Dixon DX152 Operator's Manual
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Dixon DX152 Operator's Manual

Zero-turn ride-on mower
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Operator Manual
Form Number 115 619727 Rev A
DX152 / 966664001
Please read the operator manual carefully and make sure you
Gasoline containing up to 10% ethanol (E10) is acceptable for
use in this machine. The use of any gasoline exceeding 10%
ethanol (E10) will void the product warranty.
2013-07-15
understand the instructions before using the machine.

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  • Page 1 Operator Manual DX152 / 966664001 Please read the operator manual carefully and make sure you understand the instructions before using the machine. Gasoline containing up to 10% ethanol (E10) is acceptable for use in this machine. The use of any gasoline exceeding 10% ethanol (E10) will void the product warranty.
  • Page 2 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.

  • Page 3: Table Of Contents

    COntentS IntRODUCtIOn ............5 Running ............32 Driving and transport on Public Roads .....5 Operating on Hills ..........33 towing ..............5 Stopping the engine .........34 Operating ............5 Mowing tips .............35 Good Service .............6 Moving Machine By Hand ........36 Manufacturing number .........6 MAIntenAnCe ............37 SYMBOLS AnD DeCALS .........7 Maintenance Schedule ........37 SAFetY ..............9...
  • Page 4 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.

  • Page 5: Introduction

    INTRODUCTION Congratulations Towing thank you for purchasing a Dixon ride-on mower. If machine is equipped with a tow hitch, use extreme this machine is built for superior efficiency to rapidly caution when towing. never allow children or others in mow primarily large areas. A control panel that is or on the towed equipment.

  • Page 6: Good Service

    INTRODUCTION Good Service Dixon’s products are sold only in specialized retail stores with complete service. this ensures that you as a customer receive only the best support and service. Before the product is delivered, the machine has, for example, been inspected and adjusted by your retailer.

  • Page 7: Symbols And Decals

    symbOls aND DeCals these symbols are found on the machine and in the operator manual. Study them carefully so that you know what they mean. WARNING! IMPORTANT INFORMATION Xxxx xxxxxx xxxxx xxxx xxxxxxxxx Xxxx xxxxxx xxxxx xxxx xxxxxxxxx xxxxxx xxxxxx xxxxxxxxx. xx xxxxxxxx xxxx xxxxxxxxx.
  • Page 8 symbOls aND DeCals Shut off engine and remove key before performing any maintenance Keep a safe distance Use on slopes no Read Operator Manual or repair work from the machine greater than 10° no passengers Whole body exposure Severing of fingers Do not open or remove Careful backing up, Careful going forward,...

  • Page 9: Safety

    saFeTy Safety Instructions these instructions are for your safety. Read them carefully. WARNING! WARNING! THIS CUTTING MACHINE IS CAPABLE This symbol means that important safety OF AMPUTATING HANDS AND FEET instructions need to be emphasized. It AND THROWING OBJECTS. FAILURE concerns your safety.
  • Page 10 saFeTy • Disengage blades when not mowing. Shut off engine and wait for all parts to come to a complete stop before cleaning the machine, removing the grass catcher, or unclogging the discharge guard. • Operate machine only in daylight or good artificial light.

  • Page 11: Personal Safety Equipment

    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.
  • Page 12 saFeTy • Do not use on steep slopes. • Do not try to stabilize the machine by putting a foot on the ground. • Do not mow near drop-offs, ditches, or embank- ments. the machine could suddenly roll over if a wheel is over the edge or if the edge caves in.

  • Page 13: Safe Handling Of Gasoline

    saFeTy Safe Handling of Gasoline WARNING! The engine and the exhaust system become very hot during operation. There is risk for burns if touched. Allow engine and exhaust system to cool before refueling. to avoid personal injury or property damage, use extreme care in handling gasoline.

  • Page 14: General Maintenance

    saFeTy General Maintenance • never operate machine in a closed area. • Keep all nuts and bolts tight to be sure the equipment is in safe working condition. • never tamper with safety devices. Check their proper operation regularly. • Keep machine free of grass, leaves, or other debris buildup.
  • Page 15 saFeTy Sparking can occur when working with the battery and the heavy cables of the starter circuit. this can cause battery explosion, fire or eye injury. Sparking in this circuit can not occur after the chassis cable (normally negative, black) is removed from the battery. WARNING! Avoid electrical sparking and its consequences by the following routines:...

  • Page 16: Transport

    Spark Arrestor A spark arrestor for the muffler is available through WARNING! any authorized Dixon dealer. 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...

  • Page 17: Rollover Protection System (Rops)

    CONTROls Rollover Protection system (ROPS) WARNING! the ROPS increases the basic weight of the unit by The rollover protection system's 70 lbs / 32 kg. the ROPS is an accessory. capabilities may be impaired by damage • Do not use ROPS as a lifting, attaching or if the mower is overturned or if alteration anchoring point.

  • Page 18: Controls

    CONTROls this operator manual describes the Dixon Zero turn hydraulic pumps. Using the left and right steering Rider. the rider is fitted with a four-stroke overhead controls, the flow is regulated and thereby the valve engine. direction and speed. transmission from the engine is made via belt-driven...

  • Page 19: Motion Control Levers

    CONTROls Motion Control Levers the machine’s speed and direction are continuously variable using the two steering controls. the steering controls can be moved forward or backward about a neutral position. Furthermore, there is a neutral position, which is locked if the steering controls are moved outward.

  • Page 20: Throttle Control

    CONTROls Throttle Control the throttle control regulates the engine speed and the rate of rotation of the blades. to increase or decrease the engine speed, the control is moved forward or back respectively. Avoid idling the engine for long periods, as there is a risk of fouling the spark plugs.

  • Page 21: Ignition Switch

    CONTROls Ignition Switch the ignition switch is placed on the control panel and is used to start and stop the engine. Press in and turn the key clockwise to start the engine. 8050-602 Ignition switch Release the key to the RUn position when the engine has started.

  • Page 22: Hour Meter

    CONTROls Hour Meter the hour meter displays the total operating time with the blade activated, eliminating hours being added if the key was accidentally left on. to view the operating hours, turn the key to the on position and engage the blade switch. the clutch will engage and the hours should be shown on the meter.

  • Page 23: Parking Brake

    CONTROls Parking Brake the parking brake is found on the left of the machine. Pull the lever backward to activate the brake and push forward to release it. IMPORTANT INFORMATION The machine must be not be moving when engaging the parking brake. Always set the parking brake before dismounting.

  • Page 24: Bypass Linkages

    CONTROls Bypass Linkages the levers are located on each side of the rear of the unit below the rear engine plate. the bypass linkage is used when manually pushing or pulling the unit. See Moving Machine By Hand in the Operation section.

  • Page 25: Fuel Tank

    CONTROls Fuel Tank IMPORTANT INFORMATION It is recommended that fuel be added to both tanks on initial start up. Read the safety instructions before refueling. the combined capacity for the two tanks is 11 gallons (41 liters). Regularly check the gas cap gasket for damage and keep the cap properly tightened.

  • Page 26: Operation

    OPeRaTION Read the Safety Instructions section and the To turn to the right following pages if you are unfamiliar with the machine. While moving in a forward direction, pull the right lever back towards the neutral position while maintaining Training the position of the left lever, this will slow the rotation Due to unique steering capabilities, zero turn mowers of the right wheel and cause the machine to turn in...

  • Page 27: Before Starting

    OPeRaTION Before Starting 1. Read the sections Safety Instructions and Controls before starting the machine. 2. Perform the daily maintenance before starting (see Maintenance Schedule in the Maintenance section). 3. Check that there is sufficient fuel in the fuel tank. 4.

  • Page 28: Starting The Engine

    OPeRaTION Starting the Engine 1. Sit on the seat. 2. Raise the mower deck to the transport position by locking the lift pedal fully forward. 8066-027 Set mower deck to the transport position 3. Activate the parking brake by pulling the lever fully upwards.
  • Page 29 OPeRaTION 5. Move the steering controls outward to the locked (outer) neutral 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 an odorless, colorless, poisonous gas.
  • Page 30 OPeRaTION 8. Press in and turn the ignition key to the start position. For cold starts, the choke control should be pulled out to its extent. Push the choke in after engine starts. IMPORTANT INFORMATION Do not run the starter for more than 5 seconds each time.

  • Page 31: Jumper Cables Use

    OPeRaTION Weak Battery WARNING! Lead-acid batteries generate explosive gases. Keep sparks, flame and smoking materials away from batteries. Always wear eye protection when around batteries. IMPORTANT INFORMATION The mower is equipped with a 12-volt negative grounded system. The other vehicle must also be a 12-volt negative grounded system.

  • Page 32: Running

    OPERATION Running 1. Release the parking brake by moving the lever downward. NOTE: The mower is equipped with an operator presence system. When the engine is running, any attempt by the operator to leave the seat without first setting the parking brake will shut off the engine. 2. Move the steering controls to the neutral position (N). 8066-052 Parking brake released 3. Release foot pedal latch and lower deck to set cutting height. 4. Make sure the work area is free from objects that could be thrown by the rotating blades. WARNING! 8066-027 Ensure that no one is near mower when Cutting height selection engaging blade switch. 5. Move throttle control to full throttle (rabbit symbol). 6. Engage the mower deck by pulling out the blade switch.

  • Page 33: Operating On Hills

    OPeRaTION Operating on Hills Read the Safety Instructions Driving on Slopes in the Safety section. WARNING! Do not drive up or down hills with slopes greater than 10 degrees. Do not drive across slopes. • the slowest speed possible should be used before starting up or down hills.

  • Page 34: Stopping The Engine

    OPeRaTION Stopping the Engine 1. Move the throttle to the minimum position (tortoise symbol). 8050-607 Disengage the mower deck and move throttle to minimum 2. Move the steering controls outward into the neutral position. 3. Disengage the mower deck by depressing the blade switch.

  • Page 35: Mowing Tips

    OPeRaTION Mowing Tips WARNING! • Observe and flag rocks and other fixed objects to Clear the lawn of stones and other avoid collisions. objects that can be thrown out by the • Begin with a high cutting height and reduce it blades.

  • Page 36: Moving Machine By Hand

    OPeRaTION Moving Machine By Hand WARNING! No adjustments or maintenance should be carried out unless: • the engine stopped • the ignition key removed • the parking brake activated When pushing or pulling the mower, engage the IZt (Integrated Zeroturn transaxle) bypass linkages. the linkages are located on each side of the rear of the unit below the engine plate.

  • Page 37: Maintenance

    maINTeNaNCe Maintenance Schedule the following is a list of maintenance procedures that an authorized service workshop is recommended to must be performed on the machine. For those points maintain your machine in the best possible condition not described in this manual, visit an authorized and to ensure safe operation.
  • Page 38 maINTeNaNCe Daily At least Maintenance interval once in hours each MAINTENANCE Before After year ■ Check/adjust throttle cable ● ● Check the condition of belts, belt pulleys ■ ■ Change the engine oil ■ ■ Replace the engine oil filter ■...

  • Page 39: Battery

    maINTeNaNCe Battery StAnDARD StAte APPROXIMAte BAtteRY CHARGInG tIMe* tO FULL CHARGe At 80 F / 27 the mower is equipped with a maintenance free BAtteRY Maximum Rate at: battery and does not need servicing. However, CHARGe 50 Amps 30 Amps 20 Amps 10 Amps periodic charging of the battery with an automotive...

  • Page 40: Safety System

    maINTeNaNCe Safety System this machine is equipped with a safety system that prevents starting or driving under the following conditions. the engine can only be started when: • the mower deck is disengaged. • the steering controls are in the outer, locked neutral position.

  • Page 41: Deck Belt

    maINTeNaNCe Deck Belt Deck Belt Removal Park on a level surface. Apply park brake. Lower the deck into the lowest cutting position. 1. Remove foot plate and belt shields. 2. Remove any dirt or grass that may have accumulated around the cutter housings and entire deck surface.

  • Page 42: Pump Belt

    maINTeNaNCe 11. Adjust belt tension by turning the eyebolt until there is approximately " -1" of threads showing outside the nut. 12. Belt tension should be set to 60-70 lbs. 13. Replace belt shields on both mandrel housings and secure with fasteners. 14.

  • Page 43: V-Belts

    maINTeNaNCe From the underside of the deck: 3. Remove clutch stop to access the belt. 4. With a ½" breaker bar and using the square opening in the idler arm, shift the arm to create slack in the belt. 5. With the idler arm in the slack position, slip a screwdriver, clevis pin or similar into the "...

  • Page 44: Cutting Blades

    5. torque blade bolt to 90 ft/lbs (122 nm). IMPORTANT INFORMATION Special blade bolt is heat treated. 1. Blade 2. Blade bolt (special) Replace with a Dixon bolt if required. 3. Spindle housing Do not use lower grade hardware than Blade attachment specified.

  • Page 45: Adjusting The Mower Deck

    maINTeNaNCe Adjusting the Mower Deck Leveling deck Adjust the deck while the mower is on a level surface. Make sure the tires are inflated to the correct pressure. See Technical Data under Transmission. If tires are under or over inflated, the deck cannot be properly adjusted.

  • Page 46: Anti-Scalp Rollers

    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.

  • Page 47: Caster Wheels

    maINTeNaNCe Caster Wheels Check every 200 hours. Check that wheels rotate freely. Removal and Installation 1. Remove nut and caster bolt. 2. Pull the wheel out of the fork. 3. Install in reverse order. 4. tighten caster bolt. If wheels do not rotate freely, take the unit to the dealer for service.

  • Page 48: Lubrication

    lUbRICaTION Lubrication Schedule 8058-069 12/12 every year Lubricate with grease gun Filter change 1/52 every Week 1/365 every day Oil change Level check Change hydraulic drive filters. p See engine Manufacturer's manual General Remove the ignition key to prevent unintentional Wipe away excess grease after lubrication.

  • Page 49: Wheel And Deck Zerks

    lUbRICaTION Wheel and Deck Zerks Use only good quality bearing grease. Grease from well-known brand names (petrochemical companies, etc.) usually maintains a good quality. Front Wheel Mount Lubricate with a grease gun until the grease is forced out from the caster tube. Front Wheel Bearings Lubricate 3-4 strokes with a grease gun on each set of wheel bearings.

  • Page 50: Transaxle (Transmission) Fluid Change

    lUbRICaTION Transaxle (Transmission) Fluid Change this transaxle is designed with an external filter for 10. Fill with 20W50 motor oil until oil just appears ease of maintenance. to ensure constant fluid quality at the bottom of each transaxles’ top port levels and longer life, an oil filter change interval of (approximately 2 quarts per transaxle, 4 quarts every 200 hours is recommended.

  • Page 51: Transmission Purging

    lUbRICaTION Transmission Purging Due to the effects air has on efficiency in hydrostatic drive applications, it is critical to purge 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.

  • Page 52: Troubleshooting Guide

    TROUblesHOOTING GUIDe Problem Cause engine will not start • Blade switch is engaged • Steering controls are not locked in the neutral position • Parking brake is not activated • Battery is dead • Contamination in the carburetor or fuel line •...
  • Page 53 TROUblesHOOTING GUIDe Problem Cause Machine vibrates • Blades are loose • Blades are incorrectly balanced • Blades are bent • engine is loose engine overheats • Clogged air intake or cooling fins • engine overloaded • Poor ventilation around engine •...

  • Page 54: Storage

    Drain the fuel into an Always use genuine Dixon spare parts. approved container outdoors and far An annual check-up at an authorized service away from open flame. Store the fuel...

  • Page 55: Wiring Diagrams

    sCHemaTICs DIaGRam...

  • Page 56: Technical Data

    TECHNICAL DATA Engine Manufacturer Kawasaki Type FX691V Power 22 HP Lubrication Pressure w/ Oil Filter Fuel Min 87 octane unleaded (Max ethyl alcohol 10%, Max MTBE 15%) Fuel capacity 11 gallons / 41 liters Cooling Air cooled Alternator 12v 15 amp @ 3600 rpm Starter Electric Transmission...
  • Page 57 TECHNICAL DATA Frame Cutting Width 52" (122 cm) Cutting Height 1½"-5" (2.5-12.7 cm) Uncut Circle Number of Blades Blade Length 16¼" / 41.3 cm Nose Roller Seat Premium Commercial EVC Hinged Arm Rests Hour Meter Digital Blade Engagement 200 ft-lb Deck Construction 11 gauge fabricated Productivity...
  • Page 58 TeCHNICal DaTa TORQUE SPECIFICATIONS engine crankshaft bolt 50 ft/lb (67 nm) Standard " fasteners 18 ft/lb (25 nm) Deck pulley bolts 150 ft/lb (201 nm) Standard " fasteners 33 ft/lb (44 nm) Blade bolt 90 ft/lb (122 nm) Standard " fasteners 52 ft/lb (70 nm) Standard ¼"...

  • Page 59: 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.

  • Page 60: Service Journal

    seRVICe JOURNal Action Date, mtr reading, stamp, sign Delivery Service Charge the battery Adjust the tire pressure of all wheels to 15 PSI (1 bar) Mount the steering controls in the normal position Connect the contact box to the cable for the seat’s safety switch Check that the right amount of oil is in the engine Adjust the position of the steering controls Fill with fuel and open the fuel shut off valve...
  • Page 61 seRVICe JOURNal Action Date, mtr reading, stamp, sign After the first 10 hours Change the engine oil Change the oil filter Check hydraulic oil level Inspect hydraulic hoses Inspect hydraulic belt Inspect hydraulic filter Check neutral position Check safety system Check seat belt Check fuel system for leaks Inspect safety guards and shields...
  • Page 62 seRVICe JOURNal Action Date, mtr reading, stamp, sign 25-Hour Service Check the fuel pump’s air filter Sharpen/Replace mower blades if required Check the tire pressures Check battery with cables Lubricate according to lubrication chart Check/clean the engine’s cooling air intake Clean the air cleaner’s foam pre-filter 50-Hour Service Perform the 25-hour service.
  • Page 63 seRVICe JOURNal Action Date, mtr reading, stamp, sign 100-Hour Service Perform the 25-hour service Perform the 50-hour service Change the engine oil filter Clean/replace the spark plugs Replace the fuel filter Check V-belts Check tighten caster wheel axle bolts (every 200 hours) Change the air filter’s paper cartridge Change hydraulic pump oil and filter (200 hours) 300-Hour Service...
  • Page 64 seRVICe JOURNal Action Date, mtr reading, stamp, sign At Least Once Each Year Clean the engine’s cooling air intake (25 hours) Replace the air cleaner’s foam pre-filter (300 hours) Replace the air filter’s paper cartridge Change the engine oil (50 hours) Replace the engine oil filter (100 hours) Check/adjust the cutting height Check/adjust the parking brake (50 hours)
  • Page 65 seRVICe JOURNal Action Date, mtr reading, stamp, sign...
  • Page 66 seRVICe JOURNal Action Date, mtr reading, stamp, sign...

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