hours
once
each
year 25
50 100 300
Check/adjust throttle and choke cables
z
Check the condition of belts, belt pulleys
Change the engine oil 1)
z
z
Replace the engine oil filter
z
z
Clean/replace the spark plugs
z
z
z
z
z
z
Replace the fuel filter
Replace the air filter (paper filter)
2)
z
z
z
Check the caster wheels (every 200 hours)
Replace the air cleaner’s pre-filter
2)
(foam)
Check/adjust the mower deck
Check the engine valve clearance 3)
Perform the 300-hour service
3)
Change hydraulic oil & filter (200 hours)
1)
z




z
Lubricate according to Lubrication Schedule
Check hydraulic oil at reservoir
z
z
z
z
z
z
z
z
First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
conditions, cleaning and replacement are required more often. 3) Performed by authorized service workshop.
z
2)
In dusty
z = Described in this manual
 = Not described in this manual
WARNING!
Before performing any service or adjustment checklist
• Engage the parking brake.
• Place the Blade-switch in the disengaged position.
• Turn the ignition switch to “OFF” position and remove the key.
• Make sure the blades and all moving parts have completely stopped.
• Disconnect the spark plug wire from all spark plugs and place the wire where it
cannot come in contact with the plug.
English-35
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.
Keep battery bolts tight.
Recharge at 6-10 amperes for 1 hour
To clean battery and terminals
Corrosion and dirt on the battery and terminals can
cause the battery to “leak” power.
1. Open the terminal access doors.
2. Disconnect BLACK battery cable first, then the
RED battery cable and remove the battery from the
machine.
3. Rinse the battery with plain water and dry.
4. Clean terminals and battery cable ends with wire
brush until shiny.
5. Coat terminals with grease or petroleum jelly
6. Reinstall battery.
Replacing battery
1. Lift seat and rotate forward.
2. Open terminal access doors
3. Using two ½" wrenches disconnect BLACK battery
cable then RED battery cable.
4. Using a 7/16 wrench, remove the bolts on either
side of the terminal guard and lift off guard.
5. Carefully remove the battery from the mower.
6. Install new battery with terminals in the same
position as the old battery.
7. Reinstall battery terminal guard.
8. First connect RED battery cable to positive (+)
battery terminal with hex bolt and hex nut.
9. Connect BLACK grounding cable to negative (-)
battery terminal with remaining hex bolt and hex
nut.
10. Close access doors.
11. Lower seat.
English-36
IMPORTANT INFORMATION
Do not attempt to open or remove caps
or covers. Adding or checking level of
electrolyte is not necessary.
Always use two wrenches for the terminal
screws
WARNING!
Do not short battery terminals by
allowing a wrench or any other
object to contact both terminals at
the same time. Before connecting
battery, remove metal bracelets,
wristwatch bands, rings, etc.
Positive terminal must be
connected first to prevent sparks
from accidental grounding.
2
1
CZ-22
1. Terminal guard
2. Access doors
Battery cleaning and installation
MAINTENANCE
Ignition System
The engine is equipped with an electronic ignition
system. Only the spark plugs require maintenance.
For recommended spark plugs, see Technical Data.
1. Remove the ignition cable boot and clean around
the spark plug.
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 a ¼ turn from the seated
position.
7. Replace the ignition cable.
IMPORTANT INFORMATION
Fitting the wrong spark plug type can
damage the engine.
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
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 parking brake is on.
Make daily inspections to ensure that the safety
system works by attempting to start the engine
when one of the conditions is not met. Change the
conditions and try again.
If the machine starts when one of these conditions
is not met, turn the machine off and repair the safety
system before using the machine again.
Make sure the engine stops when the park brake is not
engaged and the operator leaves the seated position.
Check that the engine stops if the mower blades are
engaged and the driver temporarily moves off the
drivers seat.
Conditions for starting
8061-018
IMPORTANT INFORMATION
In order to be able to drive, the driver
must sit in the seat and release the
parking brake before the steering controls
can be moved into the neutral position,
otherwise the engine will stop.
English-37
MAINTENANCE
Engine 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.
The cooling air intakes rotates when the engine is
running. Mind your fingers.
8061-014
Check and clean the cooling air intake
Throttle Cable
Check that the engine responds to throttle increases
and that a good engine speed is attained at full
throttle.
If doubts arise, contact the service workshop.
If adjustments are necessary, they can be made as
follows for the lower cable:
1. Loosen the clamping screw for the cable’s outer
casing and move the throttle to the full throttle
position.
2. Check that the throttle cable is mounted in the
correct hole in the lower lever, see illustration.
3. Push the throttle cable’s outer casing as far to the
right as possible and tighten the clamping screw.
8011-605
Adjusting the throttle cable
Choke Cable
If the engine produces black smoke or is difficult
to start, this can be because the choke cable is
incorrectly adjusted (upper cable).
If doubts arise, contact the service workshop.
If adjustments are necessary, they can be made as
follows:
1. Loosen the clamping screw for the cable’s outer
casing and push the choke control fully in.
2. Check that the choke cable is mounted in the
upper lever, see illustration. Push the choke cable’s
outer casing as far to the left as possible and
tighten the clamping screw.
8011-605
Adjusting the choke cable
English-38
MAINTENANCE
Air Filter Maintenance
If the engine seems weak or runs unevenly, the air
filter may be clogged. If running with a dirty air filter,
the spark plugs can become fouled.
For this reason, it is important to replace the air filter
regularly (see the heading Maintenance Schedule for
the proper service interval).
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.
IMPORTANT INFORMATION
Do not use compressed air to clean the air
filter.
Do not wash the paper filter.
Do not oil the paper filter.
Do not tap filter to clean this could cause
damage to the sealing.
Replacing Air Filter
The engine is equipped with a replaceable, high
density paper air cleaner element and an oiled, foam
precleaner which surrounds the paper element.
Check the air cleaner daily or before starting the
engine. Check for a buildup of dirt and debris around
the air cleaner system. Keep this area clean. Also
check for loose or damaged components. Replace all
bent or damaged air cleaner components.
IMPORTANT INFORMATION
Operating the engine with loose or
damaged air cleaner components could
allow unfiltered air into the engine causing
premature wear and failure.
Servicing Precleaner:
Wash and re-oil the precleaner every 25 hours of
operation (more often under extremely dusty or dirty
conditions). Replace the precleaner annually, or every
100 hours.
1. Open the door on the blower housing
to access the air cleaner element and
precleaner.
2. Unhook the latch and remove the precleaner
from the air cleaner element, or remove as
an assembly for servicing. Make sure the
base and the sealing area is clean before
reassembly is performed.
3. Wash the precleaner in warm water with
detergent. Rinse the precleaner thoroughly
until all traces of detergent are eliminated.
Squeeze out excess water (do not wring).
Allow the precleaner to air dry.
4. Saturate the precleaner with new engine oil.
Squeeze out all excess oil.
5. Reinstall the precleaner over the paper
element and secure with the latch.
6. Close and latch the door.
Servicing Paper Element:
Check the paper element every 50 hours of operation,
(more often under extremely dusty or dirty conditions).
Clean or replace the element as necessary. Replace
the air cleaner element annually, or every 100 hours.
1. Open the door on the blower housing to
access the air cleaner element.
2. Unhook the latch and remove the air cleaner
element and precleaner.
3. Remove the precleaner (if so equipped) from
the paper element. Service the precleaner as
described in Precleaner Service.
4. Gently tap the paper element to dislodge
dirt. Do not wash the paper element or
use pressurized air, as this will damage the
element. Replace a dirty, bent, or damaged
element with a new one. Handle the new
element carefully; do not use if the sealing
surfaces are bent or damaged.
5. Clean the air cleaner base as required and
check condition.
6. Reinstall the precleaner over the paper air
cleaner element and install on the base.
Secure with the latch.
7. Close and latch the door.
English-39
MAINTENANCE
Replacing the Fuel Filter
Replace the line-mounted fuel filter every 100 hours
(once per season) or more regularly if it is 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. Move the hose clamps back toward the filter.
Fuel filter
8011-468
Fuel Pump Air Filter
Regularly check that the fuel pump’s air filter is free
from dirt.
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.
The fuel pump’s air filter
English-40
8009-147
MAINTENANCE
Tire Pressures
Rear tires should have a pressure of 10 psi / 69 kPa
/.7 bar. Front tires should be at 15 psi / 103 kPa / 1 bar.
8011-564
Tire pressures
Parking Brake
Visually check that no damage is found on the lever,
cables, or switch belonging to the parking brake.
Perform a standstill test and check that there is
sufficient braking action.
To adjust the parking brake, contact the Dixon service
workshop.
WARNING!
Faulty adjustment will result in
reduced braking ability and can
cause an accident.
8061-019
Parking brake
V-belts
Check every 100 hours of operation. Check for severe
cracking and large nicks.
NOTE: The belt will show some small cracks in normal
operation.
The belts are not adjustable. Replace belts if they
begin to slip from wear.
IMPORTANT INFORMATION
The machine must be absolutely standing
still when applying the parking brake.
English-41
MAINTENANCE
Deck belt removal
1. Park on a level surface. Apply parking brake.
2. Lower the deck into the lowest cutting
position.
3. Remove bolts from belt shields and remove
shields.
4. Remove any dirt or grass that may have
accumulated around the cutter housings and
entire deck surface.
5. Carefully roll the belt over the top of the
cutter housing pulleys and remove belt.
Deck belt installation
NOTE: For ease in installing the deck belt, refer to
the routing decal on bottom of seat.
1. Wrap the deck belt around the electric clutch
pulley that is located on the engine shaft.
2. Route the belt forward between the EZT
(E-Series Zeroturn Transaxles) and up onto
the deck.
3. Place belt around spring loaded idler pulley.
4. Wrap the belt around the stationary idler
pulley and around the mandrel housings.
5. Push inward on the idler arm and carefully
route belt over stationary idler pulley. Once
belt is properly routed, slowly release idler
arm to tension belt.
6. Double check belt routing to make sure it
matches the routing decal, and the belt does
not have any twist. Correct as needed.
7. Adjust tension with deck eyebolt.
8. Replace belt shields on both mandrel
housings and secure with fasteners.
Belt Shields
2
front deck2
Removing deck belt
1
2
8061-021
1. Clutch pulley
2. Deck belt
Belt routing, deck belt
English-42
MAINTENANCE
Pump Belt
Replacing pump belt
Park the mower on a level surface. Engage the
parking brake.
Belt removal
1. Remove the deck belt (see Deck Belt
Removal in this section of the manual).
2. Remove clutch stop to access the belt.
3. Disconnect clutch wire.
4. Create slack in the belt by removing the
spring on the pump idler arm.
5. The belt should now be able to be removed
from the engine pulley and pump pulleys.
Belt installation
1. Wrap the belt around the pulley
2. Route the belt around the inside of the idler
pulley.
3. Wrap the belt around the engine pulley.
4. Reattach the spring on the pump idler arm.
5. Reconnect clutch wire.
6. Replace and secure clutch stop.
7. Reinstall the deck belt. (see Deck Belt
Removal in this section of the manual).
1
2
3
8054-002
1. Electric clutch
2. Idler spring
3. Clutch stop
Pump belt removal
Cutting Blades
In order to attain the best mowing effect, it is important
that the blades are well sharpened and not damaged.
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.
Damaged blades should be replaced when hitting
obstacles that result in a breakdown. Let the service
workshop decide whether the blade can be repaired/
ground or must be replaced.
Balance the blades after sharpening.
Check the blade mounts.
8011-604
Check the blades
IMPORTANT INFORMATION
The sharpening of blades should be
carried out by an authorized service
workshop.
English-43
MAINTENANCE
Blade replacement
3
WARNING!
Blades are sharp. Protect your
hands with gloves and/or wrap
blades with a heavy cloth when
handling.
52", 60"
1
2
3
• Remove blade bolt by turning counterclockwise.
1
IMPORTANT INFORMATION
To ensure proper assembly, center hole
in blade must align with star on cutter
housing.
• Install new or resharpened 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 45-55 ft/lbs (60-75 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-44
2
72"
1. Blade
2. Blade bolt (special)
3. Cutter housing
Blade attachment
MAINTENANCE
Adjusting the Mower Deck
WARNING!
Before performing any service or adjustment checklist:
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.
Check the tire pressure before adjustment of the
mower deck. See “Checking Tire Pressure” in
Maintenance section. Faulty mower deck adjustments
will cause an uneven mowing result.
Leveling deck
1. Position the mower on a level, preferably concrete,
surface.
2. Check the pressure in all four tires. See “Technical
Data”.
3. Rotate blades to align front to back.
4. Set the cutting height to 4" (10cm).
5. Measure front blade tip. It should be 4" from
ground. If not, turn locknut on top of front L bolt
until measurement is achieved. Check blade tip
at front on opposite front blade. Adjust locknut on
front L bolt as necessary.
6. Check that the rear blade measurement is 4¼"
(11.4cm) from ground. If not, turn locknut on top
of rear L bolt to achieve measurement. Repeat
procedure on opposite side.
Adjusting Cutting Height
1. Raise and secure the deck height lever to the
transport position (4½" / 11.5cm).
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 4½"
(11.4cm).
4. Drop the level to (for example) the 2" (5cm) cutting
height. Measure as above. Distance should be 2".
WARNING!
Blades are sharp. Protect your
hands with gloves and/or wrap
blades with a heavy cloth when
handling.
3
4
2
1
8050-808
1. Front L bolt
2. Front locknut
3. Rear locknut
4. Rear L bolt
Leveling the mower deck
NOTE: This will place the mower deck in a base
measurement position. Additional adjustment may be
required to achieve desired cut for the type of grass or
conditions being mowed.
English-45
MAINTENANCE
Anti-scalp rollers
Anti-scalp rollers are properly adjusted when they
are just slightly off of the ground when the deck is at
the desired cutting height in the operating position.
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.
The anti-scalp rollers can be set in three positions:
•
•
•
Upper position 1½ to 3" (38 to 76 mm) grass.
Middle position 3" to 4½" (76 to 114 mm) grass.
Lower position 4½" to 6" (114 to 152 mm) grass.
The rollers should be approximately ¼" (6.5 mm) from
ground. Do not adjust the rollers to support the deck.
IMPORTANT INFORMATION
The anti-scalp rollers must not be used
for gauge wheels or the roller and deck
may be damaged.
English-46
CZ-9
Anti-scalp rollers
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 the deck with
normal water pressure. Do not use a high pressure
washer or steam cleaner. Avoid spraying engine and
electrical components with water
8050-092
Use protective glasses when
cleaning and washing.
Clean regularly
Do not rinse hot surfaces with cold water. Let unit cool
before washing.
Caster Wheels
Check every 200 hours. Check that wheels rotates
freely. If wheels do not rotate freely take the unit to
your dealer for service.
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.
Only use O.E.M. specified tires.
Foam filled tires or solid tires will void the warranty.
Removal and installation of caster wheel
Remove nut and caster bolt.
Pull the wheel out of the fork and take care of the
sleeve.
Install in reverse order. Tighten caster bolt.
8011-619
Caster wheels
Hardware
Check daily. Inspect the entire machine for loose or
missing hardware.
English-47
LUBRICATION
1
2
3
4
BLADES
ON
CHOKE
THROTTLE
OFF
*
5
6
8011-672-6
12/12 Every year
Lubricate with grease gun
1/52 Every Week
Oil change
1/365 Every day
•
Lubricate with oil can
Level check
Filter change
*Change transaxles (transmission) filters.
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 disulphide grease.
For daily use, the machine should be lubricated twice
weekly.
English-48
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.
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.
1. Front Wheel Mount
Lubricate with a grease gun, one zerk for each wheel
mount, until the grease is forced out.
Use only good quality bearing grease.
Grease from well-known brand names (petrochemical
companies) usually maintains a good quality.
2. 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 bearing grease.
3. Deck spindle
Lower the cutting deck completely.
If you use grease gun without rubber hose, the foot
plate must be removed.
Lubricate with a grease gun, one zerk,
2-3 strokes.
Use only good quality bearing grease.
IMPORTANT INFORMATION
Use minimal lubrication and remove excess
lubricant so that is does not come into contact
with belts or belt pulley drive surfaces.
8011-731
Lubricating the front wheels
8011-732
Deck spindle
English-49
LUBRICATION
4. Deck outer spindle
Lubricate using a grease gun, one zerk, each side 2-3
strokes. Use only good quality bearing grease.
8011-733
Deck outer spindle (with belt shield removed)
WARNING!
Engine oil can be very hot
if it is drained directly after
stopping the engine. Allow
the engine to cool to a safe
temperature first.
Engine Oil
5. Engine Oil Filter
• Drain the engine oil in accordance with the
work description under the heading Engine
Oil/Change Engine Oil.
• Remove the oil filter. If necessary, use a
filter remover.
• Wipe new, clean engine oil onto the seal
for the new filter.
• Mount the filter by hand with +¾ turn.
• Run the engine warm, then check that
there are no leaks around the oil filter seal.
• Check the oil level in the engine, fill
if necessary. The oil filter holds 0.1 qt (0.1
liters) of oil.
Changing the oil filter
8011-734
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.
English-50
LUBRICATION
WARNING!
Engine oil can be very hot
if it is drained directly after
stopping the engine. Allow
the engine to cool to a safe
temperature first.
5. Changing the Engine Oil
The engine oil should be changed for the first time
after 5-8 hours of operation. Thereafter, it should be
changed every 50 hours. The oil drain valve is located
at the rear of the unit, to the right of the oil filter.
• Place the machine on a flat surface.
• Place a container under the engine where
the oil drain valve exits.
• Remove the valve cap.
• Allow the oil to run out into the container.
• Reinstall the oil drain valve cap.
• Replace the oil filter if necessary.
• Fill with new engine oil in accordance with
Checking the Oil Level.
• Start the engine. Run it for 3-5 minutes. Stop
and recheck the oil level.
6. Engine Oil Levels
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 be screwed into place.
Take the dipstick out again and read the oil level.
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 to above the “FULL” mark.
The oil is filled through the hole for the dipstick.
API class SF, SG, SH, SJ or higher must be used.
Synthetic oil SAE 5W-30 or 10W-30 is recommended
at all temperatures. Mineral oil SAE 5W-30, 10W-30
can be used between
-18 °C/0 °F and +5 °C/40 °F. At temperature above +5
°C/40 °F single grade SAE 30 must be used.
The engine holds 0.88 qt (1.0 liters) of oil excluding
the filter, including filter 2 qt (1.9 liters).
Oil drain valve
8011-500
Remove the dipstick
The dipstick markings
English-51
8009-159
LUBRICATION
*Hydraulic Pump
Fluid Change
This transaxle is designed with an external filter for
ease of maintenance. To ensure constant fluid quality
levels and longer life an oil filter change interval of
every 200 hours is recommended.
The following procedure can be performed with the
pump installed in the vehicle, and the vehicle on level
ground. Apply the bypass valve and lock the vehicle
parking brake.
1. Place an oil drain pan with a two gallon
capacity beneath the oil filter. Remove the
oil filter from the pump.
2. After the oil has drained, wipe the filter
base surface off and apply a film of new oil
to the gasket of the new replacement filter.
3. Install the new filter by hand, turn ¾ to one
full turn after the filter gasket contacts the
filter base surface.
4. Drain old oil filters of all free-flowing
oil prior to disposal. Place used oil in
appropriate containers and dispose of it in
accordance with laws in your area.
5. Remove the cap from the pump’s
expansion tank located on the vehicle
frame.
6. Fill reservoir with SAE 10W30 oil to just
above the MIN-ADD line on the reservoir.
After purging, check levels and add oil if
necessary.
7. Reinstall the tank cap by hand. Do not
overtighten.
8. Proceed to the purge procedure.
Purging Procedures
Due to the effects air has on efficiency in hydrostatic
drive applications, it is critical that it is purged from the
system.
These purge procedures should be implemented
any time a hydrostatic system has been opened to
facilitate maintenance or any additional oil has been
added to the system.
The resulting symptoms in hydrostatic systems may
be:
1. Noisy operation.
2. Lack of power or drive after short term
operation.
3. High operation temperature and excessive
expansion of oil.
English-52
2
3
1
8061-016
1. Pump filter
2. Pump reservoir
3. Fluid fill lines
Changing the hydraulic pump oil filter
Before starting, make sure the pump is at the proper oil
level. If it is not, fill to the specifications outlined earlier.
The following procedures are best performed with the
vehicle drive wheels off the ground, then repeated
under normal operating conditions.
1. Disengage the brake if activated.
2. With the bypass valve open and the
engine running at fast idle, slowly move
the directional control in both forward and
reverse directions (5 or 6 times). As air is
purged from the unit, the oil level will drop.
3. With the bypass valve closed and the
engine running, slowly move the directional
control in both forward and reverse
directions (5 to 6 times). Check the oil
level, and add oil as required after stopping
the engine.
4. It may be necessary to repeat Steps 2 and
3 until all the air is completely purged from
the system. When the transaxle operates
at normal noise levels and moves smoothly
forward and reverse at normal speeds,
then the transaxle is considered purged.
5. After the vehicle has been used two times,
the oil level should be checked while the oil
is cold and adjusted accordingly.
TROUBLESHOOTING
Problem
The engine will not start.
The starter does not turn the engine over.
Cause
•
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 parking brake is not activated.
•
The battery is dead.
•
Contamination in the carburetor or fuel line.
•
The fuel supply is closed or the shutoff valve for the fuel
tank is in the wrong position.
•
Clogged fuel filter or fuel line.
•
Ignition system faulty.
•
Dead battery.
•
Poor contact of the battery terminal cable connections.
•
Fuse blown.
•
Fault in the starter safety circuit.
See Checking the Safety System in the
“Maintenance Section”
The engine runs rough.
The engine seems weak.
The machine vibrates.
•
Faulty carburetor.
•
The choke control is pulled out with a warm engine.
•
Clogged fuel filter or jet.
•
Clogged ventilation valve on the fuel cap.
•
Fuel tank nearly empty.
•
Fouled spark plugs.
•
Rich fuel mixture or fuel-air mixture.
•
Wrong fuel type.
•
Water in the fuel.
•
Clogged air filter.
•
Clogged air filter.
•
Fouled spark plugs.
•
Carburetor incorrectly adjusted.
•
Air trapped in hydraulic system.
•
The blades are loose.
•
The blades are incorrectly balanced.
•
The engine is loose.
English-53
TROUBLESHOOTING
Problem
Cause
The engine overheats.
•
Clogged air intake or cooling fins.
•
Engine overloaded.
•
Poor ventilation around engine.
•
Defective engine speed regulator.
•
Too little or no oil in the engine.
•
Fouled spark plugs.
•
Poor contact with battery terminal cable connectors.
•
Charging lead is disconnected.
•
Parking brake on.
•
Bypass valve on pump open.
•
Drive belt for the transmission slack or
has come off.
•
Air trapped in hydraulic system.
•
Drive belt for the mower deck has come loose.
•
Contact for the electromagnetic coupling has loosened.
•
The blade switch is faulty or has come loose, from the
cable contact.
•
The fuse has blown.
•
Damaged seals, housing, or gaskets.
•
Air trapped in hydraulic system.
•
Different air pressure in the tires on the left and right
sides.
•
Bent blades.
•
The suspending for the mower deck is uneven.
•
The blades are dull.
•
Driving speed too high.
•
The grass is too long.
•
Grass collected under the mower deck.
Battery not charging.
The machine moves slowly, unevenly, or not at all.
Mower deck not engaging.
Transaxle leaks oil.
Uneven mowing results.
English-54
STORAGE
Storage
Winter Storage
At the end of the mowing season, the machine should
be readied for storage (or if it will not be in use for
longer than 30 days). Fuel allowed to stand for long
periods of time (30 days or more) can leave sticky
residues that can plug the carburetor and disrupt
engine function.
Fuel stabilizers are an acceptable option as regards to
the sticky residues that can occur during storage.
Add stabilizer to the fuel in the tank or in the storage
container. Always use the mixing ratios specified by
the manufacturer of the stabilizer. Run the engine for
at least 10 minutes after adding the stabilizer so that it
reaches the carburetor. Do not empty the fuel tank and
the carburetor if 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 dryer,
etc. Handle the fuel with care.
It is very flammable and can
cause serious personal injury
and property damage. Drain the
fuel into an approved container
outdoors and far away from
open flame. Never use gasoline
for cleaning. Use a degreaser
and warm water instead.
To ready the machine for storage, follow these steps:
1. Thoroughly clean the machine, especially
under the mower deck. Touch up damage
to the paint and spray a thin layer of oil on
the underside of the mower deck to avoid
corrosion.
2. Inspect the machine for worn or damaged
parts and tighten any nuts or screws that may
have become loose.
3. Change the engine oil; dispose of properly.
4. Empty the fuel tanks or add a fuel stabilizer.
Start the engine and allow it to run until the
carburetor is drained of fuel or the stabilizer
has reached the carburetor.
5. Remove the spark plug and pour about a
tablespoon of engine oil into the cylinder.
Turn over the engine so that the oil is evenly
distributed and then refit the spark plug.
6. Lubricate all grease zerks, joints, and axles.
7. Remove the battery. Clean, charge, and store
the battery in a cool place, but protect it from
direct cold.
8. Store the machine in a clean, dry place and
cover it for extra protection.
Service
When ordering spare parts, please specify the
purchase year, model, type, and serial number.
Always use genuine Dixon spare parts.
An annual check-up at an authorized service workshop
is a good way to ensure that your machine performs its
best the following season.
English-55
SCHEMATICS
NOTES:
1. SEAT UNOCCUPIED
2. BRAKE SWITCH IN OFF POSITION
3. MOTION CONTROL LEVERS OUT
4. PTO IN OFF POSITION
SOLENOID
YEL
GRN
YEL
RED/BLK
YEL
BRN
BRAKE
SWITCH
RIGHT MOTION
CONTROL LEVER
RED/BLK
TO
ENGINE
PIGTAIL
GRN
WHT
20 AMP
B
S
PUR
A2
A1
L
GRY
G
M
BRN
WHT
RED
BLK
YEL
WHT
BLU
BLK
GRN
GRN
LEFT MOTION
CONTROL LEVER
PUR
BLK
YEL
YEL/RED
BRN
BRN
BRN
SEAT
SW.
HOURMETER
PUR
BLU
PTO
SWITCH
ELECTRIC
CLUTCH
7.5 AMP
PUR
HOURMETER
BLK
BLK
ACCESSORY
OUTLET
BLK
ENGINE
GROUND
KEY SWITCH POSITIONS
POSITION 1 - OFF
B
S
A2
A1
L
M
English-56
G
POSITION 2 - RUN1
B
S
A2
L
A1
M
G
POSITION 3 - RUN2
B
S
POSITION 4 - START
B
S
A2
A2
L
A1
M
G
L
A1
M
G
TECHNICAL DATA
Ram Xs5025 / 968999722
Ram Xs6025 / 968999723
Engine
Manufacturer
Kohler
Kohler
Type
Courage Pro
Courage Pro
Power
25 hp*
25 hp*
Lubrication
Pressure with oil filter
Pressure with oil filter
Oil capacity excluding filter
1.6 qt / 1.7 liter
1.6 qt / 1.5 liter
Oil capacity including filter
1.7 qt / 1.9 liter
1.7 qt / 1.6 liter
Engine oil
(See viscosity diagram)
10W30, 5W30
SG, SH, SJ
10W30, 5W30
SG, SH, SJ
Fuel
Min 87 octane unleaded (Max
ethanol 10%, Max MTBE 15%)
Min 87 octane unleaded (Max
ethanol 10%, Max MTBE 15%)
Fuel tank capacity
5.2 gallons / 19.7 liters
5.2 gallons / 19.7 liters
Spark plugs / gap
Champion RCY12YC
.030" / 0.75 mm
Champion RCY12YC
.030" / 0.75 mm
Cooling
Air cooled
Air cooled
Air filter
Standard
Standard
Alternator
12V
12V
Starter
Electric
Electric
Speed and direction controls
Dual levers, foam gripped
Dual levers, foam gripped
Speed forward
8 mph / 12.9 km/h
8 mph / 12.9 km/h
Speed reverse
4 mph / 6.45 km/h
4 mph / 6.45 km/h
Brakes
Mechanical parking brake
Mechanical parking brake
Front caster tires, smooth tread
13 x 5.0-6, 4 ply
13 x 5.0-6, 4 ply
Rear tires, turf pneumatic
23 x 10.5-12
23 x 10.5-12
Tire pressure, front
15 PSI / 103 kPa / 1 bar
15 PSI / 103 kPa / 1 bar
Tire pressure, rear
10 PSI / 69 kPa / .7 bar
10 PSI / 69 kPa / .7 bar
Transmission
Transmission
*As rated by the engine manufacturer.
English-57
TECHNICAL DATA
Ram Xs5025 / 968999722
Ram Xs6025 / 968999723
Cutting Width
52" / 127cm
60" / 152cm
Cutting Height
1.5 - 4.5" / 3.8 - 11.4 cm
1.5 - 4.5" / 3.8 - 11.4 cm
Uncut Circle
0
0
Number of Blades
3
3
Blade Length
17" / 435 mm
20" / 510 mm
Nose Rollers
Yes
Yes
Sprung Seat
Standard
Standard
Hinged Arm Rests
Yes
Yes
Hour Meter
Standard
Standard
Blade Engagement
Electromagnetic clutch
Electromagnetic clutch
Deck Construction
11 gauge fabricated
11 gauge fabricated
4.0 acres /h 16187 m2/h
4.8 acres /h 19425 m2/h
Weight
760 lbs / 345 kg
780 lbs / 354 kg
Base Machine Length
76" / 193 cm
76" / 193 cm
Base Machine Height
42" / 107 cm
42" / 107 cm
Overall Width, Chute Up
51" / 130 cm
61" / 155 cm
Overall Width, Chute Down
60" / 152 cm
72" / 183 cm
Productivity
Productivity
Overall Dimensions
English-58
TECHNICAL DATA
Ram Xs7227 / 968999724
Engine
Manufacturer
Kohler
Type
Courage Pro
Power
27 hp*
Lubrication
Pressure with oil filter
Oil capacity excluding filter
1.6 qt / 1.7 liter
Oil capacity including filter
1.7 qt / 1.9 liter
Engine oil
(See viscosity diagram)
10W30, 5W30
SG, SH, SJ
Fuel
Min 87 octane unleaded (Max
ethanol 10%, Max MTBE 15%)
Fuel tank capacity
5.2 gallons / 19.7 liters
Spark plugs / gap
Champion RCY12YC
.030" / 0.75 mm
Cooling
Air cooled
Air filter
Standard
Alternator
12V
Starter
Electric
Transmission
Transmission
Speed and direction controls
Dual levers, foam gripped
Speed forward
8 mph / 12.9 km/h
Speed reverse
4 mph / 6.45 km/h
Brakes
Mechanical parking brake
Front caster tires, smooth tread
13 x 5.0-6, 4 ply
Rear tires, turf pneumatic
23 x 10.5-12
Tire pressure, front
15 PSI / 103 kPa / 1 bar
Tire pressure, rear
10 PSI / 69 kPa / .7 bar
*As rated by the engine manufacturer.
English-59
TECHNICAL DATA
7227 / 968999719
Cutting Width
72" / 183cm
Cutting Height
1.5 - 4.5" / 3.8 - 11.4 cm
Uncut Circle
0
Number of Blades
3
Blade Length
25" / 635 mm
Nose Rollers
No
Sprung Seat
Standard
Hinged Arm Rests
Yes
Hour Meter
Standard
Blade Engagement
Electromagnetic clutch
Deck Construction
11 gauge fabricated
Productivity
Productivity
5.8 acres /h 23472 m2/h
Overall Dimensions
Weight
797 lbs / 362 kg
Base Machine Length
78" / 201 cm
Base Machine Height
42" / 107 cm
Overall Width, Chute Up
73" / 187 cm
Overall Width, Chute Down
87" / 221 cm
English-60
TECHNICAL DATA
Accessories
Collection system
Torque Specifications
• Engine crankshaft bolt
50 ft/lb (67 Nm)
• Deck pulley bolts
45 ft/lb (61 Nm)
• Lug nuts
75 ft/lb (100 Nm)
• Blade bolt
45-55 ft/lb (60-75 Nm)
• Standard ¼" fasteners
9 ft/lb (12 Nm)
5
18 ft/lb (25 Nm)
• Standard /16" fasteners
33 ft/lb (44 Nm)
• Standard 3/8" fasteners
7
52 ft/lb (70 Nm)
• Standard /16" fasteners
• Standard ½” fasteners
80 ft/lb (110 Nm)
When this product is worn out and no longer used, it should 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 operations or damage the
unit.
English-61
CONFORMITY CERTIFICATES
Conformity Certificates
USA requirements
Labels are placed on the engine and/or in the engine compartment stating that the machine will fulfill the
requirements. This is also applicable to special requirements for any of the states, (California emission rules etc.).
Do not remove any of these labels. Certificates can also be supplied with the machine at delivery or written in the
Engine manual. Take care of them as they are valuable documents.
CE 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-62
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
Delivery Service
1. Charge the battery.
2. Adjust the tire pressure of all wheels to 15 PSI (1 bar).
3. Mount the steering controls in the normal position.
4. Connect the contact box to the cable for the seat’s safety switch.
5. Check that the right amount of oil is in the engine.
6. Adjust the position of the steering controls.
7. Fill with fuel and open the fuel shut off valve.
8. Start the engine.
9. Check that there is drive to both wheels.
10. Check the mower deck adjustment.
11. Check:
The safety switch for the parking brake.
The safety switch for the mower deck.
The safety switch in the seat.
The safety switch in the steering controls.
Parking brake functionality.
Driving forward.
Driving backward.
Engaging the blades.
12. Check the idle speed
13. Check the engine high idle speed
14. Inform the customer about:
The need and advantages of following the service schedule.
Delivery service has been carried out.
The need and advantages of leaving the machine for service
every 300 hours.
No remaining notes.
Certified:
The effects of service and maintaining a service journal on the
machine’s resale value.
Application areas for mulching.
15. Fill in the sales papers
English-63
SERVICE JOURNAL
Action
After the First 5-8 Hours
1. Change engine oil.
English-64
Date, mtr reading, stamp, sign
SERVICE JOURNAL
Action
Date, mtr reading, stamp, sign
25-Hour Service
1. Check the engine air filter.
2. Sharpen/Replace mower blades if required.
3. Check the tire pressures.
4. Check battery with cables.
5. Lubricate according to lubrication chart.
6. Check/clean the engine’s cooling air intake.
7. Clean the air cleaner’s prefilter (foam).
English-65
SERVICE JOURNAL
Action
50-Hour Service
1. Perform the 25-hour service.
2. Clean/replace the air cleaner’s filter cartridge (paper filter)
(shorter intervals for dusty operating conditions).
3. Change engine oil.
4. Lubricate according to lubrication chart.
5. Check/adjust the parking brake.
6. Change hydraulic pump oil and filter.
English-66
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 the engine oil filter.
4. Clean/replace the spark plugs.
5. Replace the fuel filter.
6. Check V-belts.
7. Check tighten caster wheel axle bolts (every 200 hours).
8. Change the air filter’s paper cartridge.
9. Change hydraulic pump oil and filter. (200 hours)
English-67
SERVICE JOURNAL
Action
300-Hour Service
1. Perform the 25-hour service.
2. Perform the 50-hour service.
3. Perform the 100-hour service.
4. Check/adjust the mower deck.
5. Clean the combustion chamber and grind the valve seats.
6. Check the engine valve clearance.
7. Replace the air cleaner’s prefilter (foam).
English-68
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 (foam) (300 hours).
3. Replace the air filter’s paper cartridge.
4. Change the engine oil (50 hours).
5. Replace the engine oil filter (100 hours).
6. Check/adjust the cutting height.
7. Check/adjust the parking brake (50 hours).
8. Clean/change the spark plugs (100 hours).
9. Change the fuel filter (100 hours).
10. Check the engine valve clearance.
English-69
Part No. 539 132401 IR
11/15/07