Dixon 966690603 Operator's Manual
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Dixon 966690603 Operator's Manual

Dixon 966690603 Operator's Manual

Ztr ride-on mower.
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Operator Manual
Ultra 52 / 966690603
Please read the operator's 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.
Form Number 115 521627 Rev A
2012-08-15

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  • Page 1 Operator Manual Ultra 52 / 966690603 Please read the operator’s 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..............29 General................ 5 Operating.On.Hills............. 30 Driving.and.Transport.on.Public.Roads....... 5 Mowing.Tips............... 31 Towing................. 5 Stopping.the.Engine..........32 Operating..............5 Moving.Machine.by.Hand.......... 33 Good.Service............... 6 MAINTENANCE............... 34 Manufacturing.Number..........6 Maintenance.Schedule..........34 SYMBOLS.AND.DECALS..........7 Battery............... 36 SAFETY................9 Safety.System.
  • 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 caution when towing. Never allow children or others in rapidly mow primarily large areas. A control panel or on towed equipment.

  • Page 6: Good.service

    INTRODUCTION Good Service retailer. See the certificate in the Service Journal in Dixon’s products are sold only in specialized retail this operator’s manual. stores with complete service. This ensures that you as a customer receive only the best support and service.

  • Page 7: Symbols.and.decals

    SYMBOLS.AND.DECALS These symbols are found on the machine and in the operator’s manual. Study them carefully so that you know what they mean. WARNING! 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 Keep a safe Read Operator’s maintenance distance from the Use on slopes no Manual or repair work machine greater than 10° No passengers Whole body exposure Severing of fingers Do not open or Careful backing up, Careful going forward, to thrown objects...

  • Page 9: Safety

    SAFETY Safety Instructions These instructions are for your safety. Read them carefully. WARNING! WARNING! This symbol means that important safety THIS CUTTING MACHINE IS CAPABLE instructions need to be emphasized. It OF AMPUTATING HANDS AND FEET concerns your safety. AND THROWING OBJECTS. FAILURE TO OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.
  • 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 embankments. 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 to a safe temperature 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 WARNING! A spark arrestor for the muffler is available through This mower is equipped with an internal your authorized Dixon dealer. combustion engine and should not be used on or near any unimproved forested, bush covered or grassy lands...

  • Page 17: Controls

    CONTROLS This operator’s 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 18: Steering.control.levers

    CONTROLS 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.

  • Page 19: Parking.brake

    CONTROLS Parking Brake The parking brake is found on the right side of the The parking brake is found on the left of the machine. Pull the lever backward to activate the brake and forward to release it. IMPORTANT INFORMATION The machine must stand absolutely still when applying the parking brake.

  • Page 20: Choke.control

    CONTROLS Choke Control The choke control is used for cold starts To provide the engine with a richer fuel mixture. For cold starts the control should be pulled up. WARNING! Gasoline is highly flammable. Observe caution and fill the tank outdoors (see the safety instruction).

  • Page 21: Seat Adjustment Lever

    CONTROLS 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.

  • Page 22: Fuel.shut.off.valve

    Recommended air pressure is 15 psi. (1 bar) Tracking must be checked on a flat and level concrete or blacktop surface. If the unit still does not track straight contact your Dixon workshop for adjustments. WARNING!

  • Page 23: Fuel.tank

    CONTROLS Fuel Tank Read the safety instructions before refueling. The machine has one fuel tank, just behind the seat. The tank capacity is 5 gallons (19 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).

  • Page 24: Operation

    OPERATION To turn to the right Read the Safety section and 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 are far more maneuverable than typical riding...

  • Page 25: 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 26: Starting.the.engine

    OPERATION Starting the Engine 1. Sit on the seat. 2. Raise the mower deck by setting the deck pedal fully forward. 3. Activate the parking brake. Set the pin to the desired mowing height 4. Disengage the mower blades by pressing the blade switch downwards.
  • Page 27 OPERATION 6. Move the throttle to the middle position. 8050-177 Set the throttle 7. If the engine is cold, the choke control should be pulled up. 8050-177 Set the throttle 8. Open the fuel tank valve. 8050-010 Open the fuel valve...
  • Page 28 OPERATION 9. Press in and turn the ignition key to the start position. IMPORTANT INFORMATION Do not run the starter for more than 5 seconds each time. If the engine does not start, wait approximately 10 seconds before retrying. 8050-780 Turn to START position 10.

  • Page 29: Weak.battery

    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 Your mower is equipped with a 12-volt negative grounded system. The other vehicle must also be a 12-volt negative grounded system.

  • Page 30: 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.

  • Page 31: 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 32: 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 until blades.

  • Page 33: Stopping.the.engine

    OPERATION Stopping the Engine Allow the engine to idle a minute To attain normal operating temperature before stopping it, if it has been worked hard. Avoid idling the engine for longer periods, as there is a risk of the spark plugs fouling. 1.

  • Page 34: 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 rear engine plate.

  • Page 35: 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 36 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 37: Battery

    MAINTENANCE Battery Always use protective glasses when Your mower is equipped with a maintenance free handling the battery. battery that does not need servicing. However, periodic charging of the battery with an automotive type battery charger will extend its life. •...

  • Page 38: Safety.system

    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.

  • Page 39: V-Belts

    MAINTENANCE 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 1.

  • Page 40: Pump.belt

    MAINTENANCE Pump Belt The belts are not adjustable. Replace belts if they begin to slip from wear. Replacing Pump Belt Park the mower on a level surface. Engage the parking brake. Belt Removal From the top side of the deck: 1.

  • Page 41: Cutting.blades

    THIS SIDE UP facing deck and cutter housing. 3. Install and tighten blade bolt securely. 4. 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.

  • Page 42: Adjusting.the.mower.deck

    MAINTENANCE Adjusting the Mower Deck WARNING! 1. Before performing any service or adjustment checklist: 2. Engage the parking brake. 3. Place the Blade switch in the disengaged position. 4. Turn ignition switch to OFF position and remove the key. 5. Make sure the blades and all moving parts have completely stopped. 6.

  • Page 43: 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 44: Caster.wheels

    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.

  • Page 45: Lubrication

    LUBRICATION 8011-672-6 12/12.Every.year Lubricate.with.grease.gun Level.check 1/52.Every.Week Oil.change Filter.change 1/365.Every.day *Change transaxles (transmission) filters. General Remove the ignition key to prevent unintentional Wipe away excess grease after lubrication. movements during lubrication. It is important to avoid getting lubricant on the belts When lubricating with an oil can, it must be filled with or the drive surfaces on the belt pulleys.

  • Page 46: Front.wheel.mount

    LUBRICATION Wheels and Deck Spindles 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, one zerk for each wheel mount, until the grease is forced out. Front Wheel Bearings Lubricate with a grease gun, one zerk for each set of wheel bearings, until the grease is forced out.

  • Page 47: Transaxle.fluid.change

    LUBRICATION Transaxle Fluid Change (Transmission) 10. Fill with 20W50 motor oil until oil just appears at the bottom of each transaxles’ top port This transaxle is designed with an external filter for (approximately 2 quarts per transaxle, 4 quarts ease of maintenance. To ensure constant fluid quality total).

  • Page 48: Troubleshooting

    TROUBLESHOOTING Problem Cause The engine will not start. • Blade lever is engaged. • Steering controls are not locked in neutral position. • Driver is not sitting in driver’s seat. • Parking brake is not activated. • Battery is dead. •...
  • Page 49 TROUBLESHOOTING Problem Cause The engine seems weak. • Clogged air filter. • Fouled spark plugs. • Carburetor incorrectly adjusted. The engine overheats. • Clogged air intake or cooling fins. • Engine overloaded. • Poor ventilation around engine. • Defective engine speed regulator. •...

  • Page 50: Winter.storage

    Drain the fuel into an purchase year, model, type, and serial number. approved container outdoors and store Always use genuine Dixon spare parts. far away from open flame. Never use An annual checkup at an authorized service workshop gasoline for cleaning.

  • Page 51: Schematics

    SCHEMATIC 8053-002...

  • Page 52: Technical.data

    TECHNICAL.DATA 966690603 Engine Manufacturer Kohler Type Courage Pro Power 25 hp 1,2) Lubrication Pressure with oil filter Fuel Min 87 octane unleaded (Max ethanol 10%, Max MTBE 15%) Fuel tank capacity 5 gallons / 19 liters Cooling Air cooled Air filter...
  • Page 53 TECHNICAL.DATA 966690603 Equipment Cutting width 52" / 132 cm Cutting height 1½ - 5" / 3.8 - 13 cm Number of blades Blade length 18" / 46 cm Nose Rollers Sprung seat Standard Hinged armrests Hour Meter Standard Blade engagement...

  • Page 54: Torque.specifications

    TECHNICAL.DATA Torque Specifications Engine crankshaft bolt 50 ft/lb (67 Nm) Standard " fasteners 18 ft/lb (25 Nm) Deck pulley bolts 75 ft/lb (100 Nm) Standard " fasteners 33 ft/lb (44 Nm) Lug nuts 75 ft/lb (100 Nm) Standard " fasteners 52 ft/lb (70 Nm) Blade bolt 55 ft/lb (75 Nm)

  • Page 55: 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 56: Service.journal

    SERVICE.JOURNAL Action Date, mtr reading, stamp, sign Delivery Service Charge battery. Adjust tire pressure of all wheels according to Technical Data. 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.
  • Page 57 SERVICE.JOURNAL Action Date, mtr reading, stamp, sign After the First 10 Hours Change engine oil. 25-Hour Service Check the fuel pump’s air filter. Check the hydraulic system’s oil level. Check the tire pressures. Lubricate the belt adjuster, mower deck. Lubricate the belt adjuster, hydraulic pumps. Check/clean the engine’s cooling air intake.

  • Page 58: Hour Service

    SERVICE.JOURNAL Action Date, mtr reading, stamp, sign 50-Hour Service Perform the 25-hour service. Clean/replace the air cleaner’s filter cartridge (paper filter) (shorter intervals for dusty operating conditions). Change engine oil. Lubricate according to lubrication chart. Check/adjust the parking brake. 100-Hour Service Perform the 25-hour service.
  • Page 59 SERVICE.JOURNAL Action Date, mtr reading, stamp, sign 300-Hour Service Perform the 25-hour service. Perform the 50-hour service. Perform the 100-hour service. Check/adjust the mower deck. Clean the combustion chamber and grind the valve seats. Check the engine valve clearance. Replace the air cleaner’s prefilter (foam). At Least Once Each Year Clean the engine’s cooling air intake (25 hours).

This manual is also suitable for:

Ultra 52

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