Set-Up Instructions for CE Kodiak Models Setup c. Using 1/2C x 3 1/4 cap screws thru the rear hole on the left and right side. d. Install the 1/2C centerlock nuts finger tight. 4. Torque all 1/2” hardware to 80 ft./lbs. (110 N•m). 5. Install and tighten knobs against the side post. Uncrate machine.
Tires Mount rear drive wheels using the lug nuts installed on the hubs. 1 Check the tire pressure in all four tires. All tires should be 15 psi. Control Arms Remove top bolt in control arm and loosen bottom bolt, rotate the control levers to the upright position. Align the levers so they are even in the neutral position. Reinstall hardware and tighten. FIG - 1 2 Seat Install 1. Motion Control Lever 2. Control Arm FIG - 1 1. Remove seat assembly from the crate. 2.
Adjusting the Mower Deck WARNING! Before performing any service or adjustment check list: 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. Deck Leveling WARNING! 1. Position the mower on a level, hard surface 2.
Tracking 1. Tracking adjustment is accomplished using the tracking bolts. The tracking bolts act as limiting device for the motion control levers when in the full-forward position. 2. Start by loosening jam nut on right tracking bolt. Back the tracking bolt out until flush with nut. 3. Loosen tracking bolts and back out until flush with nut. 4. Move unit to an open unobstructed area such as an empty parking lot or open field for tracking adjustment. 5.
Operator’s Manual KODIAK 52, 20 HONDA / 968999635 KODIAK 60, 25 KOH / 968999636 Please read the operator’s manual carefully and make sure you understand the instructions before using the machine.
OPERATOR’S MANUAL KODIAK SERIES Contents Introduction .............................................................3 General ................................................................3 Driving and Transport on Public Roads ...............3 Towing .................................................................3 Operating .............................................................3 Manufacturing Number ........................................4 Symbols and Decals ....................................
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.
INTRODUCTION 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, etc.
INTRODUCTION Unauthorized modifications to the design of the machine may absolve the manufacturer from liability for any resulting personal injury or property damage. 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.
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! Xxxxxxx xxxx xxxxxxxx xxx x Xxxxx xxxxxx xx. xx xxxxxxxx xxxxx xxx xx. 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 Xxxxxxx xxxx xxxxxxxx xxx xxx xxxx xxxxxx xx.
SYMBOLS AND DECALS Read Operator´s Manual. Whole body exposure to thrown objects. Shut off engine & remove key before performing any maintenance or repair work. Severing of fingers & toes. Keep a safe distance from the machine. Do not open or remove safety shields while engine is running. Use on slopes no greater than 10°. No passengers Careful backing up, watch for other people. Careful going forward, watch for other people.
SAFETY INSTRUCTIONS 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.
SAFETY INSTRUCTIONS • 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. • 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.
SAFETY INSTRUCTIONS 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.
SAFETY INSTRUCTIONS • Use extra care while operating machine with grass catchers or other attachments; they can affect the stability of the machine. 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 8011-519 Tragic accidents can occur if the operator is not alert to the presence of children.
SAFETY INSTRUCTIONS Maintenance 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.
SAFETY INSTRUCTIONS • Check the fuel level before each use and leave space for the fuel to expand, because the heat from the engine and the sun may otherwise cause the fuel to expand and overflow. 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 build-up.
SAFETY INSTRUCTIONS • 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. • 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.
SAFETY INSTRUCTIONS • 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. • The blades are sharp and can cause cuts and gashes. Wrap the blades or use protective gloves when handling them.
SAFETY INSTRUCTIONS Rollover Protection System ROPS The ROPS increases the basic weight of the unit by 42 lbs/19 kg. The ROPS on the US units are standard, on the European units the ROPS is an accessory. WARNING! The structures capability may be impaired by structural damage if overturned, or alteration occurs. If any of these conditions take place, the total structure MUST be replaced. • Do not use ROPS as a lifting, attaching or anchoring point. • Do not use ROPS for wrecking or towing.
CONTROLS Controls This operator’s manual describes the Dixon Zero Turn Rider. The rider is fitted with a Honda or Kohler four-stroke V-Twin engine developing 19-25 horse power. Transmission from the engine is made via two belt-driven hydraulic pumps, which in turn drive a hydraulic motor for each drive wheel. Using the left and right steering controls, the flow is regulated and thereby the direction and speed.
CONTROLS 1. 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. When both controls are in the neutral position (N), the machine stands still.
CONTROLS 2. 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 can not be manually reset. 8050-140 Hour meter 3. Park Brake The park brake is found on the left of the machine. Pull the lever backward to activate the brake and forward to release it.
CONTROLS 4. Blade switch In order to engage the mower deck, pull the knob out; the mower blades are disengaged when the knob is depressed. 8050-142 Blade Switch 5. Ignition Switch The ignition key is placed in the ignition switch on the driver’s panel and is used to start and stop the engine. IMPORTANT INFORMATION Do not run the starter for more than five seconds each time. If the engine does not start, wait about 10 seconds before retrying. 8050-141 Ignition key and hour meter 6.
CONTROLS 7. Seat Locking Device Under the rear part of the seat is a locking device that locks the seat into its folded position. The seat has hinges at the front edge and can be folded forward when the locking device is pushed. 8011-440 The seat’s locking device 8. Refueling The machine has two fuel tanks, one on each side just behind the seat. The tanks take 5.7 gallons (22 liters) each. The engine will run on a minimum of 87-octane unleaded gasoline (no oil mix).
CONTROLS 9. Fuel Shut Off Valve The fuel shut off valve is located at the right rear of the seat. The valve has three positions; right tank, left tank and center is the off position. 8011-506 Fuel valve 10. 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 11.
CONTROLS 12. 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 downward or upward 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. 8050-144 Throttle control 13.
CONTROLS Pump release valves IMPORTANT INFORMATION Only rotate valve 1/4 - 1/2 turn to release system. Tighten the valve moderately. Do not overtighten the valve when closing. That can damage the valve seat. Pump release valves are located at the pumps. 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 pumps. Use a 5/8” wrench to open valve.
OPERATION 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 recommend that this section be reviewed in it’s entirety prior to attempting to move the mower under its own power.
OPERATION Roll bar and safety belt WARNING! Operate the unit with the roll bar in the raised and locked position and use the seat belt. There is no rollover protection when the roll bar is down. If it is necessary to lower roll bar, do not wear the seat belt. Raise the roll bar as soon as clearance permits. The seat belt must be used when the roll bar is in upright position. Roll bar Before Starting • Read the sections Safety Instructions and Controls before starting the machine.
OPERATION 4. Disengage the mower blades by depressing the blade switch. 8050-131 Depress the control for disengaging the mower deck 5. Move the steering controls outward to the locked (outer) neutral position. 8011-526 Steering controls in the outward, locked neutral position 6. Move the throttle to the middle position.
OPERATION 7. If the engine is cold, the choke control shall be pulled out to its extents. 8050-134 Set the choke control 8. Open the fuel valve for the selected fuel tank. 8011-506 Open the fuel valve 9. Press in and turn the ignition key to the start position.
OPERATION 10. When the engine starts, immediately release the ignition key back to the run position. STOP IMPORTANT INFORMATION Do not run the starter for more than 5 seconds each time. If the engine does not start, wait about 10 seconds before retrying. key-run Return to run position 11. Slowly slide the choke control to the off position when the engine has started. 8050-134 Gradually slide the choke control 12. Set the desired engine speed with the throttle.
OPERATION To start an 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. If your battery is too weak to start the engine, it should be recharged. (See “Battery” in the the “Maintenance” section). If “jumper cables” are used for emergency starting, follow this procedure: IMPORTANT INFORMATION Your mower is equipped with a 12-volt negative grounded system.
OPERATION Running 1. Release the park brake by moving the lever forward. Your 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 park brake will shut off the engine. 2. Move the steering controls to the neutral position (N). 8050-138 Released park brake 3. Select the cutting height by placing the peg in one of the holes. Lock the peg on the inside with the pin. 4.
OPERATION 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 can be achieved by moving one control backward (behind the neutral position) and carefully moving the other steering control forward from its neutral position. Operating on hills Read “Slope Operation” in the “Safety Instructions”.
OPERATION Mowing Tips • • Observe and flag rocks and other fixed objects to avoid collisions. WARNING! Begin with a high cutting height and reduce it until the desired mowing result is attained. Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blades. 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.
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. 1. Disengage the mower deck by depressing the blade switch. 8050-131 Disengage the mower deck 2. Raise the mower deck by pulling the lifting lever backward to the transport position. 3.
OPERATION Moving by Hand In order for the machine to be moved with the engine turned off, the vent screws on both hydraulic pumps must be opened one quarter to one half turn. WARNING! No adjustments or maintenance to carried out unless: - the engine is stopped, - the ignition key has been removed, - the park brake is on.
MAINTENANCE 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.
MAINTENANCE Daily Maintenance Weekly Page Before After At least once each year Maintenance interval in hours 25 50 100 Check the condition of belts, belt pulleys, etc.
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. IMPORTANT INFORMATION • Keep battery bolts tight. • Recharge at 6-10 amperes for 1 hour Do not attempt to open or remove caps or covers. Adding or checking level of electrolyte is not necessary.
MAINTENANCE 9. Connect BLACK grounding cable to negative (-) battery terminal with remaining hex bolt and hex nut. 10. Fit the terminal guard. 11. Lower seat. Ignition System The engine is equipped with an electronic ignition system. Only the spark plugs require maintenance. For recommended spark plugs, see Technical Data. IMPORTANT INFORMATION 1. Remove the ignition cable boot and clean around the spark plug. Fitting the wrong spark plug type can damage the engine. 2.
MAINTENANCE Checking the 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 park 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.
MAINTENANCE Checking the Engine's 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. Replacing the Air Filter (Kohler) Heavy duty air filter If the engine seems weak or runs unevenly, the air filter may be clogged. If the engine is run with a dirty air filter, the spark plugs can become fouled, disrupting operation.
MAINTENANCE 6. Install the main filter with the open end first. Ensure that it enters its recess at the end of the housing by pushing it in to the stop. IMPORTANT INFORMATION The end cover must be installed with the rubber valve pointing downwards, otherwise the rubber valve will not function. 8011-449 Installing the main filter 7. Replace the end cap and turn the end cover so the rubber valve is pointing downwards. Secure the retaining clips.
MAINTENANCE 3. Remove the foam rubber pre-filter and clean or replace as necessary. To clean, wash with warm water using a mild detergent. Squeeze out excess water and allow to air dry. After drying, dip the filter in clean engine oil and squeeze out excess. 4. Tap the paper filter against a fixed surface to remove dust. If the paper filter is still dirty, it must be replaced. 8057-728 IMPORTANT INFORMATION Remove the paper filter Do not used compressed air to clean the air filter.
MAINTENANCE Replacing the Fuel Filter Replace the line-mounted fuel filter every 100 hours (once per season) or more often if it becomes 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.
MAINTENANCE Checking Tire Pressures All four tires should have a pressure of 15 psi / 103 kPa /1 bar. 8011-564 Checking the Park Brake Tire pressures Visually check that no damage is found on the lever, links, or switch belonging to the park brake. Perform a test drive and check that there is sufficient braking action. To adjust the park brake, contact the Dixon service workshop. WARNING! Faulty adjustment can cause an accident.
MAINTENANCE Pump belt Check belt every 100 hours for excessive wear. To replace belt. Relieve tension on the deck belt and remove deck belt from clutch. See “Deck belt” on page 44. Loosen bolt on the clutch tie down and rotate out of the way. Using a 1/2” drive ratchet inserted into the square hole in the pump idler arm, relieve the tension on the pump belt and remove belt. To reinstall belt. Swing pump idler pulley out toward engine to route belt around it.
MAINTENANCE Blade replacement: 3 1 WARNING! Blades are sharp. Protect your hands with gloves and/or wrap blades with a heavy cloth when handling. 2 5 4 • Remove blade bolt by turning counterclockwise. IMPORTANT INFORMATION To ensure proper assembly, center hole in blade must align with star on cutter housing. • Install new or re-sharpened 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.
MAINTENANCE Adjusting the Mower Deck WARNING! Before performing any service or adjustment checklist: 1. Engage the park 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. Leveling 1. Position the mower on a level, preferably concrete, surface.
MAINTENANCE To adjust 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. CZ-9 Anti-scalp roller The anti-scalp rollers can be set in three positions. • Upper position 1.
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 deck, avoiding spraying engine and electrical components with water.
LUBRICATION Lubrication Lubrication Schedule KODIAK 8011-765 12/12 Every year 1/52 Every week Lubricate with grease gun Oil change Lubricate with oil can Level check 1/365 Every day Filter change 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 disulfide grease.
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.
LUBRICATION 3. Engine Oil Kohler Engine Changing the Engine Oil Change oil after every 100 hours of operation (more frequently under severe conditions). Refill with service class SG, SH, SJ or higher oil as specified in the Viscosity Grades table on page 54. Change the oil while the engine is still warm. The oil will flow more freely and carry away more impurities. Make sure the engine is level when filling, checking or changing the oil.
LUBRICATION Checking the Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized. Check oil before each use as follows: 1. Make sure the engine is stopped, level, and is cool so the oil has had time to drain into the oil pan. 2. To keep dirt, debris, etc., out of the engine, clean the area around the dipstick before removing it. 3. Unthread and remove the dipstick; wipe oil off. Reinsert the dipstick into the tube and rest the cap on the tube.
LUBRICATION Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure. Oil Type Use high quality detergent oil of API (American Petroleum Institute) service class SG, SH, SJ or higher. Select the viscosity based on the air temperature at the time of operation.
LUBRICATION 3. Engine Oil Changing the Engine Oil The engine oil must be changed for the first time after 8 hours of operation. Thereafter, it should be changed every 100 hours. 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. 1. Place the machine on a flat surface. 2. Place a container under the engine oil drain plug. 3.
LUBRICATION 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 above the “FULL” mark. The oil is filled through the hole for the dipstick. 8009-159 The dipstick markings Use engine oil SAE 30 or SAE 10W-30 or, alternately, 10W/40, class SC–SJ (over +32 °F/0 °C). Over +68 °F/+20 °C SAE 40 can be used. Use engine oil SAE 5W-20, class SC–SJ (under +32 °F/0 °C). The engine holds 1.6 qt/1.
LUBRICATION 6. 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 molybdenum disulfide grease. Grease from well-known brand names (petrochemical companies, etc.) usually maintains a good quality. 8011-573 Lubricating the front wheels 7. Deck belt pulleys Lubricate with a grease gun two strokes. 8011-461 Deck belt pulleys 8.
LUBRICATION 9. Belt Adjuster, Mower Deck Remove the foot plate (two screws) and lubricate with a grease gun, one zerk, until grease is forced out. Use only good quality molybdenum disulfide grease. Grease from well-known brand names (petrochemical companies, etc.) usually maintains a good quality. IMPORTANT INFORMATION 8011-576 Use minimal lubrication and remove excess lubricant so that it does not come into contact with belts or belt pulley drive surfaces. The belt adjuster grease zerk 10.
LUBRICATION 12. Brake Arms Remove one rear wheel at a time (four screws). Lubricate with a grease gun, one zerk for each brake arm, until the grease is forced out. Use only good quality molybdenum disulfide grease. Grease from well-known brand names (petrochemical companies, etc.) usually maintains a good quality. 8011-579 Lubricating brake arms IMPORTANT INFORMATION Use minimal lubrication and remove excess lubricant so that is does not come into contact with the brake band. 13.
LUBRICATION 14. Changing the Oil Filter 1. Drain the engine oil in accordance with the work description under the heading Engine Oil/Change Engine Oil. 2. Remove the oil filter. If necessary, use a filter remover. 3. Wipe new, clean engine oil onto the seal for the new filter. 4. Mount the filter by hand with + 3/4 turn. 5. Run the engine warm, then check that there are no leaks around the oil filter seal. 6.
TROUBLE SHOOTING GUIDE Trouble Shooting Guide Problem Cause The engine will not start. • 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 park brake is not activated. • The battery is dead. • Contamination in the carburetor or fuel line. • The fuel supply is closed or the tap for the fuel tanks is in the wrong position. • Clogged fuel filter or fuel line. • Dead battery.
TROUBLE SHOOTING GUIDE Problem Cause The engine seems weak. • Clogged air filter. • Defective spark plugs. • Carburetor incorrectly adjusted. • Clogged air intake or cooling fins. • Engine overloaded. • Poor ventilation around engine. • Defective engine speed regulator. • Soot in the combustion chamber. • Too little or no oil in the engine. • Defective spark plugs. • Pre-ignition incorrect. Battery not charging. • Poor contact with battery terminal cable connectors.
STORAGE Storage To ready the machine for storage, follow these steps: Winter Storage 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 used oil properly. 4. Empty the fuel tanks or add a fuel stabilizer.
WIRING DIAGRAMS Wiring diagram 6. Seat unoccupied 11. Brake switch OFF pos. 8. Blade switch in OFF position 14-15. Motion control levers OUT 1. Battery 2. Accessory outlet 3. Key switch 4. To engine pigtail 5. Hour meter 6. Seat switch 7. Run relay 8. PTO switch 9. Brake relay 10. Electric clutch 11. Brake switch 12. Start relay 13. Starter solenoid 14. Left motion control lever 15. Right motion control lever BLK = Black BLU = Blue BRN = Brown GRN = Green GRY = Grey LT.
TECHNICAL DATA 968999635 968999636 Engine Manufacturer Honda Kohler Type GXV620 CV730 Power 20 hp / 14.9kW 25 hp / 18.4kW Lubrication Pressure with oil filter Pressure with oil filter Oil capacity excl filter 1.9 qts.(1.8 liters) 1.6 qts (1.7 liters) Oil capacity incl filter 2.2 qts. (2.1 liters) 1.9 qts (1.
TECHNICAL DATA 968999635 968999636 Equipment Cutting width 52" / 132 cm 60" / 152 cm Cutting height 1.5" to 5" (38-127 mm) 1.5" to 5" (38-127 mm) Uncut circle 0" / 0 cm 0" / 0 cm Number of blades 3 3 Blade length 52" (132 cm) 60" (152 cm) Anti-scalp rollers Yes Yes Frame construction Steel uni-frame Steel uni-frame Ball bearing wheels Yes Yes Seat High-density closed cell foam padded back and arm rests water-repellent fabric. Operator suspension system.
TECHNICAL DATA Accessories BioClip attachment (Mulch kit) Front baffle kit Roll Over Protection System. ROPS with seat belt. Accessory only for EC models. Standard on US models.
CONFORMITY CERTIFICATESE 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, (Californian 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.
SERVICE JOURNAL Service Journal Action Date, mtr reading, stamp, sign Delivery Service 1. Charge the battery. 2. Mount the rear wheels. 3. Adjust the tire pressure of all wheels to 15 PSI (1 bar). 4. Mount the steering controls in the normal position. 5. Connect the seat fold-up stop. 6. Connect the cable to the safety switch under the seat. 7. Mount the arm rests on the seat’s back support. 8. Check that the right amount of oil is in the engine. 9.
SERVICE JOURNAL Action Date, mtr reading, stamp, sign 20. Inform the customer about: Delivery service has been carried out. The need and advantages of following the service schedule. The need and advantages of leaving the machine for service every 300 hours. The effects of service and maintaining a service journal on the machine’s resale value. Application areas for BioClip. 21. Fill in the sales papers, etc. After the First 8 Hours 1. Change engine oil. English-70 No remaining notes.
SERVICE JOURNAL Action Date, mtr reading, stamp, sign 25-Hour Service 1. Check the fuel pump’s air filter. 2. Check the hydraulic system’s oil level. 3. Check the tire pressures. 4. Lubricate the belt adjuster, mower deck. 5. Lubricate the belt adjuster, hydraulic pumps. 6. Check/clean the engine’s cooling air intake. 7. Clean air filter dust cap.
SERVICE JOURNAL Action 50-Hour Service 1. Perform the 25-hour service. 2. Lubricate the front wheel bearings. 3. Lubricate the steering control shafts. 4. Lubricate the mower deck struts. 5. Lubricate the cutting height adjuster. 6. Check/adjust the park brake.
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 engine oil. 4. Check whether the hydraulic oil needs changing (every 300 hours). 5. Check whether the engine oil filter needs changing (every 200 hours). 6. Clean/replace the spark plugs. 7. Replace the fuel filter. 8. Clean the cooling fins on the engine and transmission. 9. Check V-belts. 10.
SERVICE JOURNAL Action 300-Hour Service 1. Inspect the machine. Come to agreement with the customer as to which additional work is to be carried out. 2. Perform the 25-hour service. 3. Perform the 50-hour service. 4. Perform the 100-hour service. 5. Change the oil and filter in the hydraulic system. 6. Clean the combustion chamber and grind the valve seats. 7. Check the play in the engine valves. 8. Dismantle and inspect starter (500 h).
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 (Oil-foam) (300 hours). 3. Replace the air filter’s main cartridge (200 hours). 4. Change the engine oil (100 hours). 5. Replace the engine oil filter (200 hours). 6. Change the oil and filter in the hydraulic system (300 hours). 7. Check/adjust the cutting height. 8. Check/adjust the park brake (50 hours). 9.
SERVICE JOURNAL Action English-76 Date, mtr reading, stamp, sign
539 130504 01/07
