Dixon 966503601 manual

Operator Man ual SZ4619 C A / 966503601 Please read the operator’ s manual car efully and make sur e you understand the instructions befor e using the machine .[...]

©2010 HTC. All rights reserved. Beatrice, NE. Printed in U.S.A. T o implement improvements, specications and designs can be altered without prior notication. 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 no[...]

INTRODUCTION ........................................................5 Driving and T ransport on Public Roads ................ 5 T owing ...................................................................5 Operating ..............................................................5 Good Service.........................................................6[...]

W ARNING! 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 in[...]

INTRODUCTION 5 Congratulations Thank you for purchasing a Dixon ride-on mower . This machine is built for superior efciency to rapidly mow primarily large areas. A contr ol panel easily accessible to the operator and a hydrostatic transmission regulated by steering contr ols both contribute to the machine’s perfor mance. This manual is a valua[...]

INTRODUCTION 6 Good Service Dixon’s products ar e sold only in specialized retail stores with complete service. This ensur es that you as a customer receive only the best support and service. Before the pr oduct is delivered, the machine has, for example, been inspected and adjusted by your Manufacturing Number The machine’s manufacturing numbe[...]

R N SymBOLS AND DECALS 7 These symbols are found on the machine and in the operator’s manual. Study them carefully so that you know what they mean. 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. IMPORT ANT INFORMA TION Xxxx[...]

Read Shut off engine and Keep a safe Use on slopes No passengers Operator’s remove key befor e distance from no greater Manual perfor ming any the machine than 10° maintenance or repair work Whole body Severing of ngers Do not open or Careful backing up, Careful going exposure to and toes remove safety watch for other forward, watch for throw[...]

SAFETy 9 Safety Instructions These instructions are for your safety . Read them carefully . IMPORT ANT : THIS CUTTING MACHINE IS CAP ABLE OF AMPUT A TING HANDS AND FEET AND THROWING OBJECTS. F AILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESUL T IN SERIOUS INJUR Y OR DEA TH. General Operation Read, understand, and follow all instructio[...]

SAFETy 10 8011-520 Ne ver tak e passengers W atch for trafc 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 per centage of riding m[...]

SAFETy 11 Personal Safety Equipment 8011-670a P ersonal protective equipment 6003-004 Mow up and do wn, not side to side Make sure that you have rst aid equipment close • at hand when using the machine. Never use the machine when barefoot. • Always wear protective shoes or boots, pr eferably • with steel toe caps. Always wear approved pr o[...]

SAFETy 12 8011-517 Ne ver allow children to oper ate the machine 8011-518 K eep children aw ay from work area Children T ragic accidents can occur if the operator is not alert to the presence of children. Childr en are often attracted to the machine and the mowing activity . Ne ver assume that childr en will remain out of the path of danger . Keep [...]

SAFETy 13 Safe Handling of Gasoline T o avoid personal injur y or pr oper ty damage, use extreme car e in handling gasoline. Gasoline is extremely ammable and the vapors ar e 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[...]

SAFETy 14 8011-515 Ne ver drive the machine in an enclosed space General Maintenance Never operate machine in a closed area. • Keep all nuts and bolts tight to be sure the • equipment is in safe working condition. Never tamper with safety devices. Check their • proper operation r egularly . Keep machine free of grass, leaves, or other • deb[...]

SAFETy 15 Sparking can occur when working with the battery and the heavy cables of the starter circuit. This can cause battery explosion, re or eye injury . Sparking in this circuit can not occur after the chassis cable (normally negative, black) is removed from the battery . Use protective goggles. • Ensure that the fuel ller cap is mounte[...]

SAFETy 16 IMPORT ANT INFORMA TION The parking brake is not sufcient 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 . W ARNING! Escaping hydraulic oil under pressure can have sufcient force to penetr[...]

CONTROLS 17 This operator’s manual describes the Dixon Zero T ur n Rider . The rider is tted with a Briggs & Stratton, four - stroke overhead valve engine. T ransmission from the engine is made via two belt- Motion Control Levers 1. Seat Adjustment Lever 2. Lift Lever 3. Blade Switch 4. Throttle / choke 5. Ignition Switch 6. Bypass Linkage[...]

W ARNING! The machine can turn very rapidly if one steering control is moved much further forward than the other . CONTROLS 18 Motion Control Levers The machine’s speed and direction ar e continuously variable using the two steering controls. The steering controls can be moved forwar d or backward about a neutral position. Further more, ther e is[...]

CONTROLS 19 Seat Adjustment Lever The seat can be adjusted lengthways. Release levers are located at the lower fr ont right, or on the right side—depending on model. When making adjustments, sit on the seat. Slide the lever and maneuver seat to appropriate placement and r elease lever . 8058-101 Seat adjustment Bypass Linkage Unlocking T ransmiss[...]

CONTROLS 20 Fuel T ank The machine has one fuel tank, just behind the seat. The tank capacity is 4 gallons (15.1 liters). The engine will run on a minimum of 85-octane unleaded gasoline (no oil mix). Environmentally adapted alkylate gasoline can be used. See also T echnical Data concer ning ethanol fuel. Methanol fuel is not allowed. When operating[...]

CONTROLS 21 Ignition Switch The ignition key is placed on the driver’s panel and is used to start and stop the engine. IMPORT ANT INFORMA TION Do not run the starter for more than ve seconds each time. If the engine does not start, wait about 10 seconds before retrying. Choke Control The choke is used for cold starts to provide the engine with[...]

CONTROLS 22 Blade Switch In order to engage the mower deck, pull the knob out; the mower blades are disengaged when the knob is depressed. 8058-019 Cut height lift le ver 8050-900 Blade s witch 8058-092 Released parking brake IMPORT ANT INFORMA TION In order to obtain an even cutting height it is important that the air pressure in all four tires is[...]

CONTROLS 23 Fuses Fuses are located on the left hand side of the machine. They are accessed by tilting the seat forward. They ar e at pin fuses of the same type used in automobiles. There ar e two fuses with ratings and functions: 20 Amp Primary fuse 7.5 Amp Mower deck coupling Fuel Shut Off V alve The fuel shut off valve is located at the left [...]

OpERA TION 24 Read the Safety section and following pages, if you are unfamiliar with the machine. T raining Zero turn mowers are far mor e maneuverable than typical riding mowers due to their unique steering capabilities. We suggest that this section be r eviewed in its entirety prior to attempting to move the mower under its own power . Additiona[...]

OpERA TION 25 8050-900 Blade s witch 8058-019 Cut height lift le ver 8058-092 Released parking brake Before Starting Read the sections Safety Instructions and • Controls befor e starting the machine. Perfor m the daily maintenance before • starting (see Maintenance Schedule in the Maintenance section). Check that there is sufcient fuel in th[...]

OpERA TION 26 8050-921 Set the throttle 8058-077 Place controls in neutral position 8050-900 Set the choke control Move the steering controls outwar d to the locked (outer) neutral position. Move the throttle to the middle position. Push throttle contr ol all the way forward to the choke position.[...]

OpERA TION 27 W ARNING! 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. IMPORT ANT INFORMA TION Do not run the [...]

OpERA TION 28 W ARNING! Lead-acid batteries generate explosive gases. Keep sparks, ame and smoking materials away from batteries. Always wear eye protection when around batteries. Weak Battery If your battery is too weak to star t the engine, it should be recharged. (See Battery in the Maintenance section.) If “jumper cables” are used for em[...]

OpERA TION 29 Running Release the parking brake by moving the lever 1. downward. Y our mower is equipped with an operator presence system. When the engine is running, any attempt by the operator to leave the seat without rst setting the parking brake will shut off the engine. Move the steering controls to the neutral 2. position (N). IMPORT ANT [...]

OpERA TION 30 Move throttle contr ol to full throttle (not choke). 7. The machine’s speed and direction ar e continuously variable using the two steering controls. When both contr ols are in the neutral position, the machine stands still. By moving both controls an equal amount forward or backwar d, the machine moves in a straight line forward or[...]

OpERA TION 31 Mowing Tips Observe and ag rocks and other xed • objects to avoid collisions. Begin with a high cutting height and reduce it • until the desired mowing r esult 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 law[...]

OpERA TION 32 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. A void idling the engine for longer periods, as there is a risk of the spark plugs fouling. Disengage the mower deck by depressing the 1. blade switch. IMPORT ANT INFORMA TION Leaving th[...]

OpERA TION 33 8058-032 Bypass linkage, EZT engaged 8058-033 Bypass linkage, EZT loc ked in the b ypass position Manual T ransport When pushing or pulling the mower , engage the EZT (Integrated Zeroturn T ransaxle) bypass linkages. The EZT bypass linkages are located on the r ear of the frame, below the rear engine guar d. Raise the deck into the hi[...]

mAINTENANCE 34 1) First change after 8-10 hours. When operating with a heavy load or at high ambient temperatures, r eplace ever y 50 hours. 2) In dusty conditions, cleaning and replacement ar e required mor e often. 3) Perfor med by authorized service workshop. ● = Described in this manual ♦ = Not described in this manual ■ = Refer to the en[...]

mAINTENANCE 35 1) First change after 5-8 hours. When operating with a heavy load or at high ambient temperatures, r eplace ever y 50 hours. 2) In dusty conditions, cleaning and replacement ar e required mor e often. 3) Perfor med by authorized service workshop. ● = Described in this manual ♦ = Not described in this manual ■ = Refer to the eng[...]

mAINTENANCE 36 Battery Y our mower is equipped with a maintenance free battery and does not need servicing. However , periodic charging of the battery with an automotive type battery charger will extend its life. Keep battery and ter minals clean. • Keep battery bolts tight. • See chart for charging times. • IMPORT ANT INFORMA TION Do not att[...]

Tire Pressures All four tires should have a pr essure of 15 psi / 103 kPa /1 bar . mAINTENANCE 37 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: The mower deck is disengaged. • The steering controls ar e in the outer , locked • neu[...]

mAINTENANCE 38 W ARNING! The machine must be standing absolutely still when the park brake is engaged. Visually check that no damage is found on the lever , linkages, or switch belonging to the parking brake. Perfor m a stand still test and check that there is a braking action. T o adjust the parking brake, contact the Dixon service workshop. Parki[...]

mAINTENANCE 39 1 2 1 3 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 Park on a level surface. Apply parking brake. 1. Lower the deck into the lowest cutting[...]

2 1 3 mAINTENANCE 40 IMPORT ANT INFORMA TION Special blade bolt is heat treated. Replace with a Dixon bolt if required. Do not use lower grade hardware than specied. Cutting Blades T o attain the best mowing effect, it is important that the blades are well sharpened and not damaged. Bent or cracked blades or blades with large nicks should be rep[...]

mAINTENANCE 41 Adjusting the Mower Deck Deck Leveling Adjust the deck while the mower is on a level surface. Make sure the tires ar e inated to the correct pressur e. See T ransmission under T echnical Data . If tires ar e under or over inated, the deck cannot be properly adjusted. The deck should be adjusted slightly higher in the rear . NOT[...]

1 2 3 4 mAINTENANCE 42 IMPORT ANT INFORMA TION DO NOT add any type of tire liner or foam ll material to the tires. Excessive loads created by foam lled tires will cause premature failures. Only use O.E.M. specied tires. 8058-083 1. Caster yoke 2. Caster bolt 3. Long spacer 4. Small spacers Caster wheels Caster Wheels Check every 200 hours.[...]

LUBRICA TION 43 General For engine lubrication, see the engine manufacturer's Owners Manual. Remove the ignition key to prevent unintentional movements during lubrication. When lubricating with an oil can, it must be lled with engine oil. When lubricating with gr ease, unless otherwise stated, use a high grade molybdenum disulphide grease. [...]

LUBRICA TION 44 8050-009 Lubricating the front wheels IMPORT ANT INFORMA TION Use minimal lubrication and remove excess lubricant so that is does not come into contact with belts or belt pulley drive surfaces. Wheel and Deck Zerks Use only good quality bearing grease. Grease fr om well-known brand names (petrochemical companies, etc.) usually maint[...]

TROUBLE SHOOTING 45 Problem Cause Engine will not start Blade switch is engaged. • Steering controls ar e not locked in the neutral position • Parking brake is not activated • Battery is dead • Contamination in the carburetor or fuel line. • Fuel supply is closed or the shutoff valve for the fuel tank is in • the wrong position Clogged [...]

TROUBLE SHOOTING 46 Problem Cause Engine overheats Clogged air intake or cooling ns • Engine overloaded • Poor ventilation around engine • Defective engine speed regulator • T oo little or no oil in the engine • Contamination in the carburetor or fuel line. • Fouled spark plugs • Battery not charging Poor contact of the battery ter[...]

ST ORAGE 47 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 carbur etor and disrupt engine function. Fuel stabilizers are an acceptable option a[...]

SCHEmA TIC 48[...]

TECHNICAL DA T A 49 T orque Specications Hex Head Cap Screws The torque values shown should be used as a general guideline when specic tor que values are not given. U.S. Standard Hardware Grade SAE Grade 5 SAE Grade 8 Flangelock Screw w/Flangelock Nut ft./lbs ft./lbs Nm ft./lbs Nm ft./lbs Nm Shank Size (Diameter in inches, ne or coarse thr[...]

TECHNICAL DA T A 50 *The power rating of the engines indicated is the average net power output (at specied rpm) of a typical production engine for the engine model measured to SAE standar d J1349/ISO1585. Mass production engines may dif fer from this value. Actual power output for the engine installed in the nal machine will depend on the ope[...]

TECHNICAL DA T A 51 SZ4619 CA / 966503601 Frame Cutting Width 46" / 117cm Cutting Height 1.5 - 4" / 3.8 - 10.2 cm Uncut Circle 0 Number of Blades 2 Blade Length 22¾" / 57.8 cm Nose Rollers No Sprung Seat Standard Hinged Arm Rests Accessory Hour Meter Standard Blade Engagement Electromagnetic clutch Deck Construction Stamped Producti[...]

CONFORmITy CERTIFICA TES 52 USA requirements Labels are placed on the engine and/or in the engine compartment stating that the machine will fulll the requir ements. This is also applicable to special requir ements for any of the states, (California emission rules etc.). Do not remove any of these labels. Certicates can also be supplied with t[...]

53 W ARRANTy DIXON® ZTR® RESIDENTIAL SpeedZTR™ and RAM 42 Residential Mowers DIXON W ARRANTS ITS ZTR MOWERS AGAINST DEFECTS IN MA TERIAL AND WORKMANSHIP FOR THE PERIODS SET FORTH BELOW . THE SOLE REMEDY UNDER THIS WARRANTY IS REPLACEMENT OR REP AIR OF P ARTS INCLUDING LABOR COSTS. THIS W ARRANTY IS SUBJECT TO THE FOLLOWING CONDITIONS AND LIMIT [...]

SER VICE JOURNAL 54 Action Date, mtr reading, stamp, sign Delivery Service Charge the battery . Adjust the tire pr essure of all wheels to 15 PSI (1 bar). Mount the steering controls in the normal position. Connect the contact box to the cable for the seat’s safety switch. Check that the right amount of oil is in the engine. Adjust the position o[...]

SER VICE JOURNAL 55 Action Date, mtr reading, stamp, sign After 10 hours Change the engine oil. Change the oil lter . Check hydraulic oil level. Inspect hydraulic hoses. Inspect hydraulic belt. Inspect hydraulic lter . Check neutral position. Check safety system. Check seat belt. Check fuel system for leaks. Inspect safety guards and shields.[...]

SER VICE JOURNAL 56 Action Date, mtr reading, stamp, sign 100-Hour Service Grease ttings (caster pivots and caster wheels) Inspect dampeners Inspect frame Inspect throttle and choke cables Inspect hardwar e Check the tire pr essures Change the engine oil and lter Change air lter Inspect spark plug Inspect fuel lter Check engine RPM Clea[...]

SER VICE JOURNAL 57 Action Date, mtr reading, stamp, sign 300-Hour Service Grease ttings (caster pivots and caster wheels) Inspect dampeners Inspect frame Inspect throttle and choke cables Inspect hardwar e Check the tire pr essures Change the engine oil and lter Change air lter Inspect spark plug Inspect fuel lter Check engine RPM Clea[...]

SER VICE JOURNAL 58 Action Date, mtr reading, stamp, sign At least once each year Clean the engine’s cooling air intake. Replace the air cleaner’s pre-lter (foam). Replace the air lter’s paper cartridge. Change the engine oil. Replace the engine oil lter . Check/adjust the cutting height. Check/adjust the parking brake. Clean/Change [...]

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P/N 115 314827R1 01/15/10[...]