MAIntenAnCe
Maintenance Schedule
The following is a list of maintenance procedures that must be performed on the machine. For those points not described in this manual, visit an authorized service workshop. An annual service carried out by an authorized service workshop is recommended to maintain your machine in the best possible condition and to ensure safe operation.
Read Maintenance in the Safety section.
Maintenance
Check the parking brake
Check the engine’s oil level (every refueling)
Check the safety system
Check for fuel and oil leakages
Check/clean the engine’s cooling air intake
Check the mower deck
Check for loose hardware (screws, nuts)
Clean under the mower deck
Start the engine and blades, listen for unusual sounds
Check for damage
Thoroughly clean around the engine
Clean around belts, belt pulleys
Check the tire pressures
Check battery
Sharpen/replace mower blades
Clean the engine’s cooling air intake
2)
Clean the air cleaner’s foam pre-filter
2)
Clean the air cleaner’s paper filter cartridge
2)
Check/adjust the parking brake
1) First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
2) In dusty conditions, cleaning and replacement are required more often.
3) For daily use, the machine should be lubricated twice weekly.
4) Performed by authorized service workshop.
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Described in this manual
♦
=
Not described in this manual
■
=
See engine manufacturers’ Owners Manual
Daily
Before After
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♦
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♦
♦
♦
♦
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At least once each year 25
Maintenance interval in hours
50 100 300
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♦
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♦
33
MAIntenAnCe
Maintenance
Check/adjust throttle cable
Check the condition of belts, belt pulleys
Change the engine oil
1)
Replace the engine oil filter
Clean/replace the spark plugs
Check the caster wheels (every 200 hours)
Check/adjust the mower deck
Check the engine valve clearance
4)
Perform the 300-hour service
4)
Lubricate according to Lubrication Schedule
3, 4)
1) First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, replace every 50 hours.
2) In dusty conditions, cleaning and replacement are required more often.
3) For daily use, the machine should be lubricated twice weekly.
4) Performed by authorized service workshop.
●
=
Described in this manual
♦
=
Not described in this manual
■
=
See engine manufacturers’ Owners Manual
Daily
Before After
At least once each year
Maintenance interval in hours
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■
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25 50
■
100
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300
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■ ■
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♦
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.
34
MAIntenAnCe
Battery
Your mower is equipped with a maintenance free battery that does not need servicing. However, periodic charging of the battery with an automotive type battery charger will extend its life.
• Keep battery and terminals clean.
• Keep battery bolts tight.
• See chart for charging times.
Cleaning battery and terminals
Corrosion and dirt on the battery and terminals can cause the battery to lose power.
1. Open the terminal access doors.
2. Disconnect BLACK battery cable first, then the
RED battery cable and remove the battery from the machine.
3. Rinse the battery with plain water and dry.
4. Clean terminals and battery cable ends with wire brush until shiny.
5. Coat terminals with grease or petroleum jelly
6. Reinstall battery.
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.
Always use protective glasses when handling the battery.
STANDARD
BATTERY
12.6V
12.4V
12.2V
12.0V
11.8V
STATE
OF
CHARGE
APPROXIMATE BATTERY CHARGING TIME*
TO FULL CHARGE AT 80
O
F / 27
O
C
50 Amps
Maximum Rate at:
30 Amps 20 Amps 10 Amps
100%
75%
50%
25%
- FULL CHARGE -
20 min.
45 min.
65 min.
35 min.
75 min.
115 min.
48 min.
95 min.
145 min.
0% 85 min.
150 min.
195 min.
*Charging time depends on battery capacity, condition, age, temperature and efficiency of charger
90 min.
180 min.
280 min.
370 min.
WARNING!
Do not short battery terminals by allowing a wrench or any other object to contact both terminals at the same time.
Before connecting battery, remove metal bracelets, wristwatch bands, rings, etc.
Positive terminal must be connected first to prevent sparks from accidental grounding.
Replacing battery
1. Lift seat and rotate forward.
2. 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.
2
1. Terminal guard
2. Access doors
Battery cleaning and installation
2
1
CZ-22
35
MAIntenAnCe
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.
Start conditions
8050-020
IMPORTANT INFORMATION
To be able to drive, the driver must sit in the seat and release the parking brake before the steering controls can be moved into the neutral position, otherwise the engine will stop.
Tire Pressures
All tires should be at 15 psi / 103 kPa / 1 bar.
8011-564
Tire pressures
36
MAIntenAnCe
Parking Brake
Visually check that no damage is found on the lever, links, or switch belonging to the parking brake.
Perform a standstill test and check that there is sufficient braking action.
To adjust the parking brake, contact the Dixon service workshop.
WARNING!
Faulty adjustment can result in reduced braking ability and can cause an accident.
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.
Deck Belt
To replace deck belt
Deck belt removal.
1. Park on a level surface. Apply park brake.
2. Lower the deck to the lowest cutting position.
3. Disengage the clutch by sliding the blade control lever downwards.
Check for proper operation of parking brake
Disengage clutch to replace deck belt
4. Carefully lift the belt away from belt keepers and off deck pulleys and remove from deck.
5. Replace belt (refer to the belt routing decal on the deck) and re-engage clutch.
8050-005
8058-074
Check deck belt for excessive wear
8050-013
37
MAIntenAnCe
EZT Belt
To replace EZT belt
Park the mower on a level surface. Engage the park brake.
EZT belt removal
NOTE: Be careful not to damage the fan blades on the EZT as this can affect cooling or damage the EZT.
1. Remove the deck belt (see To Replace Deck Belt in this section of the manual).
2. Create slack in the belt by pushing the spring loaded idler arm inward. Rotate arm to release belt tension.
3. The belt should now be able to be removed from the engine pulley and EZT pulleys.
Belt installation
1. Wrap the EZT belt around the EZT pulleys.
2. Route the belt around the inside of the idler pulley.
3. Wrap the belt around the engine pulley.
WARNING!
The engine and the exhaust system, become very hot during operation. Risk for burns if touched. Allow engine and exhaust system before servicing.
Cutting Blades
To attain the best mowing effect, it is important that blades are well sharpened and not damaged.
Replace blades that have been bent or cracked when hitting obstacles.
Let the service workshop decide whether a blade with large nicks can be repaired/ground or must be replaced. Balance the blades after sharpening.
Check the blade mounts.
Blade Replacement
1. Remove blade bolt by turning counterclockwise.
2. Install new or resharpened blade with stamped
GRASS SIDE facing towards ground/grass (down) or THIS SIDE UP facing deck and cutter housing.
3. Seat the blade's opening firmly onto the cutter housing.
4. Tighten blade bolt securely.
5. Torque blade bolt to 45-60 ft/lbs (61-81 Nm).
1
WARNING!
Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling.
The sharpening of blades should be carried out by an authorized service workshop.
2
38
IMPORTANT INFORMATION
Special blade bolt is heat treated.
Replace with a Dixon bolt if required.
Do not use lower grade hardware than specified.
3
1. Blade
2. Cutter housing
3. Blade bolt (special)
Blade attachment
8058-129
MAIntenAnCe
Adjusting the Mower Deck
WARNING!
Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling.
Check the tire pressure before adjustment of the mower deck. See Checking Tire Pressure in
Maintenance. 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 section.
3. Rotate blade to align side to side.
4. Turn front adjuster nut(s) to level deck side to side.
IMPORTANT INFORMATION
This will place the mower deck in a standard measurement position. Depending on the type of grass being mowed or environmental conditions, additional adjustments may be required to achieve the desired cut.
Side to side blade alignment
Side to side adjuster nut
8058-166
8050-015
39
MAIntenAnCe
Caster Wheels
Check every 200 hours. Check that wheels rotate freely. If wheels do not rotate freely take the unit to your dealer for service.
Foam filled tires or solid tires will void the warranty.
Removal and installation of caster wheel
1. Remove nut and caster bolt.
2. Pull the wheel out of the fork and take care of the sleeve.
3. Reinstall in reverse order. Tighten caster bolt.
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.
Caster wheels
Cleaning
Regular cleaning and washing, especially under the mower deck, will increase the machine’s life-span.
Make it a habit to clean the machine directly after use
(after it is cooled), before the debris sticks.
Use compressed air to clean the top side of mower deck. For cleaning the underside of the deck, use the cleanout port.
Attach the quick connect (from the accessory packet) to any garden hose. After mowing, snap the hose to the cleanout port and turn on water.
Restart the mower and engage the blades to use the spinning action to wash away debris. Make sure the hose is away from the mower blades.
Avoid spraying water on the engine and electrical components.
Use protective glasses when cleaning and washing.
Clean regularly
Hardware
Check daily. Inspect the entire machine for loose or missing hardware.
40
8050-908
8058-084
